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HBC-4301 Operators Manual

1. Hot Bonding Controller Operators Name Status Description Sgt Smith Manager Workshop Manager Nene fas ooo acount sted Title Workshop Manager FP Start Tasks without Additional Authorisatio Access Operator C Supervisor Manager Add User E Remove User Qy Set Password Bi Save Changes 4 Esc Return to Menu Disconnected 03 Feb 2006 11 06 09 7 Etech Page 101 CONTROLS en iro Fig 26 Password protection screen Creating a new User Using the above screen a Manager has the ability to Create new users Select the authority level Disable accounts Change passwords To add a new user click the Add User button at the bottom of the screen or press Alt A The Create New User dialog box will appear Enter the User name User description Select access level Enter the password and password confirmation The password can be between 6 and 32 characters long and can contain any numbers letters or punctuation If additional authority is required after a user has logged on to gain access to a screen that the operator may not have access to temporary access may be obtained by logging on a new Supervisor Manager Use the Supervisor Login under the File menu heading in the top left hand corner of the screen Use the start up user name password dialog box as used when starting the program All changes in the operator are logged in the process log screen i
2. 130 140 150 Temperature C Add Adhesive GH Export Adhesive X Delete Adhesive B3 Rename Adhesive 2 Save Adhesives rint Esc Return to Menu Connected Disconnected 03 Feb 2006 11 02 37 4 Fig 21 Entry of Adhesive Data Etech Page 55 CONTROLS en iro The adhesive screen cannot be accessed while a temperature cycle is running Adhesive characteristics are added to the program by entering the time temperature data points from the time temperature curing characteristics chart A minimum of 5 data points should be used The points should be spread evenly through the graph If the points are not correctly entered an error message will appear at the bottom of the graph Please Check Graph for Potential Errors This message will appear if the program deems that there is an entry error although it will not prevent the profile from being used A graph of the data will automatically be drawn as the points are entered showing a line of best fit through the data points The data points can be entered in any order and additional points can be added to the end of the table The buttons at the bottom of the screen provide the following functions Add Adhesive Add another adhesive from e Data point entry e Imported from a file e Duplicated from an existing adhesive Export Export the adhesive in a form that can be saved or e mailed to another HBC 4301 user Delete Delete
3. Inches Hg Atmospheres or bars The pressure can be displayed in Kilopascals kPa PSI or bars The external inputs must be Enabled before the measurement will be displayed or graphed The vacuum or pressure tick box selection must match the selection in the HBC 4301 control case See chapter 9 4 Monitoring the vacuum pressure for more details Etech Page 25 CONTROLS en tr This page has been left blank intentionally NEW tech CONTROLS eo un 6 CREATING A TEMPERATURE CYCLE There are 100 heat cycles stored on the hard disk that can be edited and renamed before starting a cycle Select the Temperature Profiles from the Control Functions menu You will be prompted for a cycle number Page up page down and the cursor up and down can be used to view the list of cycle descriptions available A new cycle description can be entered by using the tab key to highlight the Edit Description line or press S Alt S or Enter to continue to the edit screen The Temperature Profiles screen has a graph on the left and a table on the right The line of text above the graph is the description of the cycle 2 Novatech Controls Hot Bonding Controller HBC4301 ioj x Rear horizontal stabaliser 150 100 Soak Time Heat Rate Vacuum mins deg min Dev kPa 1 Ambient to Je I Skip 15 2 0 JJS 80 2 fom60to 120 I Skip 80 60 3 0 5 50 3 from 120 to 80 I Skip 5 2 5 5 50 4 fom80to 60 I Skp 30 2 0 00 5 60 5 bom en o
4. C Above Setpoint 43 5 6 Highest TC in Zome Acceptance TCs Table Legend 63 5 4 5 0 10 0 C Below Setpoint 10 0 C Below Setpoint Acceptance TC l Pr Process Log pt amp Esc Return to Menu Connected Disconnected 03 Febj2006 14 40 24 7 Fig 14 Status All thermocouple s screen It can be seen that the two tasks are clearly identifiable by the colour coding of the Zone number column Pressing A will toggle all the acceptance thermocouples on off The TC column identifies the thermocouple in each zone From the legend on this screen it can be seen that the hottest thermocouple number in each zone is shown in red The coldest acceptance thermocouple in each task is shown in blue If the Actual temperature is within half of the Temperature Alarm Threshold limits set in the Thermocouple and Zone Parameters screen of the set point temperature the tech CONTROLS en o Page 41 temperature will be shown in black Otherwise the temperature cell will be either light blue pink dark blue or red The two Stage columns show which part of the temperature cycle is being run for each zone The Cold Junction and the BU Cold Junction Back Up shown on the control case display with the TC TEMPS button temperatures are measured inside the control case on the thermocouple connector strips and are used for the thermocouple cold junction compensation The Case temperature is als
5. Control functions eee 19 Menu Mam etgdeeueteed tg 18 Page 104 24 INDEX O MSE E 101 P PASS WOT E 101 Periodic log Setup sicccsadeccicescecnsnaaccivede 52 PID Control oeisio iieis iriste 79 Please Check Graph for Potential Errors 56 Primary Not Connected 0 0 0 eeeeeee 35 Process E 49 50 Progression Control 24 R Repair map Monitoring 45 46 Repair Map Set up 22 R n Mode e ebtieteentk eetztasgnresutegeakterg 57 Running from the control case 12 S Secondary control case 40 Set up IOC as racsacaatassdaenaceetaoeeseneteatens 57 Specifications Hardware 11 Specifications Software 12 Start Cycle Screen eec 34 Starting and Stopping eee 33 Status all Thermocouples 41 T Temperature cycle Creating 00 27 Thermocouple Configuration e0 23 Thermocouple Table 23 Two control cases s es 39 U USB connection 86 USB stops communicating 0 0 0 84 V VACUUM E 25 Vacuum Alarms 31 Vacuum Pump Control 30 Vacuum Pump 1 ecese 29 Vacuum Pump 2 eese 29 Vacuum Pumps 29 Z Zone not ready eegen 35 Atech CONTROLS ev o Declaration of Conformity Application of Council Directive Standards to which conformity is declared Manufacturer s name Manufacturer s address Importer s Name Importer s address Type of equipment Equipment Class Model Number Serial Number 1012 89 336 E
6. Install USB R5485 Drivers D Change a setting Search amp Eject this disk Open Explore 5 Follow the prompts You may be asked to restart the computer 6 Reconnect the USB adapter Windows will now automatically detect the adapter and install the driver 7 From the Start menu Click on Control Panel Open the System control panel Select the Hardware tab along the top of the window Click the button labelled Device Manager 8 Locate and click to expand the item in the list named Ports COM amp LPT H Floppy disk drives a Human Interface Devices E IDE ATAJATAPI controllers gt Keyboards Mice and other pointing devices 7 Monitors B Network adapters Ports COM amp LPT EI Communications Port COM1 EI Communications Port COM2 ECP Printer Port LPT1 IO USB 485 1 SN D23741 Communications Port COMS EI Processors d SCSI and RAID controllers E Sound video and game controllers fF d System devices Dm mmm mm D 9 Make a note of the COM port number at the end of the line COM3 in this example Page 90 Etech CONTROLS rv un 10 Double click the entry in the list labelled NI USB 485 to bring up the properties screen Select the Port Settings tab along the top of the window Click the button labelled Advanced Set the transceiver mode to 2 wire auto Close all the windows clicking the OK buttons to save changes COM Port Number T
7. Soaking 4 A soak progress bar when soaking is in progress 5 The actual temperature being used for the control of this zone highest or average 6 The current set point temperature for this zone 7 The acceptance thermocouple the coldest thermocouple enabled as an acceptance thermocouple 8 The time that the task was started 9 The estimated finish time of the task This time will reflect the changes produced by the Automatic Adhesive Soak Extension and the Guaranteed Soak functions 10 The elapsed time The length of time for which the task has been running 11 The stage number of the temperature cycle that is currently running 12 The time that the current ramp or soak has been running The soak time will not commence until the actual temperature is within 5 C default limit of the soak temperature For further explanation of Guaranteed Soak see chapter 23 Glossary of Terms 13 The internal pressure is measured in the control case at the air inlet connection 14 The internal vacuum is measured at the vacuum pump 2 connection 15 The vacuum 1 and vacuum 2 pressures are measured in the repair by external sensors plugged into the sensor inputs 16 The vacuum pump set point shows either the vacuum pump drive level in percent when in Manual mode or vacuum set point in either kPa or inches Hg 17 The percentage of full power being sent to the heater for this zone The RED profile shows the set point temperatures that have been
8. 1 2 3 4 5 6 Accept Vacuum SL Zoor ou gt Process Log Print Esc Retum to Meru Connected Disconnected 03 Feb 2006 14 40 31 7 Fig 15 Temperature Graph Screen with Vacuum scale 9 2 1 Navigating Around the Temperature Graph Details of any part of the graph can be examined by zooming up on the graph Hold the left mouse button down while pointing to the top left corner of the area you want zoom in on Drag the mouse to the bottom right corner of the area and release the mouse button The graph will be redrawn to fit the zoom area Pressing the Z key or clicking the Zoom Out button will return the graph to the full screen tech ONTROLS ory ur Page 42 The area being graphed can be moved by holding the right mouse button down while pointing in the mid area of the graph 9 2 2 Temperature Graph Details The screen shows a graphical profile of the temperature and vacuum if selected for the selected zone The top of the screen shows 1 The identification of the operator and the task The selected adhesive None FM73 etc Confirmation of the thermocouple type selected in the control case The status of the vacuum pumps These buttons can be used to switch the pumps on and off Piet In the left panel of the screen is 1 The selected task selected from the Main menu 2 The selected zone selected with the number keys 1 2 and 3 or up to 6 if enabled 3 The status of the zone Running Idle Ramping
9. Fig 4b Thermocouple Zone Configuration using the Thermocouple Table 5pacebar to Change Zone Arrows Tab to Navigate Fields Etech CONTROLS en io Page 21 5 1 1 Repair Map Main Menu Repair Map The repair map is the easiest way to assign the thermocouples to the zones Firstly a repair shape is drawn The zones and thermocouples are then placed on top of the repair in approximately the same position as they are on the actual repair Features of the repair map e A zone that has been placed on the repair map can be moved and reshaped any time until the task has been started e Azone or a thermocouple can be removed by right clicking on a zone or thermocouple to bring up an item specific menu e A thermocouple can be selected deselected as an acceptance thermocouple by right clicking on the thermocouple to bring up the menu e The last map layout will be restored when the computer is turned on the next time e Using the Update Configuration button will transfer the map into the zone thermocouple configuration table e After a map has been created the table can still be viewed and edited until a job is started However if after editing the map does not match the table a warning will be shown when starting a job or entering the map screen e The map will be saved when a repair is completed and can be recalled later It is important that e The thermocouples are placed within the area of the zone th
10. Make sure that it is connected to the correct zone 2 Consider providing a secondary heat source for the area 17 10 The vacuum fluctuates too much in automatic control mode The control case is set to control the vacuum but it moves above and below the set point Solutions 1 Reduce the air supply pressure if a low vacuum 40 to 60kPa is required 2 Consider using the vacuum pump in manual mode 17 11 There is a Thermocouple x Critically High alarm The temperature of a valid thermocouple is gt 20 C over the set point for set points up to 130 C or gt 10 C over the set point for set points over 130 C Solutions 1 Check the solutions suggested in section 17 8 above 2 A heater output control circuit has failed Use another output if possible and have the HBC 4301 serviced 17 12 The PC will not connect to the HBC 4301 when using a USB adapter The USB adapter may not have been plugged into the PC when the HBC 4301 software was started or the USB adapter may have been unplugged while the software was running Solution Close the HBC 4301 program turn off the PC and then turn it back on and restart the HBC 4301 software The PC will reinitialise the USB port See also chapter 18 3 Installation and Setup of the USB Software Page 84 d tech CONTROLS ory ur 18 MAINTENANCE The accuracy of the Hot Bonding Controller is dependent on the electronics built into the control case The electronics was desi
11. Pressing the P key will print the screen This will provide an immediate hard copy of the temperature vacuum profile and numerical data 3 Any of the other heater zones with this task can be displayed simultaneously from the main Temperature Graph screen by simply pressing the zone number 1 to 6 4 The Acceptance graph can be switched on or off with the A key 5 Pressing the V key will switch on and off a vertical scale and two traces for the vacuum transducers on the graph The scale is from zero to full scale of the vacuum transducer 6 The ESC key from any screen will return you to the Main Menu screen The status of the two vacuum pumps can also be seen from this screen Clicking on the buttons will turn the pumps on and off Page 44 tech CONTROLS ov ur 9 3 Repair map This is the most useful screen to monitor the performance of a heat cycle at a glance The temperature of all the thermocouples can be seen superimposed onto a map of the repair The heaters can be set to an approximate shape and thermocouples placed in position as selected by the operator Once the temperature profile has been started the temperature tags will be attached to each thermocouple If a thermocouple is not within the temperature alarm thresholds default settings are 2 5 C or 5 C set in the Thermocouple and Zone Parameters screen of the set point temperature the background of the temperature tag will be set to light blue pink o
12. The HBC 4301 is controlled by the notebook PC for multi tasks Some of the Setup functions will be read only Will not be able to be changed Some of the Setup functions will not be shown The temperature and vacuum data will be saved in the control case If Local is selected A single task temperature cycle will be able to be run from the control case The HBC 4301 is monitored by the notebook PC All zones must follow the same cycle 2 Thermocouple enabling Select the hermocouples that are to be used for control or acceptance Any thermocouple that is selec ed h re but not used will raise an Open circuit alarm when the temperature cycle is started An enabled hermocouple will have a displayed A space indicates that the thermocouple has not been selected 3 Zonel thermocouples Page 64 Etech CONTROLS en o 66299 An enabled thermocouple will have a displayed A space indicates that the thermocouple has not been selected for control in this zone A thermocouple that has not been enabled will have a displayed If a thermocouple is not enabled when the Enter key is pressed the 3 line will flash the following message If a thermocouple has already been selected for another zone the it will be removed from that zone and placed in the current zone 4 Zone 2 thermocouples Same as Setup 3 5 Zo e be mocouples Same as Setup 3 6 Ac _ptance thermocouples 6631099 An enable
13. The following screens are available in the Run Mode even when the HBC 4301 is operating in Primary or Secondary mode See Control Mode in section 14 4 Thermocouple temperatures The first press of the TC TEMPS button will select the temperature of thermocouples to 8 The second press will display thermocouples 9 to 16 An unconnected thermocouple or an open circuit thermocouple will be shown as O C A thermocouple that has been connected in reverse polarity will be shown as Rev A thermocouple that is not enabled will be shown as The cold junction temperature and the cold junction backup temperature sensors must be within 3 C or a Cold Junction alarm will occur The ambient temperature and the power being delivered to the heaters will increase the temperature of the heatsink The Heatsink should not be allowed to rise over 70 C Zone temperatures The ZONE TEMP button shows the Zone number zone set point temperature if a temp ra ure cycle is running the thermocouple with the hottest temperature and the hottest temp ra ure in each zone When no thermocouple zone association known Page 59 atech CONTROLS ev iro Zone power The ZONE PWR buttons shows the status of the heater outputs The current power level is displayed together with the Auto Manual status The selection of the mode and the manual power level can be selected in the setup mode Cycle Times The TIMES butto
14. Vacuum 65 K i Low Temperature Maximum Vacuum 45 KPa High Temperature Temperature Threshold 100 oe Vacuum Units KiloPascals S Pressure Units KiloPascals S Esc Return to Menu RH Save Configuration Connected Disconnected 03 Feb 2006 10 47 42 Fig 5 Vacuum Pressure Setup Screen 5 2 1 Vacuum Pump 1 This pump has the same pumping capacity as vacuum pump 2 It can be turned on and off from the PC or the control case The vacuum level can be monitored by using either of the external vacuum sensors For more details on the specifications of the vacuum pumps see chapter 7 Vacuum Pumps 5 2 2 Vacuum Pump 2 Control The pump can be controlled in three ways 1 Manual Control Set the pump drive level to a value between 0 and 100 2 Automatic Control Fixed Vacuum Set a vacuum pressure level The HBC 4301 will control the pump 2 drive to maintain the vacuum level using the Control Sensor 3 Automatic Control Zone Control The vacuum will follow the vacuum profile set in the Control Functions Menu Zone Temperature Profiles The operator can set the vacuum level for each stage of the temperature profile The pump can also simply be turned on and off When the screen is selected the space bar can be used to toggle the pump 1 on and off If the Tab key is pressed before the space bar the pump 2 will be toggled on and off The vacuum can be displayed in Kilopascals kPa
15. Yes is selected in Setup 24 26 Low vacuum alarm level Skipped unless Yes is selected in Setup 24 27 High vacuum alarm level Skipped unless Yes is selected in Setup 24 Zone Power Control 28 Zone power control mode 29 Set zone power levels 30 PID values Measurements units selection 31 External input range 32 Display Vacuum pressure temperature units 33 Start Stop temperature cycle NOTES These items will only be available to read but will not be able to be changed if Primary or Secondary is selected in Setup 1 Etech Page 63 CONTROLS en io 14 3 Keypad operation in the Setup mode The Function keys are used to change screens The screen number is shown in the top right of the screen The Cursor keys will move the gt up and down The Option keys will change the selected value or item The Enter key will move the to the line where the gt cursor is and lock the new selection into the battery backed memory 14 4 Setup Mode Details 1 Control mode The primary control of the HBC 4301 is set with this control function Local is used when the control case is to be used without the use of PC Primary should be selected on the control case that has zones 1 to 3 Secondary should be selected on the control case that has zones 4 to 6 If Primary or secondary is selected A temperature cycle will not be able to be started or stopped from the control case
16. ability to monitor the vacuum or the pressure being applied to a repair Two sockets on the control panel VACUUM 1 and VACUUM 2 are able to read a 4 20mA signal from external transducers The measurement of vacuum pressure is then displayed on the three monitoring screens Status All Thermocouples Temperature Graph and Repair Map It can also be graphed on the Temperature Graph screen The scaling of the transducers must be done from the HBC 4301 control case Use the SETUP function 31 Set the Vac Pres to Vacuum or Pressure as required Se the Min value to the vacuum end of the range of the transducer and set the Max value to highest pressure of the transducer Transducer range Set Min to Set Max to 1 to 0 bar 1 0 1 to 9 bar 1 9 0 to 6 bar 0 6 The above configuration will allow the vacuum or pressure to be read correctly on the HBC 4301 control case 9 4 2 On th_notebook PC To read the correct value on the PC the tick box for either pressure or vacuum must be selected the same as the HBC 4301 control case The tick boxes are found on the Vacuum Pressure Setup screen The external vacuum pressure inputs must also be Enabled on the Vacuum Pressure Setup screen before they will be displayed or graphed Page 46 Etech CONTROLS en o 10 CHANGING A RUNNING TEMPERATURE PROFILE The actual heat cycle currently being run may be altered while the run is still in progress without
17. button 2 Click the Import Single Record button on the dialog box that will appear after step 1 Leave the ticks in the first and the last tick boxes Prompt before Overwriting and Re index Database Automatically 3 Select the folder and the record that you wish to import 4 Click the Open button 5 Click Done when the Database Administrative Tasks dialog box reappears The file will be imported into the data base and can be viewed from the Previous Jobs Database menu NWA tech Page 77 CONTROLS en ur This page has been left blank intentionally Page 78 d tech CONTROLS eo un 16 TUNING THE CONTROLLER USING THE PID VALUES 16 1 Background There are 3 considerations when the controller calculates the P I and D values P is for PROPORTIONAL measured in C or F current display units Tis for INTEGRAL measured in seconds Dis for DERIVATIVE measured in seconds P The distance the repair temperature is from the set point temperature The time the repair has been away from the set point temperature D The rate at which the repair temperature is varying compared to the set point temperature p The term PID refers to the three values used to calculate The power required to get the actual temperature of the thermocouple equal to the set point temperature The power can be varied from zero volts to full mains voltage on the heater mat The amount of power required has to be continuously assessed to get the tempera
18. cable is available The two HBC 4301 control cases can be connected together using either of the connectors labelled NETWORK For details of the wiring connections see chapter 18 1 External wiring Etech Page 39 CONTROLS en io 8 4 2 Configuring the cases There is only one change to be made to the control case to change it from a primary to a secondary control case as long as the communications link is set to RS485 See chapter 8 4 1 above Use the menu function 1 in the control case keypad to set the case to the appropriate state primary or secondary 8 4 3 Configuring the software When the computer is connected to the first case and the cases are networked together the bottom right hand corner of the notebook PC screen will show Connected in both the primary LH box and the secondary RH box status boxes The secondary case will then provide the connections for zones 4 to 6 and the thermocouples 17 to 32 Page 40 d tesch CONTROLS ov ur 9 MONITORING THE OPERATION NOTE It is possible to configure two tasks in the HBC 4301 software Use the 1 and 2 keys while in the Main Menu to swap between tasks After the temperature cycle has been started the temperature of the repair can be monitored from three screens Either the temperature of an individual zone can be shown as a graph or all the thermocouples can be shown grouped in numerical order and grouped in zones An additional feature of the
19. default program settings and the adhesive profiles unaltered 3 Custom Installation This allows the operator to select the components that will be installed The past jobs data base is never destroyed 1 Setup Novatech Controls HBC4301 loj xj Select Components N Which components should be installed Q Select the components you want to install clear the components you do not want to install Click Next when you are ready to continue HBC 4301 Application O Default Users Database 1KB O Default Cycle Parameters 26 KB O Default Program Settings 3KB O Sample Adhesive Profiles 1KB Current selection requires at least 1 4 MB of disk space lt Back Cancel Fig 1 Start of the Installation Screens Select Start Menu Folder Use Novatech Controls folder by clicking Next Select Additional Tasks The two options allow the operator to start the program from an icon on the desktop and or from an icon in the Quick Launch area of the Windows start bar Ready to Install Confirms the installation details Click Install to complete the installation A tick in the Launch Novatech Controls HBC4301 tick box will launch the HBC 4301 program on completion of the installation Etech Page 15 CONTROLS en io USB Adapter If a USB port is being used follow the instructions in chapter 18 3 Installation and Setup of the USB Software to install the driver for the USB adapter NOTE Make sure that the USB a
20. function 1 Set the option to Primary or Secondary Hot Bonding Start Task 1 Description Leading Edge of RH rear stabaliser delarnination Item No ws17634 RUT Adhesive FM 73 bi Esc Return to Setup Start Bonding Cycle Fig 10 Start cycle screen data entry After the above two fields have been entered an optional adhesive can be entered Etech Page 35 CONTROLS en io The adhesive entry facility allows the HBC 4301 to check the temperature cycle being started and warn the operator if the temperature is outside the recommended limit of the adhesive fAuto Modify Temperature Profle ES Warning Adjusting Heater Profile Zone 1 Stage 2 Adhesive FM 73 Current Soak Temperature 110 0 C Suggested Soak Temperature 120 09 C Current Soak Time 60 minutes Adjusted Soak Time 60 minutes The Selected Adhesive has a Cure Profile that allows higher temperatures than specified in the zone temperature profile Increasing the cure temperature may significantly reduce the cure time for the adhesive Do you wish to change the temperature Fig 11 Start cycle screen Automatic Adhesive Selection Parameters The adhesive monitoring feature also allows the HBC 4301 to automatically adjust the soak time during the soak stage if any part of the repair does not reach the cure temperature After the Start Bonding Cycle button has been clicked the bonding cycle will be started To monitor the progress o
21. has been selected Triggered after 5 minutes if the acceptance temperature is below the minimum adhesive cure temperature during soak Will only trigger once the zone control temperature comes within the deviation range of the zone set point Will re alarm automatically after 5 minutes of being accepted if the conditions are not cleared 11 2 4 No Acceptance Thermocouple only used when an adhesive has been selected Triggered if no acceptance thermocouple is found in a soak stage while attempting to automatically extend the soak time based on an adhesive profile Page 50 CONTROLS ev ur Will only trigger once the zone control temperature comes within the deviation range of the zone set point If the cause is unaddressed it will cause the soak time to fail automatic soak extension based on the acceptance temperature No soak extension will occur 11 2 5 Critical Temperature Error Triggered if any control thermocouple reads significantly above the zone set point Significant temperature error is deemed to be 20C for a set point temperature lt 130 C or 10 C for a set point temperature gt 130 C Instantly disables ALL heater outputs All heaters will be turned off and will only be re started if a Supervisor or a Manager presses the CANCEL Critical Alarm button on the Process Log screen See Chapter 22 Operators and Passwords for how to log on and off 11 2 6 Heater Fail Alarm Triggered by a heater
22. in the bonding process is the thermocouple If the two wires that make the thermocouple joint are not joined precisely significant errors in the measurement of the temperature can occur The best way to create a thermocouple junction is to weld the two wires This is best done using a TIG welder do not use oxy acetylene as the acetylene will pollute the thermocouple junction If a TIG welder is unavailable then an oxy propane mixture can be used but the junction will be inferior to a TIG welded junction The picture below shows how the two wires are positioned so that the conductors are pushing against each other and how the junction should look after the weld The wires should not be twisted together nor should the junction look like a blob of metal Fig 25 The lead on the right shows how the wires should be positioned prior to the welding process The lead on the left shows a correctly welded junction dd Ove tech Page 97 CONTROLS ev un This page has been left blank intentionally Page 98 NEW tech CONTROLS eo un 21 ACCESSORIES 21 1 Hardware expansion Connecting an additional HBC 4301 as a slave unit will expand the inputs and outputs of the Hot Bonder The program on the PC will recognise the presence of the additional HBC 4301 and enable the additional 3 zones and 16 thermocouple inputs The computer communications lead must still be connected to the HBC 4301 master case using the Computer connector There
23. level or lower the alarm level in setup 27 5 TC Calibration Fail An error has occurred during the manual thermocouple calibration trimming process Check that the correct temperatures are being fed into thermocouple 1 Check for obvious signs of physical damage on the inside of the control case on the HBC4300 3 circuit board If no obvious cause can be located send the control case for service 6 TC ADC Failure An error has occurred during the automatic thermocouple calibration process A zone that has been selected as Auto power in setup 28 will be turned off Check for obvious signs of physical damage on the inside of the control case on the HBC4300 3 circuit board If no obvious cause can be located send the control case for service 7 Internal ADC Failure An error has occurred during the automatic analog to digital converter calibration process Check for obvious signs of physical damage on the inside of the control case on the HBC4300 1 circuit board If no obvious cause can be located send the control case for service 8 Cold Junction Temperature Error The temperature difference between the two ambient temperature sensors used for measuring the cold junction temperature is greater than 3 0 C NOTE This may indicate that there are thermocouple temperature errors caused by the fault causing this alarm Check the temperature of the two sensors on the control case by pressing the TC Temps button three times Check the calibratio
24. must also be an additional network lead from either of the Network connector on the master HBC 4301 to a Network connector on the slave HBC 4301 When the additional HBC 4301 slave unit has been detected it will be possible to use the Thermocouple and Zone Parameters screen to configure the zones 4 to 6 and the thermocouples 17 to 32 Other hardware expansion cases such as a 16 thermocouple only expansion case will become available in the future 21 2 Bonding accessories Accessories case The accessory case has been designed to carry all the items required with the HBC 4301 control case The case is 710 x 455 x 250mm and has wheels and a fold away handle for easy handling by one person The standard configuration of the control case includes e 20 high quality silicon heater blankets of 10 different sizes a 1m lead and connector 75x150 mm 50x300 mm 150x150 mm 50x450 mm 200x 200 mm 150x300 mm 200x300 mm 300x300 mm 300x450 mm 450x450 mm e 2 vacuum hoses 5m long fitted with a quick connect coupling vacuum transducer bag entry port and a bleed tap Hand held thermocouple thermometer 2 External vacuum sniffer type 30 gauge with a bag entry port 15m 3 phase power lead 16 type K thermocouples 24 gauge 5m long with mini thermocouple plugs 3 heater extension cables 3m long Other configurations are also available and the blanket quantity and sizes can be tailored to meet in
25. output running at 100 power for 60 seconds 11 2 7 Heatsink Temperature Error Triggered by the heatsink temperature reading over 70 C Does not stop the heater operation 11 2 8 Cold Junction Temperature Triggered if the cold junction sensor and backup cold junction sensor readings are more than 3 C apart 11 2 9 Case Temperature Alarm Triggered if there is a difference of more than 6 C between the case temperature sensor reading and the average of the cold junction backup cold junction temperature sensors reading 11 2 10 High Low Vacuum Alarms Manual Mode Triggered as soon as the external vacuum readings are outside the vacuum alarm parameters Auto Mode Triggered as soon as the external vacuum readings are away from the vacuum set point by more than the specified level Alarm conditions for each of the three vacuum sensors act independently for each of the two tasks Will re alarm automatically after 60 seconds of being accepted if the conditions are not cleared For further details on the cause of alarm messages see chapter 14 1 Run Mode Alarms and chapter 17 Troubleshooting Guide In addition to the actual alarm message the date and time of the message is also recorded dd Wetech Page 51 ee CONTROLS 11 3 Periodic Data Logging The periodic data log keeps a record of the repair at predetermined intervals A variety of process parameters can be included in the periodic log that can be c
26. ov tr 5 1 4 Task Progression Control The control of a zone during a cycle run can be selected to be from the hottest thermocouple that is enabled for the zone or from the average of all thermocouples enabled for the zone if this option is available from the Thermocouple and Zone Parameters screen If a thermocouple goes open circuit during a run cycle the program will automatically display it as o c open circuit in the Status All Thermocouples screen and will disable it from zone control If an individual thermocouple appears faulty or you want to remove it from control of that zone it can be disabled during a run by unplugging it Within 2 seconds it will be recognised as open circuit and removed from control of the zone The HBC 4301 incorporates a Guaranteed Soak function This means that the soak times will automatically extend to make sure that the heater is within the Dev level set in the Zone Temperature Profiles screen default is 5 C 0 C will disable the automatic soak extension for the required time for each soak period The Progression Control sets the way the set point temperature is generated If None is selected the set point for each zone within a task will progress to the next stage in a temperature cycle independently of all other zones in the task If Tied Zones is selected the program will synchronise the start time of each of the ramp stages of the temperature cycle The soak time of a zone that h
27. stopping the cycle Select Change Zone in Progress F4 from the main menu An edit box will appear for selection of heater zone of control Select the zone number between 1 amp 3 or optionally up to 6 that you wish to modify and press Jor click on OK 2 Novatech Controls Hot Bonding Controller HBC4301 Soak Time Heat Rate Vacuum degjmin Dev A 1 Ambient to I Skp 15 2 0 Ifs 20 Zone 1 Temperature Cycle 2 from ep por 120 60 2 0 s 50 110 3 from 120 to 80 I Skp 100 5 ER 5 50 4 fom80to 60 T Skp 30 2 0 5 60 5 fom60to 0 I Skp o 2 0 s 60 50 6 from Amb to 0 VV Skip o 2 0 5 80 0 for Ambient 120 80 2 5 E S Temperature C ed WNA 2 S D E is Time Hours d H 05 1 25 3 35 GH Export Profile 3 Import Profile Connected Esc Return to Menu 03 Feb 2006 10 48 30 7 mn Disconnected Fig 17 Change zone in progress screen 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 Logically only the part of the profile that has not yet been reached can be changed The following table shows what can be changed after a job has been started Ramp rate Soak temperature Soak time When ramping Not changeable C
28. the control case 14 5 1 Introduction The HBC 4301 was designed to be used with a notebook PC However the control case can be used to run a temperature profile without the PC with some limitations They are Function Running from the control case Running from the PC Zone control All zones running the same temperature profile Zones can be set to independent temperature profiles Zones control can be made to wait for slow zones Number of running tasks 1 2 Adhesive temperature control Not available Cure time based on the adhesive characteristics Identification of the job Date time only Alpha numeric entry of Item description Item number Operator name Date time Monitoring the progress of the job Individual thermocouple Graph showing temperature and vacuum trends Map of the repair with colored temperature flags Table of individual thermocouples Recall of past jobs No recall available The data must be sent to the PC for storage and recall Trend graphs of temperature and vacuum Map of the repair Alarm and operator intervention log file Linked pictures and document files Page 72 tech CONTROLS ov ur 14 5 2 Configuring the temperature profile Before a temperature cycle can be run the shape of the temperature and vacuum cycle must be defined This is done by entering the Temperature ramp rate T
29. 8kg 3 2 Operational Specifications Number of simultaneous tasks Temperature control Display of temperatures Mapping Graph Table Selection of control T C Selection of acceptance T C Zone control Display modes 2 Repairs independently started and monitored 0 to 300 C PID Custom drawn map of the repair showing the Zone Thermocouple positions amp temperatures Colour coded tags show the hottest coldest temperatures A graph shows the control temperature for each zone The operator can select on one graph Control temperature for each zone coldest thermocouple for the repair set point temperatures and the vacuum Data is included for stage elapsed time and estimated finish time and zone power level Graph includes a zoom and pan feature A colour coded table shows the temperature of all thermocouples with colour coding of the hottest coldest control low and high thermocouples Control will be from the highest or average temperature of the thermocouples in each zone Any thermocouples can be nominated as acceptance thermocouples The acceptance thermocouple will be plotted on the graph The soak time can be automatically adjusted based on the temperature of the acceptance thermocouple Multiple zones within a job can be tied at the beginning of each stage or one zone can be nominated as the master with the other zones set to follow the master Imperial or metric No of ramp so
30. 9 3 Intvac 14 IntPres 260 03 02 06 14 21 13 Information Report Temperature C Vacuum kPa Pressure kPa TC L DCH TC 3 TC 4 TCHS 60 2 57 6 58 5 54 8 TC 11 TC 12 TC 14 TC 15 WAL 5___5 A 5 571 an n Cancel CRITICAL Temperature Alarm TC 6 60 3 TC 7 56 8 TC S 59 1 TC 9 56 8 TC 10 59 8 58 5 EECH 58 5 RN d nn process tog d r Alarm Report 4 Esc Return to Prev Connected Disconnected 03 Feb 2006 14 40 44 7 Accept Active Alarms Fig 18 Alarm and process reports screen The Cancel CRITICAL Temperature Alarm button will allow the job to be restarted after the heaters have been turned off as a result of an extreme over temperature in any zone This may have occurred because the thermocouples are not listed in the correct zone or because of a component failure in the HBC 4301 See chapter 11 2 5 for more details The P key can be used to print an alarm report of all the alarms process messages and status reports for the current job or it can be viewed printed later from the Previous Jobs Database screen using the View Log button Page 49 d tech CONTROLS ev io 11 1 Process Log An alarm is silenced by entering the Process Log screen This screen is accessed from the Main Menu by pressing the F7 key or using the mouse It can also be accessed from any of the three monitoring screens Status all Thermocouples Temperature Graph Repair Map by clickin
31. All Thermocouples screen will change to dark blue and red at these trigger points The temperature boxes in these screens will also change to light blue and when the temperature exceeds half of the trigger values The temperatures can be displayed in either Centigrade or Fahrenheit The serial Com Port of the computer used to communicate with the HBC 4301 control box can be set as either COM1 COM2 or COM3 or whichever serial ports are available Page 24 NET tech CONTROLS ov ur 5 2 Vacuum Pressure setup E Novatech Controls Hot Bonding Controller HBC4301 ioj x File Edit Help Primary Controller Secondary Controller au l l Primary Controller Vacuum Pump 2 Control Vacuum Input 1 Logging amp Alarms e Heng rop 50 E Enabled Taki C Task2 Both Vacuum Pump 1 Automatic Control Minimum Vacuum 25 KPa Fixed Van 30 KPa Maximum Vacuum 65 Pa CIS Zone 4 Low Temperature Maximum Wacuum 45 KPa Zone 2 Zones High Temperature KEE Vacuum Pump 2 Aw e Temperature Threshold bon ES Cont d Vacuum Input 2 Logging amp Alarms e IT Enabled Taki Task2 Both By A Minimum Vacuurr kp secondary Controller Oi Ma UHT Im T Programmed Vacuum Input Alarm Conditions acuum Above Set Pt 1c kPa acuum Below Set Pt 10 kPa Internal Vacuum Logging amp Alarms External Inputs Vacuum C Pressure W Enabled C Task1 Task2 Both Minimum Vacuum 25 Pa Maximum
32. Atech CONTROLS rn un HBC 4301 Hot Bonding Controller Operators Manual Januar y 2006 TABLE OF CONTENTS TABLE OF CONTENTS E 1 1 GETTING GOING FAST vccccscsccsscccccceccssseccssccsectscsssssosscsccsessssestessctecscscssssccescssotesdssetessccsese 7 ZAIN TRODU ER L EE 9 Si SPE CIBICA MN LA IEN 11 3 1 HARDWARE SPECIFICATIONS s s sssssssessessssessseerersesessseeterenessssesterreessssesterresssscsterrerssssese 11 3 2 OPERATIONAL SPECIFICATIONS cccccccccccccssessececccccccsssscssesccecccesssessscsccsccsesusunssesceecesseuuenens 12 WH ER TA EE 15 4 1 INSTALLING THE SOFTWARE cccccccccccssesessecccccccesesssscscccccssssueuscscescssssausueusecesceseseseneusessses 15 4 2 TURN THE COMPUTER ON 16 4 3 USING THE MENUS ON THE COMPUTER s snsssessssseesesssssssseererrsssssesterrssssesesrereeesssseseeree 17 ALAMAN MENU O an EE EE 18 5 CONFIGURING THE THERMOCOUPLES AND ZONES ccccccscscscssssssscsssssccceees 21 5 1 THERMOCOUPLES AND ZONES ccccccccccccccsssssececcccccesssscesesccsccsssussescsceccssesuuuusseececcesseuuenens 21 EE ee 22 5 42 Ihermoco ple Eege 23 D313 Zone ET 23 eli Task Pr gression EE 24 5 1 5 Temperature Alarm Threshold EE 24 5 2 VACUUM PRESSURE epp 25 5 2 1 EE 25 3 2 2 Vacnum Pump 2 Controls Son casein ae oka oa ead a as A 25 6 CREATING A TEMPERATURE CYCLE cccccscscscssscscssssscssscscscscssscccccccccscscscsesesees 27 Te VACUUM PUMPS wees sescecitistcccteiccects g nge Se
33. EC 92 31 EEC EN61000 6 1 2001 IEC61000 4 2 2001 IEC61000 4 3 2002 IEC61000 4 4 1995 IEC61000 4 5 1995 IEC61000 4 6 1996 IEC61000 4 8 1993 IEC61000 4 11 1994 EN61000 6 3 2001 CISPR 22 2002 IEC61000 3 2 2001 IEC61000 3 3 2002 IEC 68 2 2 IEC 68 2 3 AS1099 2 6 Novatech Controls Pty Ltd 309 Reserve Road Cheltenham VIC 3192 AUSTRALIA Hot Bonding Controller ISM Group 1 Class B HBC 4301 Year of manufacture 2003 the undersigned hereby declare that the specified above conforms to the above directive s and standards s Place Melbourne Date December 9 2003 Tt te Signature Full Name Terry Brereton Position General Manager
34. HBC 4301 hot bonding controller is the ability to create a map of a repair The map can be used to recall the physical layout of a previous repair but can also be used to monitor the hot and cold areas of the repair For further details see chapter 9 3 Repair Map 9 1 Status all Thermocouples This screen displays The current operating status of all of the thermocouples and zones The start time and cycle run time The vacuum level of both remote transducers The ambient temperature The temperature of the power controller heat sink 2 Novatech Controls Hot Bonding Controller HBC4301 Ioj x File Edt Help Item Description Rear stab TtemNo 2344 rue Ge Operator Default Date amp Time 03 02 06 14 06 13 Adhesive None TC Type K Type Control Stage Progression Tied rumz Pump __ Temperature C Stage J cITemp sp Zone ITC Status Set Actual No Time CaseTemp 26 3 C J1 i Ramping 88 3 C 86 8 C 2 00 09 25 Heatsink Temp 36 1 C 2 82 0 C Int Pressure 260 kPa 3 86 6 C Int Vacuum 19 kPa 4 82 7 C Vacuum 1 IS 5 Ramping 88 3 C ZASE 2 00 09 25 Se 6 86 8 C Pump Set Pt 50 S 7 80 3 C Task 1 Running 8 84 5 C Starting Time 14 06 13 9 80 8 C Est Finish Time 16 57 13 10 83 8 C Elapsed Time 00 34 11 z 11 Ramping 88 3 C 87 0 C 2 00 09 25 Task 2 Idle 12 83 1 C Starting Time 13 82 1 C Est Finish Time 14 80 5 C Elapsed Time 15 tc o c 10 0 C Above Setpoint 5 0 10 0
35. O SMALL The actual temperature will oscillate above and below the set point slower than the proportional oscillation 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 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 Page 80 Atech CONTROLS en o 16 5 Derivative 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 i e When the set point gets to the top of a ramp but the power out is still set high expecting a continuing ramp up The D value will help stop over shooting of the soak temperature The larger the number the larger the derivative effect A 0 will turn all derivative 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 a big enough blanket to heat the patch at the required rate Increase the D value by 20 of the current value D VALUE TOO LARGE The temperature will be too slow to reach set point Reduce the D value by 20 of the current value If this does not produce smooth temperature control then set the PID values to the default values 16 6 Tuning the PID
36. RMS eerste ONSE eege EENEG ale eg 103 EE 103 Guran Ced SOON a ss avccdeecsiuwns E E E a 103 Map Repair E 103 POSO EE 103 El EE 103 KOIDE eege Eeer 103 EE EE EE 103 EE 103 ZONE eases Erg Ebbe Ebbe 103 DAs INDEX E EEE EE EEE 104 Page 4 Atech CONTROLS en o Note Throughout this manual several important keys have been referred to by an abbreviation Le A Refers to the Enter key ESC Refers to the Escape key 4 T e amp gt Refers to the Cursor keys Copyright NOVATECH CONTROLS PTY LTD 2006 Edition February 2006 This manual describes the notebook PC software version 1 6 0 and the control case software version 1 53 2 August 2005 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 Controls Pty Ltd Novatech Controls The 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 Controls 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 Controls Technical Enquiries Novatech Controls welcome comments
37. THE PID VALUES E 79 16 3 PROPORTIONAL E AE 80 16 A INTEGRAL VALUE ceia r R R 80 16 5 DERIVATIVE VALUR ssiri ninss a A EE EEES AEE EEEa 81 16 6 TUNING THE PID VALUES ccsccccccccceceesessnsececesececsenssnsaecesececsesensaaeseeeccesesesensaaeeeceeeens 81 17 TROUBLESHOOTING GUIDE eseesscsccessseccesscccessccecssscecessocceessccecsseceesecsecessseoeesseceese 83 17 1 A ZONE DOESNOT HEAT CN 83 17 2 A ZONE HEATS ABOVE THE SET POINT TEMPERATURE c cccccececessesssseceeeccesesessssaeeececeens 83 17 3 THE COMPUTER KEEPS BEEPING ccccesesssssececeseceesesscaeceseccesesensaeceeeccesesesensaaeeeceeeens 83 17 4 THERE ARE TOO MANY TEMPERATURE TOO HIGH LOW ALARMSl 83 17 5 THE SCREEN OF THE E 83 17 6 THE TEMPERATURE DOES NOT CONTROL TO THE SET POINT 83 17 7 A TEMPERATURE IS READING OCT 84 17 8 THE TEMPERATURE IN ONE ZONE GOES HIGH WHILE THE OTHER ZONE GOES LOW 84 17 9 THERE IS A HEATER FAIL ALARM scscicsascsdcssilacedsaceasectarcaccesessaca saline teiQiaulinoeaatiadens 84 17 10 THE VACUUM FLUCTUATES TOO MUCH IN AUTOMATIC CONTROL MODE ccceseeeees 84 Etech Page 3 CONTROLS en iro 17 11 THERE IS A THERMOCOUPLE X CRITICALLY HIGH ALARM ssssossssessssresssseessesresessee 84 17 12 THE PC WILL NOT CONNECT TO THE HBC 4301 WHEN USING A USB ADAPTER 84 TS MAINTENANCE IEN 85 18 1 EXTERNAL WIRING irori nena buseddesesspconubaseescesdsaceuadasexecesesnecwebeutes 85 EE teen 85 Serial comnm
38. Turn the vacuum off Connect one of the vacuum inlets onto one of the vacuum ports on the vacuum bag Connect the vacuum gauge to the other vacuum port Turn on the vacuum with the VAC ON button on the HBC 4301 control case or from the PC 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 Hold the vacuum for several minutes Disconnect the vacuum pipe from the control panel Watch the vacuum reading for the External Sensor on the computer and monitor the leak rate If the vacuum falls by more than 7kPa per minute it is not acceptable Re work the vacuum bag sealant and the vacuum ports until the vacuum falls by less than 7kPa per minute There are two major functions that contribute to the successful repair of a bonded panel 1 2 The vacuum allows the atmosphere to exert pressure to keep all the components of the patch evenly pressed together until the adhesive has cured 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 AER tech Page 98 CONTROLS en ur This page has been left blank intentionally Page 96 d tech CONTROLS eo un 20 MANUFACTURE OF THE THERMOCOUPLE One of the most critical components
39. UMPS 7 1 Introduction The HBC 4301 control case is supplied with two vacuum pumps Both pumps are turned on and off electronically from either the control case or from the PC In addition the vacuum pump 2 can be controlled to adjust the vacuum pumping rate The air supply pressure can be monitored at the PC or at the control case The air supply pressure should be between 400 and 600kPa Provision has been made for two external vacuum or pressure sensors that can be connected directly to the repair vacuum bag These sensors can be logged and graphed with the temperature profile See Main Menu Temperature Graph The range of the external transducers must be set in the control case setup function 31 7 2 Vacuum Pump 1 The vacuum pump 1 can be switched on and off from either the PC or the control case The pump cannot have the vacuum level set It is intended that it be used as a backup pump or for providing a separate vacuum source when two tasks are being run See the next two subsections for the details of controlling the pump from the PC and the control case 7 3 Vacuum Pump 2 The vacuum pump 2 in the HBC 4301 is electronically controlled The air supply is pulsed on and off rather than operating all the time This has the advantage that the noise and the volume of compressed air are reduced The pump will be switched off if the vacuum level is close to or above the required vacuum level The vacuum control in the HBC 4301 can b
40. ak control stages Six Temperature ramp rates Cycle profile Cycle duration Page 12 0 5 to 10 00 C per minute in 0 1 degree increments Up to six ramp soak stages each cycle 6 x 2000 minutes per stage in one minute increments Netech CONTROLS eo un Cycle memory Heater T C configuration Operator controls Hard copy of data Map Graph Other screens Storage of finished cycle Import and Export Retrieval of previous runs Manual power output over ride Alarm identification Alarm status aNeitech Up to 100 pre programmed cycles Selectable on the keyboard or automatically selected from the repair map Remote from control case using notebook PC Local keypad display for backup operation Available any time during or after the end of the cycle in colour or b amp w including Zone thermocouple positions amp temperatures and the hottest coldest temperatures process log Operator selected temperature vacuum graph including zoom views plus 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 data Other items can be printed during or after a run including Adhesive profiles Alarm report Process log and Temperature profile Completed run is saved on the hard disk or direct to a network drive floppy disk if available Other related files can be linked to the saved job such as Pict
41. and 27 Set the vacuum level in kPa for the high vacuum and the low vacuum alarms Press the ENTER button The alarm will be active if the vacuum level is above or below the vacuum set level by the amount set in setup functions 22 or 26 and 27 5 Press the SETUP button to return to the RUN mode Etech Page 31 CONTROLS en iro This page has been left blank intentionally Page 32 WWE tech CONTROLS eo un 8 STARTING AND STOPPING A HEAT CYCLE 8 1 The easiest way to get a selected cycle running If the heater zones and thermocouples have already been configured in the Thermocouple and Zone Parameters screen the procedure is 1 a E eg Select the Task by pressing 1 or 2 from the main menu The selected task will be highlighted in green Select Start Heat Cycle F5 from the main menu From the table screen press the L key to select a pre recorded temperature cycle Press J to choose the default Enabled Zones or select the required zone number Scroll through the list of cycle recipes until you find the one you want to run or type the number in the Cycle No box followed by a J Change the Description if required or to continue The operator now has the option to edit the time temperatures vacuum of the selected cycle The changes entered this way will not be saved to disk for any future runs The changes to the temperature profile will only be used for the running of this cycle Press ESC to contin
42. and suggestions relating to the product and this manual All correspondence should be addressed to Technical Enquiries Novatech Controls Pty Ltd 309 Reserve Road Cheltenham Tel 61 3 9585 2833 Victoria 3192 Fax 61 3 9585 2844 Australia Web site www novatech com au Novatech Controls authorised dealers should carry out all maintenance and service on the product Novatech Controls 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 Controls 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 Etech Page 5 CONTROLS en io This page has been left blank intentionally G off rech CONTROLS eo un 1 GETTING GOING FAST Once you are familiar with the HBC 4301 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 each topic follow the chapter headings or references 1 Heaters and thermocouples Chapter 5 11 Place as many thermocouples and heaters on the patch area as required Note which heaters and thermocouples are associated 1 2 Connect all thermocouples to the input connectors 1 3 Connect the heater power leads to th
43. arget temperature Hold time Vacuum level This data can be entered for up to 6 stages of the temperature cycles The values are entered into setup functions 8 to 19 in the control case These functions are enabled in function 7 The rate x x will be ramped up and down by the option keys and set by the enter key The will be used to show the locked status Range 0 1 to 10 0 C min or 20 0 F min 0 to disable the stage and all following stages The temperature yyy will be ramped up and down by the option keys and set by the enter key The will be used to show the locked status Range 0 to 400 C or 800 F The rate zzz will be ramped up and down by the option keys and set by the enter key The will be used to show the locked status Range 1 to 360 minutes 14 5 3 Starting and stopping the temperature profile The cycle can be started once the temperature and the vacuum profile have been entered and the thermocouples and the heaters have been connected Use menu function 33 After selecting Yes the operator will be prompted to confirm the start A second selection of Yes will start the cycle Stopping the cycle is done by using the same function 33 Etech Page 73 CONTROLS en io 14 5 4 Data logging in the control case When a cycle is run from the control case in Local mode without a PC the temperature and vacuum profile is saved in battery backed memory The data will be retained
44. as completed the soak time before another zone will automatically extend to make sure that all zones start the next ramp at the same time If one zone is slower to respond than another they may get out of step Tying the stages will hold the faster zones in the soak stage until the slower zones catch up The Follow Zones mode can be used where one zone is slower than others and it is required that all zones are kept at the same temperature The temperature of the slow zone can be used as the set point temperature of the faster zones so that the temperature of all the zones will exactly follow the same temperature profile To use the Follow Zones mode select Follow Zones from the Zone Heater Profile Control section of the Thermocouple amp Zones Parameters screen and then start the temperature profile as described in chapter 8 If the temperature of one zone is unable to keep up with the set point temperature select the slow zone as the Master in the Zone Configuration section of the Thermocouple amp Zones Parameters screen The slow zone will still attempt to follow the original programmed set point but the other zones will follow the actual temperature of the slow zone 5 1 5 Temperature Alarm Threshold The values set in the Above Set Point and Below Set Point boxes determine the levels at which the Thermocouple High Temperature and Thermocouple Low Temperature alarms are triggered The temperature boxes in the Repair Map screen and the Status
45. at they are to be controlling e A thermocouple placed outside all zones will still be monitored and can be selected as an acceptance thermocouple but will not be used for the control of a zone NOTE When a repair cycle is running the map can be used to monitor the temperatures The temperature of each thermocouple is displayed attached to the thermocouple position If a thermocouple is above or below the set point the temperature flag will change colour It is necessary to use the pointing device to create the repair map To create a repair map 1 Select Repair Map from the Main Menu F3 2 Click the Design Repair Map tab 3 Select the shape of the repair either Ellipse or Round Rectangle 4 If Round Rectangle selected use the Horizontal and Vertical slide bars to shape the corners of the rectangle Use the Repair Angle to rotate the Ellipse or Rectangle Windows 2000 and later Click the Layout TC s amp Heaters tab 7 Place the heaters over the repair shape by clicking the Add Heater Zone button nm NOTE Place the cross where the top LH corner is required Press amp hold the LH mouse button and drag the bottom RH corner of the heater to the required position 8 Place a thermocouple by clicking the Add Thermocouple button NOTE Individual heaters and thermocouples can be deleted by right clicking the item Use the left button to drag and re shape the heaters and move thermocouples Pa
46. calculated and sent to the temperature controller The actual set points will vary from the selected cycle profile when the Guaranteed Soak control and the Automatic Adhesive Soak Extension operate Superimposed on this will be the actual temperature profile verses time for the current process as it has been running This is the hottest or average temperature as selected for this zone The blue trace records the acceptance thermocouple temperature Etech Page 43 CONTROLS en tr i e The lowest temperature of all the thermocouples nominated as acceptance thermocouples on the Thermocouple and Zone Parameter screen From the main Temperature Graph F2 screen you have several option keys NOTE The three buttons on the left of the control bar Table Graph and Map are common to the three monitoring screens Status all Thermocouples Temperature Graph and the Repair Map 1 Pressing T provides immediate access to the Status all Thermocouples screen without going through the Main Menu 2 Pressing G provides immediate access to the Temperature Graph screen without going through the Main Menu 3 Pressing M provides immediate access to the Repair Map screen without going through the Main Menu 4 Pressing the Z key will zoom back to the full screen view of the graph Zooming up to take a more detailed look at any area of the graph can be achieved by dragging the mouse over the desired area from top left to bottom right 2
47. case is set to Local mode Select Yes to enable the vacuum alarms and the display of the related menu items The cursor keys will move the gt The enter key will lock the position of the 25 Vacuum a arm sensor The cursor keys will move the gt The enter key will lock the position of the 26 Va uum low alarm level This functio is only ava lable if the control case is set to Local mode The level yy will be ramped up and down by the option keys and set by the enter key The w llb used to show the locked status Range 0 to 0 kPa 0 to 29 2 InHg 0 to 0 99 Atm 0 will turn off the vacuum alarm In vacuum control mode Auto and Programmable The ip level will be the set point minus this value In vacuum control mode Manual The ip level wil be this value Page 68 de tech CONTROLS ory ur 27 Vacuum high alarm level In vacuum control mode Auto and Programmable The trip level will be the set point plus this value In vacuum control mode Manual The trip level will be this value The level yy will be ramped up and down by the option keys and set by the enter key The will be used to show the locked status Range 0 to 00 kPa 0 to 29 2 InHg 0 to 0 99 Atm 0 will turn off the vacuum alarm 28 Set zone power mode The cursor keys will move the cursor between the three zones Theo ion keys will toggle between the Auto Manual Temp and the enter key will set the at t
48. cuum flow rate L min Fig 7 Pumping Rate of the Vacuum Pumps The graph shows the relationship of the maximum vacuum pressure to the volume of an air leak into the bonded repair bag Both pumps can be connected to one repair to increase the suction flow Press the Vacuum Display button to show the status of the vacuum pumps One press will show the status of pump 1 and the second press will show the status of pump 2 Either pump can be turned on or off by then pressing the Vacuum Pump button while displaying the required pump number status 7 5 1 Manual Control Mode 1 Press the SETUP button to enter the setup mode 2 Use the Function keys to find the setup function 20 Select Manual mode Press the ENTER button 3 Go to setup function 21 Set the vacuum drive percentage level A higher number will provide a higher vacuum pressure and flow rate Press the ENTER button 4 Press the SETUP button to return to the RUN mode The pump 2 will now cycle on and off at a fixed pumping speed Monitor the vacuum on either the internal vacuum sensor or with one of the external vacuum sensors Adjust the pump drive rate to adjust the vacuum level 7 5 2 Automatic Mode Fixed Vacuum Level NOTE If setup 1 is selected as Primary or Secondary mode the vacuum pump settings of the PC will overwrite the vacuum pump settings of the control case Page 30 Etech CONTROLS ev o Press the SETUP button to enter the setup
49. d and can be re examined as shown in figure 16 Digital photographs of the repair can also be recalled 15 4 Adding a Linked File to a previous job Digital photographs and other file types can be linked to a repair history For example a photograph of the finished repair or a description of the surface preparation written in Microsoft Word can be linked to the repair From the Review Previous Jobs menu select highlight the repair to which you want to link a file Click the Add Link button at the bottom of the screen When the Open dialog box opens up use the Files of Type window to select the type of file you want to include in the repair i e Picture document spreadsheet Use the Look In window to find the file that you want to link to the repair Click the file and then click Open Page 76 Etech CONTROLS en o When reviewing a previous repair select the repair you want to recall Any linked files will be listed in the lower panel of the screen Double click the link file to view them in an appropriate application program To view the temperature graph repair map and the alarm and process log files click the View Record button The temperature graph of the repair will appear From this screen gt The repair map can be viewed by clicking the View Setup button gt The process log can be viewed by clicking the View Log button The number buttons on the bottom of the screen can be used to show hide any of the zone
50. d thermocouple will have a displayed A space indicates that the thermocouple has not been selected A thermoc uple that has not been enabled will have a display d N NEA tech Page 65 TE TECH 7 Editing a temperature profile The cursor keys will move the gt The enter key will lock the position of the 8 Configure the temperature profile stage 1 Menu functions 8 to 20 will be hidden if No is selected in function 7 The stage number will increment from 1 6 in the next functions The cursor key will move between the 3 lines The ra e x x will be ramped up and down by the option keys and set by the enter key The will be used to show the locked status Range 0 1 to 10 0 C min or 20 0 F min 0 to disable the stage and all following stages The temperature yyy will be ramped up and down by the option keys and set by the enter key The will be used to show the locked status Range 0 to 400 C or 800 F The rate zzz will be ramped up and down by the option keys and set by the enter key The will be used to show the locked status Range 1 to 360 minutes 9 Configure the temperature profile Vacuum level stage 1 The st ge number will increment from 1 6 in the next functions The option keys will change the value The enter key will lock the value No set point is required if Manual mode is selected in function 20 Page 66 Etech CONTROLS en ur 10 Configure the temperature
51. d to be controlled by a notebook PC The PC could be supplied with different serial communications Traditionally a notebook PC was supplied with one RS232 serial port but more commonly they are now supplied with only USB ports To overcome the lack of serial ports often a USB to RS232 serial port adapter is supplied Unfortunately these adapters do not fully support the control lines in the serial port and therefore cannot be used to control the HBC 4301 The HBC 4301 has been designed to accommodate this situation by providing two communication standards RS232 and RS485 Set the HBC 4301 to RS232 mode if If the controlling computer has an RS232 serial port 9 pin D connector and the HBC 4301 is only to be used as a stand alone hot bonder not networked with another HBC 4301 to achieve 6 32 zones thermocouples Set the HBC 4301 to RS485 mode if The controlling computer does not have an RS232 port but has a USB port The HBC 4301 is to be used as one of a networked pair to achieve 6 zones and 32 thermocouples Changing the HBC 4301 RS232 RS485 mode The HBC 4301 has a link on the microcontroller PCB that is mounted under the shield in the base of the HBC 4301 To change the link position 1 Turn the HBC 4301 power off and remove the power plug from the Power socket 2 Remove the two securing in the front corners of the control panel and hinge up the control panel 3 Remove the three screws that s
52. dapter is NEVER unplugged from the PC while the HBC 4301 program is running If this happens the PC will close the USB port and it will not be available until the HBC 4301 program is closed and restarted Remove the HBC 4301 CD from the computer and store it in a safe place 4 2 Turn The Computer On Allow the computer to start running Windows The batteries will always start the computer if they are charged 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 4301 control box Computer Power to the computer power adaptor Plug the power adaptor into the computer If only one control case is being used either the serial port or a USB port can be used with the appropriate cable If two cases are to be used 6 zones and 32 thermocouples the USB port must be used Correctly matching cables must be used Use the RS232 communications lead to connect the computer s serial port on the rear of the computer 9 pin D connector to the HBC 4301 control box Computer connector Use the RS485 communications lead and the USB RS485 adapter to connect the USB port of the computer to the HBC 4301 control box Computer connector When the program is started for the first time the factory installed Operator Password to gain access to the program is Operator Default Password password Note The entry is case sensit
53. dividual needs Etech Page 99 CONTROLS en io This page has been left blank intentionally Page 100 WWE tech CONTROLS eo un 22 OPERATORS AND PASSWORDS Introduction When the program is first installed a default user and password can be used to gain access to all parts of the program with Manager authority If security is an issue the default user should be removed and a new user installed The initial default access is gained by using Operator Default Password password The HBC 4301 has a protection structure built into the program There are three levels of authority within the structure The level determines the parts of the program that will be available Password protection Operator Supervisor Manager Create users at all levels of authority S Delete or disable accounts i Create or modify the adhesive files 2 View and edit the adhesive characteristic screen i View the adhesive characteristic screen i S e Access to the Operators and Passwords screen ki ii Create users at the operator level of authority 2 Create or modify the temperature profiles ZS Change a zone temperature profile while a task is in S Progress Access to the data base of previous jobs E Access to the vacuum control setup screen Operational parts of the program Change tasks x E novatech Controls Hot Bonding Controller HBC4301 B x Fie Edt Help
54. e can be set to the correct time and temperature for the selected adhesive In addition the soak time can be automatically adjusted to the correct cure time for the coldest part of a repair the coldest acceptance thermocouple 13 2 Controlling a repair to match the Adhesive Characteristics During the running of the cycle the coldest of the acceptance thermocouples is plotted on the Temperature Graph screen The temperature of the acceptance thermocouples is analysed during the cure stage of the cycle The correct soak time required to cure the adhesive is calculated and automatically adjusted There will be a process log report made of the soak time entered into the process log screen at the end of the soak time The report is recorded on the Process Log screen in both cases The report will show gt zone number gt extended soak time calculated 13 3 Entering a New Adhesive If it is necessary to use an adhesive that is not already in the default list of adhesives in the HBC 4301 program another adhesive can be added The password requirements of the program will only allow modifications to the adhesives to be done by a Manager For further details see chapter 22 Operators and Passwords E Novatech Controls Hot Bonding Controller HBC4301 Oj x File Edit Help Adhesive List ki FM 300 2 FM 73 FMS 1026 CLVI Soak Time Hours IV Use Fixed Ramp Rate 160 170 Ramp Rate 3 0 Cimin
55. e power outlet sockets 2 Cable connections Chapter 4 2 1 Connect the 3 phase or single phase power lead to the power input socket 2 2 Turn on the circuit breakers for all the heater zones that are connected Always include 1 Master 2 3 Connect the power leads to the computer power pack 2 4 Plug the power pack into the computer JA Connect the Computer lead from the control case to the computer serial port or USB port It is very important to always connect the USB adapter before starting the HBC 4301 program 2 6 Connect the printer lead from the computer to the printer optional 3 Turn on the main supply power switch on the wall 4 Make sure that the control case is configured for Primary or Secondary control mode Setup function 1 Chapter 14 4 Control Mode 5 Turn on the computer and start the HBC 4301 program Enter your operator name and password lf starting the program for the first time the Operator name will be Default and the password will be password 6 Select a heat cycle Chapter 6 Edit a pre designed cycle if necessary from the Zone Temperature Profiles screen Control Functions Menu F3 or go straight to the next step by configuring the system using an existing cycle 7 Configure the thermocouple zone layout by drawing the Repair Map Main Menu F3 Current Thermocouple Configuration Chapter 5 7 1 Click the Add Heater button Etech Page 7 CONTROLS e
56. e set manually or controlled to a pre programmed level The pre programmed level can be a fixed vacuum or can be automatically changed for each stage of the temperature cycle 7 4 Controlling the Vacuum Pumps from the PC NOTE The control case must be set to Primary or Secondary before the pump can be controlled from the remote PC The HBC 4301 was designed to be operated from the PC with the HBC 4301 control case set to Primary or Secondary mode in the setup functions In this remote mode of operation the vacuum pumps can be turned on and off at the control case or from the PC and the vacuum level can be controlled to a pre set level at the control case or from the PC The pump can be made to operate e Ata fixed pumping rate e Toa fixed vacuum level that automatically compensates for leaks e At programmed vacuum levels For more details of the PC screen that controls the operation of the pump see chapter 5 2 Vacuum Pressure Setup in which there is a description of the screens that is available from the Control Function Menu NS futsch Page 29 CONTROLS en io 7 5 Controlling the Vacuum Pumps from the Control Case Either of the pumps can be turned on and off from the control case In addition the pumping rate of pump 2 can be controlled The pumps are the same size and therefore have the same pumping capacity 90 0 80 0 70 0 60 0 Vacuum kPa 50 0 40 0 Va
57. ecure the shield over the main PCB Carefully remove the shield 4 Locate the RS232 RS485 link see pictures below and set as required 5 Replace the shield hinge down the control panel and replace the two securing screws NOTE The Novatech Controls communications cable used for RS232 is different to the cable used for RS485 Page 88 tech CONTROLS ov ur RS232 RS485 link Networking 2 HBC 4301 hot bonders When networking two HBC 4301s together the link on both hot bonders must be set to the RS485 position Novatech Controls can supply the additional cable to connect between the two hot bonders The cable to the first hot bonder must be an RS485 cable and it will come from a USB adapter CN tesch Page 89 ee CONTROLS ri 18 3 Installation amp Setup of the USB Software If connected disconnect the USB adapter from your computer Locate the Novatech Controls HBC4301 Installer CD insert into CD drive Press Cancel and exit the HBC 4301 autorun installer Open My Computer by double clicking the icon Right click the CD Icon labelled HBC4301 and select Install USB RS485 Drivers ae al a F My Computer Fie Edit view Favorites Tools Help La Back E ke 52 Search E Folders E Address 2 My Computer 3 Floppy 4 System Tasks ZS amp Local Disk C View system information Shared __ Install HBC 4301 Software TS Add or remove programs E Dougla
58. el 61 3 9585 2833 Fax 61 3 9585 2844 www novatech com au 18 1 External Wiring Heater outputs HBC 4301 Control Case l l Heat blanket A Phase Burst O Blower or Power control O Lamp l l Etech Page 85 CONTROLS en io Serial communications Computer RS232 HBC 4301 Control Case HBC 4301 Primary Control Case Notebook Computer RS 232 transmit RS 232 receive Common DB 9 DB 9 female male National Instruments NI485 USB to Network Adapter Notebook Computer USB port DB See also Chapter 18 2 and 18 3 Get DBO Network primary case to secondary case HBC 4301 l HBC 4301 Primary Control Case Secondary Control 3 3 2 2 1 1 i Sec Be Shield TTT AAA Vacuum transducers Vacuum 1 Vacuum 2 HBC 43 om Vacuum pressure Control Case i Tanscucer 1 4 20mA 2 2 O 4 20mA o E oan Shield TIT l Page 86 l CONTROLS rv o Mains power HBC 4301 3 Phase Power Conin Case eg Active phase 1 White e Active phase 2 Orange NI D Active phase 3 Brown EES Neutral Blue eeng E Earth Green Yellow ZIT HBC 4301 i Single Phase Power Control Case l 1 SES Active Brown 3 o Se Neutral Blue ot Earth Green Yellow i Note The cable colours may not always be the same as shown here tech ee CONTROLS Page 87 18 2 Changing from RS232 serial port to RS485 USB port Introduction The HBC 4301 was designe
59. ene seas s e O s Te eror e Seene KSE 29 TA INTRODUCTION 63 25 E SA T E A adeadd Ubenetsteed 29 T VACUM PUMP a teak es cet Maat aa a E A sa OER 29 TEDA ACUUM AE 29 7 4 CONTROLLING THE VACUUM PUMPS EROMTHEBC 29 7 5 CONTROLLING THE VACUUM PUMPS FROM THE CONTROL CAS 30 7 5 1 Manual Control Mode 30 7 5 2 Automatic Mode Fixed Vacuum Lee 30 7 5 3 Automatic Mode Programmed Vacuum Levels csccccccssccsceesscsecessessececessuecssesssaaes 31 7 5 3 Vacuum Alarms LOCAL mode 31 8 STARTING AND STOPPING A HEAT CYCLE 2 cccccscscscscscscscscscscscscscscscscccccsesssees 33 8 1 THE EASIEST WAY TO GET A SELECTED CYCLE RUNNING 33 8 2 THE START CYCLE SCREEN DETAILS 34 8 3 HALT IER CYCER EE 37 8 4 OPERATING WITH TWO CONTROL CAS 39 8 4 1 EE 39 OC EE 40 8 4 3 EE 40 9 MONITORING THE OPERATION occcssecssscsaseossaesenssssessessesasorsasctscesseseserenscaseossssesnetstceve 41 9 1 STATUS ALL THERMOCOUPLES EE 41 9 2 TEMPERATURE GRAPE EE 42 9 2 1 Navigating Around the Temperature Grapn vicacccssitectacseduensanteniceassdeecasseteaasapsdeneaes 42 9 2 2 Temperature Graph LI CUAU Ss cinsiecosassadeaastandeatenandcaattunn pesesadentisaodimensaksnestaannsesaasenes 43 9 3 REPAIR MAP isicsazctacesucaueinnlanaanensceussesskienpesvdasaetuneaa e EER EEE EE Ea RE a EEEN E EEEE 45 9 4 MONITORING THE VACUUMIPRESSURE E 46 9 4 1 On the control COSC ceccccccccccccscssecsccccsccsssscsssssscsscsecssssscssessssecessesecsasessesscessesssssasess 46 9 4 2 O
60. escription of the item to be bonded e Item number Page 34 NEW tech CONTROLS ov ur Primary Not Connected Esc Return to Menu Connecting Disconnected 03 Feb 2006 10 50 13 7 Fig 9 Start Cycle Table Screen warning message If the button Start Bonding Cycle does not appear in the bottom right hand corner of the table screen the reason will be identified in the button position Messages include Message in the button Reason and the solution Primary Not Connected The PC is not communicating with the primary HBC 4301 control case Check that the HBC 4301 has been set to Primary in setup function 1 and the communications cable at both ends Secondary Not Connected The PC is not communicating with the secondary HBC 4301 control case Check that the HBC 4301 has been set to Secondary in setup function 1 and the communications cable at both ends Zone x not ready One of the nominated zones does not have any thermocouples associated with the zone Check the Repair Map layout and that the thermocouples are operating correctly not o c No enabled zones No zones have been associated with the task Check the Repair Map layout Task active The task is running already Use the Halt Heat Cycle function from the Main Menu to stop the heat cycle Local mode The control case is set to Local mode Use the Setup button and the Function buttons on the HBC 4301 control case to find setup
61. f a temperature profile is running To return to the original operator click the Logout button in the top left hand corner of the screen Page 102 tech CONTROLS ory ur 23 GLOSSARY OF TERMS Cycle The recipe for the temperature profile is called the cycle The cycle includes six stages Each stage has a ramp and a soak stage Guaranteed Soak If the actual temperature is not within the Dev temperature set in the Temperature Profiles screen default setting is 5 C of set point at any time during a soak stage the soak time will frozen This can cause the total cycle time to be extended beyond the calculated time by a few minutes but guarantees that the zone will have the required time at the curing temperature Map Repair Map The control program has the ability to draw save and recall a map of the repair layout See chapter 9 3 Monitoring the Operation Repair Map Passwords The passwords control access to some of the more sensitive parts of the program See chapter 22 Operators and Passwords PID The P I and D Proportional Integral and Derivative values are used to allow tuning of the HBC 4301 temperature controller See chapter 16 Tuning the Controller Using the PID values Ramp Rate A temperature cycle is made up of temperature ramps and temperature hold times The ramp rate is entered in degrees per minute See chapter 6 Creating a Temperature Profile Soak Time A temperature cycle is made
62. f the cycle see chapter 9 Monitoring the Operation Page 36 Etech CONTROLS en o 8 3 Halt Heat Cycle Selecting this screen will stop the temperature profile for the selected task Main Menu Fi Status All Thermocouples F2 Temperature Graph F3 Repair Map F8 Control Functions Menu F9 Exit Program Fig 12a Halt current task screen If the task is not running the following dialog box will be shown Status All Thermocouples Temperature Graph Control Functions Menu Exit Program Fig 12b The current task is not running Etech Page 37 CONTROLS en o If a task is stopped before the cycle has been completed or if the temperature cycle is left to complete the whole cycle the following dialog box will be shown Status All Thermocouples E 1 Taek 4 C lt Ke t Operator Default _ Item Description Main stay al Item Number 234523 w F8 Control Functions Menu F9 Exit Program Fig 13a The task has been stopped completed There is no choice the profile must be saved An unwanted task can be deleted by someone logged in as a manager from the Previous Jobs Database screen ao HP Color HP Ties PostScr Inkjet CP1700 LaserJet 4550 F9 Exit Program Fig 13b The task has been stopped completed If the printer is not connected when the task is finished the graphs map process log can be printed later by recalling the job from the Previous J
63. face Before starting the assembly stage the HBC 4301 controller and accessory equipment supplied with the controller should be checked to make sure it is complete and in operational condition 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 19 1 Thermocouples The thermocouple placement is extremely important to a successful bond The HBC 4301 has provision for 16 thermocouples which can be expanded to 32 if required The HBC 4301 also allows for up to 3 heaters again expandable to 6 for large repairs If the area to be bonded spans areas with different thermal loading more than one heater must be used i e The patch may go from honeycomb core to a structural member 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 se
64. g the Process Log button at the bottom of the screens The L key is a shortcut key to the Process Log screen from the monitoring screens The Esc key will take you back to the monitoring screen that you came from The Process Log button will flash when a new alarm occurs The HBC 4301 will record all events that occur during a repair The following is a list of some of the possible process messages that are saved to the log file Start task Stop task Resume task Finish task Finish adhesive soak stage Communications reset timeout Communications re established Periodic log Zone PID parameters changed Thermocouple control state changed TC acceptance stage changed TC Disabled Zone cycle changed Control case reset Supervisor login logout These log types also cause a periodic data log to be added to the process log file simultaneously 11 2 Alarm List In the same way as the process log records the messages during a repair the alarm messages are also recorded Some of the alarm messages are 11 2 1 Thermocouple Temperature High Low Triggered by any control thermocouple that drifts more than the Temperature Alarm Threshold degrees from it s zone set point 11 2 2 Thermocouple Open Circuit Reversed Triggered by any open circuit thermocouple Prevents the affected thermocouple from being used as a control or acceptance 11 2 3 Acceptance Temperature Low only used when an adhesive
65. ge 22 Etech CONTROLS ev o When the layout is complete click the Update Configuration button to transfer the layout to the Thermocouple amp Zones Parameters table If further changes are required simply use the F3 Repair Map key from the Main Menu 5 1 2 Thermocouple Table Control Functions Menu Thermocouple amp Zone Parameters This screen can be used to configure the program to match the repair configuration It can be created from the Repair Map See chapter 5 1 1 The table changes will be save when exiting the screen Selections are generally made by pressing the space bar Features of the Thermocouple Table e The screen uses colour coding to quickly identify the zones and the tasks Task 1 is coloured pink and task 2 is coloured blue Disabled thermocouples and zones are grey e To place a thermocouple in a zone toggle using the space bar the Zone cell in the appropriate thermocouple column and make sure that the zone selected for the thermocouple is in the correct task A zone can be disabled from the task row in the Zone Configuration table e In addition to the thermocouple zone configuration this screen allows the operator to select the highest average temperature control zones tied follow mode etc NOTE Although this screen allows the operator to change the configuration of zones and thermocouples a change in this screen will not update the Repair Map It is better to make any changes f
66. ght 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 19 5 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 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 the 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 19 6 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 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 number of thicknesses or plies of the bleeder cloth that are used regulates the amount of resin that is absorbed If there is too much absorption the repair will be resin dry and if not eno
67. gned to need very little maintenance or calibration This has been achieved by the use of extremely stable voltage references which are used in a continuous self calibrating process as well as built in self checking processes This is all scheduled and controlled by an internal microcomputer However for safety the control box should be thoroughly checked by trained and competent personnel every year The annual check and calibration should include Calibration of the thermocouple inputs Calibration of the vacuum and pressure measuring electronics Calibration of the external vacuum sensors Checking of the zone power outputs Operational check of the earth leakage detector Physical and electrical check of the sockets and cables The software in the HBC 4301 control case includes a restricted access calibration function The entire calibration procedure is carried out from the keypad of the HBC 4301 control case The calibration factors are stored in permanent memory in the control case There are no potentiometer adjustments Instructions for the calibration procedure are contained in a separate instruction manual This manual is supplied with the HBC 4301 control case but should be kept separate from the HCB 4301 to ensure unauthorised personnel do not change the calibration settings When the calibration check adjustment is required and a suitably trained organisation is not available contact Novatech Controls Pty Ltd T
68. graphs The Accept and the Vacuum buttons will show hide the acceptance thermocouple and vacuum graphs The Export button will allow the temperature graph to be saved as a text table so that it could be viewed in detail graphed in an application program such as Excel or e mailed At the bottom of these screens the Print button can be used to keep a hard copy of the temperature graph and the repair map The process and alarm log file will be opened in WordPad and can be printed from this program 15 5 Transferring a job file to another HBC 4301 computer Repairs done using another HBC 4301 computer can be exported to another computer Each repair record is a compressed file that contains three separate files These files are Config txt Graph of the temperature and vacuums Log txt All alarm messages warnings operator changes and data reports Repair map Repair map showing the physical layout of the repair When the compressed file is transferred the files are placed in date order in the list of previous jobs and can be viewed using the Previous Jobs Database menu The job can be exported by clicking the Export Record button on the bottom of the Previous Jobs Database screen or pressing the x key Select the folder that you want to save the job in The file name can be changed before saving The exported job can be imported into another computer from the Previous Jobs Database menu by 1 Clicking the Administrative Tasks
69. hangeable Changeable When soaking Not changeable Not changeable Not changeable A stage that has not yet Changeable Changeable Changeable started A stage that has been Not changeable Not changeable Not changeable completed For example the target temperature of a stage may be changed if the set point is still ramping up to the soak temperature The ramp rate target temperature and soak time can be changed of a stage that has not been started Etech CONTROLS en io Page 47 The prompt line at the bottom of the screen shows the options S Save profile Save the current profile changes X Export profile Export the current profile to the hard disk floppy disk or a network drive T Import profile Export the current profile to the hard disk floppy disk or a network drive P Print Prints the table and the graph ESC to accept exit the screen NOTE Changing the profile of one heater zone will not affect the other zones For more details on editing the shape of the graph see chapter 6 Creating a Temperature Cycle Page 48 OEA tech CONTROLS en o 11 PROCESS LOG ALARMS The Process Log screen is available from the Main Menu F7 The screen provides a periodic report of a repair with a record of all the process messages that have occurred during a task and all the alarm messages The process log file is one of the files that is saved with the repair and can be recalled and p
70. he HBC 4301 keypad display Run Mode This is the normal mode All the thermocouples can be monitored by their thermocouple number hottest coldest zone temperature identify thermocouple problems cycle times and monitor alarm conditions Setup Mode This mode is accessed by pressing the SETUP button It allows thermocouple zone association setting of alarm levels manual and automatic setting of the vacuum and heater outputs A task can be started and stopped Extended Setup Mode This is a restricted access mode The calibration of the cold junction temperature external vacuum sensors internal vacuum and the internal pressure sensors can be changed and the date time can be set In addition the calibration of the thermocouples can be trimmed A full description of the calibration is available in a separate Advanced Operators Manual Calibration Etech Page 57 CONTROLS en io HOT BONDING CONTROLLER HBC 4301 ege a SECH e 7ENs ot Tey sETUp prARay o gd tien enen Sun ONMES Po GH ON i Ee Py pre y LI A j au e Unono Drneg CURso Fig 22 HBC 4301 Control case keypad and display The SETUP LED shows the current mode If the LED is on the current mode is Setup Extended Setup mode If the LED is off the current mode is RUN mode The operation of the buttons is identified on the label surrounding the buttons by the colour of the text In the RUN
71. he Run mode after 30 seconds without any keys being pressed The following list is a summary of the accessible control functions 1 Control case mode Local Primary Secondary Thermocouples 2 Enabled thermocouples 3 Zone 1 thermocouples 4 Zone 2 thermocouples 5 Zone 3 thermocouples 6 Acceptance thermocouples Thermocouple temperature profile 7 Enable editing of the temperature cycle Yes No 8 Set the temperature rate hold temperature hold time Stage 1 9 Set the vacuum programmed level Stage 1 10 Set the temperature rate hold temperature hold time Stage 2 11 Set the vacuum programmed level Stage 2 12 Set the temperature rate hold temperature hold time Stage 3 13 Set the vacuum programmed level Stage 3 14 Set the temperature rate hold temperature hold time Stage 4 15 Set the vacuum programmed level Stage 4 16 Set the temperature rate hold temperature hold time Stage 5 17 Set the vacuum programmed level Stage 5 18 Set the temperature rate hold temperature hold time Stage 6 19 Set the vacuum programmed level Stage 6 Vacuum Pump Control 20 Vacuum control mode Manual Auto 21 Vacuum manual setting Skipped unless Manual selected in Setup 20 22 Vacuum control sensor Skipped unless Auto selected in Setup 20 23 Vacuum control level Skipped unless Auto selected in Setup 20 Vacuum Alarms 24 Enable vacuum alarms 25 Vacuum alarm sensor Skipped unless
72. he nd of the line 29 Manually set zone power temperature The c rsor keys will move the gt The option keys will adjust the power temperature The enter ey wil s t the at the end of the line and lock in the data 30 Se the PID alues The cursor keys will move the cursor between the three settings The op ion keys will ramp the value up and down and the enter key will set the at the end of the line P Range 00 degrees I Ra ge 1 100 seconds 0 wil d sable the integral action D Ran e 1 20 seconds Page 69 Etech pos CONTROLS en iro O will disable the derivative action 31 External inputs This function is only available if the control case is set to Local mode The cursor keys will move the cursor between the two measuring units The option keys will toggle between the Vacuum Pressure and the enter key will set the at the end of the line This will affect the way most run time displays and menu items display the vacuum and pressure The cursor keys will move the cursor between the external input options It is possible to use a transducer with an input range anywhere within 1 bar to 10 bar with a min mum of 1 bar A transducer that has a range that covers vacuum only pressure only or both vacuum and pressure can be used For example Transducer type Transducer Vac press Set minimum Set maximum range selection to range to range 1 Vacuum only 1 to 0 bar vacuu
73. infs 30 min s Heat Rate 2 0 C min 2 0 SC mm 2 0 C min Set Point Ambient Ambient Ambient Stage 5 Soak Time 0 min s D min s 0 min s Heat Rate 209 C min 209 C min 2 0 C min Set Point Stage 6 Soak Time Heat Rate EZ Edt Profile Select Profile Copy Profile Start Bonding Cycle Esc Return to Menu Connected Disconnected 03 Feb 2006 10 49 05 7 Fig 8 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 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 on the Start Heat Cycle screen are D Edit After the cycle has been selected fine tuning of the cycle for one or more of the zone profiles may need to be done Pressing the D 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 Zone In Progress F4 L Select Cycle Press the L key to select a different temperature profile to be run for any of the zones Oo Copy Press the C key to copy the temperature profile from one zone to another zone S Start Press the S key to continue the cycle start process You will be prompted with a window to enter the e D
74. ive The password must be between 6 and 32 characters This will log the user on with the authority of a Manager For further details of the password system see chapter 22 Operators and Passwords Authentication Required gp x Etech CONTROLS en un Please Enter a Valid Login to Continue Operator Password Cancel Device 1 Connected HBC v1 53 Fig 2 Start Screens After the operator has been authorised the program will continue on with the start up splash screen and to look for the HBC 4301 control case connected to the nominated serial port The d tech CONTROLS ev ur Page 16 Version at the top of the splash screen shows the version of the computer software The report at the bottom of the splash screen during the start up shows the version of the software running in the control case and which control cases have been found on the network A status box at the bottom of the Main Menu screen will report the status of the connection Dots will be seen following the word Connecting until communication is established If the HBC 4301 control case is not communicating with the PC the power output will be inhibited from the zone outputs unless the zones are set to Manual power control If communications between the PC and the control case are lost during a temperature cycle both the PC and the control case will sound an alarm 4 3 Using The Menus On The Computer The function keys or the cursor
75. keys can be used to select the menu functions The ESC key is always used to exit back to the previous menu The tab key or the enter key can be used to move between the fields within a menu function A prompt line has been provided at the bottom of the some screen showing the selection of keys available for the current cursor position A pointing device can also be used with the program however once an operator is familiar with the program it will be generally quicker to use the keys Etech Page 17 CONTROLS en iro 4 4 Main Menus Notes on Using the Menu screens The program functions accessible via the menu system have been split into two groups gt Main Menu gt Control Functions Menu When the program first starts the Main Menu is displayed and provides access to the most common of the functions that are required to run a repair cycle Main Menu Temperature Graph Repair Map Change Zone In Progress Start Heat Cycle Halt Heat Cycle Process Log Control Functions Menu Exit Program Fig 3a Main menu screen Controls Hot Bonding Controller HBC4301 F2 Vacuum Pressure Setup F3 Temperature Profiles F4 PID Parameters F5 Previous Jobs Database Fo Adhesives Profile Manager Operators and Passwords Return to Main Menu Fig 3b Control Functions Menu Page 18 Etech CONTROLS PTY LTO The Control Functions Menu which is displayed when F8 is
76. lected to control the temperature to the set point and the coldest thermocouple will be monitored to allow an extended soak to be calculated 19 2 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 blankets When the cycle is complete the release film allows the bagging materials to be removed easily without them bonding to the repaired area Etech Page 93 CONTROLS en io 19 3 Heater Blankets The HBC 4301 has provision for between 3 and 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 4301 will individually control the blankets to maintain the required temperatures The heat blanket is assembled straight over the release film to enable good thermal coupling to the repair 19 4 Breather Cloth Breather cloth is used to maintain an even vacuum over the whole patch 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 ti
77. log file to the hard disk NOTE A procedure should be implemented to make sure that past jobs are not lost The completed job files should be exported to a safe place on a regular basis Etech Page 75 CONTROLS en iro 15 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 Date time VVVVV 2 Novatech Controls Hot Bonding Controller HBC4301 Bj x File Edit Help Filter Records by showal zl Date Time Operator Item Description Item Number Joes if 3 09 2003 13 09 34 Default septOSbuttstrap4stagesrdattempt 507f 10 82 kB 30 09 2003 15 28 21 Default d d 5 97 MB 1 10 2003 12 23 02 Default d d 5 80 KB 16 10 2003 08 57 33 Authentication Bypass 1 zone test 16 10 03 ser 1003 4256456 w 5 04 kB 16 10 2003 14 02 02 Default Test for zone 2 ser 1003 2345345 w 5 41 kB 30 10 2003 14 59 28 Default Test Blankets 234 03 4 57 kB 10 11 2003 15 28 16 Default Test wing 34564 w 2 82 kB 10 11 2003 15 54 44 Default Test wing 2 2 zonw 12345 w 3 08 kB 10 11 2003 15 58 45 Default Test zing 2 zone 2 34534 e 4 04 KB 11 11 2003 08 27 48 Default 2 tasks 2 zone 32454 re 4 32 kB 11 11 2003 08 39 02 Default 2 task 1 zone 345345 3 17 kB 11 11 2003 10 03 12 Default 2 task 2 zone changed tc pa
78. m 2 Pressure only 0 to 6 bar pressure 3 Vacuum and pressure 1 to 9 bar vacuum 4 Vacuum and pressure 1 to 9 bar pressure Set the vacuum pressure tick box on the Vacuum Pressure Setup screen on the PC the same as is se ected in the control case 32 Units selection This function is only available if the control case s set to Local mode Thec or keys will move the cursor between the measuring parameters Theo on keys will toggle the unit options and the enter key will set the at the end of the line s will affect the way run time displays and menu items display the vacuum pressure and temperature The op sare Vacuum kPa atmospheres nches of mercury and bars Pressure kPa PSI and bars Temper r Metric and imp rial Page 70 d tech CONTROLS ory ur 33 Start and stop function The screen will display START or STOP depending if he heat cycle is running or not Select yes with the cursor keys press enter and return to he run mode The temperature cycle will start stop in run mode If the cycle data that has been entered is not valid the screen will flash CHECK CYCLE DATA Valid is when There is at least one stage enabled The option will automatically return to STOP after the cycle has been started If the cycle is running and the function is entered to stop the cycle the display will show d eWatech Page 71 CONTROLS en ur 14 5 Running a job from
79. mode Use the Function keys to find the setup function 20 Select Automatic mode Press the ENTER button 3 Go to setup function 22 Set the vacuum level in kPa Press the Enter button 4 Press the SETUP button to return to the RUN mode ar The control case will now attempt to control the pumping rate of vacuum pump 2 to maintain the set vacuum pressure If the leak rate of the repair is very small the pump may stay off operate for a few occasional pump cycles If the leak rate of the repair is high the leaks should be plugged A high leakage rate wastes energy and causes the pump to operate unnecessarily NOTE If the leak rate is less than 0 1 1 min at a low control vacuum i e less than 45kPa 13 3 Inches Hg the vacuum pressure may vary by 6 kPa or 1 8 Inches Hg Providing a leak of 0 31 min will allow better control of the vacuum at low vacuum levels 7 5 3 Automatic Mode Programmed Vacuum Levels In Local mode when running a temperature cycle from the control case the vacuum will follow the vacuum steps set in setup 9 11 13 15 17 and 19 Automatic vacuum mode must be selected in setup function 20 7 5 3 Vacuum Alarms Local mode 1 Press the SETUP button to enter the setup mode 2 Use the Function keys to find the setup function 24 ENABLE VAC ALARM Select Yes and press the ENTER button 3 Go to setup function 25 and select the sensor that is to be used for the alarm 4 Go to setup functions 26
80. mode the buttons are identified by the blue text In the SETUP mode the buttons are identified by the green text In SETUP mode most operations are done by using the FUNCTION up down keys to select the required screen followed by the OPTION up down keys to select the required value or item In some screens the CURSOR keys are used to point to a thermocouple or zone before the OPTION keys are used to change the state of the thermocouple zone After all operations are computed the ENTER key is used to lock in the change NOTE A change is not recorded until the ENTER key has been pressed If a different screen is selected with the Function keys or the operator exits the setup mode with the setup key the change will be lost If no keys are pressed for 30 seconds the HBC 4301 will return to the RUN mode and changes will be lost unless the ENTER key has been pressed Page 58 Netech CONTROLS ru un 14 1 Run Mode Button Functions in Run Mode A flashing character in the bottom right corner of the screen is simply a heart beat indicator to show that the HBC 4301 electronics are operating normally The HBC 4301 is in remote or computer control mode The HBC 4301 is in local mode and a temperature profile is not running Idle The HBC 4301 is in local mode and is running a Ramp stage of a temperature profile lach The HBC 4301 is in local mode and is running a Hold stage of a temperature profile
81. n iro 7 2 Draw the zone heater shape s Select the desired zone number or press OK to select the next available zone 7 3 Click on the Add Thermocouple button and click where the thermocouple is to be placed for the zone Select the desired thermocouple number or press enter to select the next available thermocouple 7 4 The Update Configuration button will automatically transfer the configuration to the Thermocouple and Zone Parameters screen Use this screen to fine tune the configuration Tie Stages PID numbers Chapter 16 Vacuum 7 5 Use the Control Functions Menu Vacuum Pressure Setup F8 F2 screen to configure the vacuum pump and alarms 8 Select Start Heat Cycle F5 from the main menu 8 1 Check that all required heater zones are Enabled If not ESC back to the Repair Map window 8 2 Select the cycle by clicking Select Profiles or pressing Select Profile L The temperature profiles were setup earlier in the 6 F8 F3 8 3 Select required zones by using the cursor keys Normally use Enabled Zones and then S or d 8 4 Change the cycle description if necessary and press to continue 8 5 ESC out of the Cycle Setup screen back to the Start Cycle window 8 6 Press S to continue the starting procedure 8 7 Enter Item being repaired and Part No 8 8 Select the adhesive type to use the automatic cure cycle 8 9 Press S to go to the Immediate Auto window Immediate mode will start the c
82. n is used to show the duration time of each stage of the temperature cycle during a task Vacuum Pressure levels The VACUUM button has two screens Alternate presses of this button will toggle from having either pump 1 or pump 2 as the focus of the vacuum control screens The pump number s shown in the top right of the screen The measurements are Air s pp y pressure the available vacuum measured at the pump 1 and the vacuum level measured at the external vacuum sensors Vacuum On Off The VAC N OFF button also has two screens Alternate presses of this button will toggle one of the acuum pumps on or off The pump number is determined by the Vacuum button seet epr viou screen description When the ACUUM pump is on the display will show the status of the vacuum pump the pump ope a ing mode th vacuum control point level in Manual mode kPa in Auto mode Note ha th nternal pressure is a reading of the vacuum pump supply pressure The inte nal vacuum reads the vacuum at vacuum pump 2 The vacuum at pump 1 must be read by one of the external sensors Page 60 tech CONTROLS en o If the pump is off the following screen is shown The pump can be turned on using the VAC ON OFF button Alarms The ALARM button shows the new alarms and the alarms that have been accepted by the operator Repeated presses of the ALARM button will show all the new alarms followed by all the a arms that have previously been acce
83. n of the sensors by following the calibration process in the Advanced Operators Manual Calibration 9 Heatsink Temperature High The temperature of the Heatsink on the control case is greater than 70 C Check the temperature of the heatsink on the control case by pressing the TC Temps button three times If possible reduce the current load on the heater outputs Check the calibration of the heatsink sensor by following the calibration process in the Advanced Operators Manual Calibration 10 Case Temperature Error The temperature difference between the cold junction temperature sensors and the case temperature is greater than 6 0 C Check the temperature of the case sensor on the control case by pressing the TC Temps button three times Check the calibration of the sensor by following the calibration process in the Advanced Operators Manual Calibration 11 Remote Alarm An alarm has been sent to the control case from the PC Check the PC Process Log screen to determine what alarm is active 18 Setup RAM Failure The memory cell that holds the setup mode configuration and calibration data has failed All heater outputs will be turned off Check memory cell MEM1 on the HBC 4300 1 PCB or contact Novatech Controls tech CONTROLS ov ur Page 62 14 2 Setup Mode Summary When the setup button is pressed the HBC 4301 enters the Setup mode The HBC 4301 will still communicate with the PC in setup mode It will automatically return to t
84. n the notebook EE 46 10 CHANGING A RUNNING TEMPERATURE PROFILE u ccssssssessssscecessscees 47 11 PROCESS LOG ALAR A LE 49 11 1 PROCESS LOG E 50 INZA MT DES EE 50 11 2 1 Thermocouple Temperature High LOW snennesseenseessnssenssesssssessssessrssserssessssee 50 11 2 2 Thermocouple Open Circuit E sisscssvacsnnscateassasncndnannncbasssachiamselivadsaanaideans 50 11 2 3 Acceptance Temperature Low only used when an adhesive has been selected 50 11 2 4 No Acceptance Thermocouple only used when an adhesive has been selected 50 11 2 5 Critical Temperature ETTOT ee gees aeee 51 11 26 Heater Fail Alarm vesccnajenccsspusinaaccnanneans EEN ol 11 2 7 Heatsink Temperature EE ss ccsscsesscies degkeet Nee wesaaspensanes 51 11 2 8 Cold Junction Temperature eegegegeda Eege 51 11 2 9 Case Temperat re E 51 11 2 10 High Low Vacuum Alarms ssscccseschesntavscsessatsspaveesdcetaaainaveniartavenserdarsoiass sncsaetaavas ee 51 11 3 PERIODIC E EE 52 12 HOW TO CLOSE THE PROGRAM ssessessesssesccsscesoesooeseessesoossosssesooesosssessossosssessose 53 1S ADHESIVE CONTROL sssssssscisssosessisetossocsesosksisestsdtsssess ssssseo s sososso ssess sssssoessosstos osses 55 13 1 INTRODUCTION E 55 13 2 CONTROLLING A REPAIR TO MATCH THE ADHESIVE CHARACTERISTICS ceseeeeeeeees 55 13 3 ENTERING A EE E 55 14 BACKUP OPERATION FROM THE CONTROL CASE sessoescessessoesocssessossocssessoes 57 14 1 RON EE 59 Button Functions in Run Mode
85. o measured from inside the control case and is used as a safety backup for the two cold junction sensors The Heatsink temperature should not be allowed to go over 70 C This will only be likely if the ambient temperature is over 45 C and all three zones are driving heaters at over 80 duty cycle The Vacuum1 and Vacuum2 show the measurements taken by the external vacuum sensors The status of the two vacuum pumps can also be seen from this screen Clicking on the buttons will turn the pumps on and off 9 2 Temperature Graph A graph of all the zone control temperatures can be graphed together Any of the zone temperature graphs can be selected by using the keys shown at the bottom of the graph EJNovatech Controls Hot Bonding Controller HBC 4301 ioj x File Edit Help Item Description Rear stab Item No 2344 Pump 1 Operator Default Date amp Time 03 02 06 14 06 13 bh Adhesive None TC Type K Type Control Stage Progression Tied rumz Pump 2 Task 1 Kee Zone 1 140 Ramping to Soak Temp 130 Control Temp 87 2 C TC1 SetPtTemp 88 6 C 120 Accept Temp 77 6 C TC5 110 Start Time 14 06 13 Est Finish Time 16 57 13 100 Elapsed Time 00 34 17 90 Stage 2 9 Stage Time 00 09 31 5 S 12 Soak Time 00 00 00 H amp 70 A H Int Pressure 263 kPa C ep Int acuum 14kPa Yacuum1i 50 Yacuum2 40 PumpSetPt 50 Power 51 8 35 20 er H EI 1 15 2 25 3 Time Hours Table Graph Map SelectZone
86. obs Database screen Page 38 tech CONTROLS PTY LTO 8 4 Operating with two control cases 8 4 1 Connecting the cases The computer must be connected to one of the HBC 4301 control cases Use the connector labelled COMPUTER on the control case and the USB adapter connected to the computer If the HBC 4301 was purchased as a single control case an RS232 communications lead will have been supplied When a second control case is to be networked to the first case the following changes must be made 1 The computer must have an RS485 communications port Do not make an RS485 port by using a USB port to an RS232 port and then another adapter to make the RS485 port The only 2 options are e Ifthe PC has a true hardware RS232 port then an RS232 to RS485 adapter can be used e Ifthe PC only has USB ports then use a USB to RS485 adapter 2 An RS485 network cable must be used instead of the RS232 lead from the PC to the first control case 3 A Novatech network cable must be used between the two cases 4 Both control cases must have their internal communications link set to RS485 This link is found on the Main PCB under the shield in the base cHassis of the control case 5 Remove LK3 located beside the RS232 RS485 link onthe main PCB NOTE The RS485 communications cable can still be used with a single HBC 4301 i e After this link has been set to RS485 it does not need to be changed back to RS232 as long as the RS485
87. og screen and can be printed or exported from that screen Page 52 tech CONTROLS rv un 12 HOW TO CLOSE THE PROGRAM The program has been designed to run under Windows 98 NT4 2000 or XP When closing the HBC 4301 program follow the standard procedures for the Windows operating system that is on the PC Stop any tasks that are running and follow the prompts to save the data for later review Close the HBC 4301 program by pressing the F9 key from the Main Menu or double click on the Exit Program line in the main menu Press J to quit the program or use the tab key and then J to cancel the closure Then follow the shut down procedure for Windows Main Menw Fi F2 F3 F4 F5 Status All Thermocouples Temperature Graph Repair Map Halt Heat Cycle Process Log Control Functions Menu CONTROLS oy un tech Fig 20 Closing the Program NOTE All active jobs must be stopped before the operator can close the program Etech Page 53 CON TROLS PTY LTO This page has been left blank intentionally Page 54 d tech CONTROLS eo un 13 ADHESIVE CONTROL 13 1 Introduction The cure cycle can be automatically set based on the time temperature data on particular common adhesives types A Manager can add additional adhesives by using Control Functions menu Adhesives Profile Manager As a temperature cycle is started the highest temperature soak stag
88. olutions 1 The PC battery has gone flat and the computer has gone into stand by mode Check the power and power pack leads 2 The temperature vacuum profile and process log alarms will be saved and the job can be re started 17 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 Thermocouple and Zone Configuration screen 2 Change the PID values back to the default values of P 15 I 80 D 10 3 Re tune the controller PID values See chapter 16 Tuning the Controller Using the PID Values Etech Page 83 CONTROLS en io 17 7 A temperature is reading o c Solutions 1 The thermocouple may be open circuit or have a broken connector in the thermocouple plug 17 8 The temperature in one zone goes high while the other zone goes low The heaters and thermocouples may be in opposite zones Solutions 1 Check that the heaters are connected to the correct zone 2 If this occurs an alarm Excessive Zone Temperature will be active and heaters will be cut off automatically They will be re enabled if the Cancel CRITICAL Temperature Alarm button on the Process Log screens is pressed The button can only be accessed by a Manager or a Supervisor 17 9 There is a Heater Fail alarm The heater has been running at 100 power level for more than one minute Solutions 1 Check which heater is nominated in the alarm
89. olutions The zone has not been enabled on the Thermocouple and Zone Configuration screen The zone power auto manual selection is not set to Auto in the control case Setup mode If the power output lamp is on the blanket is probably faulty The heater is plugged into the wrong power outlet socket One of the thermocouples configured for that zone in the Thermocouple and Zone Configuration screen is actually in another zone St Ex ZER Za E 17 2 A zone heats above the set point temperature Solutions 1 The auto manual selection is not set to Auto in the control case Setup mode 2 One of the thermocouples configured for that zone in the Thermocouple and Zone Configuration screen is in another zone 3 The PID control values are not set correctly See Chapter 16 Tuning the Controller Using the PID Values 17 3 The computer keeps Beeping Solutions 1 The computer communications cable is not connected to the computer 2 The power is not on at the control case Check the green power LED on the power supply inside the control case and the fuse in the power supply 17 4 There are too many temperature too high low alarms Solutions 1 Thermocouples and zones are configured incorrectly in the Thermocouple and Zone Configuration screen 2 The incorrect PID number has been selected in the PID field of the zone control section in the Thermocouple and Zone Configuration screen 17 5 The screen of the PC goes blank S
90. onfigured by using the Periodic log Setup button at the bottom of the screen Novatech Controls Hot Bonding Controller HBC4301 ST SE File Edt Help Thermocouple Configuration TC 1 2 D 4 s le H 8 D 10 DI In 13 DI 15 Im Task i 2 al 1 1 a 1 1 a 1 1 J 1 1 1 S Zone a L ul ak 1 1 2 2 2 2 2 2 3 3 3 3 Accept es Yes No Yes Yes Yes Yes Yes Yes No Yes Yes No No No No TC 17 18 19 20 21 22 E 24 Ei l 26 EI 28 2 EI 21 32 Task Disable Disable Disable see XI Disable Disable Disable Disable Disable Zone None None None I Enabled None None None None None Accept No No No U Log Every minutes No No No No No JS Active Thermocouples I Active Zones Zone Configuration Acceptance Cold Junction JV Vac Pres 1 Int Vacuum Ee 1 J2 E Ambient E Heatsink 7 VacjPres2 E Int Pressure Task Task 1 PID Ctrl Thin Master E P a Temperature Alarm Threshold Above Setpoint 5 0 ES H H h Disabled Below Setpoint E c Periodic log ER Celsius Temperature Units H setup button D ee EN E Save Configuration Bs Periodic Log Setup r Esc Return to Menu Spacebar to Change Zone Arrows Tab to Navigate Fields Connected Disconnected 03 Feb 2006 11 01 21 4 Fig 19 Status log options screens When the log occurs the selected values can be seen on the Process L
91. pe Control rum2 Gre Design Repair Map Layout TCs amp Heaters Add Heater Zone Add Thermocouple CG Load Map E Save Map X Clear Map Update Configuration Table Graph Map Esc Return to Menu Sprint 03 Feb 2006 10 46 16 4 Fie Edt Help Thermocouple Configuration TC d 2 3 4 5 6 We 8 9 10 11 12 13 14 15 16 Task KH 1 1 1 1 E 1 1 eh 1 1 ah 1 al 1 Zone al 1 tb IL 1 il 2 2 2 j2 2 3 3 3 Accept Yes Yes No hee ves ves vee ives ves lno Yes es We No No No TC 17 18 19 20 21 22 23 24 25 26 27 28 29 30 ou 32 Task Disable Disable Disable Disable Disable Disable Disable Disable Disable Disable Disable Disable Disable Disable Disable Disable Zone None None None None None None None None None None None None None None None None Accept No No Ho No No No No No No No No No No No No No Zone Configuration Task Progression Control Zone 1 2 3 Progression Control Task Task 1 Task 1 Task 1 ied zones 3 PID Ctrl Thin Thin Thin Master E m a Temperature Alarm Threshold Zone 4 S 6 Above Setpoint po oc Task Disabled Disabled Disabled Below Setpoint 5 0 c PID Ctrl Thin Thin Thin Temperature Units Celsius z EE a a a COM Port kou d Save Configuration Bs Periodic Log Setup r Esc Return to Menu
92. plate Thick Plate 60 15 70 6mm aluminium plate have been found to control the temperature of the heaters within 2 C of the set point 16 3 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 either I amp D and proportional action alone could control the temperature quite well It sets the output proportional to the deviation of temperature above and below the set point When the actual temperature is within this band the controller will select a power level between off and full on The larger the number the smaller the proportional effect Proportional action cannot be turned off P VALUE TOO SMALL If the P value is too small the controller will provide 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 Increase the P value and test the stability again 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 Decrease the P value and test the control again 16 4 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 or fastest action I VALUE TO
93. ple type Temperature range Accuracy Number of heater zones inputs Type of controlled output Heater current max Heater power Power supply safety protection Vacuum sources Vacuum control Pump 1 Vacuum control Pump 2 Air supply Mains voltage supply Power Safety switch Environmental Rating The main microcomputer Thermocouple reading circuitry Backup keypad display Automatic vacuum control pumps and circuitry 16 expandable to 32 Type K or J Up to 300 C 600 F 1 C 3 expandable to 6 zones Phase angle and burst fired SCRs to operate infra red heater lamps or mats 10 Amps 7 2kW total at 240vac supply 2 4kW per zone 3 3kW total at 110vac supply 1 1kW per zone Earth leakage circuit protection on each heater 2 Air operated ejectors down to 85 kPa Manual on off Automatic programmable or manual setting 150 to 800 kPa Normal operation 500kPa 200 Um both pumps running at 100 Single phase or 3 phase 85 to 265VAC 50 60 Hz phase to neutral 10Watts for controller plus heater power Earth leakage detector on each zone 30mA Operating Temperature 25 C to 55 C Relative Humidity 5 to 95 non condensing tech CONTROLS en iro Page 11 Degree of Protection Case Size HBC 4301 Case Weight HBC 4301 IP65 with the case closed IP30 with the case open 520 mm wide by 425 mm deep by 220 mm high 14 kg plus notebook computer approx 2
94. pressed in the Main Menu provides access to functions that are used to configure a heat cycle or to save and recall completed cycles 1 To select a function either 1 Press the corresponding function key i e In the Main Menu Function key F3 will select Repair Map 2 Use the up down cursor keys to highlight the required function Press the key 3 Double click with the pointing device either an external mouse or the built in touch pad 2 To access the Control Functions menu press the F8 key and then press a function key as shown in the Control Function menu 3 To return from a function to the Main Menu press ESC All operations are accessible using the keyboard or the pointing device except the drawing of the repair map needs the pointing device CN tesch Page 19 CONTROLS en ur This page has been left blank intentionally d tech CONTROLS eo un 5 CONFIGURING THE THERMOCOUPLES AND ZONES NOTE It is possible to configure two tasks in the HBC 4301 software Use the 1 and 2 keys while in the Main Menu to swap between tasks 5 1 Thermocouples and Zones The configuring of the thermocouples in the zones that they are physically mounted in can be done two ways Repair Map Thermocouple Zone Configuration table T Novatech Controls Hot Bonding Controller HBC4301 Fie Edt Help Item Description Ten No Pump 1 1 Operator Authentication Bypass Date amp Time bd p Or Adhesive TCType K Ty
95. profile stage 2 Configure the temperature profile Vacuum level stage 2 12 Configure the temperature profile stage 3 Configure the temperature profile Vacuum level stage 3 14 Configure the temperature profile stage 4 Configure the temperature profile Vacuum level stage 4 16 Configure the temperature profile stage 5 Configure the temperature profile Vacuum level stage 5 18 Configure the temperature profile stage 6 Configure the temperature profile Vacuum level stage 6 20 Vacuum control mode The cursor keys will move the gt The enter key will lock the position of the This function will not appear if Pressure has been selected in function 31 21 Vacuum manual setting Skipped unless Manual selected The option keys will change the value The enter key will lock the value 22 Vacuum con rol sensor Sk pped if Manual selected The c rsor keys will move the gt The enter key will lock the position of the Etech Page 67 CONTROLS en io 23 Vacuum control level Skipped unless Auto selected The level yy will be ramped up and down by the option keys and set by the enter key The is used to show the locked status Range 0 to 100 kPa 0 to 29 2 InHg 0 to 0 99 Atm 0 will turn off the vacuum pump This will be used as the set point for the control of the pump in automatic control mode 24 Vacuum menus enable This function is only available if the control
96. pted by the operator and are still active If there are no NEW alarms the screens will only show the previously accepted alarms After all alarms have been accepted the alarm beeper will stop and the alarm light will stop flashing but will be ON until all alarms conditions have been removed For example the following screens show a typical alarm message when the ALARM button is pressed Pressing the button within 2 seconds will accept the alarm and silence the horn The active alarms can be displayed any time by pressing the ALARM button The available alarms the causes and the solutions are listed _elow 1 Thermocoup e o c xx The nominated hermocouple xx is open circuit It wil au omatically be removed from being used for con ro of he heaters Unplug the thermocouple and check the termination of the wires in the thermocouple plug Repair or replace the thermocouple 2 Thermocouple Reversed The nominated thermocouple xx is wired in the reverse direction It will automatically be removed from being used for control of the heaters Unplug the thermocouple and reverse the termination of the wires in the thermocouple plug 3 Low Vacuum The vacuum on one of the external sensors is low Reduce the air leaks on the repair increase the vacuum pumping level or raise the alarm level in setup 26 4 High Vacuum The vacuum level on one of the external sensors is high Etech Page 61 CONTROLS en o Reduce the vacuum pumping
97. r 0 T Skip o 2 0 5 60 6 from Amb to 0 k Skip o 20 fs 80 0 For Ambient a S Temperature C Ed WNA jao 15 Time Hours ER 3 35 BR Save Profile GH Export Profile GG Import Profile E Prit Esc Return to Menu Connected Disconnected 03 Feb 2006 10 59 47 7 Fig 6 Temperature Profiles Screen Use the Tab key cursor keys or the mouse to move to the data point you wish to change and type the new value Use the ESC key to take you back to the main menu screen A prompt dialog box will appear when exiting this screen if changes have been made The 5 cells in each stage are 1 Target temperatures 2 Soak time 0 to 2000 mins 33 hours per stage with a maximum of 200 hours for a complete cycle Heat cool rate in C F minute 0 5 to 10 00 4 Deviation temperature for the guaranteed soak function to 10 C F 0 to disable the guaranteed soak feature 5 The controlled vacuum level for this stage of the cycle The automatic control of the vacuum is not available if Pressure is selected on the Vacuum Pressure Setup screen Get NOTE Any stage can be skipped if the Skip tick box is ticked Use the mouse and the left click or the tab key to move to the tick box and the space bar to select deselect the skip Etech Page 27 CONTROLS en ur This page has been left blank intentionally d tech CONTROLS eo un 7 VACUUM P
98. r dark blue red Using this method a cold or hot area of the repair will stand out at a glance S Novatech Controls Hot Bonding Controller HBC4301 ioj x File Edit Help Item Description Rear stab Item No 2344 nee GH Operator Default Date amp Time 03 02 06 14 06 13 Adhesive None TC Type K Type Control Stage Progression Tied rumz Pump 2 Task 1 Zone 1 Ramping to Soak Temp ControlTemp 87 3 C TC1 Set Pt Temp 88 9 C Accept Temp _77 8 C TCS Start Time 14 06 13 Est Finish Time 16 57 13 Elapsed Time 00 34 24 Stage 2 Stage Time 00 09 38 Soak Time 00 00 00 Int Pressure 263 kPa Int Vacuum 14kPa Vacuumi Vacuum 2 PumpSetPt 50 Power 52 5 Table Graph map Selectzore i 2 3 4 5 6 Process Log nm Esc Return to Menu Connected Disconnected 03 Febj2006 14 40 38 7 Fig 16 Repair Map Screen In addition to colour coding of the actual temperatures the control thermocouple circle if the highest thermocouple temperature has been selected for control is set to red and the acceptance thermocouple is set to blue When the repair is finished the repair map is also saved When a repair temperature profile is retrieved for later examination the position of the heaters and thermocouples will also be available Etech Page 45 CONTROLS rn io 9 4 Monitoring the vacuum pressure 9 4 1 On the control case The HBC 4301 has the
99. ransceiver Mode or 7 rT IV Bias Resistors Enabled Cancel Defaults 11 Go back to the desktop and launch the Novatech Controls HBC 4301 program 12 From the main menu select the Control Functions Menu F8 and the Thermocouple and Zone Parameters F1 13 Change the COM port box to select the port noted down in step 9 above Temperature Alarm Threshold Above Setpoint 5 0 C Below Setpoint 5 0 C Temperature Units Celsius X COM Port 14 Close the program saving changes when prompted 15 Next time you start the HBC 4301 program make sure that the USB adapter is already plugged into the computer The port will be properly configured and connect automatically CN tesch Page 91 CONTROLS en io This page has been left blank intentionally Page 92 d tech CONTROLS eo un 19 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 4301 Hot Bonding Controller For complete information on the bond process please refer to the adhesive manufacturer or the Training Notes 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 Sur
100. re used to access the configuration of both tasks The tasks are enabled from the Main menu by pressing either the 1 or the 2 keys A display and keypad is provided as part of the HBC 4301 control case for backup operation and for running a repair with reduced functionality The HBC 4301 takes full advantage of the technology of the current notebook PC s It uses the high resolution colour screen to clearly identify the set point temperature hottest temperatures coldest temperature vacuum set point and vacuum levels The repair temperature graph cycles can be saved and printed later The alarm messages and data logs are also saved for later reference In addition a thermocouple zone map of the repair can be created and a digital photograph can be linked to the internal database Both of these can be saved along with the temperature profile of a repair and can be retrieved for later examination for quality control records The thermocouples are grouped into the zones using the Thermocouple and Zone Configuration screen All the enabled zones are scanned for the hottest thermocouple or the average temperature if available from the Thermocouple and Zone Parameter screen to determine the temperature to be used for control of the zone The hottest thermocouple average temperature in each zone and the coldest thermocouple in the task are plotted on a graph An open circuit thermocouple will automatically be removed from control The vacu
101. rinted later Entering the Process Log screen will accept any new alarms and stop the audible alarm from the HBC 4301 When the alarm messages have been assessed press the ESC key to exit the screen Clicking the Accept Active Alarms button will also silence the alarm if the screen is open when an alarm occurs NOTE The new messages are at the bottom of the screen and it may be necessary to scroll through to the last messages 2 Novatech Controls Hot Bonding Controller HBC4301 File Edit Help Task 1 Process Log Date 03 02 06 Time 14 06 13 Log Description Task Started Operator Default Supervisor Item Description Item Number Adhesive Thermocouple Type Temperature Control Default Rear stab 2344 None K Type Stage Progression Tied 1 6 0 1009 Software Version HBC 4301 Serial Number 03 02 06 1 2 06 13 Zone 1 PID Parameters The PID parameters are set to P 60 I 15 D 70 03 02 06 1 Hi 1 06 13 Zone 2 PID Parameters The PID parameters are set to P 60 I 15 D 70 03 02 06 1 706713 Zone 3 PID Parameters ID parameters are set to P 60 I 15 D 70 03 02 06 1 m 2 06 13 C Vacuum kPa Pressure kPa TC 3 TC 4 TCHS 31 9 29 7 To 14 TC 15 31 4 310 0 TC 6 30 7 TC 7 30 2 ler 30 5 TC 9 29 3 TC 10 31 57 29 4 TC 13 31 7 Zone 2 30 7 Zone 3 24t Case T 26 3 Colddne HeatSnk Vacl 27 47 34 47 s Vac2 ape Accept 2
102. rom the Repair Map screen and then let the computer update the thermocouple table automatically NOTE After a temperature cycle has been started it is not possible to change the temperature zone configuration except to change the PID values Acceptance status of a thermocouple Remove a thermocouple Use the tab and the cursor keys to navigate around the screen and the space bar to change a selection The prompt line shows the available keys for each cell Thermocouple Configuration The table shows the association of the tasks zones and thermocouples A thermocouple in the task can be enabled as an Acceptance thermocouple from the Accept row of the table A thermocouple shown as None in the Zone row is enabled but will not be used for control of any zone It can still be monitored or used as an Acceptance thermocouple NOTE Thermocouples 17 to 32 and zones 3 to 6 can only be used if a secondary control case is connected 5 1 3 Zone Configuration This table allows the operator to link the zones into a task and set the PID group The actual PID numbers are set in the PID Parameters screen Control Functions Menu PID Parameters The PID option is a convenient way to allow for different thicknesses of the structure being patched There are three sets of PID values selected with the space bar They can be individually set in the PID Parameters screen Control Functions Menu PID Parameters NeW tech Page 23 CONTROLS
103. rted file A database of the compressed files is assembled and can be accessed through the Control Functions Menu Previous Jobs Database 15 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 a hard drive or Zip tape backup system The backup to network 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 Transfer the jobs at a regular interval 1 e every week to a network server that has backup facilities Individual jobs can be transferred to a flash disk floppy disk for temporary storage The computer saves the following information Date Time as the job is started Operator name Item description Part number Adhesive profile if selected A graph containing the following Set point temperature profile Hottest temperature of each zone Thermocouple type The coldest temperature of the repair The vacuum profile All alarm reports All supervisor operator changes and automatic interventions A map of the repair with thermocouple and zone positions Files that are linked to the repair such as digital photographs e o o o o o VVVVWV 15 2 Saving the current job when finished As each repair is finished the computer will save a copy of the temperature profile of the job the map and the
104. seseseseceseseseseseseseeees 68 235 VACUUM alarm Sens Ornani A E E A A AR 68 26 Vacuam low alarm Jee 68 27 EE 69 28 Set zone power mM de erennere aranaise 69 29 Manually set zone power temperature assssssssssssesssseseesssssessssresssseresssreeesseseesssseeee 69 SO SEE tee Ee 69 SEET 70 32 Units selection oo cccccccccccccccesececesesesesecesesesecesesesesesesesesesesesesesesesesesesesesesesesecesesesesesesesesens 70 33 Start and stop JUNC OM seriis aE a EEEE tans Mausiaaeved sand EAEE Ea 71 14 5 RUNNING A JOB FROM THE CONTROL CASb 712 LA Sel EE 72 14 5 2 Configuring the temperature E 73 14 5 3 Starting and stopping the temperature Grofe 73 14 5 4 Data logging in the control case sscceessscesseceececeeseeceseeecusneesusceecseneecsueeeesteeeenaeees 74 15 REVIEWING A PREVIOUS REPAIR eeessseceessoceessccccssscecessscceessceceessececsscsecsesseceesseceese 75 15 1 THE CONCEPT OF A BACKUP SYSTEM ssiccsctscccssaricdenadessacebsunsdddseviaadssaeibiedsasteccstoinodlaneienans 75 15 2 SAVING THE CURRENT JOB WHEN FINISHED cccceesessnsecesecececeessnaeceeeccesesesenssaeeeeeeeens 75 15 3 RETRIEVING A PREVIOUS IOp 76 15 4 ADDING A LINKED FILE TO A PREVIOUS JOB cccccccssssssssecececececsessnseceeeccesesesensaeeeeeeeens 76 15 5 TRANSFERRING A JOB FILE TO ANOTHER HBC 4301 COMPUTER ss scceeeesteeeeessseeeees TT 16 TUNING THE CONTROLLER USING THE PID VALUES sseeeeeeeeeeeeeeeeeeeeeeeek 79 16 1 EE 79 16 2 CHANGING
105. ssscsssiccscesssscewiesciavathspeanenavaescaasnadaavevaedeiaainacepvensaesacavaeaoess 59 Thermocouple temperatures ed Eed 59 Zone TEIN ROTI OS eeneg 59 KE 60 Cicle TUNES ir E O ee 60 Vacu m Pr ss r levels E 60 Vacuum EE 60 RE 61 14 2 SETUP MODE SUMMARY ssrin ci oit ciusud eerundeceuieradaceedl tandiianaeemacededeeeseeaaaligs 63 14 3 KEYPAD OPERATION IN THE SETUP MODERNER 64 14 4 SETUP MODE DOB TANI S icc catczarenuianssncuzstad evadatedecstataestasassdscoses dearer EO EK aean i 64 I Control MODS Eegen 64 EEN 64 3 Zone l EIERE 64 El 65 5 Zone DLE TINOCOU ege EE 65 E EE 65 7 Editing a temperature DVO TC deeg 66 Page 2 Atech CONTROLS en o 8 Configure the temperature profile stage 1 wie seis ccuvsisnssarsadvincsrdaaraeniarasanescasasinseavdecnlrwers 66 9 Configure the temperature profile Vacuum level Stage IA 66 10 Configure the temperature profile stage 2 67 12 Configure the temperature profile stage 3 ss cawsdusnatasnivantindphuncedussidunidewnniadwariuanldanveassia 67 14 Configure the temperature profile stage 2 67 16 Configure the temperature profile WEN 67 18 Configure the temperature profile stage iere edelegeesdieh 67 20 Vacuum conirol ele 67 21 Vacuum manual setting Skipped unless Manual selected 67 22 Vacuum control sensor Skipped if Manual zelecied 67 23 Vacuum control level Skipped unless Auto zelecied 68 24 Vacuum menus enable uu cccccccccccccccccccesesesssesssesesesesesesesesesesesesesesesesese
106. the selected adhesive Rename Rename the selected adhesive Save Save the adhesive files Use Fixed Ramp If the tick box is ticked the ramp rate for all stages of the job will use Rate this rate for all stages of the job Print Print the graph and coefficients of the selected adhesive Esc Return to Menu Return to the Control Functions Menu Page 56 CONTROLS ory ur 14 BACKUP OPERATION FROM THE CONTROL CASE The HBC 4301 control case has a built in 8 key keypad and a 20 character by 4 line display They can be used to monitor the status of the thermocouples and vacuum system as well as set the power levels of the outputs in a manual mode They can also be used to configure start and stop a heat cycle The Local mode is designed to enable the HBC 4301 to configure and run without the use of the PC However as the HBC 4301 was designed to take full advantage of the graphics available in the PC using the HBC 4301 without the PC reduces the available features For example Remote Mode Using a PC Local Mode Starting a temperature Two simultaneous tasks A single task profile Temperature profile Indefinite record time Not saved record Extended zone and Guaranteed soak times and Fixed soak times thermocouple options automatic adhesive based soak time monitoring Number of zones and Up to 6 zones and 32 3 zones and 16 thermocouples thermocouples thermocouples There are 3 modes of operation of t
107. tntfecdfione 86 UE 86 Mains HOW eecht ageet 87 18 2 CHANGING FROM RS232 SERIAL PORT TO RS485 USB PORT 88 TVO AUCTION E 88 Changing the HBC 4301 RS232 RS485 mode woudccushittannstidaetsauednadigtiddeesiedacncameneasioueenses 88 Networking 2 HBC 4301 hot DEET eege geesde 89 18 3 INSTALLATION amp SETUP OF THE USB SOoPrwaAbt 90 19 ASSEMBLY AND BAGGING sssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssss 93 IOlToppwMocCoUptLtps 93 192 RELEASE EE 93 19 3 HEATER BLANKETS eostin n n a n a a a a a aiae iesea 94 19 4 BREATHER Com 94 19 5 VACUUM Pops 94 19 6 BLEEDER CLOTH tas2tsvececedsvodsseasdecedecacessaddevecedecavessbessvecedecetecssdessedagececeusbous ecsceecgeuneeesvoes 94 19 7 VACUUM BAG SEALANT sreeccie oeren eriisireero aion ra NEEE E ETEA EN EEEE aaaea 94 19 8 VACUUM BAG FILM 2 0 ccccscsccccccccccssessscecccccsccesusssecccecsseeuuuusscececsssceuuuueascecesseeauensnsnesss 95 20 MANUFACTURE OF THE THERMOCOUPLE esssosssosssosssosssosssossessssssssssssssssso 97 21 ACCESSORIES E 99 21 1 HARDWARE EXPANSION accessissent e a a NEE E S aar 99 21 2 BONDING ACCESSORIES ccccccccccccccsssssescccccccessusseeccecssseusuusscececcsseesuuusscecesseseesuunensnseses 99 IERA AIID A AE COS AET AASE A ANETE E AAA 99 22 OPERATORS AND PASSWORDS sseeseeesesosos0sososssosssosssosssosssssssssssssssssssssssssssssssssssssso 101 TTT OAUCTION eege eege 101 Creating Eegenen 102 23 GLOSSARY OF TE
108. ttern 1234 3 87 kB 11 11 2003 14 20 10 Default Take 2 of 2 zone test 23456435 4 01 kB 11 11 2003 15 12 10 Default Zone 3 task 2 1234543 3 10 kB 11 11 2003 16 52 39 Default Take 3 task 2 2345 2 93 kB 12 11 2003 09 53 09 Default Test with a distorted FM73 2 zone 234564 1 02 MB 12 11 2003 13 36 02 Default test extended soak time rr 9 37 kB 19 11 2003 13 29 09 Default Test cycle for Ser 1004 1234 e 7 23 kB 19 11 2003 15 20 06 Default Test cycle for Ser 1005 2 234652345 e 5 76 kB 19 11 2003 16 52 43 Default Test cycle for ser 1006 2 23465 e 5 35 1B 20 11 2003 10 08 26 Default test cycle ser 1007 s 6 90kB 21 11 2003 10 35 55 Default Leading edge of RH rear stabiliser delamimination W517634 RUT 3 95 kB 21 11 2008 12 26 51 Default Leading edge of RH rear stabiliser delamination W517634 RUT 546 18 KE Attached Files 8 O E Primary Data xis View Record View Eile Add File Remove File X Delete Record gj Export Record l Administrative Tasks lt 4 Esc Return to Menu Connected Disconnected 03 Feb 2006 11 50 08 7 Fig 23 Review Previous Jobs Menu The recalling of a repair will allow access to the temperature vacuum information that was saved as the repair was finished as listed in figure 23 The hottest temperatures are graphed for each zone and the coldest temperature for the repair is also shown Parts of interest in the graph can be expanded to show the detail as described in the chapter 9 2 1 The map of the repair is recalle
109. ture to the set point or to maintain the temperature at the set point 16 2 Changing the PID values E Novatech Controls Hot Bonding Controller HBC4301 loj x Fie Edt Help Heater Control PID Parameters 1 Thin Plate Proportional Band oc Integral 22 secon ds Derivative 45 secon ds 2 Normal Proportional Band 75 c Integral Up secon ids Derivative 60 seconds 3 Thick Plate Small Blanket Proportional Band 60 e Integral 15 zem ids Derivative 70 seconds E Save Configuration O Load Defaults Esc Return to Menu Connected Disconnected 03 Feb 2006 11 04 23 7 Fig 24 PID parameters screen 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 Etech Page 79 CONTROLS en io NOTE There is provision for 3 sets of PID values to be saved in the HBC 4301 program Before you re tune the controller make sure the correct values are being used in the Zone Control section of the Thermocouple and Zone Configuration screen and the PID parameters screen The PID values should not have to be changed The values of P I D Thin Plate 95 22 45 0 6mm aluminium plate Normal Plate 75 18 60 2mm aluminium
110. ue and J to save changes Press S to enter the details of the work being done Use the tab key to toggle between the fields The Description and Item number must both have an entry or the task cannot be started The operator is given the option to have the computer automatically monitor the cycle that has been selected against the known adhesive characteristics Confirmation of the changed parameters will appear for each zone that is selected Press the J key to start the temperature cycle To monitor the cycle in progress go to the Repair Map Temperature Graph or the Status All Thermocouples screen See chapter 9 1 Etech Page 33 CONTROLS en iro 8 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 BER File Edit Help Bonding Cycle Temperature Profile Lo Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6 Task 1 Enabled Enabled Enabled Set Point 60 5 C 60 45 C 60 45 C Stage 1 Soak Time 15 min s 15 min s 15 min s Heat Rate 2 0 C min 2 0 C min 2 0 C min Set Point 120 5 C 120 5 C 120 5 C Stage 2 Soak Time 60 min s 60 min s 60 min s Heat Rate 3 0 C min 3 0 C min 3 0 C min Set Point 80 5 C 80 5 C 80 5 C Stage 3 Soak Time 5 min s 5 min s 5 min s Heat Rate 2 5 C min 2 5 C min 2 5 C min Set Point 60 5 C 60 45 C 60 45 C Stage 4 Soak Time 30 min s 30 m
111. ugh the repair will be resin rich It is most important that both of these situations are avoided by using the correct amount of bleeder cloth 19 7 Vacuum Bag Sealant Vacuum bag sealant is used to provide an air lock between the 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 94 tech CONTROLS ev ur 19 8 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 other end of the vacuum pipe 3 Sr Zen 7 8 9 10 11 12 13 Test the ultimate vacuum by turning on the vacuum with the VAC ON button on the HBC 4301 control case or from the PC Note the vacuum obtained on the Status all Thermocouples screen for the Internal Vacuum Sensor The vacuum will be about 70kPa with a supply line air pressure of 400kPa
112. um can be controlled automatically The vacuum level can be programmed as easily as the temperature and will then automatically change as the repair goes through the temperature cycle The control system allows the pump to adjust to any changes in the leak rate of the repair and still maintain the same vacuum level It may even stop the air supply to the pump if the vacuum is close to the set point A second vacuum pump is included for two simultaneous repairs with manual electronic on off control Etech Page 9 CONTROLS en io The adhesive curing characteristics can be programmed into the computer so that the guess work is taken out of curing time The curing stage time is adjusted automatically if an adhesive is nominated as the temperature cycle is started If a zone is needed to provide some background heat into a repair any of the zones can be controlled in the manual mode using the local keypad display on the control case The same controls can be used to control a repair process with some reduced functionality The graph of the repair is saved in the control case and can be downloaded to a computer later Page 10 Altech CONTROLS en o 3 SPECIFICATIONS 3 1 Hardware Specifications NATO Stock Number is 6685 66 145 0064 The central or main component of the HBC 4300 series is the HBC 4301 control case The case contains the notebook computer for transportation and also Heater control Number of T C inputs Thermocou
113. until another job is started even if the power is turned off on the control case When a job is started the following data is saved Date time Control case serial number Thermocouple configuration Thermocouple type PID values Vacuum pressure setup Temperature vacuum profile Expected finish time While the job is running the following data is saved Control temperature for each zone Power level for each zone Acceptance temperature External vacuum pressure input levels Internal vacuum In addition to the above all temperature alarms are also recorded with a date time stamp Page 74 Etech CONTROLS en o 15 REVIEWING A PREVIOUS REPAIR The Hot Bonding Controller program has the ability to save and recall jobs to and from a database storage system in both the PC and the control case While a task is running the PC saves the zone temperature data vacuum data repair map data logs and process events to the hard disk As a task is finished these files are compressed and saved back to the hard disk If a file is linked to a task after the repair has been finished for example pictures of the finished repair a linked file is also compressed and saved in the task record file The size of a typical repair file will be about 10k without any linked files NOTE The linked file itself is saved in the compressed file If this task file is exported it will include all other documents in the expo
114. up of temperature ramps and temperature hold times The soak time is entered in minutes See chapter 6 Creating a Temperature Profile Stage The temperature cycle is broken up into 6 stages Each stage has a ramp and a soak stage Zone Each of the three 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 three zones available with the HBC 4301 but an additional three zones can be added see chapter 21 2 Bonding Accessories Etech Page 103 CONTROLS en io A ACCESSOTICS CASE eege esee 99 Adhesive Control EE 55 Alarm ASE E 50 Alarm Temp Thresbold A 24 Alasin edanan ie aes 49 B Backup Operation ssiccccssssccssnosccssnessedesaens 57 C Changing a Running Temp Profile 47 Close the EE 53 Connections Communications ccceeeeeeeeseeeeeees 86 External transducers eeeeeeeeeee 86 Heater outputs lt 5 5cecassseceacdeedencandgaceeesass 85 later Zeie GENEE EEeEEe 87 Secondary case sisicesasvsscnssaspeacsasnsdecsnneas 86 Controlling the Vacuum Pumps 29 Critical Temperature Alarm 49 E Exit Program ssssessessssesrrsesssresseressssessnss 53 Extended Set up MOG ezegtergoeeer grnseeg 57 G Getting Going Fast 7 EE eebe eg 103 Lapierre eenegen Sege 42 Graph Navigating 42 Guaranteed Soak seenen 24 H Hardware expansion 99 I Installing the Software 15 L Local Modessa 35 M Menu
115. ures Text documents Files can be imported or exported in text format that could be read by MS Word or MS Excel format including Temperature profiles and previous temperature graphs Selected by part number operator adhesive job description or date time Data retrieved includes Zone temperature e vacuum graphs repair map alarms and warning messages pictures and documents Graphs can be exported to Excel Auto manual over ride on each heater output On screen display and hard copy print Temperature deviation Thermocouple burnout Thermocouple reversed Vacuum over under condition Heater mat failure Hardware failure Communication failure Page 13 CONTROLS en un Alarm indication Audible Tone generator and PC speaker Visual Flashing red light on control case Power fail re start Re start at last point Cycle data is stored on disk every 15 seconds Page 14 tech CONTROLS en o 4 STARTING 4 1 Installing the Software Insert the Novatech Controls HBC 4301 installation CD in the CD drive in the PC The Setup Wizard will start running Select Components The drop down box gives the operator three options 1 Full Installation Installs the HBC 4301 control program and overwrites the saved temperature profiles default program settings and the adhesive profiles 2 Upgrade Current Installation Overwrites the current version of the program but leaves the saved temperature profiles
116. values The easiest way to get started on a repair is to use the default values that are set in the program and are shown in the table above Chapter 16 2 Changing the PID Values This requires that the job be assessed as Thin Normal or Thick The description of these jobs is also shown in chapter 16 2 A more conservative approach until more experience is gained with a new job is to use proportion control only This means turning off the integral and the derivative parts of the PID and setting the Proportional factor wide Set the following Proportional Band 60 Integral 0 Derivative 0 The result will be that the temperature of the zone will follow the set point smoothly but will be 5 to 10 C below the set point Introducing some integral action will bring the temperature much closer to the set point Start with the following but increase the integral to 100 if cycling starts Proportional Band 60 Integral 50 Derivative 0 This will usually result in the temperature following the set point within to 2 C To further improve the response to a sudden change in the set point such as when the ramp temperature reaches the soak temperature a small derivative could be added Try starting with Proportional Band 60 Integral 50 Derivative 4 CN tesch Page 81 CONTROLS en ur This page has been left blank intentionally Page 82 d tech CONTROLS eo un 17 TROUBLESHOOTING GUIDE 17 1 A zone does not heat up S
117. ycle 8 10 Press any key to confirm each automatic temperature time if required 9 Monitor the Repair Progress Chapter 9 9 1 Select Repair Map F3 from the main menu 9 2 Select Temperature Graph F2 from the main menu 9 3 All enabled zones can be selected from the Temperature Graph screen by pressing the desired zone number I to 3 9 4 Select Status All Thermocouples F1 for a table of temperatures 10 Alarms If alarms occur because of temperature deviations on warm up check the Process Log F7 screen Entering the screen will accept the alarm and silence the horn Page 8 d N PA tech CONTROLS en o 2 INTRODUCTION The HBC 4300 series is a feature packed hot bonding controller system built to suit the requirements of today s aviation and bonding industries It is based on a versatile electronic vacuum control case and a notebook computer as the operator interface The computer is stored in the lid of the HBC 4301 control case To operate the hot bonding controller the computer can be placed on a bench or desk up to 100m away from the control case A network cable is used to communicate between the computer and the control case The number of inputs and zones can be increased from 3 zones to 6 zones from 16 thermocouples to 32 thermocouples with the use of an external expansion case HBC 4301 or HBC 4302 The system is capable of running two independent task at the same time The same keys a

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