AvionTEq HEATCON HCS9000B User manual

HCS9000B/HCS9200B-OMI-40518 November 2013
This Technical Manual Applies to HCS9000B and HCS9200B Revision 16
Composite Repair Sets (Hot Bonders) with Serial Numbers listed below:
Serial Numbers –1611XXXX and Subsequent
HCS9000B / HCS9200B
Composite Repair Set; Hot Bonder
Operation and Maintenance Manual
with
Illustrated Parts Catalog
To buy, sell, rent or trade-in this product please click on the link below:
http://www.avionteq.com/Heatcon-HCS9200B-Single-Dual-Zone-Hot-bonder-Composite-Bonding-Repair-System.aspx
www.avionteq.com

HCS9000B/HCS9200B Proprietary Notice
Hot Bonder/Controller
HCS9000B/HCS9200B-OMI-405 HEATCON® COMPOSITE SYSTEMS A
Manual Title: "HCS9000B/HCS9200B Operation and Maintenance Manual with Illustrated Parts Catalog"
Copyright 24 October 2011
All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored on a
retrieval system, or translated into any language in any form by any means without the expressed written
permission of HEATCONCOMPOSITE SYSTEMS.
Manual Number:HCS9000B/HCS9200B-OMI-405
Changes/Revisions: Original –24 October 2011
Revision 1 –28 August 2012
Revision 2 –20 September 2012
Revision 3 –18 November 2013
Orders: Additional Copies May be Obtained From:
HEATCONCOMPOSITE SYSTEMS
600 Andover Park East
Seattle, WA 98188-7610
Phone: [phone]
Fax: [phone]
Email: [email protected]
HEATCONCOMPOSITE SYSTEMS Europe
Blackstone Road
Stukeley Meadows Ind. Est.
Huntingdon (CAMBS)
PE29 6EF England
Phone: [phone]
Fax: [phone]
Email: [email protected]
PROPRIETARY NOTICE
The drawings and related information contained herein are derived in part from proprietary and
patent data of HEATCONCOMPOSITE SYSTEMS and/or its suppliers. Reproduction and/or use of
this information is restricted to use by the original purchaser or its duly assigned agents solely for the
expressed purposes of installing, operating, or maintaining the equipment described herein. This
information may not be used for the purposes of re-procurement or manufacture of the equipment
described herein.

Change Record HCS9000B/HCS9200B
Hot Bonder/Controller
B HEATCON® COMPOSITE SYSTEMS HCS9000B/HCS9200B-OMI-405
CHANGE PAGE
RECORD
NOTE: A vertical line in the outer margins of the page indicates the portions of this
manual affected by changes.
Dates of issue for the original and changed pages are:
Original –24 October 2011
Revision 1 –28 August 2012
Revision 2 –20 September 2012
Revision 3 –18 November 2013
Total number of pages in this document is 84 pages consisting of:
Page. Revision
No.
A-B..................................................................1
i-iv...................................................................2
v-70.................................................................3

HCS9000C/HCS9200C Front Matter
Hot Bonder/Controller
Change 2 iii
TABLE OF CONTENTS
TABLE OF CONTENTS....................................................................................................................................I
LIST OF FIGURES..........................................................................................................................................III
LIST OF TABLES ...........................................................................................................................................IV
ABBREVIATIONS AND ACRONYMS.............................................................................................................V
WARNINGS AND CAUTIONS......................................................................................................................VIII
TECHNICAL SPECIFICATIONS .....................................................................................................................X
CHAPTER 1 —GENERAL...........................................................................................................................1
1.0 Introduction..........................................................................................................................................1
1.1 Related Publications............................................................................................................................1
1.2 Overview..............................................................................................................................................1
1.3 Quick Start Guide................................................................................................................................2
CHAPTER 2 —FUNCTIONAL DESCRIPTION ............................................................................................4
2.0 AC Power Control................................................................................................................................4
2.1 DC Control Power................................................................................................................................4
2.2 Central Processor Unit ........................................................................................................................4
2.3 Sensor Input and Signal Conditioning.................................................................................................4
2.4 Operator Interface and Display ...........................................................................................................4
2.5 Printer..................................................................................................................................................5
2.6 Vacuum System ..................................................................................................................................5
2.6.1 Internal Pneumatic Vacuum System...................................................................................................5
2.6.2 Internal Electric Vacuum Pump System (HCS9200B-EV Option).......................................................5
2.6.3 Internal Electric Vacuum Pump System (HCS9000B-EV Only)..........................................................5
2.7 Proportional, Integral And Derivative (PID) Control ............................................................................6
2.7.1 PID Control Basics ..............................................................................................................................6
2.7.2 Proportional.........................................................................................................................................6
2.7.3 Integral.................................................................................................................................................6
2.7.4 Derivative ...........................................................................................................................................7
2.8 Network Operation .............................................................................................................................7
CHAPTER 3 —OPERATION........................................................................................................................9
3.0 Controls and Indicators .......................................................................................................................9
3.1 Equipment Setup and Power-On.......................................................................................................12
3.1.1 Equipment Setup...............................................................................................................................12
3.1.2 Power-On Procedure.........................................................................................................................15
3.2.1 Setup - Internal Electric Vacuum Pump System (HCS9200B-EV Option)........................................15
3.2.2 Operation - Internal Electric Vacuum Pump System ((HCS9000B-EV Option) ................................15
3.3 Security Password Protection (Option) .............................................................................................16
3.3.1 Password Control Levels...................................................................................................................16
3.3.2 Password Assignment.......................................................................................................................17
3.4 Operator Graphic User Interface Screens.........................................................................................18
3.4.1 Welcome Screen...............................................................................................................................18
3.4.2 Main Menu and Status Monitor Screen.............................................................................................19
3.4.3 User Settings Screen.........................................................................................................................21
3.4.3.1 Temperature Control Modes Screen.................................................................................................22
3.4.3.2 Thermocouple Mode Options Screen................................................................................................23
3.4.3.3 Thermocouple Control and Display Modes Screen...........................................................................23
3.4.3.4 Printer Options Screen......................................................................................................................24
3.4.3.5 Display Options Screen.....................................................................................................................25
3.4.3.6 Segment Completion Signal Screen .................................................................................................26
3.4.3.7 USB Import & Export Options Screen...............................................................................................27
3.4.3.8 Import &Export Cure Program Library Screen…………………………………………….................….28
3.4.3.9 Date and Time Settings Screen ........................................................................................................29
3.4.3.10Advanced Options Screen.................................................................................................................30
3.4.3.11Alternate PID Settings.......................................................................................................................31
3.4.4 Program Selection Screen ................................................................................................................32
3.4.4.1 Edit Program Screen.........................................................................................................................33

Reference Pages HCS9000B/HCS9200B
Hot Bonder/Controller
iv HEATCON® COMPOSITE SYSTEMS HCS9000B/HCS9200B-OMI-405
3.4.4.2 Run Program Screen.........................................................................................................................34
3.4.4.3 8 Step Cure Configuration.................................................................................................................35
3.4.5 Graph Screen ....................................................................................................................................36
3.4.6 Precure Operational Test Screen......................................................................................................37
3.5 Changing an Active Program.............................................................................................................39
3.6.1 Slave Mode........................................................................................................................................39
3.6.2 20 TC Mode.......................................................................................................................................40
3.7 Alarms................................................................................................................................................41
3.7.1 Max Power Warning & Alarm ............................................................................................................43
3.7.2 Event Log...........................................................................................................................................45
3.8 Data Logging Mode ...........................................................................................................................46
3.9 Cure Data Export...............................................................................................................................48
3.10 Cure Data Reprint..............................................................................................................................49
3.11 Autotune Function..............................................................................................................................50
3.12 Power Loss During a Cure ................................................................................................................50
3.13 Setting PID Values for Dual PID Operation.......................................................................................51
3.13.1 Modifying PID Settings .....................................................................................................................51
CHAPTER 4 —MAINTENANCE.................................................................................................................53
4.0 Scheduled Maintenance....................................................................................................................53
4.1 Preventive Maintenance....................................................................................................................53
4.2 Equipment Maintenance....................................................................................................................53
4.2.1 Chassis Removal...............................................................................................................................53
4.2.2 Chassis Installation............................................................................................................................53
4.3 Inspection and Test Procedures........................................................................................................54
4.3.1 Equipment Requirements..................................................................................................................54
4.4 Operational Test................................................................................................................................55
4.4.1 Operational Test Procedure ..............................................................................................................55
4.5 Printer Maintenance...........................................................................................................................57
4.5.1 Printer Ribbon Replacement .............................................................................................................57
4.5.2 Printer Paper Replacement ...............................................................................................................58
CHAPTER 5 —TROUBLESHOOTING........................................................................................................59
5.0 General Troubleshooting...................................................................................................................59
5.1 Test Equipment Requirements..........................................................................................................59
CHAPTER 6 —PARTS LIST.......................................................................................................................61
6.0 Using The Parts List ..........................................................................................................................61
ADDENDUM A —VACUUM BAGGING TIPS ..........................................................................................70
Vacuum Bagging Materials.............................................................................................................................70

HCS9000C/HCS9200C Front Matter
Hot Bonder/Controller
Change 2 v
LIST OF FIGURES
Figure Title Page
2-1 HCS9200B Display Screen Under Network Control .......................................................................7
2-2 Network Port Location (HCS9000B) ............................................................................................... 8
2-3 Network Controller (HCS9300NW) .................................................................................................8
3-1 Controls and Indicators HCS9000B - Single Zone .........................................................................9
3-2 Controls and Indicators HCS9200B - Dual Zone.......................................................................... 11
3-3 Bonder Connection Diagram .........................................................................................................14
3-4 Vacuum Bag to Bonder Connection Diagram ...............................................................................14
3-5 Password Sign-In Screen ..............................................................................................................16
3-6 Set New Passwords ......................................................................................................................17
3-7 Welcome Screen ...........................................................................................................................18
3-8 Main Menu and Status Monitor Screen .........................................................................................20
3-9 User Settings Screen ....................................................................................................................21
3-10 Temperature Control Mode Options Screen..................................................................................22
3-11 Thermocouple Mode Options Screen ...........................................................................................23
3-12 Thermocouple Control and Display Modes Screen ......................................................................24
3-13 Printer Options Screen ..................................................................................................................25
3-14 Display Options Screen .................................................................................................................26
3-15 Segment Completion Signal...........................................................................................................27
3-16 USB Import & Export Options Screen ...........................................................................................28
3-17 Import & Export Cure Program Library Screen .............................................................................29
3-18 Date and Time Settings Screen ....................................................................................................29
3-19 Advanced Settings Screen.............................................................................................................30
3-20 Alternate PID Settings Screen .......................................................................................................31
3-21 Program Selection Screen............................................................................................................ 32
3-22 Edit Program Screen .....................................................................................................................33
3-23 Run Program Screen .....................................................................................................................34
3-24 Edit Program Screen (8-Step) .......................................................................................................35
3-25 Edit Cure Step Popup (8-Step) .....................................................................................................35
3-26 Graph Screen ................................................................................................................................37
3-27 Precure Operational Test Screen .................................................................................................38
3-28 Slave Mode Graph Screen ..........................................................................................................410
3-29 Alarms Popup Window ..................................................................................................................41
3-30 Max Output Power Warning Popup Window..................................................................................43
3-31 Max Output Power Alarm Popup Window......................................................................................44
3-32 No Output Power Detected Popup Window...................................................................................44
3-33 Event Log Screen ..........................................................................................................................45
3-34 Data Logging Parameters Screen .................................................................................................46
3-35 Data Logging Mode Graph Screen ...............................................................................................47
3-36 Export Data to USB Flash Drive Screen........................................................................................48
3-37 Reprint Completed Cure Screen....................................................................................................49
4-1 Printer Ribbon Installation .............................................................................................................57
4-2. Printer Paper Installation ...............................................................................................................58
6-1. HCS9000B Replaceable Parts.......................................................................................................61
6-3. HCS9200B Replaceable Parts ......................................................................................................64
6-4. HCS9200B / HCS9200B Accessories........................................................................................... 67
A-1. Vacuum Bag Layup Materials .......................................................................................................70

Reference Pages HCS9000B/HCS9200B
Hot Bonder/Controller
vi HEATCON® COMPOSITE SYSTEMS HCS9000B/HCS9200B-OMI-405
LIST OF TABLES
Table Title Page
1Technical Specification...................................................................................................................viii
3-1 Controls and Indicators HCS9000B - Single Zone.........................................................................10
3-2 Controls and Indicators HCS9200B - Dual Zone ...........................................................................11
3-3 Alarm Popup Windows...................................................................................................................42
4-1 Equipment Required for Testing.....................................................................................................54
5-1 Troubleshooting Guide...................................................................................................................59
6-1 HCS9000B Replaceable Parts List ................................................................................................64
6-2 HCS9200B Replaceable Parts List ................................................................................................68
6-3 HCS9200B / HCS9200B Accessories List .....................................................................................70

HCS9000B/HCS9200B Abbreviations and Acronyms
Hot Bonder/Controller
HCS9000B/HCS9200B-OMI-405 HEATCON® COMPOSITE SYSTEMS vii
ABBREVIATIONS AND ACRONYMS
ASCII American Standard Code for Information Interchange
AC Alternating Current
bit Binary digit (one bit of data - either 0 or 1)
CAGE Contractor and Government Entity (Code)
CB Circuit Breaker
CCA Circuit Card Assembly
cfm Cubic feet per minute
COM Communication
COTS Commercial off The Shelf
CPU Central Processor Unit (Computer)
cu. ft. Cubic foot/feet
DC Direct current
DEG Degree
Dev Deviation
ENT ENTER Key
ESC ESCAPE Key
FIFO First-In-First-Out
GUI Graphical User Interface
HCS HEATCON®Composite Systems
ºF Degree Fahrenheit
ºC Degree Celsius
Hi High
Hz Hertz (cycles)
In. Hg. Inches of Mercury
ID Identification
I/O Input/Output
LCD Liquid Crystal Display
LED Light Emitting Diode
Lo Low
mb Millibars
KPa Kilo Pascal
No. Number
OEM Original Equipment Manufacturer
PB Proportional Bandwidth
P/N Part Number
Par Paragraph
PC Personal Computer
PID Proportional Integral Derivative
psi Pounds per square inch
QD Quick Disconnect
S/N Serial Number
Sniffer Vacuum through-bag- connector with check valve
SSD Solid State Flash Disk
TC Thermocouple
USB Universal Serial Bus
V Volt

Warnings and Cautions HCS9000B/HCS9200B
Hot Bonder/Controller
viii HEATCON® COMPOSITE SYSTEMS HCS9000B/HCS9200B-OMI-405
WARNINGS AND CAUTIONS
WARNINGS and CAUTIONS are used throughout this manual to alert personnel to the hazards associated
with the operation and use of the HCS9000B/HCS9200B Composite Repair Set (Hot Bonder), and with the
materials and processes used to repair composite structures.
A WARNING statement is used where serious personal injury or death may result if the instructions are not
observed.
A CAUTION statement is used where injury to personnel, damage to equipment or improper results might
occur if the instructions are not observed.
Below are the WARNINGS and CAUTIONS used in this manual. Before operating this equipment read and
understand these WARNINGS and CAUTIONS.
WARNING
USE OF THIS EQUIPMENT IN A MANNER NOT IN ACCORDANCE WITH THE MANUFACTURER’S
PROCEDURES AND/OR DIRECTIVES SPECIFIED IN THIS MANUAL MAY IMPAIR OR NEGATE
THE PERSONNEL AND EQUIPMENT PROTECTION FEATURES PROVIDED BY THIS
EQUIPMENT.
WARNING
BEFORE CONNECTING ELECTRICAL POWER TO THE HOT BONDER/CONTROLLER, ENSURE
THAT THE POWER PLUG INSTALLED ON THE INPUT POWER CABLE IS OF AN APPROVED
TYPE, WITH PROPER RATINGS FOR THE INTENDED USE, AND IN ACCORDANCE WITH
LOCAL ELECTRICAL CODES AND ACCEPTED INDUSTRY SAFETY STANDARDS. (REFER TO
LOCAL CODES)
WARNING
BEFORE CONNECTING ELECTRICAL POWER TO THE HOT BONDER/CONTROLLER, ENSURE
THE FACILITY SOURCE POWER IS RATED FOR THE REQUIRED AMPERAGE AND THAT THE
HOT BONDER/CONTROLLER IS EQUIPPED WITH A POWER CABLE AND PLUG CAPABLE OF
THAT AMPERAGE. (REFER TO LOCAL CODES)
WARNING
LETHAL VOLTAGES ARE PRESENT IN THE UNIT IS CONNECTED TO THE SOURCE POWER.
ENSURE ALL ELECTRICAL POWER IS REMOVED FROM THE UNIT BEFORE ATTEMPTING
ANY MAINTENANCE ACTION. ONLY PROPERLY TRAINED TECHNICAL PERSONNEL SHALL
PERFORM INTERNAL CHECKS.
WARNING
THE POSSIBILITY OF FIRE AND/OR SERIOUS DAMAGE TO THE AIRCRAFT STRUCTURE MAY
RESULT FROM IMPROPERLY PLACING THERMOCOUPLES OUTSIDE THE FOOTPRINT OF
THE HEAT BLANKET. ALWAYS ENSURE THERMOCOUPLES ARE PLACED UNDER THE HEAT
BLANKET AND INSIDE THE 2-INCH BOUNDARY OF THE USABLE AREA OF THE HEAT
BLANKET.