BTU TCA User guide

TCA/TCAS SYSTEM MANUAL
Manual Number: TM 5250517 Rev. 0
Issue Date: Apr 15/2003
BTU International
(Corporate
Headquarters)
23 Esquire Road
N. Billerica, MA 01862 USA
Phone: [phone]
Phone: [phone] (Outside MA)
Fax: [phone]
BTU Europe Limited Unit 14 Armstrong Mall, Southwood Summit Centre
Farnborough, Hants, England GU14 ONR
Phone: [phone]
Fax: [phone]
BTU Overseas, Limited 01-116, LHK Building
701 Sims Drive
Singapore 387383
Phone: [phone]
Fax: [phone]
24-Hour Help USA: 1.800.998.0666
UK: 0.800.96.8910
Ireland: 1.800.55.7687
Mexico: 1.800.547.1783
TCA11014

LIMITATION OF LIABILITY
BTU International, Inc. (BTU) believes that the information in this publication is correct as of the print date. BTU
reserves the right to make changes in specifications and information without notice. BTU is not responsible for
inadvertent errors.
The terms and conditions for use and the licensing of BTU products and BTU software are directed by contracts
that are made between BTU and its customers. Representations of products that are in this document will not be
cause for warranty by or liability to BTU.
BTU will not be liable for damages that include but are not limited to direct, indirect, incidental, special, or
consequential damages (including but not limited to loss of profits) that are related to this document in any way,
even if BTU was advised or aware, or knew or should have known, about the possibility of such damages.
Copyright.
• The products and software programs that are described in this manual are confidential information and
proprietary products of BTU or its licensers.
• No part of this document may be reproduced in any form, including by electronic retrieval systems, without
the prior written permission of BTU.
Registered Trademarks and Trademarks.
• Items noted with ® are registered trademarks.
• Items noted with ™ are trademarks.
Correspondence.
• Contact the address on the front cover with questions and concerns that are related to this document.
Copyright 2001 BTU International, Inc. All rights reserved. Printed in the USA.
LIST OF REVISIONS
Revision
Number
Revision
Date
Comments
Revision 0 Apr 15/2002 This manual supersedes all revisions of TPM 10054.

Contents
TM 5250517 Rev. 0
Page Contents-1
Apr 15/2003
TCA/TCAS SYSTEM MANUAL
CONTENTS
LIMITATION OF LIABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
LIST OF REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
How-to-Use Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Technical Help. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Equipment Label.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2
Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3
Manual Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4
Related Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4
Symbols, Abbreviations, and Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
Precautions for Hydrogen Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
Material Safety Data Sheets.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
Safety Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5
Electrical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7
Standard and Optional Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-15
Safety Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-18
Lockout/Tagout Procedure (Without Main Disconnect Switch Option). . . . . . . . . . . . . . . S-18
Lockout/Tagout Procedure (With Main Disconnect Switch Option). . . . . . . . . . . . . . . . . S-19
Emergency Stop Procedure.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-22
Disposal of Equipment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-23
Environmentally Responsible Recycling of Equipment.. . . . . . . . . . . . . . . . . . . . . . . . . S-23
Shipping Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-23
End-of-Life Decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-23
Disposal of Hazardous Maintenance Materials.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-24
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Equipment Features and Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Equipment Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Frame and Panel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Conveyor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical and Control System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Electrical Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Conveyor Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Gas Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Light Tower, Three- or Four-Color (Option).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Main Control Panel (MC-98). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Atmosphere System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Atmosphere Control Panel (Hydrogen Furnaces Only). . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Heating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Muffle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Facility Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Plumbing Requirements.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Water Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Exhaust Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
CDA and N2 Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Air Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
H2 Requirements (If Applicable).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Electrical Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Heating System Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

TCA/TCAS SYSTEM MANUAL
Contents
TM 5250517 Rev. 0
Page Contents-2
Apr 15/2003
Cooling System Requirements.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Equipment Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Receive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Move. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Store. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Install the Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Adjust the Furnace Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Install PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Install Light Tower (Option).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Set Up the Product Feed Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Assemble the Equipment (If Shipped in Separate Sections). . . . . . . . . . . . . . . . . . . . . . 2-18
Connect Electrical Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Summarized Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Calculate Cover Gas Flow (All Furnaces). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Calculate Atmosphere Curtain Flow Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Start and Operate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Normal Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Emergency Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Idle the Furnace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
System Alerts or Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Respond to Interlock and Alarm Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Operate Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Operate the Belt Cleaners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Operate the O2 Analyzer (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Operate an EMO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Operate the Product Feed Conveyor (Option).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Operate the Hand Crank (Option).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Operate the Heat Barrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Troubleshoot the Frame and Panel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Troubleshoot the Conveyor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Troubleshoot the Conveyor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Troubleshoot the Atmosphere System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Troubleshoot the Temperature System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Troubleshoot the Atmosphere System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Troubleshoot the O2 Analyzer (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Troubleshoot the Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Troubleshoot the Electrical and Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Troubleshoot the Product Tracking/Smart Tracker. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Troubleshoot the Furnace Controller System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Troubleshoot the UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Preventive Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Overall Furnace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Inspect the Separation Joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Adjust the Furnace Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Clean the External Surfaces.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Replace the Silicone Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Frame and Panel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Clean the Exhaust Stacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Conveyor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Clean the Conveyor System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Maintain the Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Contents
TM 5250517 Rev. 0
Page Contents-3
Apr 15/2003
TCA/TCAS SYSTEM MANUAL
Lubricate the Drive Chain and the Drive Chain Sprockets. . . . . . . . . . . . . . . . . . . . . . . 5-23
Lubricate the Idler Pulley Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Fill the Drive Motor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Adjust the Exit Table Drive Pulley (External Belt Drive). . . . . . . . . . . . . . . . . . . . . . . . 5-29
Adjust the Conveyor Belt System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Adjust the Exit Table Drive Pulley (Internal Belt Drive). . . . . . . . . . . . . . . . . . . . . . . . 5-34
Adjust the Belt at the Entrance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Adjust the Drive Chain Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Adjust the Belt Tracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Replace the Drive Motor Brushes.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Maintain the Ultrasonic Belt Cleaner (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Electrical and Control System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Replace the UPS Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Calibrate TC Inputs and Belt Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Adjust Product Tracking Sensor.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Reset CB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Replace a Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Replace the MCP Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Replace the Light Tower Lamps.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Delete Temporary Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Run Error-checking (Windows NT Systems). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Run Disk Defragmenter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Atmosphere System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Replace the Air/Gas Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Replace O2 Gas Line Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Adjust Automatic Gas Sampling System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Calibrate the O2Analyzer with Calibrated Gas (Option). . . . . . . . . . . . . . . . . . . . . . . . 5-70
Calibrate the MSA Gas Monitor System with Calibrated Gas (Option). . . . . . . . . . . . . . . 5-71
Heating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Adjust Temperature-Actuated Water Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Muffle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
CORRECTIVE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Overall Furnace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Leak Test (Metal Muffle Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Frame and Panel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Conveyor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Shorten the Conveyor Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Electrical and Control System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Test Furnace Interlocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Atmosphere System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Test Gas System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Do a Temperature Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Test a Timed Flow Purge (H2Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Heating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
COMPONENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Overall Furnace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Frame and Panel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Replace the Access Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Conveyor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Replace the Drive Return Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Replace the Conveyor Belt (Belt Installed Now).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Install the Conveyor Belt (No Belt Installed Now). . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Replace the Drive Shear Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Replace the Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Replace the Drive Motor Optical Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Replace the Ultrasonic Belt Cleaner (Option).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

TCA/TCAS SYSTEM MANUAL
Contents
TM 5250517 Rev. 0
Page Contents-4
Apr 15/2003
Electrical and Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Replace the UPS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Replace the Main Power Disconnect Switch (Option). . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Replace the FCU.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Replace the PC.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Replace the Belt Speed Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Replace the SSR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Replace the Light Tower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Atmosphere System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Replace the Flowmeters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Replace the Atmosphere Curtain Assembly (Teflon-Coated).. . . . . . . . . . . . . . . . . . . . . 7-38
Replace the Atmosphere Curtain Assembly (Sheet-Metal). . . . . . . . . . . . . . . . . . . . . . . 7-40
Replace a Gas Dispersion Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Heating System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44
Replace the TC.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Replace the Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50
Muffle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50
DRAWINGS, SPECIFICATIONS, OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Engineering Diagram and Equipment Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Electrical Diagram Lines and Line Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Electrical Wire Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Plumbing Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Ordering Spare Parts or Warranty Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
MATERIAL SAFETY DATA SHEETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
CALIBRATION SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
VENDOR MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

Intro
TM 5250517 Rev. 0
Page I-1
Apr 15/2003
TCA/TCAS SYSTEM MANUAL
INTRODUCTION
I.1 Contents.
How-to-Use Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Technical Help. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Equipment Label.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2
Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3
Manual Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4
Related Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4
Symbols, Abbreviations, and Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
I.2 How-to-Use Instructions.
I.2.1 Read this section so that you understand how to use the manual.
I.2.2 You can use the printed manual or the online manual. Adobe Acrobat Reader® is installed
on your PC so that you can use the manual online.
I.3 Technical Help.
I.3.1 If you have problems when you install or operate the equipment, review the installation
procedures. If the problem continues, call BTU. Use the telephone numbers that are printed
on the front cover of this manual.
I.3.2 Keep the reference manuals and serial number available when you call.

TCA/TCAS SYSTEM MANUAL
Intro
TM 5250517 Rev. 0
Page I-2
Apr 15/2003
I.4 Equipment Label.
I.4.1 The serial number of the equipment is on the front cover of the manual and on the
equipment label (located near the electrical connections). Make sure that you know the
serial number when you call for information.
I.4.2 For a typical equipment label, refer to Figure I-1.
Figure I-1. Equipment Label (Typical)
Figure Legend
Item Description
1 Serial number
2 Model number
International
N. Billerica, MA USA 01862
SERIAL
MODEL
ATMOSPHERE
PH.
HZ.
VOLT
AMP
KVA
IN RUSH
AMP SEC.
MAX TEMPERATURE
SHIPMENT DATE
MISC1001R1
1
2

Intro
TM 5250517 Rev. 0
Page I-3
Apr 15/2003
TCA/TCAS SYSTEM MANUAL
I.5 Tools and Equipment.
I.5.1 The following tools are necessary to maintain the equipment:
• Ammeter (clip-on)
•Cutters
• Drift pin punch set
• Feeler gauges
•Greasegun
•Hammer
• Hex wrenches
• Lamp puller (or a plastic sleeve)
• Multimeter (digital or analog)
• Needle-nose pliers
• SAE and metric wrenches
•Screwdriverset
•Stainlesssteelwirebrush
• Torque wrench, 0-50 in.-lb
• Torque wrench, 0-50 ft-lb
• Vacuum cleaner with HEPA-rated filter bag
I.5.2 The following consumable items are necessary to maintain the equipment:
• Adhesive, high-temperature RTV gasket or sealant
• Brush, stiff, non-metallic, bristle
• Brush (to apply lubricant)
• Cleaner (glass or other non-abrasive grease-cutting cleaner)
• Detergent (mild)
• Detergent (strong)
• Identification tags
• Isopropyl alcohol
• Lubricating grease (NSK LG2)
•Oil,gear
• Oil, gear and chain lubricating
• Pads, plastic scrub
• Thread adhesive (Loctite No. 222 or equivalent)
• Thread dope, nickel anti-seize pipe
• Thread tape (Teflon®)
• Water (distilled or de-ionized)
• Wipes, lint-free

TCA/TCAS SYSTEM MANUAL
Intro
TM 5250517 Rev. 0
Page I-4
Apr 15/2003
I.6 Manual Description.
I.6.1 For a description of manual sections, refer to Table I-1
Table I-1. Description of Chapters and Appendices
I.7 Related Manuals.
I.7.1 For other manuals that are used to operate the equipment, refer to Table I-2
Table I-2. Related Manuals
Section Description
INTRODUCTION Gives instructions to use this manual and references to
technical resources that are available from BTU.
SAFETY Gives safety related practices that are used in this
manual and dangers that are related to the use of the
equipment.
Chapter 1, SYSTEM DESCRIPTION Gives a description of the equipment.
Chapter 2, INSTALLATION Gives equipment install data and instructions.
Chapter 3, OPERATION Gives procedures to operate the equipment.
Chapter 4, TROUBLESHOOTING Gives procedures to troubleshoot the equipment.
Chapter 5, PREVENTIVE
MAINTENANCE
Gives procedures to maintain the equipment so that
problems do not occur.
Chapter 6, CORRECTIVE
MAINTENANCE
Gives procedures to maintain the equipment when
problems occur.
Chapter 7, COMPONENT
REPLACEMENT
Gives procedures to replace parts of the equipment.
Appendix A, DRAWINGS,
SPECIFICATIONS, OPTIONS
Includes equipment-specific drawings.
Appendix B, RECOMMENDED SPARE
PARTS
Includes parts that are available to support operation
and maintenance of the equipment.
Appendix C, MATERIAL SAFETY DATA
SHEETS
Includes MSDSs that may apply to hazardous materials
related to your equipment.
Appendix D, CALIBRATION SHEETS Includes the calibration sheets from the final test of yor
equipment.
Appendix E, VENDOR MANUALS Includes vendor manuals that apply to your equipment.
Manual Title Contents Qty
WINCON Operation Manual Gives instructions to operate the PC 1

Intro
TM 5250517 Rev. 0
Page I-5
Apr 15/2003
TCA/TCAS SYSTEM MANUAL
I.8 Symbols, Abbreviations, and Terms.
NOTE
NOTE
The following table is applicable to all BTU products.
I.8.1 For a list of symbols, abbreviations, and terms that are used in this manual, refer to Table
I-3
Table I-3. Symbols, Abbreviations, and Terms
Symbol/
Abbreviation/Term Definition
+/- Plus or minus
<Lessthan
</= Less than or equal
=Equal
> Greater than
>/= Greater than or equal
°C Degree Celsius
AAmpere
ac or AC Alternating Current
AH Alarm Horn (or Audible Alarm)
Alarm A furnace alarm condition warning, usually stops the furnace operation unless
it is a deviation alarm
Alert A furnace alert condition, warns of an impending alarm condition (usually, a
temperature or gas condition has exceeded the alert deviation limits)
Bill of Materials A list of all parts and assemblies that are used to build a system (also BOM)
BOM Bill of Materials
Btu British Thermal Units
CAP Cooled Air Plenum
Catenary The curve or loop that a flexible belt or chain forms when it is supported only at
two points, as with an anchor chain or the mesh belt on your conveyor furnace
CB Circuit Breaker
CCU Central Cooling Unit
CCW Counterclockwise
CDA Compressed, dry air
CE Community of Europe
CFS Conveyor Furnace System
Circuit Breaker An electrical device made to open a circuit automatically on a predetermined
over current to prevent equipment damage
cm Centimeter
cm/min Centimeter per minute
CON Contactor
Control Cabinet The housing for the control panel, whether mounted on the furnace or
separately mounted

TCA/TCAS SYSTEM MANUAL
Intro
TM 5250517 Rev. 0
Page I-6
Apr 15/2003
Control Circuit The circuit of a control apparatus or system that carries the electrical signals
directing the performance of the controller
Controller A device or group of devices that serves to govern, in some predetermined
manner, the operation of the furnace or other device (also Furnace Controller)
Cover Gas Any process gas sent into the process chamber to cover the product being
processed. Because it is a very imprecise term, its use must be avoided
wherever more than one kind of processing is likely to be encountered
CR Control Relay
CT Current Transformer
CW Clockwise
dc or DC Direct Current
DCA Direct Chip Attachment (use in surface mount technology)
Dewpoint Meter Used to measure moisture in the process atmosphere (refer to Hygrometer)
DISC Disconnect Switch
DOP Dioctyl Phthlate
Eductor Cooling option for enhanced convection cooling in conveyor furnaces
Emergency Stop Button Used to stop the conveyor and shut off the heaters in an emergency while
controller circuits and safety devices continue to operate
EMO Emergency Off (refer to Emergency Stop Button)
EMS Emergency Stop Button (refer to Emergency Stop Button)
ENCO Optical Encoder
EPB Emergency Push Button (refer to Emergency Stop Button)
EPO Emergency Power Off Button (refer to Emergency Stop Button)
Equilibrium Zone The zone or zones of a furnace where the temperature continues to increase
until the entire product has a uniform soak temperature
EMO Emergency Stop Button
Explosive Gas Any gas that burns with explosive force when mixed with O2from the air or
from an O2-rich compound (for example, methane or H2)
FCU Furnace Control Unit
FEC Heater Fully enclosed coil heaters that have a durable iron-chromium-aluminum alloy
resistance element embedded in a cast-fiber insulating plate to give clean,
energy efficient continuous processing at temperatures up to 1150°C
Symbol/
Abbreviation/Term Definition

Intro
TM 5250517 Rev. 0
Page I-7
Apr 15/2003
TCA/TCAS SYSTEM MANUAL
Forming Gas Any mixture formed by combining two or more gases. Where a furnace uses H2
as its primary process gas, the term forming gas usually refers to the mixture
formed when a large amount of inert N2is mixed with a small amount of highly
reactive H2(often in a 96 percent N2: 4 percent H2ratio). This kind of forming
gas is used to remove H2atmosphere from the process chamber. The slight
admixture of H2lets impurities in the product complete the process of binding
with H2, yet the gas thus formed is non-explosive when mixed with outside air.
Because it is very imprecise, the term must be avoided in favor of purge gas
(96 percent N2: 4 percent H2) or emergency purge gas (100 percent N2)
FRU Field replaceable unit
FS Flow Switch
ft Foot/Feet
FU Fuse
Furnace Control Unit The microprocessor of the furnace system (FCU)
Furnace Controller A computer interface to the FCU that incorporates data storage capabilities
(also called Controller, Computer, or PC)
gal gallon
Gas Refer to cover gas, explosive gas, forming gas, inert gas, non-explosive gas,
process gas, and purge gas
GEM Generic Equipment Module (refer to Generic Equipment Module)
Generic Equipment Module A host communication software that is used with the windows version of the
controller software
GND Ground
gpm Gallons per minute
H2Hydrogen
H2OWater
HAP Heated Air Plenum
Host A remote supervisory computer system that uses the management software to
interface with the furnace
hp Horsepower
Hr Hour
HTR Heater
HVAC Heating, Ventilation, Air Conditioning
Hygrometer Used to measure the amount of moisture in the process atmosphere (also
Dewpoint meter)
Hz Hertz
ID Inside Diameter
in. Inch
Inconel™ 601 A high-nickel, chromium and silicon alloy selected for its resistance to corrosion
and its high heat transfer characteristics
Symbol/
Abbreviation/Term Definition

TCA/TCAS SYSTEM MANUAL
Intro
TM 5250517 Rev. 0
Page I-8
Apr 15/2003
Inert gas A gas whose chemical properties make it non-reactive. For example, N2or CO2
are inert because they have no free electrons to form a molecular bond with
other elements or compounds
INST Instrument
Interlock A switch device that limits or inhibits the operation of a unit or furnace to
prevent damage or personal injury.
IPC Institute for Interconnecting and Packaging Electronic Circuits
ipm Inches per minute
kg Kilogram
kPa Kilopascal
kVa Kilovolt-amperere
kW Kilowatt
lLiter
l/hr Liter per hour
l/min Liter per minute
lb Pound
LH Left Hand
Lockout/Tagout An OSHA safety standard (29 CFR 1910.147) procedure that requires locks,
tags, and hasps to disable equipment before you maintain, clean, and inspect
the equipment
LRE Low Resistance End
LS Limit Switch
LT Light
MMeter
Magnehelic An instrument for measuring static gas pressures (also manometer)
Manometer An instrument for measuring static gas pressures, usually in inches of water
column (also magnehelic)
Material Return
Authorization Number
An authorization number assigned by BTU that is used when you return parts
for warranty replacement (also MRA number)
MB Megabyte
Menu Driven A type of software program that lets the operator make selections from a list of
options or functions on the screen
mm Millimeters
mm/min Millimeters per minute
MRA Number See Material Return Authorization Number
MSDS Material safety data sheet
MTR Motor
Mu Micron
Muffle The chamber that surrounds the product as it enters and leaves the furnace
Symbol/
Abbreviation/Term Definition

Intro
TM 5250517 Rev. 0
Page I-9
Apr 15/2003
TCA/TCAS SYSTEM MANUAL
N.m Newton meter
N2Nitrogen
NFPA National Fire Protection Agency
Non-Explosive Gas A gas or gas mixture that is inert and non-combustible such as N2
NPT Nominal Pipe Thread
ØPhase
O2Oxygen
OD Outside Diameter
OEM Original Equipment Manufacturer
Original Equipment
Manufacturer
Original equipment manufacturer, products purchased from other
manufacturers for use in the furnace (for example, the O2analyzer or the UPS)
OL Overload
Orifice Plate A perforated panel that is used to distribute an even flow of air or gas from the
heaters to the process chamber (also Heated Air Panel)
OSHA Office of Safety and Health Administration
Office of Safety and Health
Administration
Occupational Safety and Health Administration, the regulatory body that
oversees work place safety in the U.S.
PB Push Button
PC Personal Computer
Personal Computer Display
Input Unit
Part of the control system that uses the MS-DOS version of furnace controller
software (superseded by WINCON)
PCDIU Personal Computer Display Input Unit
PID Proportional Integral Derivative
PL Plug
Plenum Module Assembly The upper and lower heated zone includes a plenum area where the gases are
heated, recirculated, and forced through the perforated orifice plate in the
plenum to heat the products on the conveyor system
PLL Progammable Logic Controller
PN Part Number
POT Potentiometer
PPC Proportional Pressure Controller
ppm Parts per million
Process Gas The gas or gas mixture used in a chemical process within a furnace
Profile A graphic composite of the process zone temperatures over the length of the
furnace as monitored by profile TCs
Proportional Integral
Derivative
A mathematical algorithm used to control to a setpoint
PRX Proximity Switch
PS Pressure Switch
Symbol/
Abbreviation/Term Definition

TCA/TCAS SYSTEM MANUAL
Intro
TM 5250517 Rev. 0
Page I-10
Apr 15/2003
psi Pounds per square inch
psia Pounds per square inch absolute
psig Pounds per square inch gage
Purge gas Any non-explosive gas or gas mixture used to remove a process gas from the
furnace process chamber. Because it is inert and relatively inexpensive, N2is
usually the purge gas of choice, especially for emergencies
PWRS Power Supply
qt/min Quarts per minute
RA Number Return Authorization Number
Ramp The process of rapid heating such that when graphed over time, would form an
incline that looks like a ramp
RCF Refractory Ceramic Fiber
Refractory Ceramic Fiber A type of high temperature insulation used in the furnace
RCS Retractable Center Support
Ready State A mode of operation when the furnace has stabilized and is ready to process
products
RECP Receptacle
RES Resistor
Return Authorization
Number
An authorization number assigned by BTU that is used when returning parts for
paid repair (also RA number)
RH Right Hand
RMS Root mean square
scfm Standard cubic feet per minute
SCR Silicon Controlled Rectifier
Semiconductor Equipment
and Materials International
Give safety standards for electrical equipment
SEMI S2 Semiconductor Equipment and Materials International
SMEMA Surface Mount Equipment Manufacturer’s Assocation, which merged with the
Institute for Interconnecting and Packaging Electronic Circuits (IPC). IPC/
SMEMA council includes suppliers to electronics assemblers. It starts and drives
technical, managerial, and financial programs to enhance working relationships
and equipment compatibility within the electronics assembly industry
SMG System Monitor Graphic
SOL Solenoid
Sparger A device that sends air or gas into the atmosphere surrounding product being
processed for full gas infiltration of the product and efficient evacuation of
effluents
Spike The high temperature or reflow zone of an SMT furnace where the product is
exposed to a rapid increase in temperature, which forms a spike in a heat
profile graph
SS Selector Switch
SSR Solid State Relay
Symbol/
Abbreviation/Term Definition

Intro
TM 5250517 Rev. 0
Page I-11
Apr 15/2003
TCA/TCAS SYSTEM MANUAL
TTransformer
TAS Temperature Actuated Switch
TB Terminal Block
T/C or TC Thermocouple
Thermocouple Used to measure temperature based on the fact that wire of dissimilar
elements (such as copper and iron) change in their conductivity with changes
in temperature. TCs send temperature input to controller software to
automatically shut down heaters in case of overtemperature
TR Timing Relay
Trim Pot A miniature trimming potentiometer which usually has a small screw
adjustment
TRS Turbo Reflow Solder
Uninterruptable Power
Supply
A device that is used as an emergency power supply when the primary source
of power to the system is lost
UPS Uninterruptable Power Supply
USBC Ultrasonic Belt Cleaner
VVolt
Vac Volts Alternating Current
Vdc Volts Direct Current
WWatt
WINCON (Windows® software)
WINCON Controller
Software
Proprietary software that controls the operation of BTU thermal processing
equipment that uses Microsoft Windows®
Symbol/
Abbreviation/Term Definition

TCA/TCAS SYSTEM MANUAL
Intro
TM 5250517 Rev. 0
Page I-12
Apr 15/2003

Safety
TM 5250517 Rev. 0
Page S-1
Apr 15/2003
TCA/TCAS SYSTEM MANUAL
SAFETY
WARNING
WARNING
!
The customer must be aware of the outgasses and emissions of their
process. Outgases and emissions can cause injury. Also, the customer
should investigate the need for an air permit for organic flux emissions.
WARNING
WARNING
!
You risk serious injury and cancelled manufacturer’s warranty if you do not
obey the instructions in this manual.
S.1 Contents.
Precautions for Hydrogen Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
Material Safety Data Sheets.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
Safety Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5
Electrical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6
Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7
Standard and Optional Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-15
Safety Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-18
Lockout/Tagout Procedure (Without Main Disconnect Switch Option). . . . . . . . . . . . . . . S-18
Lockout/Tagout Procedure (With Main Disconnect Switch Option). . . . . . . . . . . . . . . . . S-19
Emergency Stop Procedure.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-22
Disposal of Equipment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-23
Environmentally Responsible Recycling of Equipment.. . . . . . . . . . . . . . . . . . . . . . . . . S-23
Shipping Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-23
End-of-Life Decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-23
Disposal of Hazardous Maintenance Materials.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-24
DANGER
DANGER
!
H2is explosive when it mixes with air.
S.2 Precautions for Hydrogen Equipment.
S.2.1 This equipment may use H2. Make sure that the N2flowrate to the plenums is more than
the cover gas (H2) flowrate into the exhaust.
S.3 Material Safety Data Sheets.
S.3.1 For a description of hazardous materials, refer to Appendix C, MATERIAL SAFETY DATA
SHEETS.
S.3.2 Hazardous materials used with OEM products include MSDSs as required. Refer to
Appendix E, VENDOR MANUALS. You must have the MSDS for all hazardous materials
that are not used with this equipment.

TCA/TCAS SYSTEM MANUAL
Safety
TM 5250517 Rev. 0
Page S-2
Apr 15/2003
S.4 Safety Precautions.
S.4.1 The equipment has high electrical voltages, high temperatures, high gas pressures, and
moving parts. If you obey the instructions in this and other manuals when you install,
operate, and do maintenance of the equipment, you will reduce or prevent exposure to
these dangers.
S.4.2 For precautions that relate to items in the equipment, refer to Table S-1.
Table S-1. Precautions
Precaution Description
General • Do obey all procedures written in this manual (this will protect you from dangers
that other methods can not prevent).
• Do obey all DANGER, WARNING and CAUTION labels.
• Do use only trained personnel to install, operate, and do maintenance.
• Do give instructions to all personnel in electrical, mechanical, compressed gas,
chemical, and other types of safeties that are related to the operation and
maintenance.
• Do use teams of two or more persons to do maintenance. One person must
monitor the controls and indicators, and one person must monitor the system
operation.
• Do wear safety glasses and protective clothing when you do maintenance on the
system.
• Do turn off compressed gases and electric power at the source before you do
maintenance on the system, when possible.
• Do turn off electric power to the system, in accordance with the lockout/tagout
procedure, before you connect or disconnect cables.
• Do close and latch all access panels or doors when you are not doing
maintenance.
• Do periodic checks of the operation of all the safety interlocks.
• Do be extremely careful when you use flammable solvents such as alcohol for
cleaning. Make sure that the electric power is off and the equipment is cool
enough to prevent a fire.
• Do de-energize the system and disconnect the power source before you move the
system.
• Do move equipment carefully. Jolts or drops can damage the equipment.
• Do not remove warning labels from the system.
• Do not operate damaged or leaking equipment.
• Do not operate without cooling fluid available to the system (if applicable).
• Do not wear watches and/or jewelry when you work on electrical equipment.
• Do not override safety interlocks (if a procedure requires work while the power is
on, obey the procedure).
Chemical • Dangerous materials are used for processes and maintenance procedures.
Cleaning solvents, lubricants, adhesives, and other chemicals are recommended in
this manual. Refer to MSDSs, and refer to all local, state, and federal regulations,
when you use chemicals, rags, and brushes to operate and do maintenance. For
hazardous items that are not identified in this manual, the end user must keep
MSDSs.