PVA DeltaTherm IR Cure Module User manual

156B155B155B
DeltaTherm IR Cure Module
Operation Manual
Revision C
WHERE
PRECISION
DRIVES
PRODUCTION

DeltaTherm IR Cure Module
Revision C /September 2022
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157B156B156BThis document is based on information available at the time of its publication. While efforts
have been made to ensure the contents of this manual are accurate, the information
contained herein does not purport to cover all specific details or variations in hardware, or
to provide for every possible contingency in connection with installation, operation, or
maintenance. Features may be described herein which are not present in all hardware and
software systems. Precision Valve and Automation, Inc. assumes no obligation of notice to
holders of this document with respect to changes subsequently made.
158B157B157BPrecision Valve and Automation, Inc. makes no representation or warranty, expressed,
implied, or statutory with respect to, and assumes no responsibility for the accuracy,
completeness, sufficiency, or usefulness of the information contained herein. No warranties
of merchantability or fitness for purpose shall apply.
159B158B158BThis document, including the information contained herein, is the property of
Precision Valve and Automation, Inc. and is considered confidential and proprietary
information. It is delivered on the express condition that it not be used, disclosed, or
reproduced, in whole or in part, for any reason without prior written consent of
Precision Valve and Automation, Inc.
160B159B159BCopyright © 2020
161B160B160BPrecision Valve and Automation, Inc.
162B161B161BAll Rights Reserved.

DeltaTherm IR Cure Module
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370B369B407BTable of Contents
328B327B349B Introduction...........................................................................................................5
329B328B366B PVA Contact Information ........................................................................................................5
330B329B367B Document History.....................................................................................................................5
331B330B368B Safety ..........................................................................................................................................6
332B331B369B Theory of Operation ................................................................................................................ 8
333B332B370B Personal Protective Equipment............................................................................................ 8
334B333B371B Waste Disposal.......................................................................................................................... 8
335B334B372B Hazards Due to Contact ......................................................................................................... 8
350B Operating, Handling, Transportation, and Storage .........................................9
336B335B373B Dust and Debris.........................................................................................................................9
337B336B374B Temperature and Humidity.....................................................................................................9
338B337B375B Location ......................................................................................................................................9
351B SMEMA .................................................................................................................. 10
352B Installation and Setup .........................................................................................11
339B338B376B Installation.................................................................................................................................11
353B Operating Safety................................................................................................. 12
340B339B377B Notices and Warnings ............................................................................................................12
341B340B378B Safety Devices and Guarding...............................................................................................12
367B366B404B Safety Circuit ...................................................................................................................12
368B367B405B Doors..................................................................................................................................12
342B341B379B Exhaust Requirements ..........................................................................................................13
369B368B406B Air Velocity Test Point....................................................................................................13
354B Operation.............................................................................................................. 14
343B342B380B Startup Procedure ..................................................................................................................14
344B343B381B Light Tower Operation ...........................................................................................................15
345B344B382B Machine Safety Check ...........................................................................................................16
346B345B383B Shutdown Procedure.............................................................................................................16
347B346B384B Cycle Stop................................................................................................................................. 17
355B Auto Cycle ............................................................................................................ 18

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356B Manual Mode ....................................................................................................... 20
348B347B385B IR Panels .................................................................................................................................. 20
349B348B386B Conveyor Speed......................................................................................................................21
350B349B387B Conveyor Width .......................................................................................................................21
351B350B388B Conveyor Jog.......................................................................................................................... 22
352B351B389B Sensors .................................................................................................................................... 23
353B352B390B SMEMA Control....................................................................................................................... 23
357B Setup Mode.......................................................................................................... 24
354B353B391B IR Panels .................................................................................................................................. 24
355B354B392B Conveyor Speed..................................................................................................................... 26
356B355B393B Conveyor Width .......................................................................................................................27
357B356B394B Rename Recipe....................................................................................................................... 28
358B357B395B Global Settings ....................................................................................................................... 29
358B Fault Recovery Procedure ................................................................................ 30
359B358B396B Recovery from Emergency Stop or Open Door Error..................................................... 30
360B359B397B Recovery from an Exhaust or Intake Fan Failure............................................................ 30
361B360B398B Recovery from a Parameter Out of Range Error............................................................. 30
362B361B399B Recovery from an Over-Temperature Error......................................................................31
363B362B400B Recovery from an Auto Conveyor Adjust Error................................................................31
359B Error Messages ....................................................................................................32
360B Troubleshooting..................................................................................................35
364B363B401B Calling Technical Support .................................................................................................... 35
365B364B402B Fault Diagnosis....................................................................................................................... 36
361B Maintenance ........................................................................................................37
362B Notes .................................................................................................................... 38
363B Warranty ...............................................................................................................39
366B365B403B PVA Warranty Policy.............................................................................................................. 39
364B Appendix A –Definitions ................................................................................... 40
365B Table of Figures ................................................................................................... 41

DeltaTherm IR Cure Module
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Introduction
163B162B162BBefore you operate this system, read the operation and setup manual. This will help you to
become familiar with the product and ensure successful operation.
164B163B163BIf any questions or problems arise, contact PVA’s Technical Support department.
PVA Contact Information
165B164B164BMain Office PVA
166B165B165BOne Mustang Drive
167B166B166BCohoes, NY 12047
168B167B167BTel [phone]
169B168B168BFax [phone]
170B169B169BWebsite: https://pva.net
171B170B170BEmail: [email protected]
172B171B171BTechnical Support
173B172B172BTel [phone]
174B173B173BEmail: [email protected]
Document History
Revision
Revision Date
Reason for Changes
REV C
September 2022
Exhaust Requirement Update
REV B
January 2020
DeltaTherm Version 1.9 Release
REV A
December 2018
Initial Release
267B266B266BNote: All photographs and CAD model representations in this document are a
“general representation” of the system and its components. The actual appearance
of the system and its components can differ based upon customer specific
configuration.

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Safety
175B174B174BCertain warning symbols are affixed to the machine and correspond to notations in this
manual. Before operating the system, identify these warning labels and read the notices
described below. Not all labels may be used on any specific system.
Always wear approved safety glasses when you operate or work near the
workcell.
Before you operate the system, read and understand the manuals provided
with the unit.
Never put hands or tools in areas with this symbol when the machine is in
operation. A dangerous condition may exist.
Read and understand the manuals provided with the unit before any repairs
or maintenance is done. Only a qualified individual should do service.
Use caution when there are pressurized vessels. Find and repair any leaks
immediately. Always wear appropriate safety equipment when you work
with pressurized vessels or vessels that contain chemicals
Shear hazard from moving parts. Avoid contact.
Do not remove protective guarding.
In situations where inattention could cause either personal injury or damage
to equipment, a warning notice is used.

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Do not smoke near the PVA UV cure machine. Always have a fire
extinguisher available for emergency use.
Before performing any repairs or maintenance to the system, turn off power
and lock out the power disconnect switch.
Warning notices are used to emphasize that hazardous voltages, current,
temperatures, or other conditions that could cause personal injury exist in
this equipment or may be associated with its use. Only qualified personnel
should enter areas designated with this symbol.
Laser light source present. Do not stare directly into the beam. Do not use in
the presence of highly reflective surfaces
Pinch hazard from moving parts. Avoid contact.
Hot surface. Avoid contact.
Warning, Ultraviolet (UV) light hazard. Do not look directly at the UV light
source.

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Theory of Operation
176B175B175BThe DeltaTherm IR Cure Module is an infra-red (IR) curing machine that can handle multiple
boards. Upstream and downstream ends are SMEMA (Surface Mount Equipment
Manufacturers Association) rated for use in a production line. The system is designed to
operate with PVA workcells.
177B176B176BThe operator controls the machine with the operator interface; this includes setup, manual
operation, and automatic operation. Machine status and error messages are shown on the
screen and the light tower. The operator(s) must, by reading the manual or by training,
understand the operation of this machine. Any uses other than those listed above could
result in a dangerous condition and cannot be protected against by the safety features
installed on the system.
178B177B177B
0B0B0BFigure 1: DeltaTherm IR Cure Module Functional Block Diagram
Personal Protective Equipment
179B178B178BOperators must use eye protection. Always wear gloves when handling materials and
solvents. Refer to MSDS sheets on the material being dispensed for other precautions.
Waste Disposal
180B179B179BDispose of all used parts and materials in accordance with local laws and regulations.
Hazards Due to Contact
181B180B180BThe DeltaTherm IR Cure Module is made to minimize injury from contact with any
accessible portion of the machine. In some modes, it is possible to access the work area
while the machine operates. Only a qualified person should do this. All hot surfaces have a
warning label.

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Operating, Handling, Transportation, and
Storage
182B181B181BThe system should have minimal vibration when handled and transported. Use an air-ride
truck for roadway transport. The machine is made to operate in an industrial environment
but abuse will reduce its performance.
Dust and Debris
183B182B182BAll enclosures and connector covers should be closed tightly. Put a cover over the system
if dust or other airborne debris is present in the storage area.
Temperature and Humidity
184B183B183BStorage and operation should be done in an area at 40-105°F (4–41°C) and low humidity.
Do not let the machine have condensation on it.
Location
185B184B184BThe machine should be installed and stored on a level surface away from standing water,
possible overspray, and leaks.

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SMEMA
186B185B185BFor manufacturing lines (multiple machines utilizing conveyor systems), it is necessary for
the individual modules to communicate reliably. Make sure the SMEMA and Intermodule
cables are correctly connected.
268B267B267BNote: On the diagrams, the J# refers to the label on the machine, not the label on the
cable.
187B186B186BThe Surface Mount Equipment Manufacturers Association (SMEMA) Electrical Equipment
Interface Standard is used to make sure the sequence of boards is correct. If these
connections are not in place, boards cannot move from one machine to another.
188B187B187BSMEMA cables have male 14-pin amp-type CPC connectors. The cables are straight-
through so orientation does not matter. On each module, the wire to the J1 plug must
connect to the J2 plug on the machine upstream. Similarly, the J2 plug on each machine
must connect to the J1 plug on the machine downstream, as shown below.
189B188B188B
1B1B1BFigure 2: SMEMA Process Flow

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Installation and Setup
269B268B268BWARNING: The following procedures should be done by qualified persons in
accordance with this manual and applicable safety regulations. A “qualified person”
is defined as “a person or persons who, by possession of a recognized degree or
certificate or professional training, or who, by extensive knowledge, training, and
experience, has successfully demonstrated the ability to solve problems relating to
the subject matter and work.” (ref. ANSI/ASME B30.2-1983.)
Installation
1. 24B23B23BPlug the machine into an appropriate power source as shown on the legend plate on
the module. The electrical service should be correctly grounded and the power
source “clean”. If high power equipment operates off the same source, a line
conditioner may be necessary. Poor quality power can cause errors in machine
operation.
270B269B269BWARNING: Failure to obey electrical specifications can cause damage to the machine
or injury to installation personnel. Electrical hookup must be done by a qualified
electrician and must obey any applicable local standards.
2. 25B24B24BClose any access doors and engage the EMERGENCY STOP button.
3. 26B25B25BTurn the main power switch to “On”.
190B189B189B
2B2B2BFigure 3: Power Switch "On"

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Operating Safety
Notices and Warnings
•27B26B26BUse safety glasses, gloves, and long-sleeved clothing.
•28B27B27BRead and understand all operating manuals before you use this equipment.
•29B28B28BDo not disable the safety features of the machine.
•30B29B29BLock-out and tag the air and power supplies before you clean or service any part
of the system.
•31B30B30BRelieve the pressure before you remove any hose.
•32B31B31BDo not replace any hose with a hose of inadequate pressure rating.
•33B32B32BUse only replacement parts recommended or supplied by the manufacturer.
•34B33B33BStay away from all moving parts when the system is in operation.
Safety Devices and Guarding
191B190B190BThe DeltaTherm IR Cure Module has safety features that protect the operator from hazards
during normal operation of the machine.
271B270B270BNote: Do not bypass, disable, or tamper with the safety features. Precision Valve &
Automation, Inc. is not responsible for any damages incurred, mechanical or human,
because of changes or destruction of any safety features.
Safety Circuit
192B191B191BThe main power to the machine is monitored and controlled by the safety circuit. The
safety circuit has a control relay and one or more safety devices. The tripping contact of
the relay will disconnect power if the relay fails. Self-checking consists of positive guided
contacts which are mechanically forced to operate together. If the relay fails, the power
contact will open. The safety devices monitor the state of the EMERGENCY STOP button
and other safety mechanisms. When the safety relay detects that one or more of the safety
devices is open, the power to the motors and pneumatics is stopped.
Doors
193B192B192BAccess to the machine is provided by two doors. Modules have door protection through a
non-defeatable limit switch. The IR panels are disabled if a door is open.

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Exhaust Requirements
Machine
Exhaust
Requirement
Machine Duct Size
Air Velocity at Test
Point (ft/min)
Air Velocity at
Test Point (m/sec)
DeltaTherm 4’
200 CFM
4” (102mm)
2292
11.6
DeltaTherm 8’
300 CFM
6” (152mm)
1528
7.8
DeltaTherm 8’ H
140 CFM
6” (152mm)
713
3.6
DeltaTherm 12’
600 CFM
6” (152mm)
3056
15.5
DeltaTherm 12’ H
210 CFM
6” (152mm)
1070
5.4
DeltaTherm 16’
1000 CFM
6” (152mm)
5093
25.9
DeltaTherm 16’ H
280 CFM
6” (152mm)
1426
7.2
194B193B193BNote: Check machine specifications. Custom order machines and processes may require
higher exhaust flow rates.
Air Velocity Test Point
195B194B194BMeasure the velocity at the inlet to the factory supplied duct.
196B195B195B
3B3B3BFigure 4: Air Velocity Test Point

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Operation
272B271B271BNote: The screens shown in this manual are examples. However, the terminology
used on the screens is consistent for all machines. ON/OFF options are displayed by
showing black background with white lettering for ON and white background with
black lettering for OFF.
Startup Procedure
1. 35B34B34BClose all doors.
2. 36B35B35BEngage the EMERGENCY STOP button.
197B196B196B
4B4B4BFigure 5: Emergency Stop Button
3. 37B36B36BTurn the main power switch to ON.
4. 38B37B37BPush the green POWER ON button on the front of the DeltaTherm module.
198B197B197B
5B5B5BFigure 6: Power On Button

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5. 39B38B38BEnter your password as necessary, if in protected mode.
6. 40B39B39BOperate the system as necessary.
199B198B198B
6B6B6BFigure 7: Enter Password
Light Tower Operation
200B199B199BThree stacked indicator lights and a buzzer are used to show the machine status. The
lights are green, amber, and red. The buzzer is below the green light. The lights are visible
from all sides of the machine. The indicators operate as follows:
•41B40B40BThe green light is on when the machine is in Auto Cycle and operates within
specified parameters. It is off at all other times.
•42B41B41BThe amber light is on when the machine is in Auto Cycle but the specified
parameters have not been reached. It is off at all other times.
•43B42B42BThe red light is on steady when the machine is not in Auto Cycle due to operator
intervention. It flashes when the machine is in cycle, but the cycle is stopped
because of a machine problem. It is off at all other times.
•44B43B43BThe buzzer cycles when the red light flashes with machine errors. It also cycles
briefly when a board is at the end of the machine and must be unloaded (if the
offload alert option is selected in the Setup mode).
State
Red
Amber
Green
Buzzer
Cycle Stop
ON
OFF
OFF
OFF
Auto Cycle
OFF
ON
OFF
OFF
In Cycle
OFF
OFF
ON
OFF
Machine Error
FLASH
OFF
OFF
FLASH
7B7B7BFigure 8: Light Tower & Buzzer Status

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Machine Safety Check
201B200B200BWhen the machine is started, it must initialize. After it has initialized successfully, the
operator interface shows the following screen:
202B201B201B
8B8B8BFigure 9: PVA Screen
203B202B202BThe machine safety check ensures that the DeltaTherm IR Cure Module safety devices
(emergency stop, door interlocks, etc.) operate correctly. For the startup procedure, the
operator must start and complete the safety check successfully. After you start the safety
check, you must activate and deactivate the safety devices. Some safety checks are timed
and will cause a failure if the action is not done in the set time.
Shutdown Procedure
204B203B203BDo the following procedure to shut down the cure module.
1. 45B44B44BWait for all boards to clear the cure module.
2. 46B45B45BPress Auto Stop on the OIT. Wait for the PVA screen to appear.
3. 47B46B46BWait one minute for the module to cool. The exhaust fan will be on.
4. 48B47B47BTurn the main power switch to OFF.
5. 49B48B48BMake sure you remove all parts before you shut down the cure module.
273B272B272BCAUTION: If you plan to perform maintenance during the shutdown, be sure to lock
out and tag the machine.

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Cycle Stop
205B204B204B
9B9B9BFigure 10: Cycle Stop
206B205B205BOptions in Cycle Stop are: Auto Cycle, Manual, and Setup.
Select “F1” or the auto cycle icon to operate the module in Auto Cycle.
Select “F3” or the manual icon to operate the module in Manual mode.
Select “ESC” or the settings icon to go to Setup mode and view or
change the operating parameters of the module.
Select the Home icon or “F3” from any mode to return to Cycle Stop.

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Auto Cycle
207B206B206BAuto Cycle is the normal operating mode for the DeltaTherm IR Cure Module. In Auto Cycle,
the cure module can operate as part of a production line. All communication with adjacent
machines is done without operator input. In Auto Cycle, the machine uses the parameters in
setup mode. The screen below shows Auto Cycle with four zones top and bottom.
208B207B207B
10B10B10BFigure 11: Auto Cycle
1. 50B49B49BThe Panel Temperature shows the current temperature of the heater panel.
2. 51B50B50BThe Panel Temperature Setpoint shows the current recipe’s temperature setpoint
of the heater panel.
3. 52B51B51BThe At Temperature indicator will light up when the panel temperature is within
the allowable setpoint deviation value.
4. 53B52B52BThe Current Recipe Name will display at the top of the screen.
5. 54B53B53BThe Board Counter displays the number of boards in the oven. In the event of an
incorrect value (PIP flashing), press and hold for 5 seconds to reset this to zero
6. 55B54B54BThe Autocycle Messages section displays the current Auto Cycle state and status
messages.
7. 56B55B55BPress to the Heater Panel Trend icon to view a graph of panel temperature values
over time.
8. 57B56B56BTo view the next set of panels and zones, press the Next Zone button.
9. 58B57B57BThe SMEMA Status shows the current status of SMEMA inputs and outputs.
10. 59B58B58BThe current Conveyor Speed will display at the bottom of the screen.

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•60B59B59BWhen in Auto Cycle, the DeltaTherm IR Cure Module operates the exhaust fan
and the intake fan.
•61B60B60BThe IR panels will start and increase to the set system parameters. It may take a
few minutes to increase to the set values.
•62B61B61BWhen the machine is in the range of the system parameters, auto cycle will start.
Differences in the parameters may occur to maintain optimum conditions.
274B273B273BNote: With two-sided IR ovens, the upper panels may indicate temperatures higher
than the setpoint due to absorption of energy from the lower panels. This is normal.
•63B62B62BIf the DeltaTherm IR Cure Module is the last machine in a line, the alarm will
signal when a board exits. This only occurs if a downstream SMEMA signal is not
present.
•64B63B63BWhen the conveyors stop for a board to be removed, the cure module will
maintain the parameters. The module will not time-out if a board is not removed.
•65B64B64BIn Auto Cycle, the PLC will send a signal through the RS485 cable to the next
machine every 5 seconds to tell the next machine the width of the conveyor.
•66B65B65BPush the Home Button on screen or F3 Key to leave Auto Cycle at any time.
Boards in the system are not removed when you exit.
275B274B274BNote: Make sure all boards have exited the system before you exit Auto Cycle.

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Manual Mode
IR Panels
209B208B208BThe panel temperature is shown for each zone. A zone is an area in the oven that is
controlled and monitored independent of other areas. Usually an oven has four zones.
210B209B209B
11B11B11BFigure 12: Manual IR Panels
1. 67B66B66BSelect the Heater Panel switch to turn the desired panel on or off. The indicator to
the left of the switch will show the heat output. The heater panel will heat up to the
current setpoint.
2. 68B67B67BThe Setpoint boxes are the target set points for each zone and heater panel. To
change the target Setpoint, press the designated box. A new screen will be shown.
•69B68B68BThe left side box in the Zone Control area is the target temperature (display
temperature is filtered) for each zone and the deviation point for that zone.
•70B69B69BTouch the screen and a keypad will be shown.
•71B70B70BEnter the necessary value.
•72B71B71BPush ENT, and the zone screen will be shown again.
3. 73B72B72BThe Actual boxes show the actual temperatures (display temperature is filtered) for
each zone.
4. 74B73B73BSelect Apply to All to copy the setpoints of the Zone 1 upper and lower heater panel
to every zone and panel.
5. 75B74B74BSelect the View Trend icon to view each panel’s temperature history on a graph.