RTC H-1209X User manual

Owners Manual
Controlled Atmosphere Infrared Oven
August 28, 2006
May 26, 2009May 26, 2009
Radiant Technology Corporation.
1335 S. Acacia Avenue, CA 92831-5315, SA
Ema l: serv ce@rad anttech.com
Webs te: www.rad anttech.com

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Owner’s Manual
MODEL: H-1209X
SERIAL N MBER: 2115150301
FACTORY ORDER N MBER: 40334
RADIANT TECHNOLOGY CORPORATION
1335 South Acacia Avenue
Fullerton, CA. 92831-5315
[phone] TEL
[phone] FAX
http://www.radianttech.com
Near-Infrared
Heating Technology

TABLE of CONTENTS
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1. INTROD CTION ................................................................................................................................ 6
1.1. Manual Contents Organization.................................................................................................... 6
1.2. Installation Requirements ............................................................................................................ 6
1.2.1. npacking ...................................................................................................................... 6
1.2.2. Machine Placement ........................................................................................................ 1
1.2.3. Machine Inspection ........................................................................................................ 7
1.2.4. Providing Power ............................................................................................................ 7
1.2.5. Providing Gas and Air ................................................................................................... 7
1.2.6. Process Exhaust Requirements ...................................................................................... 2
1.2.7. Installation of the Transport Belt ................................................................................... 2
1.2.8. Removal of Shipping Restraint Screws ......................................................................... 3
1.2.9. Radiant Technology Customer Service Startup (Optional) ........................................... 3
2. GENERAL SAFETY G IDELINES ................................................................................................. 10
2.1. Electric Shock Hazard ............................................................................................................... 10
2.2. Hazardous Materials .................................................................................................................. 10
2.3. Normal Good Laboratory Practice ............................................................................................ 10
3. OPERATING INSTR CTIONS........................................................................................................ 11
3.1. Power Controls and Indicators .................................................................................................. 11
3.1.1. Power Status Indicators ............................................................................................... 11
3.1.2. Controls........................................................................................................................ 11
3.2. Basic Operation ......................................................................................................................... 12
3.2.1. Main Power .................................................................................................................. 12
3.2.2. ninterruptible Power Supply ( PS) “ON” Switch (Option) ..................................... 12
3.2.3. Power On/Startup ......................................................................................................... 12
3.2.4. Fans .............................................................................................................................. 12
3.2.5. Furnace Log-on and Initial Operation .......................................................................... 12
3.2.6. Security and ser Information ..................................................................................... 13
3.2.7. Screen Menu (Located at bottom of screen) .................................................................. 8
3.2.8. Atmosphere Supply Gas ................................................................................................ 9
3.2.9. Furnace Startup (Process Screen) .................................................................................. 9
3.2.10. Transport Speed ........................................................................................................... 17
3.2.11. Power Off ..................................................................................................................... 12
3.2.12. Replace Covers ............................................................................................................ 12
3.2.13. Shutdown Sequence ..................................................................................................... 12
3.2.14. Auto Shutdown Sequence. ........................................................................................... 12
3.2.15. Gas Shut Off ................................................................................................................ 13
3.3. Software Operation ................................................................................................................... 13
3.3.1. Recipe Setup Screen (Off Line Edit) ........................................................................... 13
3.4. Process Monitor Screen ............................................................................................................. 14
3.4.1. Power Saving Feature (Option) ................................................................................... 14

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3.5. Recipe Setup .............................................................................................................................. 14
3.5.1. Setpoint Modification (Levels 2 and 3) ....................................................................... 14
3.5.2. Power Distribution (Levels 2 and 3) ............................................................................ 14
3.5.3. PID Zone Tuning (Levels 2 and 3) .............................................................................. 15
3.5.4. Transport Speed (Levels 2 and 3) ................................................................................ 16
3.6. Gas Flow Screen ........................................................................................................................ 16
3.6.1. Gas Flow Settings ........................................................................................................ 16
3.6.2. Fan Speed Settings (Levels 1, 2, and 3) ....................................................................... 16
3.7. Alarm Status (All Levels) ......................................................................................................... 16
3.8. Data Log/Alarms and Alerts ...................................................................................................... 16
3.8.1. Occurrence and Timed Logging Control (Levels 1, 2, and 3) ..................................... 16
4. SERVICE INSTR CTIONS ............................................................................................................. 18
4.1. Routine Maintenance................................................................................................................. 18
4.1.1. Daily Maintenance ....................................................................................................... 18
4.1.2. Monthly Maintenance .................................................................................................. 18
4.1.3. Other Scheduled Maintenance ..................................................................................... 19
4.2. Troubleshooting ........................................................................................................................ 24
4.2.1. nable to log on, the OPTO22 control system does not have any power ................... 24
4.2.2. Temperature ................................................................................................................. 24
4.2.3. Conveyor System ......................................................................................................... 25
4.3. Hardware, Software Troubleshooting ....................................................................................... 26
4.3.1. Controller Communication .......................................................................................... 26
4.3.2. Process Problems ......................................................................................................... 27
4.3.3. Abnormal sensor behavior ........................................................................................... 27
4.3.4. Remote control setup ................................................................................................... 28
4.3.5. Calibration ................................................................................................................... 28
4.4. General Repair ........................................................................................................................... 29
4.4.1. Lamp Change Procedure .............................................................................................. 29
4.4.2. Transport Belt Replacement ........................................................................................ 32
4.5. Element Test Procedure ............................................................................................................ 33
4.5.1. Required Equipment .................................................................................................... 33
4.5.2. Test Procedure ............................................................................................................. 33
5. THEORY OF OPERATION - PROCESSING .................................................................................. 35
5.1. Energy Source ........................................................................................................................... 35
5.2. Characteristics of Infrared Radiation ........................................................................................ 35
5.3. Atmosphere Purity and Control ................................................................................................. 35
5.4. Thick Film Processing ............................................................................................................... 35
5.4.1. Profile .......................................................................................................................... 36
5.5. Solder Fusion, Die Attach, and Sealing Processing .................................................................. 36
5.5.1. Profiling for Solder Fusion, Die Attach, and Sealing .................................................. 36

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6. PROD CT SPECIFICATION ........................................................................................................... 38
7. OPTIONS ........................................................................................................................................... 39
7.1. Temperature Profile - Profile Menu (Option) ........................................................................... 39
7.2. Element Monitor (Option) ......................................................................................................... 39
7.3. Moisture and Oxygen Analyzer System (Option) ..................................................................... 41
7.3.1. Introduction .................................................................................................................. 41
7.3.2. Description ................................................................................................................... 41
7.3.3. Operation ..................................................................................................................... 42
7.4. Hydrogen Operation (Option) ................................................................................................... 43
7.4.1. Introduction .................................................................................................................. 43
7.4.2. Description ................................................................................................................... 44
7.4.3. Installation Requirements ............................................................................................ 46
7.4.4. Operating Instructions, OPTO22 Control System ....................................................... 46
7.4.5. Hydrogen Flowmeters .................................................................................................. 47
7.4.6. Functional Checkout (With Helium) ........................................................................... 47
7.5. Modem/PcAnywhere (Option) .................................................................................................. 50
7.5.1. Windows 95 Format .................................................................................................... 50
7.6. Product Viewing Area (Option) ................................................................................................ 51
7.7. Exhaust Stack Heater (Option) .................................................................................................. 51
7.8. Voltage Control (Option) .......................................................................................................... 51
7.9. Product Sensor and On-Screen Tracking (Option) .................................................................... 52
APPENDIX A: DOC MENTATION .................................................................................................... 56
Configurator ....................................................................................................................................... 56
Channel Assignment Sheet ................................................................................................................ 56
Drawings and Bills of Material .......................................................................................................... 56
APPENDIX B: CONTROLLER INSTALLATION ............................................................................... 57
APPENDIX C: ENGINEERING SPECIFICATIONS ........................................................................... 58
00025 Procedure for Jumpering Analog, I/O and Expansion Cards for OPTO 22 ........................... 59
00028 SCR Power Control PCB Calibration, OPTO 22 Control System ......................................... 62
00034 Calibration Procedure for Motor Speed Controller Board and Conveyor Belt (OPTO 22) ... 63
00036 Setup for OPTO 22 Controller G4LC32 (WIN 95

 Software) ............................................. 66
APPENDIX D: MATERIAL SAFETY DATA SHEETS ...................................................................... 74
MSDS ................................................................................................................................................. 74

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FIG RES
Figure 3.1.2.1 Control Panel ................................................................................................................... 11
Figure 3.2.6.1 Security Window, Log-on ............................................................................................... 13
Figure 3.2.8.1 Gas Flow Window ........................................................................................................... 14
Figure 3.2.9.1 Process Control Window ................................................................................................. 11
Figure 3.3.1.1 Recipe Window ............................................................................................................... 13
Figure 3.8.1.1 Event Logging ................................................................................................................. 17
Figure 4.1.3.1 Scheduled Maintenance Window .................................................................................... 19
Figure 4.1.3.2 ser Selectable Maintenance Description ....................................................................... 20
Figure 4.1.3.3 Maintenance Frequency Dialog Box ............................................................................... 20
Figure 4.4.1.1 Lamp Schematic showing Kaowool Packing .................................................................. 30
Figure 4.4.2.1 Belt Orientation ............................................................................................................... 32
Figure 4.4.2.2 Belt Installation ............................................................................................................... 33
Figure 4.4.2.3 Inserting Belt Splice ........................................................................................................ 33
Figure 5.5.1.1 Element Monitor PLC Control ........................................................................................ 39
Figure 5.5.1.2 Element Monitor System Diagram .................................................................................. 40
Figure 5.5.1.3 Element Monitor Status Window .................................................................................... 41
Figure 7.3.3.1 O
2
Analyzer Sampling Window ...................................................................................... 43
Figure 7.4.2.1 H2 / Forming Gas Sequential Operation ......................................................................... 44
Figure 7.5.1.1 Process Screen showing Lane Button(s), View Button and Recipe Button .................... 53
Figure 7.5.1.2 Recipe Screen showing Product Length Box .................................................................. 54
Figure 7.5.1.3 Send Value Window ........................................................................................................ 54
Figure 7.5.1.4 Product Tracking Window showing the Clear Product Counts Button ........................... 55
Figure 7.6. Product Viewing Window………………………………………………………………….51
Figure 7.7.Exhaust Stack Heater……………………………………………………………………….51

TABLE of CONTENTS
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Sect on 1
INTRODUCTION and INSTALLATION REQUIREMENTS
1. INTRODUCTION
1.1. Manual Contents Organization
This manual is intended for users of the Radiant Technology infrared furnace system. The
manual will help in understanding the machine's capabilities, uses, routine maintenance, and
basic design features. The introductory section sets forth requirements for proper installation
and initial startup.
Section 3 will be of specific interest to personnel who will set up and operate the furnace
system. The service manual, beginning with Section 4, contains detailed information,
including adjustments, alignments, maintenance, and troubleshooting. Section 5 contains a
theory of operation. The Product Specification, which introduced and laid the groundwork
for the machine, is included in Section 6. Technical information applicable to your machine
is covered in this section. Section 7 contains special operating instructions for options and
custom features not found on standard production machines.
Each model and furnace contains many unique parts and assemblies that are not common
to all. In addition to the unique parts, many custom features and options are routinely
ordered and shipped with these furnaces. In order to control and record these variations, a
top assembly bill of material, or “customer configurator”, has been included in Section
Appendix A of this manual. This document, controlled by a serial number, is the index to all
the documentation, which built a particular furnace.
1.2. Installation Requirements
1.2.1. Unpacking
Remove the banding from the shipping container and carefully disassemble. The
shipping container should contain the shipping manifest listing the model of your
furnace system and all options, accessories, and special configurations, which were
ordered according to the original purchase order or specification. If any item listed
is unaccounted for, immediately notify the carrier and the Radiant Technology
Customer Service Department.
1.2.2. Machine lacement
Locate the machine on an unyielding floor in the final installation position. Lift the

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machine at the approximate locations shown on the installation drawing (see
Documentation Section), and slide the shipment skid out from under the machine.
Do not attempt to lift the machine at one point or at points other than
recommended; failure to follow these instructions invites frame damage and will
void the warranty.
NOTE: The lifting device must extend under the machine and support both
sides of the frame structure.
Remove the base covers and adjust the leveling screws to level the frame within .06
inch overall. Each of the leveling screws should support an equal amount of
weight.
1.2.3. Machine Inspection
Remove the upper and lower side covers from both sides of the machine. Inspect
all lamp connections for soundness and for loose hardware that may have become
dislodged during shipment. Inspect the lower electrical compartment for shipping
damage, loose connections, or components. Finally, inspect the furnace interior,
checking for broken lamps, foreign objects, or any components that may have come
loose during shipment. Report any shipping damage immediately to the Radiant
Technology Customer Service Department.
1.2.4. roviding ower
These machines are built and tested to the voltage specified on the nameplate
located adjacent to the power entrance hole in the lower electrical compartment.
Electrical power, matching the specifications on the nameplate, is to be connected
to the contactor or circuit breaker located directly above the entrance hole. A
ground terminal is provided for a safety ground. (5-wire system is optional.) All
city and local codes should be followed when wiring this system for power.
1.2.5. roviding Gas and Air
Oil-free dry shop air, at a maximum recommended dew point of 59°F, is to be
brought to the machine through a customer supplied line with a minimum inside
diameter of 3/4 inch. In addition to the supply line, a pressure gauge and regulator
is required if the supply pressure fluctuates or goes above 70 psi. Connections for
gas require the same line size and a regulator to control the pressure to 70 psi
maximum. The supply temperature of both gas and air should be above the dew
point of the room air to prevent condensation from forming on the feed lines and
dripping into the furnace.
WARNING: The flowmeters on these furnaces are rated at 70 psi maximum;
operating beyond 70 psi exposes the operator to possible injury.

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1.2.6. rocess Exhaust Requirements
In most applications, process exhaust and heat should be vented to the outside
atmosphere. It is the customer's responsibility to review the process, local laws,
and facility in deciding on an exhaust system. Insulated exhaust tubing and a
collector hood with a 4 inch inside diameter, or larger, is routinely used. Do not
make any direct connections to the chamber exhaust stacks. A minimum 8.0”
clearance between the exhaust stacks and venting device is required
1.2.7. Installation of the Transport Belt
A portion of the transport belt which goes through the furnace chamber was
intentionally left uninstalled to protect the furnace interior during shipment. When
installing the belt, it will be helpful to have an assistant available to help guide the
belt into the furnace entrance.
1.2.7.1.The portion of the belt which goes through the furnace is rolled up and
secured at the entrance end of the furnace. nroll the belt and attach it
securely to the pull wire that was left in the furnace chamber.
1.2.7.2.Pull the belt through the chamber from the exit end of the furnace, while
an assistant guides the belt into the entrance.
1.2.7.3.Once the belt has been pulled completely through the chamber, remove
and discard the pull wire. Splice as shown in Figure below.
1.2.8. Removal of Shipping Restraint Screws
Large furnaces operating at high temperatures experience considerable growth from
thermal expansion. All models are equipped with support slides which allow stress
free expansion to take place. To secure the process chamber during shipment,
restraining brackets (painted red) attach directly between the chamber and frame.

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The screws which secure these brackets to the frame must be removed before
bringing the furnace up to operating temperature.
WARNING: Failure to remove slide restraint screws invites structural
damage and will void the warranty.
1.2.9. Radiant Technology Customer Service Startup (Optional)
It is the customer's responsibility to accomplish the tasks described in 1.2.1 through
1.2.8, prior to scheduling a visit by a Radiant Technology Customer Service
technician. When the Customer Service technician visits the user's plant, the
technician will require the full-time help of at least one customer representative
who will be responsible for the operation and maintenance of the furnace system.
Tasks to be performed by the Customer Service technician include:
1.2.9.1. Prepare the machine for operation.
1.2.9.2. Apply power and bring up the machine to a fully operational state.
1.2.9.3. Run through the installation test procedure.
1.2.9.4. Report to the customer any deficiencies noted in the installation of the
machine.
1.2.9.5. Instruct the appropriate personnel in the customer's plant how to set up and run
the furnace system.
1.2.9.6. Teach the appropriate personnel in the customer's plant how to do the
necessary preventive maintenance.
1.2.9.7. Turn over the machine and documentation to the customer.
1.2.9.8. Specification Limitation.
1.2.9.9. The specifications, as noted in this manual, are for standard production
machines only. These specifications may not apply if the machine was ordered
with custom features or non-standard options.