TIP 1000 Thermal Process Controller User`s Manual
Contents
1. 16 EEEE PEET EET 16 TIP 1000 Manual Rev A 1 0 Introduction Congratulations on the purchase of your new TIP 1000 Thermal Process Controller EIT is combining its 31 years of experience in process control and electronics engineering with the 25 years of heater technology experience of Tutco Farnam in a new Thermal Process Control system The days of guesstimating and retuning temperatures and flow rates each time you have to run a process are a thing of the past With your new TIP 1000 you will be able to actually assign numbers to needed process values and be able to dial up those numbers in a flash for future runs You have complete control with a digital readout of the temperature air flow rate and air exhaust velocity Only two parameters may be regulated at any one time with output temperature always being one of them The TIP 1000 provides an unprecedented level of repeatability and reliability in the thermal process control industry Furthermore the risk of heater burnout has been virtually eliminated with a tight loop control system vastly improving the life span of the heater The typical thermocouple in the hot air stream has been eliminated and the function replaced with a very accurate predictive algorithm that is unaffected by errors caused by hot and cold spots as well as long exposures to high temperatures You can look forward to great cost savings in not having to replace heater parts and fewer product er2. 11 Display layout Main Display Set Point Error Flags l Figure 13 Volume flow rate screen no error flags 9 3 SCFM Select MANV0811003 Page 11 TIP 1000 Manual Rev A Figure 14 Air Velocity screen The Air velocity is not being regulated on this screen This is indicated by the series of dashes on the lower left of the screen 44 6 ft s Select Error Alarm Conditions In the event that a user selected value cannot be regulated an alarm will sound bringing immediate attention to the discrepancy The following are the alarm flags that will be displayed on screen Temp Temperature out of regulation by 20 F CFM Volume flow rate out of regulation by 0 5 SCFM or more Air Vel Air velocity out of regulation by 5 ft s Note Alarm is disabled for 20 seconds after any set point changes Figure 15 Temperature is out of regulation Temp error flag is flashing 352 F 215 Temp Select 8 0 Quick Start Guide Terminate power cord with desired 240VAC plug Green wire goes to ground and the black and white wires each go to separate lines Set Temperature 1 Press select button located below the display until you cycle to Temperature screen 2 Use the up and down arrows located to the right of the display to change the target temperature Targ
3. M Velocity nozzle 20 85 ft sec 6 1 25 7m sec Enclosure Dimensions 16 4 L x15 4 W x11 6 H 41 7 cm x 39 1 cm x 29 5 cm Power Input Heater full power 1900 VA Q 8 amps 0 95PF and Blower Heater Material Stainless Steel 2 micron very clean air suitable for a wide variety of applications Control Accuracy Temperature 3 of Full Scale Output Temperature CF Flow rate 2 of Full Scale Velocity 5 of Full Scale Figure 2 Achievable temperatures F and C at various flow rates Maximum Temperatures in Regulation Supplying Maximum Temperatures in Regulation Supplying 1500 Watts to Heater at 73 F Room Temp 1500 Watts to Heater at 23 C Room Temp 1350 665 1200 Z 565 1050 o B 465 900 S d 750 365 vo 600 Lr t 285 450 B 200 oO 165 150 B5 4 5 5 5 B 5 7 5 8 5 9 5 127 156 184 212 241 269 SCFM SLPM Note Red area is achievable temperatures at various flow rates Maximum values on graph will be less at lower ambient temperatures and or lower available heater power Maximum flow rate will decrease as temperature goes up MANV 0811003 Page 5 TIP 1000 Manual Rev A Additional features e Prevents heater damage with automatic heater shutoff in the event of air flow loss e System stores current operating values on power down and restores values on power up e Splash resistant design Alarm Conditions When the system is in an alarm condition it will continually flash the display and s
4. Seller shall have a reasonable opportunity to examine all goods claimed to be defective Transportation charges for the return of each defective goods to the original point of delivery or such other place designated by the Seller shall be paid by the Purchaser who shall be credited by Seller for such reasonable transportation cost This warranty supersedes and is in lieu of any other warranty expressed or implied or no agreement or understanding varying or extending this warranty will be binding upon Seller unless in writing signed by a duly authorized officer of Seller MANV0S11003 Page 15 TIP 1000 Manual Rev A 12 0 Application Notes Nozzle Temperature Profile Below 1s the temperature profile across the heater nozzle at various distances Individual heater profiles may vary slightly across the x axis due to internal mechanical alignment The information below is intended purely as reference material Graph 1 Nozzle Temperature Profile TIP 1000 Nozzle Temperature Profile at 5 5 SCFM 550 F Set Point 75 F Room Temp Nozzle Distance 0 Nozzle Distance 1 Nozzle Distance 2 Temperature F 1 2 1 0 8 0 6 0 4 0 2 50 0 0 0 2 Position from center of nozzle inches 1 MANVO0S11003 Q Page 16 1500 KW Heater TIP 1000 Manual Rev A
5. TIP 1000 Thermal Process Controller User s Manual EIT Inc 108 Carpenter Drive Sterling VA 20164 Phone 703 478 0700 Fax 703 478 0815 Email sales eitinc com MANVO0S11003 TIP 1000 manual Rev A 11 3 2008 Table of Contents 1 0 Introduction 2 0 WARNINGS 3 0 Applications 4 0 TIP 1000 Description 5 0 Specifications TED MOOG creen todas ancient teed cal tend ALIE oe ated Additional Featureset e reor eie tob eee edt Sees ote Alarm CondltlobiSooeeccenadsonteesiced tette E N Normal Operating Conditions sss 6 0 Setup Guide Typical Operation Guide oie oae e sedie tous tst 7 0 Display Interface Menu Screen Layout and Functions Error Alarm Conditions oido et Eesti 8 0 Quick Start Guide DeL Leimperatute asd Gulsdeadclexe tli beds rule oto Celo eiue tdid Set Volume Flow Rate Option 1 esuuusse Set Aur Velocity ODUOIE 2 unsoiescs dete etras eret Icu Ud Dart Stops UM eraan a dae pedis Ire ibd 9 0 Maintenance PETI ue credentes Hid EM a seo Ee E Power Cables aasitenteoidexxtetuleuiduie thie adentro Li TUE HO uo xau ete cp ee EE a EE RET 10 0 Customer service and support 11 0 Warranty 12 0 Application Notes Nozzle Pemperature Prone cuori MANV0S11003 Page 1 res 5 obo re 6 6 npn E E 6 ee ee ee 10 TEN 10 E 12 eut 12 Socata 13 14 14 Soho o ned 14 15 15
6. ace if necessary Such wear is caused by regular movement of cables against a sharp corner and should be avoided to prevent damage or injury Any cable rated for 230V AC 1s acceptable but may need to be re terminated with the proper plug Contact EIT to purchase replacement Manufacturer McMaster Carr Power Cord P N 7082K85 Hose If the connecting hose from blower to heater has a hole in it all output values will be incorrect Hoses with any leakage should be repaired or replaced prior to continued use Contact EIT to purchase replacement Manufacturer McMaster Carr Hose P N 5304K45 MANV0S11003 Page 14 TIP 1000 Manual Rev A 10 0 Customer service and support For service and support call the following number Phone 703 478 0700 Fax 703 478 0815 Email sales 9 eitinc com Our normal hours are 9 4 30 EST 11 0 Warranty EIT Seller warrants to Purchaser that the goods manufactured and sold by it will be free from defects in materials for a period of 12 months from the day of delivery of the goods Seller s liability under this warranty shall be limited at the Seller s elections to the purchase price or the replacement or the repair of such defective goods No claim under this warranty shall be valid unless made in writing to the Seller within 12 months of the delivery of the goods sold hereunder nor will any claim be allowed on goods which have been processed or altered in any manner normal inspection procedures excepted
7. et temperature is displayed on the lower left corner of the display MANV0811003 Page 12 TIP 1000 Manual Rev A Set Volume Flow Rate Option 1 Press select button located below the display until you cycle to Air Flow screen 2 Use the up and down arrows located to the right of the display to change the target air flow Target air flow 1s displayed on the lower left corner of the display Set Air Velocity Option 2 Press select button located below the display until you cycle to Air Velocity screen 2 Use the up and down arrows located to the right of the display to change the target air velocity Target air velocity is displayed on the lower left corner of the display Note Option and 2 cannot be set concurrently Choose to set one or the other Start Stop Unit Press the Start Stand by button to start regulation of user selected values Press this button again to go to Stand by mode The heater will shut off immediately but the blower will continue to run for 60 seconds MANV0S11003 Page 13 TIP 1000 Manual Rev A 9 0 Maintenance Filter Make sure air intake is not blocked or clogged by dust or other particulate matter The air filter should be replaced every 1000 hours of operation or sooner if being used in a very dirty environment Contact EIT to purchase replacement Manufacturer Solberg Manufacturing 2 micron filter P N 10 Power Cables Inspect for any wear or breaking of insulation and repl
8. ook closely at Figures 4 7 Figure 4 Above Heater Power Sensing connection on left hose connection on right Figure 5 Below Heater Power Sensing cable and Heater Hose shown connected MANV 0811003 Page 7 TIP 1000 Manual Rev A MSN Figure 6 Above Close up of Connector on the side of the Blower Assembly Note arrows showing mating notches for cable assembly Figure 7 Below Close up of Cable Note arrows to help align cable MANV 0811003 Page 8 TIP 1000 Manual Rev A Figure 8 Close up of connector on Heater Assembly This connection has been made at the factory prior to shipping and should not be disconnected Note Do not block exhaust fan located on opposite side of display on blower assembly Figure 9 Menu Start Stand by e Turn the system on using the circuit breaker located near the power cord input The menu will stabilize with numbers after a few seconds on power up Set desired output operating temperature using select and arrow keys Press Start Stop to turn blower and heater on Depending on selected output temperature it may take several minutes to get to desired temperature e An alarm will sound if the system is not in regulation with the defined Temperature Airflow and Velocity set points e Pressing a button to change any set point will disable the alarm for 20 seconds to allow time for the system to reach the desired value without alarming e Also note that it will take 60 seconds fo
9. ound an audible alarm The volume of the audible alarm can be adjusted by turning the small disc on the alarm to a louder or quieter volume Condition for Alarm Output Temperature Display temperature differs from set point by more than 20 F more than 0 5 CFM more than 5FPS Note Audible alarm is disabled for 20 seconds after any parameter change or if the start button is pressed Normal Operating Conditions e Ambient Operating Temperature range 0 F to 110 F 17 C to 43 C e Humidity up to 90 non condensing e Elevation calibrated to sea level Note EIT has been a pioneering leader in the process control industry for over 30 years We have used our best practices in developing this product Please note that this product is not yet CE or UL certified but we plan to pursue these approvals in the future Please use the product at your own risk MANV081 1003 Page 6 TIP 1000 Manual Rev A 6 0 Setup Guide The TIP 1000 Blower System is normally shipped in one box and the heater and connecting hose in another box Carefully unpack each box 1 Attach desired plug termination to blower power cord The green wire goes to eround and the black and white wires are both hot each connecting to 120VAC to make a total of 240 Figure 3 Wire termination 2 The heater hose and a combination power sensing cable must be attached to the Blower Assembly The power sensing cable only attaches one way do not force the connection L
10. r the blower to turn off after the Start Stop button is pressed This is to allow the heater to cool down before airflow is completely stopped MANV0811003 Page 9 TIP 1000 Manual Rev A Typical Operation Guide Select button cycling each time the select button is pressed the display menu will cycle in the following sequence Figure 10 Menu Cycling t om td Output Air Temperature Volume Flow Rate I Air Velocity Only two parameters can be regulated at the same time with one always being Output Air Temperature You can set either of the other two to be regulated by simply pressing the up down arrow to choose a value on that screen If the Volume Flow Rate in SCFM is being regulated then the Air Velocity menu screen will have dashes for the set point value Figure 10 If Air Velocity is being regulated then the Volume Flow Rate menu screen will have dashes for the set point value If you are on the unregulated Volume Flow Rate or Air Velocity menu screen then any set point adjustment on that screen will make the system regulate to that parameter Volume Flow Rate or Air Velocity and disable the other one 7 0 Display Interface Menu screen layout and functions e Main display shows actual values e Set point target value that main display is trying to reach MANV 0811003 Page 10 TIP 1000 Manual Rev A Error flags Select button Set point adjustment arrows Up Down Start stop button Figure
11. rors due to more consistent output The TIP 1000 is a self contained plug amp play system The system contains everything that you need It takes just a few minutes to plug it in and connect the heater to the control box You do not need to specify a separate compressor or control package In short you save time and save money MANV0811003 Page 2 TIP 1000 Manual Rev A 2 0 WARNINGS Do not touch heater when in operation or immediately after long periods of operation Do not open chassis when unit is plugged in There is risk of shock and there are no user serviceable parts There are ESD sensitive components inside Do not operate if the exhaust fan doesn t work or 1s blocked See section 6 0 3 0 Applications Day to day processes in which a particular process window output temperature and or flow rate determines the quality of the product are ideally suited for the TIP 1000 Such processes include Drying curing or activation of coatings adhesives resins labels amp inks Heat shrinking of films and covers Heating amp Heat Staking Electronics Assembly Processes Thermal Process Laboratories Sterilization amp Sanitizing Assembly Lines MANV 0811003 Page 3 TIP 1000 Manual Rev A 4 0 TIP 1000 Description The TIP 1000 is a closed loop thermal process controller with the ability to regulate output temperature air velocity and volume flow rate Only two parameters may be regulated at any one time
12. with output temperature always being one This breakthrough is possible due to sensors throughout the system which report back to a single controller board Figure 1 The controller board issues incremental commands reduce heater power increase air flow to maintain the user s desired output values process window This constant adjustment and feedback loop maintain stable repeatable process conditions Figure 1 Block Diagram TIP 1K Block Diagram Mass Air Temperature E Fiter zc Blower H Throttle Temperate E Heater H owt 12VDC 5VDC 12VDC Audio 12VDC 240VAC Controller 240VAC Board Cooling Fan Another issue that the TIP 1000 addresses 1s potential premature heater failure due to loss of air flow The tightly controlled closed loop system on TIP 1000 ensures that the moment such an event occurs the controller board shuts down all power to the heater and sounds an alarm to warn the user of the event This dramatically increases the life of the heater and reduces the chance of making poor products MANV0811003 Page 4 TIP 1000 Manual Rev A 5 0 Specifications TIP 1000 All specifications subject to change Specifications Heater Power 1 5 KW 208 240 VAC 6 25 amps 50 60 Hz unity PF System will operate on reduced voltage but may be below maximum temperature specification Output Temperature Range 150 F 1150 F 65 C 620 C Flow Rate 4 5 10 0 SCFM 127 311 LP
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