DPL-24A Manual - OPTEK

OPERATIONS TECHNOLOGY, INC. 

Manual 

DPL-24A Differential Pressure Laminator 

Revision B 

Software Revision Only 

3/14/2012 

Operations Technology, Inc DPL-24A PC & Software Manual Rev. B - 03/14/2012 

1

THE DPL-24A ..................................................................................................................................................... 4 

INTRODUCTION ........................................................................................................................................................ 5 

Lamination Overview - Setup ......................................................................................................................... 6 

Lamination Overview - Lamination Cycle ....................................................................................................... 7 

Lamination Detail ........................................................................................................................................... 8 

Principles of Operation ................................................................................................................................... 9 

Facilities Requirements ................................................................................................................................. 13 

Substrate Specifications ................................................................................................................................ 13 

Productivity ................................................................................................................................................... 13 

Substrate size ................................................................................................................................................ 13 

Substrate ....................................................................................................................................................... 13 

Installing the DPL-24A .................................................................................................................................. 14 

Operating the DPL-24A ................................................................................................................................. 16 

Example Operation ....................................................................................................................................... 17 

PRECAUTIONS ....................................................................................................................................................... 18 

MAINTENANCE ...................................................................................................................................................... 19 

Precision Digital Temperature Controllers .................................................................................................... 19 

Touch-Panel Controller ................................................................................................................................. 19 

Filter Regulator ............................................................................................................................................. 19 

Diaphragm .................................................................................................................................................... 19 

Platen ............................................................................................................................................................ 19 

Recommended Spares Package .................................................................................................................... 20 

WARRANTY........................................................................................................................................................... 21 

1. PERIOD OF WARRANTY ............................................................................................................................. 21 

2. LIABILITY OF WARRANTY .......................................................................................................................... 21 

TOUCH SCREEN PC & SOFTWARE .................................................................................................................... 23 

GETTING STARTED .................................................................................................................................................. 24 

Front Panel Overview .................................................................................................................................... 24 

Front Panel - External Drive Access ............................................................................................................... 25 

OPERATIONS PANEL ............................................................................................................................................... 26 

Overview ....................................................................................................................................................... 26 

Heater Status ................................................................................................................................................ 27 

Units .............................................................................................................................................................. 28 

Cycle Status ................................................................................................................................................... 28 

Operations .................................................................................................................................................... 29 

Vacuum Dwell ............................................................................................................................................... 30 

Pressure Dwell .............................................................................................................................................. 31 

Drawer Status ............................................................................................................................................... 32 

Cycle End Options ......................................................................................................................................... 32 

Auto Start...................................................................................................................................................... 32 


2

SETTINGS PANEL .................................................................................................................................................... 33 

Overview ....................................................................................................................................................... 33 

Pump ............................................................................................................................................................. 34 

Dwell Timers ................................................................................................................................................. 34 

Heater Controller - Top & Bottom ................................................................................................................. 34 

MAX Temperature ........................................................................................................................................ 35 

Display Units ................................................................................................................................................. 35 

Password....................................................................................................................................................... 35 

Keypad .......................................................................................................................................................... 36 

Presets .......................................................................................................................................................... 36 

Preset Slots ................................................................................................................................................... 36 

Preview ......................................................................................................................................................... 37 

Save & Load Buttons ..................................................................................................................................... 37 

SUPERVISOR PANEL ................................................................................................................................................ 38 

Overview ....................................................................................................................................................... 38 

Completed Cycles .......................................................................................................................................... 39 

Supervisor Options ........................................................................................................................................ 39 

Save Logs Option .......................................................................................................................................... 39 

Save Cycle Data Option ................................................................................................................................. 39 

Update Software ........................................................................................................................................... 40 

Exit Application ............................................................................................................................................. 42 

Current Date & Time ..................................................................................................................................... 42 

Machine Log Panel ........................................................................................................................................ 42 

Data Management ....................................................................................................................................... 42 

Data Files ...................................................................................................................................................... 43 

Refresh Data Button ..................................................................................................................................... 43 

Export Files Button ........................................................................................................................................ 43 

Delete Files Button ........................................................................................................................................ 43 

Data Table .................................................................................................................................................... 44 

PLC STATUS PANEL ................................................................................................................................................ 45 

Overview ....................................................................................................................................................... 45 

Digital Outputs .............................................................................................................................................. 46 

Digital Inputs................................................................................................................................................. 47 

Analog Inputs ................................................................................................................................................ 47 

Connection .................................................................................................................................................... 48 

ABOUT PANEL ....................................................................................................................................................... 49 

Overview ....................................................................................................................................................... 49 

Software & Contact Information .................................................................................................................. 50 

Quick Guide ................................................................................................................................................... 51 


3

The DPL-24A 


4

Introduction 

T 

he DPL-24A Differential Pressure Laminator has been designed to give 

the operator a superior method for laminating sheet supported 

emulsions such as dry film solder mask and primary imaging film. Such 

materials can be applied to various thicknesses and sizes of substrates. 

Experimentation is being done on alternative uses for this device, among them 

High Vacuum, Multi-Layer, Pressing of Printed Circuit Boards and micro-BGA 

interconnects. 

The substrate can be pre-laminated manually, or by utilizing a cold-roll 

lamination technique. Once pre-lamination is complete, the substrate is then 

placed on the vulcanized rubber platen and finally pushed into the chamber. 

Products of differing thicknesses and geometries can be intermixed during a 

cycle if adequate “hold-down” techniques are employed. 

The massive 1000 LB chamber is constructed of Ductile Iron and uses only two 

o-rings. This design ensures a positive seal for best vacuum performance. 

Utilizing a high quality, high volume 65 CFM, 3 horsepower, rotary vane vacuum 

pump, an end point below two Torr is typically achieved. 

Vacuum lamination of printed circuit boards has been utilized for many years. 

But it was not until the development of the DPL-24A that a system provided 

vacuum prior to the application of positive pressure. 

No pressure is applied to the product during the vacuum dwell cycle. In this 

way maximum evacuation of air from between the substrate and the laminate 

is assured. 

During the pressure cycle a flexible diaphragm encapsulates the product and 

true isostatic lamination is achieved. Unlike roll laminators, the DPL–24A’s 

diaphragm descends directly towards the platen. No lateral stress is applied, 

hence less distortion of the film can occur. 


5

Introduction 

Lamination Overview - Setup 

Turn On Vacuum Pump 

Set Timers 

Vacuum Dwell Pressure Dwell 

Set Heaters 

Top Heater Set Point Bottom Heater Set Point 

Set Options 

Cycle Options Save Cycle Data 

Manage Cycle Data 

Refresh Export Delete 


6

Introduction 

Lamination Overview - Lamination Cycle 

Substrate 

Removed 

Pressure 

Dwell 

Substrate 

Placed 

Pre- 

Pressure 

Vacuum 

Dwell 


7

Introduction 

Lamination Detail 

� The vacuum is displayed on the Operations Panel, computer calibrated, digital gauge 

integrated in the touch-panel controller. 

� The temperatures of both the upper and lower heat platens are controlled 

independently by integral, precision, Temperature Controllers. 

� The substrate is exposed to a Vacuum Dwell for a time determined by an integral digital 

timer. 

� At the end of the Vacuum Dwell, a preheated silicone rubber diaphragm descends onto 

the work-piece and drives the spring-mounted drawer mechanism into intimate contact 

with the lower heater platen. 

� A positive pressure of up to 10 PSI is applied to the top of the diaphragm to bring the 

combined differential to nearly 25 PSI. 

� A short (1 second) Pre-Pressure step is taken to prepare valves for the Pressure Dwell. 

� The Pressure Dwell is adjusted by an integral digital timer identical to that employed by 

the Vacuum Dwell. 

� Upon completion of a cycle, the drawer mechanism is retracted and the product(s) 

removed for further processing. 

� The entire process is governed by a microprocessor driven touch-panel controller. 

Programming modifications are available from the factory. 


8

Introduction 

Principles of Operation 

When the DPL-24A is initially turned on, two precision controllers 

independently drive the top and bottom heaters to heat the diaphragm and 

drawer platen to the specified temperatures. After a brief warm-up time, the 

laminator is ready for use. 

The drawer is pulled open to allow access to load the vulcanized rubber 

platen with materials ready for lamination. Products of differing thicknesses 

and geometries can be intermixed during a cycle if adequate “hold-down” 

techniques are employed. The layered material is placed on the platen 

mounted in the sliding drawer. When the drawer is closed, the platen is 

positioned in the vacuum chamber and an O-ring seal on the drawer face 

contacts the opening in the vacuum/pressure vessel. 

Prior to the start of the cycle there is a vacuum drawn above the diaphragm. Air 

at atmospheric pressure is in the bottom of the vessel holding the diaphragm 

upwards. As shown in Figure 1, the diaphragm is suspended above the material 

on the drawer platen. The drawer platen is spring loaded upwards to allow the 

drawer to be opened and closed. 


9

Introduction 

Principles of Operation - Continued 

When the cycle starts, vacuum is drawn on both ports, above and below the 

diaphragm. Utilizing a high volume vacuum pump, an end point approaching two 

Torr is achieved. This vacuum is displayed on a digital gauge located on the touchpanel 

controller. A programmable timer determines the Vacuum Dwell time before 

continuing to the next step Figure 2. It is important to note that this dwell time will 

allow air between the layers of material to be evacuated before the lamination 

pressure cycle begins thereby eliminating trapped bubbles. Because the vacuum is 

equal above and below the diaphragm, the diaphragm does not move and does not 

contact the material in the drawer. 


10

Introduction 


At the end of the Vacuum Dwell, positive air pressure at up to 10 PSI is applied 

to the port above the diaphragm bringing the pressure differential to nearly 25 

PSI Figure 3. The preheated silicone rubber diaphragm descends onto the 

work-piece. This action drives the spring-mounted drawer platen into contact 

with the lower heater platen. Isostatic pressure is transferred to the material 

by the diaphragm. The stretching effect that occurs with roll type laminators is 

minimized. The flexible diaphragm conforms to the surface shape assuring 

positive contact between the layers, thereby eliminating voids. The pressure 

dwell time is controlled by another timer identical to the vacuum dwell timer. 


11

Introduction 


At the end of the Pressure Dwell cycle, the top port is connected to the vacuum 

pump again, and the bottom port is vented to atmospheric pressure. As shown 

in Figure 4, this returns the diaphragm and drawer platen to their original 

positions and allows the drawer to be opened for unloading. 


12

Specifications 

Facilities Requirements 

Dimensions: 44" Wide X 44" Deep X 60" High, exclusive of leveling feet (1" to 2") 

Weight: 2,200 LBS (shipping) 

Electrical Requirements: 208/220 VAC, 3 Phase, 40 Ampere/Phase 

Compressed Air: Dry, Filtered, 80 PSI, 3 CFM 

Substrate Specifications 

Productivity 

Cycle time is adjustable from 0 to infinity and is determined by application 

parameters such as part complexity, thickness, mass, etc. Typical times for a 

circuit board may be 30 seconds for Vacuum Dwell and 20 seconds for Pressure 

Dwell. 

Substrate size 

Items up to 24" X 24" can be laminated. Smaller substrates can be processed in 

multiples if space permits and can be intermixed providing adequate holddown 

techniques are observed. 

Substrate 

Thicknesses from .001" to .375" can be accommodated utilizing standard holddown 

bars . 


13

Installation 

Installing the DPL-24A 

IMPORTANT! Due to the weight of the unit, a forklift is mandatory for 

removal of the DPL-24A from the pallet and, for final positioning. 

1. Upon receipt of the equipment please inspect for obvious external damage. 

2. Remove wooden crating (if provided) and inspect for damage to the machine 

itself. Do not attempt to slide the chamber drawer! 

3. Using a forklift roughly place the DPL-24A utilizing the attached pallet,. 

4. Remove lower back panel. 

5. Remove the four bolts securing 

the unit to the pallet. 

6. Raise unit with forklift blades 

positioned under the main 

vessel, being careful not to 

damage the main valve (see 

illustration below) 

7. Install leveling feet (included) 

into holes formerly occupied by 

shipping bolts. 

8. Position, lower, and level the unit. 

LIFT HERE 

VACUUM PUMP 

9. WARNING: IT IS IMPERATIVE THAT OIL BE ADDED TO THE VACUUM 

PUMP BEFORE OPERATION! 


14

Installation 

Installing the DPL-24A - Continued 

10. Supply Compressed Air to input nozzle on right side rear of the machine. 

11. Adjust primary regulator to 70-80 PSI. 

12. Adjust secondary regulator to 5-10 PSI. 

WARNING: DO NOT ATTEMPT TO ADJUST 

REGULATOR PAST STOP!!! 

DO NOT REMOVE PIN UNDER ANY CIRCUMSTANCES!!! 

13. Wire and Connect 220 VAC, 3 Phase, 40 Ampere power to input cable. 

14. Activate “Main Power” switch on front panel. 

15. Activate “Vacuum Pump” switch on 

touch-panel. 

16. With one person at switch and one 

person at the pump, “JOG” the vacuum 

pump switch on the touch-panel and 

monitor the pump to ensure proper 

rotation indicated by the arrow found on 

motor end case. 

ROTATION LABEL (REAR OF PUMP) 

Note: If the rotation is opposite to that indicated - 

reverse the connection on any two phases of incoming power. 

The DPL-24A is now ready for operation. 


15

Operation 

Operating the DPL-24A 

1. Ensure circuit breaker is in the “ON” position. 

2. Activate “MAIN POWER” switch. 

3. Activate “VACUUM PUMP” switch on touch-panel in the Settings Panel. 

4. Chamber drawer may now be opened for inspection. 

WARNING: PLATEN MUST BE IN POSITION WHEN CYCLING MACHINE! 

5. Return drawer to home position. 

6. Activate “TOP” and “BOTTOM” Heaters on touch-panel controller. 

7. Adjust controllers for desired temperature. 

8. Allow 20-40 minutes for unit to reach set-point and stabilize (if under 200 

degrees F). 

9. Product may now be processed through laminator. 


16

Operation 

Example Operation 

1. Set both Temperature Controllers to 160 Degrees F. 

2. Set Vacuum Dwell to 30 Seconds. 

3. Set Pressure Dwell to 20 Seconds. 

4. Place Pre-laminated product on Platen. 

5. Slide Hold-Down Device into place. 

6. Slide Drawer into Vessel. 

7. Press the START button. 

8. Machine will complete one Automatic Cycle 

9. Cycle Status will show Cycle Ready, and START button will be active . 

10. Slide the drawer out, and remove substrate. 

NOTE: If at any time the operator desires to exit the cycle, depress the STOP 

button and machine will return to a Cycle Ready state. Atmospheric pressure will 

be vented to the chamber and the drawer may be opened. 

NOTE: If at any time the operator wishes to hold the cycle at a given step, depress 

the STEP button. The machine program will hold at the present step indefinitely. 

To resume the program sequence, press the STEP button. 

NOTE: If the operator wishes to step through the program manually, depress the 

STEP button. The unit will advance one program step with each pressing of the 

button, maintaining that step’s conditions after completion of the timer setting. 


17

Precautions 

CAUTION: NEVER ATTEMPT TO REMOVE DRAWER FROM VESSEL WITH VACUUM 

PUMP OFF. EMERGENCY RESET BUTTON MUST BE DEPRESSED. IN STEPS OTHER 

THAN STEP 0, VACUUM IS APPLIED TO THE DOOR AND WITHDRAWAL IS 

IMPOSSIBLE. 

IF VACUUM PUMP IS OFF, THE DIAPHRAGM MAY BE IN CONTACT WITH THE 

VULCANIZED PLATEN AND PERSISTENT PULLING MAY CAUSE DAMAGE. 


18

Maintenance 

Precision Digital Temperature Controllers 

These integral devices provide precise control of temperature for the upper and lower heater 

platens independently. They are calibrated at the factory and should not need further 

adjustment. 

Touch-Panel Controller 

This unit controls activation, deactivation, and timing of the various valves in the DPL-24A as 

well as the temperature control functions. A program stored in memory is utilized to direct the 

sequence of events. Custom programming can be accomplished by the customer or by the 

factory for specialized applications. The controller does not require preventive maintenance. 

Filter Regulator 

Normally, clean, filtered, dry air should be supplied to the machine. The DPL-24A, however, has 

an additional filter incorporated into the primary regulator. This filter requires minimal 

maintenance (open petcock and drain out water occasionally). 

Diaphragm 

The 50 Durometer, .125" thick, Silicone Rubber Diaphragm is the major wear item in the 

system. It is advisable to keep a replacement Diaphragm on-hand in the event of a puncture or 

rupture. This unit is available “pre-punched” from the factory. Cleaning of the Diaphragm is 

accomplished with Isopropyl Alcohol only. 

Platen 

All work is pressed on this Vulcanized Rubber Platen. It is advisable to keep a standby Platen on 

hand if replacement becomes necessary due to normal wear or abrasion. Cleaning is 

accomplished either on or off the machine with a soft cloth, moistened with Isopropyl Alcohol 

only. 


19

Maintenance 

Recommended Spares Package 

PART # DESCRIPTION QUANTITY PRICE TOTAL 

1008 HEATER, SILICONE 1 PIECE $700.00/EA $700.00 

1027 ‘O' RING, DOOR 1 PIECE $40.00/EA $40.00 

1028 ‘O' RING, VESSEL 1 PIECE $35.00/EA $35.00 

1041 FAN, EXHAUST, 220V 1 PIECE $50.00/EA $50.00 

1045 COVER SHEET (SILICONE) 1 PIECE $95.00/EA $95.00 

1070 VALVE, ACTUATOR 1 PIECE $50.00/EA $50.00 

1077 DIAPHRAGM, 1 PIECE $300.00/EA $300.00 

1078 PLATEN, 24" X 24" 1 PIECE $300.00/EA $300.00 

1089 VACUUM PUMP OIL 5 GAL $30.00/GAL $150.00 

1094 SPRING, DRAWER 4 PIECES $4.00/EA $16.00 

9117-0021 RELAY, MAIN 1 PIECE $120.00/EA $120.00 

9117-0022 RELAY, SOLID STATE 1 PIECE $120.00/EA $120.00 

9199-0033 POWER SUPPLY (24VDC) 1 PIECE $35.00/EA $35.00 

9409-0291 DRAWER SLIDE, LARGE 1 PAIR $1,600.00/PR $1,600.00 

12/01/11 

MINIMUM ORDER FOR SPARES AND REPAIR PARTS IS $50.00 

ORDER PARTS FROM: 

OPERATIONS TECHNOLOGY INCORPORATED 

PO BOX 408 

30 LAMBERT ROAD 

BLAIRSTOWN, NJ 07825 

PHONE (908) 362-6200 

FAX (908) 362-5966 

info@optek.net 

TOTAL ...………. $3,611.00 


20

Warranty 

1. PERIOD OF WARRANTY 

Operations Technology Incorporated warrants this product to be free of defects in 

material or workmanship for a period of 180 days commencing on the shipping date 

from Blairstown, New Jersey. 

2. LIABILITY OF WARRANTY 

Operations Technology Incorporated warrants to the original purchaser that 

equipment sold under this agreement shall be free from defects in material and 

workmanship. Defective materials will be replaced or repaired at the discretion of 

Operations Technology Incorporated. Liability will be determined by Operations 

Technology Incorporated. All liability is expressly limited to said repair or 

replacement of defective parts, all other damages and warranties, statutory or 

otherwise, being expressly waived by the purchaser. This warranty is null and void if 

the equipment failure is due to negligence, accident, abuse, or improper operation. It 

is also nullified by tampering, alteration, or unauthorized repair of subject equipment 

or components. This warranty does not include filters, oil, Platen, and Diaphragm as 

they are generally considered to be consumable items. 

The user shall return all allegedly defective materials to Operations Technology 

Incorporated via approved routing – charges prepaid. Upon determination of 

liability, Operations Technology Incorporated will either submit a quotation for 

repairs or rectify the defect at no charge. 

This warranty cannot be countermanded by the purchaser and is the only warranty 

relative to the transaction. No other warranty, expressed, implied, or statutory shall 

apply. 

Effective Date 12/1/11 

Revised 12/1/11 


21

Other Products 

OPERATIONS TECHNOLOGY INC. 

#30 LAMBERT ROAD 

P. O. BOX 408 

BLAIRSTOWN, NJ 07825 

Phone (908) 362-6200 

FAX (908) 362-5966 

Regular & Large Format X-Ray Inspection & Measurement 

The OPTEK 1272XA The OPTEK 712XA 

Regular & Large Format Video Inspection & Measurement 

The OPTEK 713VSA 

5 

SIZES 

AVAILABLE 

For information, demos, data sheets, applications, 3D models and much more visit 

www.optek.net 


22

Touch Screen PC & Software 

Version 0.2 

Release Date: 03/06/2012 

Bug Fixes: 

Fixed a bug for upper limits on MAX Temperature setting 

Enabling "Auto start on drawer close" no longer immediately starts a cycle 

Additions: 

Increased MAX Temperature upper limit to 400F/204C 

Added checkbox to Supervisor options to enable/disable Preset Save 

Added checkbox to Supervisor options to enable/disable Preset Load 


23

2 

Getting Started 

Front Panel Overview 

3 

4 

1. Front Panel 

2. Thumb Screw 

3. Main Power Switch 

1. Front Panel - The main user interface for the DPL-24A. 

2. Thumb Screw - Use these to access the rear of the Touch Screen PC. 

3. Main Power Switch - Turns machine ON and OFF. 

4. Emergency Stop Switch - Immediately powers down machine. 

5. Touch Screen PC - Used to operate the DPL-24A. Powers on with machine. 

6. USB Port - Used to export cycle data and update software. 

5 

6 

4. Emergency Stop Switch 

5. Touch Screen PC 

6. USB Port 


24 

1 

2

Getting Started 

Front Panel - External Drive Access 

To access the external USB drive, loosen both thumb screws (2), and pull them towards you. The front 

panel will swing down, allowing you to access the rear of the Touch Screen PC. 

The drive is located on the left hand side of the Touch Screen. The drive shown may vary from the one 

depicted. To remove the drive, gently pull it out, as you would any other USB device. 

Location of external USB drive. 

IMPORTANT: The drive must be re-inserted into the same USB port for logging to function 

correctly. 


25

Operations Panel 

Overview 

1 2 

5 6 

7 8 

1. Top Heater Status 

2. Bottom Heater Status 

3. Toggle Fahrenheit / Celsius Button 

4. Operations Box 

Operations Panel - The main panel used on the DPL-24A. 

3 

5. Vacuum Status 

6. Pressure Status 

7. Cycle Status 

8. Drawer Status 


26 

4 

9. Cycle End Options 

10. Auto Start 

9 

10


Heater Status 

The Heater Status boxes display information about the Top and Bottom heaters inside the DPL-24A. The 

Top and Bottom Heater boxes operate in an identical manner. 

CURRENT TEMPERATURE - The large red LCD numbers indicate the current temperature. 

The current units are displayed in the center of the two Heater Status boxes. 

CONTROLLER ACTIVE - Will read either CONTROLLER ON or CONTROLLER OFF. 

These controllers can be independently activated on the Settings Panel. 

CONTROLLER STATUS - Displays the current state of the controller. 

There are 4 states: OFF, HEATING, COOLING and SET-POINT, described in detail below. 

OFF - The controller is turned OFF in the Settings Panel. 

HEATING - The controller is continually sending voltage to the heater. 

COOLING - The controller is not sending voltage to the heater. The Set-Point has been lowered. 

SET-POINT - The controller is pulsing the voltage off and on to stay at the desired Set-Point. 


27


Units 

Displays the Current units, either F for Fahrenheit or C for Celsius. 

TOGGLE UNITS BUTTON - Switches the current units between Fahrenheit and Celsius. The 

changed units will also be reflected in the Settings Panel for Set-Points, and MAX . 

Cycle Status 

The cycle status box shows the current Cycle Status of the DPL-24A. The following lists all statuses: 

Cycle Ready - DPL-24A is ready to cycle. 

Vacuum Dwell - Air is being evacuated from the vessel. 

Pre-Pressure - Valves are manipulated in preparation for Pressure Dwell. 

Pressure Dwell - The vessel is opened to atmospheric pressure, and the diaphragm descends. 

SS - Vacuum Dwell - Single Step mode for Vacuum Dwell. 

SS- Pre-Pressure - Single Step mode for Pre-Pressure. 

SS - Pressure Dwell - Single Step mode for Pressure Dwell. 


28


Operations 

Allows the user to start an Automatic cycle, step through a cycle, hold an Automatic cycle, or completely 

stop a cycle, regardless of current step. START and STEP Buttons will be disabled and grayed out while 

the drawer is in the open position 

START BUTTON - Starts an Automatic cycle. The machine will automatically step 

through the Vacuum Dwell, Pre-Pressure, and finally Pressure Dwell. Times may be set for Vacuum 

Dwell and Pressure. Pre-Pressure is Factory set for 1 second. Upon cycle completion, the drawer may 

be opened. Once started, the button will be disabled until the STOP BUTTON is pressed, or until the 

cycle has completed. Pressing the STOP BUTTON at anytime will return the machine to a Cycle Ready 

state. Pressing the STEP BUTTON at any time during an Automatic cycle, will cause the machine to 

HOLD at the current step until the STEP BUTTON or STOP BUTTON is pressed. You may not continue the 

automatic cycle. The Settings Panel, Supervisor Panel and About Panel will be disabled during cycles. 

STEP BUTTON -Steps through each cycle step in order; Vacuum Dwell, Pre-Pressure, 

Pressure Dwell. The timers are inactive while in Single Step Mode. You must press the STEP BUTTON 

again to complete each state. Pressing the STOP BUTTON at anytime will return the machine to a Cycle 

Ready state. Single Step mode is indicated by the prefix SS in the CYCLE STATUS BOX. You may press 

this button at anytime during an Automatic Cycle initiated by the START BUTTON. Doing so will cause 

the machine to HOLD at the current cycle step. 

STOP BUTTON - Stops the cycle regardless of mode (Automatic or Single Step) and 

returns the machine to a Cycle Ready state. For an emergency situation, the large red EMERGENCY 

STOP BUTTON located to the left of the Touch Screen, should be used immediately. 


29


Vacuum Dwell 

This box shows the status of the Vacuum Dwell cycle step. 

CURRENT PRESSURE READING - This box shows the current pressure measurement in 

torr. The torr is non-SI unit of pressure with a ratio of 760 to 1 standard atmosphere. There is a dial 

indicator to quickly indicate that pressure is dropping. A more precise reading is shown below the dial. 

ACTIVE CYCLE INDICATOR - In addition to the Cycle Status read-out, this icon will blink when 

the step is currently active. 

PROGRESS BAR and COUNT-DOWN TIMER 

Visually shows time remaining with a green progress bar, with a more precise count-down 

timer directly below. 


30


Pressure Dwell 

This box shows the status of the Pressure Dwell cycle step. 

ACTIVE CYCLE INDICATOR - In addition to the Cycle Status read-out, this icon will blink when 

the step is currently active. 

PROGRESS BAR and COUNT-DOWN TIMER 

Visually shows time remaining with a green progress bar, with a more precise count-down 

timer directly below. 

NOTE: The readings from the Vacuum Dwell status box will continue to drop during the Pressure Step. 


31


Drawer Status 

DRAWER STATUS - Indicates whether the drawer is OPEN or CLOSED. 

Cycles may not be started with the drawer in the open position. 

Cycle End Options 

completion when selected. 

CYCLE END OPTIONS - Options that will be run on cycle 

TURN OFF HEATERS - Turns off heaters at the end of the cycle. Useful for overnight cycles. 

Auto Start 

START ON DRAWER CLOSE OPTION - Starts an automatic cycle 

when the drawer is closed. There is a delay of 2 seconds before the cycle is Auto Started. 

NEW for 0.2 - You may check this option without the drawer having to be open, as in previous 

software versions. The Auto start will begin on the next drawer close. 


32

3 

5 

Settings Panel 

Overview 

1 

2 

4 

1. Pump ON/OFF 

2. Dwell Timers 

3. Top Heater Controller Settings 

4. Bottom Heater Controller Settings 

6 

Settings Panel - Use this panel to setup the machine for use and to activate specific options in the 

Supervisor Panel. 

IMPORTANT: Press CLEAR on the Keypad before entering numbers. In case a box is highlighted 

unintentionally, simply change to the Operations Panel, or select another box. 


33 

7 

8 

5. Max Temperature 

6. Display Units Toggle 

7. Password Entry Box 

8. Keypad 

9 

9. Presets Box


Pump 

TOGGLE PUMP BUTTON - Toggles the Vacuum Pump ON and OFF. When ON, the 

symbol will turn ORANGE. 

Dwell Timers 

DWELL TIMERS - To Change the timers (in seconds) for either the 

Vacuum Dwell or Pressure Dwell, first press the input box you want to change, then press CLEAR on the 

KEYPAD. You may now enter a new number using the KEYPAD. Timers are only active during an 

Automatic Cycle. 

Heater Controller - Top & Bottom 

HEATER CONTROLLER SETTINGS (TOP) - Toggles the Heater 

Controllers ON and OFF. When ON, the symbol will turn ORANGE. When ON the Heater Status box on 

the Operations Panel will change from CONTROLLER OFF to CONTROLLER ON. To Change the Set 

Point for the heater, first press the input box, then press CLEAR on the KEYPAD. You may now enter a 

new number using the Keypad. 

NOTE: If you attempt to set a temperature higher than the MAX Setting, the temperature will default to 

the MAX Setting. For more information on changing this setting, see MAX below. 

NOTE: The Set Point will automatically update with the correct temperature conversion if the Toggle 

Fahrenheit / Celsius Button is pressed on the Operations Panel, and the Display Units Toggle 

on the Settings Panel. In some cases, the Set Point may be set lower or higher than anticipated 

due to rounding errors. Please adjust accordingly. 


34


MAX Temperature 

MAX TEMPERATURE - The maximum allowed temperature 

setting. This updates with the Toggle Fahrenheit / Celsius Button on the Operations Panel, and 

the Display Units Toggle on the Settings Panel. 

NOTE: The MAX Setting is a factory option and may be changed only when authorized by Operations 

Technology, Inc. Call the factory for consultation on changing the MAX Setting. 

Display Units 

DISPLAY UNITS - Displays the currently selected units. Changing this setting 

will update Heater Controller Set-Points, MAX. Changing units will also update the temperatures 

display in the Operations Panel. 

NOTE: Toggling Units will not update the Presets. 

Password 

PASSWORD INPUT - This input will enable certain options in the Supervisor 

Panel. To enter a password, first press the PASSWORD INPUT BOX. You may now enter a new number 

using the KEYPAD. When a correct number has been successfully entered, the check to the right of the 

input box will turn green. If you make a mistake entering the password, press CLEAR on the KEYPAD. 

IMPORTANT: To deter unauthorized access, you must immediately enter the Supervisor Panel. If 

you enter any other Panel, the Password will be cleared and you must enter it again before gaining 

access to certain Supervisor options. The password will be reset upon leaving the Supervisor Panel. 


35


Keypad 

Presets 

Preset Slots 

KEYPAD - Used to clear and input numbers into input boxes. 

PRESETS - Manage custom presets. The presets are stored on internal memory. 

PRESET SLOTS - Up to 5 custom presets may be stored at a time. Pressing on a preset will 

highlight it. The preset will then be shown in the Preview box. No changes are made to a preset by 

selecting it in this box. 


36


Preview 

PREVIEW - The preview box automatically updates when a preset is selected in 

PRESETS. All information about the stored preset is displayed to the user. If a preset has not been 

saved to a preset slot, it will be indicated in this box. Depending on your specific machine configuration, 

this sample preview may be different than yours. 

Save & Load Buttons 

SAVE & LOAD BUTTONS - Save and Load custom presets. 

NEW in 0.2 - To enable SAVE and LOAD buttons, you must first enter the supervisor password in 

the Settings Panel. You must then go to the Supervisor Panel and check the boxes for Enable Preset 

save and/or Enable Preset load. 

To SAVE a preset, first highlight a PRESET slot by pressing on it, then press the SAVE BUTTON. All 

settings shown in the PREVIEW box will be overwritten by the currently selected settings and options 

throughout the software. If a preset already exists in the chosen preset slot, you will be prompted to 

confirm overwriting it. 

To LOAD a preset, first confirm in the Preview box, that these are the settings you wish to load. Any 

current setting in either the Settings Panel, or Operations Panel may be overwritten. Then, highlight a 

PRESET slot by pressing on it, then press the LOAD BUTTON. 

NOTE: The PUMP and HEATER CONTROLLERS will not be turned ON by loading a preset. You must turn 

them on manually. 


37

Supervisor Panel 

Overview 

1 

7 

2 

3 

1. Completed Cycles Display 

2. Supervisor Options 

3. Current Date & Time 

4. Machine Log Panel 

4 5 

5. Data Management Panel 

6. Data Files 

7. Refresh Data Button 

8. Export Files Button 

6 7 

9. Delete Files Button 

10. Data Table 


38 

8 

9 

10


Completed Cycles 

COMPLETED CYCLES - Shows the Lifetime Machine Cycles as well as Cycles 

since the last time the DPL-24A was powered on. Cycles that were forced to stop with the STOP 

BUTTON do not add to the total. 

Supervisor Options 

SUPERVISOR OPTIONS - Options that become available after a 

successful Supervisor Password Login. You must login from the Settings Panel. See the Settings Panel 

chapter for information on how to do this. 

Save Logs Option 

SAVE LOGS OPTION - You may be asked to enable this feature to 

store machine logs to an external disk drive. The DPL-24A comes with an external drive pre-installed. 

For instructions on how to remove this drive, consult the Front Panel - External Drive Access section in 

the Getting Started chapter. 

Save Cycle Data Option 

SAVE CYCLE DATA - Enabling this feature will store data from a successfully 

completed cycle. A cycle that has been stopped with the STOP BUTTON will not be logged. For more 

information on what data is saved, see the sub-chapter DATA TABLE below. 


39


Enable Preset save ( New for 0.2) 

ENABLE PRESET SAVE OPTION - Checking or un-checking this item will 

enable or disable the Save Button in the Settings Panel. By default for 

security reasons, it is unchecked on startup, and will not be saved in a Preset or on Shutdown. You must 

manually enable this option each time the DPL-24A is started. 

Enable Preset load ( New for 0.2) 

ENABLE PRESET LOAD OPTION - Checking or un-checking this item will 

enable or disable the Load Button in the Settings Panel. By default for 

security reasons, it is unchecked on startup, and will not be saved in a Preset or on Shutdown. You must 

manually enable this option each time the DPL-24A is started. 


40

Update Software 

UPDATE SOFTWARE - Press this button to begin the update procedure. 

WARNING! ONLY UPDATE SOFTWARE WITH APPROVAL FROM 

OPERATIONS TECHNOLOGY! 

Failure to gain prior approval may require you to send the Touch Screen PC back to the factory 

for service. 

Update Tools 

You will need the following to complete an upgrade: 

1. An empty formatted USB drive. 

2. A USB mouse. 

3. Contact Operations Technology for a software update file. 

Update Procedure 

1. Extract the files from the archive. 

2. Copy the update folder named DPLgui onto the root of an empty formatted USB drive. 

3. Enter the supervisor password on the Settings Panel. 

4. Go into the Supervisor Panel and press the Update Software Button. 

5. Follow the onscreen instructions to load the files from the USB Drive onto the computer. 

6. Once finished the software will exit, and then launch an Explorer Shell. This may take a few minutes. 

7. Once the Explorer Shell is on the screen, remove the USB drive and plug in the USB mouse. 

8. Navigate to the c:\update.bat file and run the file by double-clicking on it. 

9. The software will restart. 


41


Exit Application 

EXIT APPLICATION - Exits the application and launches an Explorer 

Shell. Mainly used for troubleshooting. Only use this when directed to do so by Operations Technology. 

Current Date & Time 

Machine Log Panel 

CURRENT DATE & TIME - Displays the current date and time. 

MACHINE LOG PANEL - Pressing this tab will open the machine log 

window. This is mainly used for troubleshooting purposes. There will only be visible output if the SAVE 

LOGS OPTION is checked under SUPERVISOR OPTIONS. This view is used to ensure that the logging 

function is working properly. The output will move very quickly and as such, cannot be easily read. 

Once the log reaches a certain length, it is dumped to an external drive, the log is cleared, and the 

output will begin again. 

Data Management 

DATA MANAGEMENT PANEL - Pressing this tab will open the Data 

Management Panel. This panel will always be enabled, but it will only be updated with cycle data if the 

Save Cycle Data Option is checked in the Supervisor Options box. 


42


Data Files 

DATA FILES - These are the data files currently stored on internal memory. 

Each day, a new data file is created using the date as a name. Every time a cycle is completed 

successfully, the file is appended with a new line. The files are stored in CSV (Comma Separated Values) 

format for easy database and spreadsheet imports. Pressing a file, will update the Data Table. 

Refresh Data Button 

REFRESH DATA BUTTON - Forces a data refresh. To avoid constant writes to 

the internal drive, cycle runs are stored in memory and intermittently written to the internal drive. 

Pressing this button forces a write to the drive, and then updates the Data Table with the data. 

Export Files Button 

EXPORT FILES BUTTON - Press this button to export files to a USB drive. 

You will need to insert a USB drive into the USB slot to the right of the Touch Screen. To export a single 

file, highlight the file you want to export first, then press the Export Files Button. You can also export all 

files at once, by pressing the ALL button when presented with the Save Dialog box. 

IMPORTANT: It is recommended to press the Refresh Data Button before exporting files, to ensure 

that any cycles stored in memory are written to the internal drive first. 

Delete Files Button 

DELETE FILES BUTTON - Press this button to delete the stored data files. 

You will be prompted for confirmation before deletion. The files will be deleted permanently. 


43


Data Table 

DATA TABLE - Displays the data contained in the highlighted 

Data File. A more detailed description of each column is below. 

ID - The cycle ID. It is based on the lifetime runs found in Completed Cycles on the Supervisor Panel. 

Date - The date the cycle was started. 

Start - The starting time of the cycle. 

End - The ending time of the cycle. 

Total - Total elapsed time, in seconds, of the cycle from start to finish. 

Vac - The time entered for Vacuum Dwell. 

Press - The time entered for Pressure Dwell. 

Top - The temperature of the top heater at the time of cycle completeion. 

Btm - The temperature of the bottom heater at the time of cycle completeion. 

Torr - The lowest recorded vacuum reading during the entire cycle. 


44

PLC Status Panel 

Overview 

1. Digital Outputs 

2. Digital Inputs 

1 2 

3 

3. Connection Status 

4. Analog Inputs 

PLC Status Panel - This panel is used to monitor the Inputs and Outputs as reported by the 

PLC(Programmable Logic Controller). It's primary use is for troubleshooting. It may also be used to 

attempt a re-connect to the PLC in the unlikely event of a communications failure. 


45 

4


Digital Outputs 

DIGITAL OUTPUTS - The status of the Digital Outputs as reported by 

the PLC. A Green LED on a Digital Output indicates that the Output is active. The following list describes 

the different outputs in more detail. 

DO0 Vessel Valve Out - Voltage is being applied to the Vessel Valve relay 

DO1 Differential Valve Out - Voltage is being applied to the Differential Valve relay. 

DO2 Pressure Valve Out - Voltage is being applied to the Pressure Valve relay 

DO3 Vacuum Pump On - Voltage is being applied to the Vacuum ON relay. 

DO4 Top Heater On - Voltage is being applied to the Top Heater relay. 

DO5 Bottom Heater On - Voltage is being applied to the Bottom Heater relay. 

DO6 Not Used - Reserved for future use. 

DO7 Not Used - Reserved for future use. 

During normal operation, you will see changes in these outputs as the machine cycles. 

NOTE: You may notice the Top & Bottom (DO4 & DO5) Outputs are blinking intermittently. This is 

normal and will occur when either Heater Controller has reached it's Set-Point mode of operation. 


46


Digital Inputs 

DIGITAL INPUTS - The status of the Digital Inputs as reported by the 

PLC. A Green LED on a Digital Input indicates that the Input is active. The following list describes the 

different Inputs in more detail. 

DI0 Drawer Closed - Indicates whether the Drawer is OPEN or CLOSED. 

DI1 Not Used - Reserved for future use. 

DI2 Not Used - Reserved for future use. 

Analog Inputs 

ANALOG INPUTS - The status of the Analog Inputs as reported by the PLC. This 

is reported in voltage. The following list describes the different Inputs in more detail. 

Top Heater - AN[0] - Voltage on Thermocouple Signal Conditioning Board for the Top Heater. 

Bottom Heater - AN[1] - Voltage on Thermocouple Signal Conditioning Board for the Bottom Heater. 

Vacuum Gauge - AN[6] - Voltage from Vacuum Sensor on rear of vessel. 


47


Connection 

CONNECTION STATUS - Shows the current connection status for the PLC. Mainly 

used for troubleshooting. The Manual Reconnect Button will only become functional in the event of a 

communications failure, or a physical disconnect occurs between the Touch Screen PC and the PLC. 


48

About Panel 

Overview 

1 2 

1. Software & Contact Information 

2. Quick Guide 

About Panel - A general information panel. You may be asked to view this panel to assist with 

troubleshooting, or with general machine maintenance. 


49

About Panel 

Software & Contact Information 

Software & Contact Information - Contains the DPL-24A Software Version and 

Release Date as well as contact information for Operations Technology. To reiterate: 

ADDRESS 

Operations Technology, Inc. 

30 Lambert Rd. 

P.O. Box 408 

Blairstown, NJ 07825 USA 

SUPPORT 

Phone: 908-362-6200 

Fax: 908-362-5966 

WEB 

www.optek.net 

info@optek.net 


50

About Panel 

Quick Guide 

Quick Guide Bars 

information about a Panel. 

QUICK GUIDE - Gives a general overview of the Panels. 

QUICK GUIDE BARS - Pressing one of these bars will open up more 


51

DPL-24A Manual - OPTEK

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?