Digital Equipment Corporation 220240 Specifications

BARNSTEAD|THERMOLYNE CORPORATION
Type F6000 Furnace
OPERATION MANUAL
AND PARTS LIST
Series 1060
MODEL NUMBER
F6010
F6010-33
F6018
F6020C
F6020C-33
F6020C-33-60
F6020C-33-60-80
F6020C-33-80
F6020C-60
F6020C-60-80
F6020C-80
F6028C
F6028C-60
F6028C-60-80
F6028C-80
F6030CM
F6030CM-33
F6030CM-33-60
F6030CM-60
F6038CM
F6038CM-60
VOLTAGE
220-240
220-240
208
220-240
220-240
220-240
220-240
220-240
220-240
220-240
220-240
208
208
208
208
220-240
220-240
220-240
220-240
208
208
CONTROL
Basic Automatic
Basic Automatic
Basic Automatic
Automatic
Automatic
Automatic
Programmable
Programmable
Automatic
Programmable
Programmable
Automatic
Automatic
Programmable
Programmable
Multi-Programmable
Multi-Programmable
Multi-Programmable
Multi-Programmable
Multi-Programmable
Multi-Programmable
DISPLAY (°C&°F)
X (°C only)
X (°C only)
X (°C only)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
RS232 COMM.
X
X
X
X
X
X
(-60 Models) - Ashing furnace
LT1060X1 • 7/2/97
1
Table of Contents
Important Information
This manual contains important operating and safety information. The user must carefully
read and understand the contents of this manual prior to the use of this equipment.
Safety Information ..............................................................................................................................................3
Alert Signals..................................................................................................................................................3
Warnings ......................................................................................................................................................3
Introduction..........................................................................................................................................................4
Intended Use ................................................................................................................................................4
General Usage..............................................................................................................................................4
Principles of Operation........................................................................................................................................6
Furnace ........................................................................................................................................................6
Temperature Controller: Basic Automatic ....................................................................................................6
Temperature Controller:Automatic ................................................................................................................6
Temperature Controller:Programmable ........................................................................................................6
General Specifications ........................................................................................................................................7
Environmental Conditions ............................................................................................................................7
Declaration of Conformity ............................................................................................................................8
Unpacking..........................................................................................................................................................11
Installation ........................................................................................................................................................12
Site Selection..............................................................................................................................................12
Electrical Connections ................................................................................................................................12
Basic Automatic Temperature Control Operation (F6010, F6010-33, F6018) ..................................................13
Automatic Models (F6020C, F6020C-33, F6020C-33-60, F6020C-60, F6028C, F6028C-60) ........................15
Programmable Control Models (4 Ramp & 4 Dwell) (F6020C-33-60-80, F6020C-33-80, F6020C-60-80,
F6020C-80, F6028C-60-80, F6028C-80)..........................................................................................................18
Multi-Programmable Control Models (F6030CM, F6030CM-33, F6030CM-33-60, F6030CM-60, F6038CM,
F6038CM-60) ....................................................................................................................................................24
Installation and Operation of Air Control ..........................................................................................................33
Furnace Loading ..............................................................................................................................................36
Maintenance and Servicing ..............................................................................................................................37
Preventive Maintenance ............................................................................................................................38
General Cleaning Instructions ....................................................................................................................38
To Replace a Heating Ellement ..................................................................................................................38
To Replace a Platinel II Thermocouple in Programmable and Automatic Furnaces ..................................39
To Replace a Chromel/Alumel Thermocouple (Basic Automatic Furnaces) ..............................................39
To Replace a Solid State Relay..................................................................................................................40
To Replace a Door Switch (MIcro Switch) ..................................................................................................41
To Realign Door Switch (Micro Switch) ......................................................................................................42
To Replace Control Module ........................................................................................................................43
Programmable Models ........................................................................................................................43
Automatic Models ................................................................................................................................43
Basic Automatic Control - PC Board ....................................................................................................43
Troubleshooting ................................................................................................................................................44
Replacement Parts List ....................................................................................................................................47
Wiring Diagrams................................................................................................................................................48
Ordering Procedures ........................................................................................................................................52
Two Year Limited Warranty ..............................................................................................................................53
2
Safety Information
Alert Signals
Warning
Warnings alert you to a
possibility of personal injury.
Your Thermolyne F6000 type furnace has been designed
with function, reliability, and safety in mind. It is your responsibility to install it in conformance with local electrical
codes. For safe operation, please pay attention to the
alert signals throughout the manual.
Warning
Please note the following WARNINGS:
Caution
Cautions alert you to a
possibility of damage to the equipment.
Note
Notes alert you to pertinent facts and
conditions.
Hot Surface
Hot surfaces alert you to a
possibility of personal injury if you
come in contact with a surface during
use or for a period of time after use.
Hot Surface
Caution: Hot surface. Avoid Contact.
This warning is presented for compliance with California
Proposition 65 and other regulatory agencies and only
applies to the insulation in this product. This product contains refractory ceramic, refractory ceramic fiber or fiberglass insulation, which can produce respirable dust or
fibers during disassembly. Dust or fibers can cause irritation and can aggravate preexisting respiratory diseases.
Refractory ceramic and refractory ceramic fibers (after
reaching 1000°C) contain crystalline silica, which can
cause lung damage (silicosis). The International Agency
for Research on Cancer (IARC) has classified refractory
ceramic fiber and fiberglass as possibly carcinogenic
(Group 2B), and crystalline silica as carcinogenic to
humans (Group 1).
The insulating materials can be located in the door, the
hearth collar, in the chamber of the product or under the
hot plate top. Tests performed by the manufacturer indicate that there is no risk of exposure to dust or respirable
fibers resulting from operation of this product under normal conditions. However, there may be a risk of exposure
to respirable dust or fibers when repairing or maintaining
the insulating materials, or when otherwise disturbing
them in a manner which causes release of dust or fibers.
By using proper handling procedures and protective
equipment you can work safely with these insulating
materials and minimize any exposure. Refer to the appropriate Material Safety Data Sheets (MSDS) for information regarding proper handling and recommended protective equipment. For additional MSDS copies, or additional
information concerning the handling of refractory ceramic
products, please contact the Customer Service
Department at Barnstead|Thermolyne Corporation at 1800-553-0039.
3
Introduction
Intended Use
The Type 6000 Basic Automatic, Automatic and Programmable furnaces are general laboratory and heat treating
furnaces. For optimum element life, observe the following
temperature ranges. These furnace models are intended
for applications requiring temperatures from 100°C
(212°F) to 1093°C (2000°F) for continuous use, or temperatures from 100°C (212°F) to 1200°C (2192°F) for intermittent use.
(-60) Coal Ashing models continuous temperature range
is from 100°C (212°F) to 975°C (1787°F). Continuous use
is operating the furnace for more than 3 hours.
The unit consists of: 1) a heating chamber; 2) a basic automatic control without over temperature protection OR an
automatic proportioning-digital set, digital read control
with over temperature protection; 3) a door interlock relay
for user safety.
The Type 6000 Programmable furnace is designed to
control a programmed temperature profile. The profile is
in the format of ramps and dwell segments. The first
ramp, RAMP 1, starts at the initial measured furnace temperature. This ramp is positive going at a programmed
rate until the programmed level is reached. The set point
will stay at this level for a period determined by the setting of DWELL 1. Additional positive or negative going
ramps are now initiated starting at the level at the end of
DWELL 1. When the second ramp reaches the second
programmed level, the set point stays at that level for the
duration of the segment. Depending upon the model
ordered, additional ramp and dwell segments may be
added. See specific model number for total number of
program segments.
The Type 6000 Programmable Ashing Furnace (-60) is
designed to operate like the programmable type 6000 described above plus the ability to inject and control an inert
atmosphere. The Type 6000 Automatic furnace is
designed as a single set point automatic temperature controlled furnace able to reach and maintain one temperature value
General Usage
Do not use this product for anything other than its intended usage.
4
INTRODUCTION
MODEL
NUMBER
DIGITAL
F6020C-80
F6020C-33-60-80
F6020C-33-80
F6020C-60-80
F6028C-60-80
F6028C-80
F6030CM
F6030CM-33
F6030CM-33-60
F6030CM-60
F6038CM
F6038CM-60
DIGITAL
COMMUM.
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
NUMBER OF
RAMP
SEGMENTS
4
4
4
4
4
4
8
8
8
8
8
8
NUMBER OF
DWELL
SEGMENTS
4
4
4
4
4
4
8
8
8
8
8
8
NUMBER OF
STORED
PROGRAMS
1
1
1
1
1
1
4
4
4
4
4
4
5
Principles of Operation
Note
When in the program RUN mode, the
programmer/controller serves to provide a programmed temperature profile as described earlier. When in the
AUTOMATIC mode, the unit serves
as a single set point automatic temperature controller.
Furnace
The furnace chamber is heated by four electric resistance
heaters which are embedded in a refractory material. The
chamber is insulated with a ceramic fiber insulation. The
control is located under the furnace chamber and is well
insulated from the heat generated in the furnace chamber.
A door safety switch removes power to the heating elements whenever the furnace door is opened. The choices
of temperature controllers are as follows:
Temperature Controller: “Basic
Automatic”
The basic automatic control provides simple automatic
control to one set point temperature. A single digital display will indicate either furnace chamber temperature or
set point temperature. This controller does not provide
over temperature protection.
Temperature Controller:
“Automatic”
This furnace controller consists of a microprocessor
based three mode temperature controller having adjustable over temperature protection and appropriate output
switching devices to control the furnace.
Temperature Controller:
“Programmable”
This furnace controller consists of a microprocessor
based three mode temperature controller/programmer
with adjustable over temperature protection and appropriate output switching devices to control the furnace.
6
General Specifications
For F6000 Furnace
Model #
Dimensions
in. (cm)
Overall
Chamber
Weight
Electrical
Ratings
Width
Height
Depth
Width
Height
Depth
LBS. (kg)
Volts
Amps
Watts
Freq.
Phase
Oper. Temp.
Range
°F(°C)
F6020C
F6020C-33
F6020C-33-60
F6020C-33-60-80
F6020C-33-80
F6020C-60
F6020C-60-80
F6020C-80
F630CM
F6030CM-33-60
F6030CM-33-60
F6030CM-60
F6028C
F6028C-60
F6028C-60-80
F6028C-80
F6038CM
F6038CM-60
F6010
F6010-33
F6018
19.25 (48.9)
21 (53.3)
20 (50.8)
12.75 (32.4)
6.75 (17.1)
10 (25.4)
96 (43.5)
220-240
18.3
4400
50/60
1
19.25 (48.9)
21 (53.3)
20 (50.8)
12.75 (32.4)
6.75 (17.1)
10 (25.4)
96 (43.5)
208
19.2
4000
50/60
1
19.25 (48.9)
21 (53.3)
20 (50.8)
12.75 (32.4)
6.75 (17.1)
10 (25.4)
96 (43.5)
220-240
12.9
3095
50/60
1
19.25 (48.9)
21 (53.3)
20 (50.8)
12.75 (32.4)
6.75 (17.1)
10 (25.4)
96 (43.5)
208
11.2
2325
50/60
1
212-2192°F
(100-1200°C)
*212-1787°F
(*100-975°C)
212-2192°F
(100-1200°C)
*212-1787°F
(*100-975°C)
212-2192°F
(100-1200°C)
212-2192°F
(100-1200°C)
Notes: The maximum ramp rates for this furnace for heat up are: 12°C (22°F) per min. from 25°C - 537°C
(75°F-1000°F), 10°C(18°F) per min. from 537°C-1093°C (1000°F-2000°F).
* (-60) coal-ashing furnaces
Environmental Conditions
Operating: 17°C - 27°C; 20% to 80% relative humidity, non-condensing. Installation Category II
(over-voltage) in accordance with IEC 664. Pollution Degree 2 in accordance with IEC 664.
Altitude limit: 2,000 meters.
Storage: -25°C to 65°C; 10% to 85% relative humidity.
7
GENERAL SPECIFICATIONS
Declaration of Conformity
(-33 Models only)
Barnstead|Thermolyne hereby declares under its sole responsibility that this product conforms with the technical
requirements of the following standards:
EMC: EN 50081-1 Generic Emission Standard; EN
50082-1 Generic Immunity Standard;
Safety: IEC 1010-1-92 Safety requirements for electrical
equipment for measurement, control, and
laboratory use; Part I: General Requirements
IEC 1010-2-010 Part II: Particular requirements
for laboratory equipment for the heating of
materials
per the provisions of the Electromagnetic Compatibility
Directive 89/336/EEC, as amended by 92/31/EEC and
93/68/EEC, and per the provisions of the Low Voltage
Directive 73/23/EEC, as amended by 93/68/EEC.
The authorized representative located within the European Community is:
Electrothermal Engineering Ltd.
419 Sutton Road
Southend On Sea
Essex SS2 5PH
United Kingdom
Copies of the Declaration of Conformity are available
upon request.
8
Push To Set Temperature Button
Digital Display
Cycle Light
ON/OFF
Power Switch
Temperature Set point
Adjustment Knob
Figure 1: Basic Automatic Controller
Furnace Chamber Temperature
Secret Key
Temperature Set point
Cycle Light
Alarm Indicator
Down Button
Up Button
Scroll Button
Figure 2: Single Set point Controller
9
Output Indicator
Furnace Chamber
Temperature
Non-functional
Alarm Indicator
Non-functional
Set point Temperature
"SEL" Button
Down Button
Up Button
Enter Button
Figure 3: Programmable (4 Ramp & 4 Dwell)
Alarm Active
Temperature Set point
Adaptive or Self
Tune Selected (AT)
Furnace Chamber
Temperature
(At Startup, Displays
Software Version
Number)
Digital
Communications
Parameter
Selected on
Secondary Display:
SP = Set point
OP = Output
Power
Time = Time
Remaining in
Program
Down Button
Condition of Program,
Ramp or Dwell and if
Program is Held, Ramp
Dwell Segment Currently
Running
Up Button
Nonfunctional
Run/Hold Button
Scroll Button
Figure 4: Multi-Programmable Control (8 Ramp & 8 Dwell)
10
Screw Retaining Instrument in Sleeve
Unpacking
Note
(-60) Models are supplied with two
stainless steel trays, handle and
porcelain pegs.
Note
The Type 6000 furnaces do not come
with a power cord because current
requirements are too great to be handled by ordinary power cords and
standard wall supply. (F6010, F601033 and F6018 are supplied with cord
and plug).
Visually check for any physical damage to the shipping
container. Inspect the equipment surfaces that are adjacent to any damaged area. Open the furnace door and
remove packing material from inside the furnace chamber. Vacuum the chamber prior to use to remove the insulation dust due to shipment.
Retain the original packaging material if re-shipment is
foreseen or required.
11
Installation
Caution
Be sure ambient temperature does not
exceed 104°F (40°C). Ambients above
this level may result in damage to the
controller.
Allow at least six inches of space
between the furnace and any vertical
surface. This permits the heat from furnace case to escape so as not to create a possible fire hazard.
Warning
To avoid electrical shock, this furnace
must be installed by a competent,
qualified electrician who ensures compatibility among furnace specifications,
power source and grounding code
requirements. (Disregard Step 2 if you
have Model F6010, F6010-33 or
F6018.).
Caution
For supply connections, use 10 AWG
or larger wires suitable for at least
90°C. Failure to observe this caution
could result in damage to furnace.
Warning
Do not use in the presence of flammable or combustible materials; fire or
explosion may result. This device contains components which may ignite
such material.
Hot Surface
“Caution: Hot Surface. Avoid Contact.”
To avoid burns, this furnace must not
be touched on the exterior or interior
surfaces during use or for a period of
time after use.
12
Site Selection
Install furnace on a sturdy surface and allow space for
ventilation.
Electrical Connections
1.
The electrical specifications are located on the
specification plate on the back of the furnace.
Consult Barnstead/Thermolyne if your electrical
service is different than those listed on the specification plate. Prior to connecting your Type
6000 furnace to your electrical supply, be sure
the front power switch is in the OFF position.
2.
Your 6000 furnace may be wired either directly
through a conduit system or by using a power
cord and plug which conforms to the National
Electrical Codes and electrical code requirements of your area. The terminal block to be
used in wiring is located on the lower rear of the
furnace.
NOTE: Please observe the alert signals on the lefthand side of this page before operating your
furnace.
Basic Automatic Temperature
Control Operation
Models F6010, F6010-33, F6018
Power Switch
The On/OFF power switch will illuminate when power is
turned ON. Also, the digital display will illuminate.
Cycle Light
The amber cycle light will illuminate whenever the power
is being applied to the heating elements. The cycle light
will turn on and off as furnace reaches set point.
Warning
To avoid electrical shock, this furnace
must have the door switch operating
properly.
Door Safety Switch
The door safety switch removes power from the heating
elements when the door is opened. Open and close the
door a few times; note that the amber CYCLE light will be
out when door is open. This check must be done when
furnace is heating or when cycle light is illuminated. If this
condition is not true, consult the Troubleshooting section
before proceeding.
Digital Readout
The digital readout continuously displays chamber temperature unless the Push To Set Temperature button is
depressed. Then set point temperature is displayed.
Push To Set Temperature
Button
When this button is depressed, the digital display will indicate set point temperature. When the button is released,
the actual chamber temperature is displayed.
Temperature Adjustment Knob
Turning this knob clockwise will increase set point temperature. Turning the knob counterclockwise will decrease
temperature.
13
BASIC AUTOMATIC TEMPERATURE CONTROL OPERATION
Temperature Controller
This controller provides accurate control at one single
temperature setting. To set temperature, simply:
1. Turn Power switch ON.
Note
If at any time the Temperature
Adjustment knob is turned in either
direction, the set point will change,
even if the Push To Set Temperature
button is not depressed. To view the
current set point temperature, depress
the Push To Set Temperature button.
2.
While depressing the Push To Set Temperature
button, turn the temperature knob until you
reach the desired set point temperature as indicated on digital display.
3.
Release the Push To Set Temperature button.
The digital display will now indicate the actual chamber
temperature. The furnace will heat to the new set point
temperature. The CYCLE light will remain on until the furnace temperature is within 1°C of the set point temperature; then the CYCLE light will turn on and off as the controller maintains the set point temperature.
Sensor Break Protection
This controller provides sensor break protection in the
event the thermocouple opens. If an open thermocouple
condition occurs, the digital display will indicate 5 degrees
or less and the power to the heating element will be shut
off (CYCLE light will extinguish).
14
Automatic Models
Note
The temperature control in these models is a single set point device. By
using the UP or DOWN buttons, a specific temperature can be chosen. The
control will cause the furnace chamber
to heat to the chosen temperature and
hold it at this temperature until you
turn off the power switch or select
another temperature.
Models F6020C, F6020C-33, F6020C-33-60, F6020C-60,
F6028C, F6028C-60
Controls and Displays
Power Switch
Switch power switch to the “ON” position. The controller
will illuminate when power is on.
Furnace Power Indicator
The amber furnace power light will illuminate whenever
the door is closed. This light will go out only when the
door is open or when there is an over-temperature condition.
Warning
To avoid electrical shock, this furnace
must have the door switch connected
and operating properly. If the furnace
power light does not go out while the
door is open, consult the
Troubleshooting section before proceeding.
Note
When performing the operations with
the controller remember that if more
than eight to 10 seconds elapse before
the buttons are used again, the display
screen will automatically switch back
to displaying chamber temperature. If
this happens, light up the front panel
again and step through each parameter until you reach the point at which
the interruption occurred. The parameter values you adjusted earlier, however, will not be lost or altered. Holding
down the SCROLL button allows
longer viewing time.
Door Safety Switch
The door safety switch removes power from the heating
elements when the door is opened. Open and close the
door a few times, note that the amber furnace cycle light
will go out while the door is open. If the furnace cycle light
does not go out while the door is open, consult the Troubleshooting section before proceeding.
Control Buttons
To illuminate the “DOWN” button, “SCROLL” button, and
“UP” button, touch anywhere on the front panel.
Digital Readout
The Digital Readout continuously displays chamber
(upper display) and set point (lower display) temperatures
unless the “SCROLL” button is depressed.
Startup Display
When the power switch is turned on, the controller will
perform a self-test to make sure controller is operating
properly. (If all four 1’s do not light up or fails to go to
“8888” contact Barnstead|Thermolyne.
15
AUTOMATIC MODELS
Caution
Do not exceed limitations for continuous or intermittent operating temperature shown in the General
Specifications section. Exceeding
these limits will result in severely
reduced heating element life.
Adjusting Furnace Set point
Temperature
•
To illuminate the “DOWN” button, “SCROLL”
button, and “UP” button, touch anywhere on the
front panel.
•
Push the “UP” button or the “DOWN” button to
modify the temperature set point (lower digital
display).
Tuning
This control incorporates a self tuning feature which determines the optimum control parameters for the best
temperature accuracy. We recommend that you tune the
furnace to your specific application to obtain the best results. Perform the following procedures when you first set
up your furnace and each time you change your load type
or operating temperature.
To tune your furnace:
Note
If the power to the furnace is turned off
or interrupted while in tuning, upon
returning power to the furnace, the
controller display will indicate, “LinE
FAIL” because sampled data could be
questionnable.
If the controller cannot maintain temperature set point, “tunE FAIL” will
appear on display.First, correct the
problem responsible for not maintaininig the temperature set point, then
restart the tuning procedure.
16
1.
Load your furnace with a load characteristic of
those you intend to heat in it.
2.
Set the furnace’s set point to the temperature
you intend to use for your application.
3.
Push the “SCROLL” button until ‘tunE” appears.
To start the tuning function, push the “UP” button.
When the tuning process is started, the lower display will
flash ‘tunE” along with the furnace temperature set point.
During tuning, the temperature set point cannot be
changed. To change temperature set point ‘tunE” must be
turned “OFF.” (To stop the tuning function, push the
“DOWN” button.)
AUTOMATIC MODELS
Changing Temperature
Indication
Push “SCROLL” button once, “°C” will appear. This indicates temperature measurement. (Contact Thermolyne if
control needs to be changed to °F.)
Note
HIAL-HIGH ALARM (over temperature
protection - OTP). The controller is fitted with a mechanical relay which is
de-energized in the alarm mode. This
relay, when de-energized, removes
power from the heating elements. If
the primary control circuit fails, the
OTP will control the furnace temperature at the preset value you have
entered. It does not shut off the furnace but will maintain the chamber
temperature at that value.
Setting the High Alarm
Temperature Over Temperature
Protection (OTP)
Push “SCROLL” button until “AL.SP” (Alarm Set point) appears. The lower display should indicate 1100°C.
Depress either the “UP” or “DOWN” button to select the
OTP value you desire. Thermolyne recommends that you
set the value either at the maximum operating temperature of the furnace or a value of 20 degrees above your
working temperature if you desire to provide protection for
your workload.
17
Programmable Control Models
(4 Ramp & 4 Dwell)
F6020C-33-60-80, F6020C-33-80, F6020C-60-80,
F6020C-80, F6028C-60-80, F6028C-80
Warning
To avoid electrical shock, this furnace
must have the door switch operating
properly.
Note
For optimum control of a single set
point operation, set the “CTrL” parameters to “FUZY” to take advantage of
the controller’s fuzzy logic capabilities.
Note
The furnace will begin to heat to the
current set point temperature when you
turn the power switch ON.To examine
the control parameters without heating
the furnace, depress and hold the
DOWN button until the set point (lower)
display reads “20.”
Note
When examining the parameters, if you
depress and release either the “SEL,”
“UP” or “DOWN” buttonbottom and
more than 1 minute elapses before the
buttons are used again, the display
screen will automatically switch to displaying chamber temperature. If this
happens, you will have to step through
each parameter until you reach the
point at which the interruption
occurred. The parameter values you
checked earlier, however, will not be
lost or altered.
18
This controller consists of a microprocessor based threemode (Proportional, Integral, Derivative), programmable
temperature controller with “Fuzzy” logic capability, programmable over-temperature protection and appropriate
output switching devices to control the furnace. The digital
readout continuously displays chamber (upper display)
and set point (lower display) temperatures unless the
“SEL” button is depressed.
The programmable control can be used as a single set
point control or as a programmable control.
Single Set Point Operation
To use as a single set point control simply push “UP” or
“DOWN” button to choose a specific temperature.
1. The set point temperature presently set in the
control will be read out on the lower display
2.
To change this set point, depress the “UP” or
“DOWN” button until the desired set point value
is displayed, then release the button.
3.
At this point, the furnace will begin to heat if the
new set point temperature you have chosen is
higher than the present chamber temperature.
Programmed Operation
Control Parameters
You can gain access to the control parameters by holding
the “SEL” button depressed for about 3 seconds. “LoCt”
will be displayed in the upper display.
Depressing “SEL” once again shows the next parameter
and its current value on the display. The parameter value
can either be modified with the buttons or left unmodified.
Pressing the enter button (>) will allow you to modify the
current value using the “Up” and “Down” buttons. Press
PROGRAMMABLE CONTROL MODELS
the enter button again to set the new value as the current
value. (See “Programming Controller” for information on
programming.)
The control parameters in order are:
LoCt - Parameter lock level. Determines the number of
parameters displayed when you press “SEL”. It should be
set to “0002.” If it does not, set to “0002.”
Nod - Mode. By pushing “UP” or “DOWN” buttons, this
can be set to “Auto” or “NAn” (Manual). Set to “Auto”. In
Manual mode, you must enter values to control the furnace chamber temperature.
At - Autotuning feature. Will automatically set optimum
P.I.D. values for your process. For Tuning, set to “on.” For
normal operation, set to “oFF.”
StAt - Status. Displays current status of program and
cannot be changed.
Tine - Time. Displays the time remaining in the current
program.
ProG - Program options. Can be set to one of three options: “oFF”, “rUn” or “hold”. “oFF” will stop any running
program and reset the program to the beginning. “rUn”
will start a program from the beginning or resume a program from “hold” from the point it was held. “hold” will
interrupt a running program without resetting the program
to the beginning.
Sü-1 - Set point 1. The temperature at which the first
ramp is aiming and at which the first dwell will be held.
tN1r - Ramp time 1. The time the controller will take to
charge the chamber temperature from its present temperature to the value of Set point 1. This time may be limited
by the physical capabilities of the furnace.
tN1S - Dwell time 1. The length of time the controller will
hold the furnace at the Set point 1 temperature.
Sü-2 - Set point 2.
tN2r - Ramp time 2.
19
PROGRAMMABLE CONTROL MODELS
tN2S - Dwell time 2.
Sü-3 - Set point 3.
tN3R - Ramp time 3.
tN3S - Dwell time 3.
Sü-4 - Set point 4.
tN4r - Ramp time 4.
tN4S - Dwell time 4.
P-on - Power-on start. Push the “Up” or “Down” Buttons
to set to “Yes” or “No.” When set to “Yes,” your furnace
will immediately begin running the set program when you
power on your furnace. For most applications, set to
“No.”
The next three parameters - Proportional band, Integral
and Derivative - are the three control parameters of a
P.I.D. control system. The values for these parameters
are set during the tuning process. You should not change
them; doing so may cause your controller to operate
incorrectly.
P - Proportional band
i - Integral
d - Derivative
Note
Over Temperature Protection (OTP):
The controller is fitted with a mechanical relay which is de-energized in the
alarm mode. This relay, when de-energized, removes power from the heating
elements. If the primary control circuit
fails, the OTP will control the furnace
temperature at the value you have
entered for AL11. It does not shut off
the furnace, but will maintain the
chamber temperature at that value.
AL1T - Alarm type. This parameter determines how the
controller responds to any alarm input. It should display
“0031.” If it does not, set it to “0031.”
AL11 - Furnace over temperature alarm. This parameter determines the absolute upper limit on the furnace
chamber temperature. We recommend a setting of
“1200°C” since 1200°C is the maximum temperature your
furnace can obtain without damage to furnace components. You may wish to set the parameter lower if you
need to ensure a crucial process is protected from high
temperature.
AL12 - High deviation alarm. This parameter determines
20
PROGRAMMABLE CONTROL MODELS
how far the furnace chamber temperature can rise above
your set point. We recommend a setting of 20; since a
P.I.D. control process involves some degree of temperature overshoot, a setting of less than 20 may interfere
with the function of your controller.
LooP - Thermocouple break alarm detection time. For
proper operation of your furnace, this parameter should
be set to “0.00”. If it is not, set it to “0.00”.
CTrL - Control type. Push the “Up” or “Down” buttons to
set to “Pid” or “FUZY”. Programmed operation requires
P.I.D. control. Single set point operation will achieve better control using Fuzzy logic control.
Programming Controller
Caution
Remember that whenever the power
switch is turned ON, the furnace will
begin to heat at the set point temperature that was previously set. This
value will remain unchanged for up to
a year without power being supplied to
the control.
Note
If you desire to skip a ramp or dwell
segment, follow this procedure: For a
dwell segment, enter a setting of “0”
minutes; for a ramp segment, enter a
setting of “00.00” hour.minutes. This
will cause the controller to skip to the
next segment as fast as the furnace
can heat or cool down.
This controller allows you a maximum of 4 ramp and 4
dwell segment combinations, thus enabling 4 different set
point levels to be achieved. Each ramp is programmed by
specifying the ending temperature level and the required
time to ramp to that temperature. The controller then
automatically calculates the ramp rate required to attain
the ending temperature level based on the desired ramp
time. Dwell segments then can be attached to each temperature level to hold that temperature for a specified
amount of time.
To run a program, first determine your ramp times, ending
temperature levels and dwell times. It is helpful to graph
your program out for ease of loading the program into the
controller.
Make sure “ProG” (program options) is set to “oFF” (to
stop the program) when entering program values.
Push “SEL” button until “Sü-1” is displayed. Push the Enter button (>) to select the current value. Push “UP” or
“DOWN” button and set Set point 1 in °C. Push the Enter
button to enter the set value as the current value.
Push “SEL” button until “TN1r” is displayed. Push the Enter button (>) to select the current value. Push “UP” or
“DOWN” button and set Ramp time 1 in hours and minutes in the format “X.XX” (hour.minutes). This is the time
Ramp 1 will take to reach Set point 1. Push the Enter but21
PROGRAMMABLE CONTROL MODELS
ton to enter the set value as the current value.
Push “SEL” button until “TH1S” is displayed. Push the Enter button (>) to select the current value.
Push
“UP” or “DOWN” button and set Dwell time 1 in hours and
minutes in the format “X.XX”
(hour.minutes). Push the
Enter button to enter the set value as the current value.
Set “Sü-2” “TN2r” “TN2S” “Sü-3” “TN3r” “TN3S” “Sü-4”
“TN4r” and “TN4S” in the same manner as “Sü-1” “TN1r”
“TN1S”.
Program Execution
Push “SEL” button until “ProG” is displayed. Pushing “UP”
or “DOWN” button, select “run.” When “run” is selected,
the program will start from the actual furnace temperature
at that point in time.
Note
The temperature control in these models is a programmable and automatic
single set point device. When the program has ended, the controller will
maintain the chamber temperature at a
value equal to the last programmed
level (Set point 4) until the program is
canceled. It will not automatically cool
to ambient unless Set point 4 is set at
ambient. When a program is canceled,
the controller will maintain the chamber temperature at a value equal to the
single set point mode set point.
Set point
While the program is in “run” or “Hold,” the set point
shown on the bottom display is the current working set
point.
Program End
When the program ends, the controller will hold the furnace at the value of Set point 4 until you stop the program
Program Stop
To stop program, push “SEL” button until “ProG” is displayed. Push “UP” or “DOWN” button until “oFF” is displayed. This will terminate program.
Self Tuning Feature
This programmable control has an automatic tuning feature which installs optimum tuning parameters to give the
best temperature accuracy with your load and set point or
program. No manual loading of tuning parameters is
needed. Barnstead|Thermolyne highly recommends
using this feature to provide the best temperature
accuracy the controller can attain. Use this feature the
22
PROGRAMMABLE CONTROL MODELS
first time you use your furnace and each time you change
your set point or program or the type of load you are
heating. To use the Tuning feature:
Note
For processes which cannot tolerate
the overshoot naturally generated during the tuning process, select “Lo”
rather than on for the “AT” setting. The
“Lo” setting will tune your furnace at a
temperature below your set point, then
apply the result to your set point. This
approach prevents the necessary tuning overshoot from exceeding your
actual set point.
1.
Select the temperature at which you intend to
operate. If you will be running a program, enter
the value of Set point 1 as a single set point.
2.
Load your furnace with a characteristic sample
of the load you will be heating.
3.
Push “SEL” button until “AT” is displayed, then
push “UP” or “DOWN” button to turn “AT” “on.”
During the operation, “TunE” flashes in the lower display.
Do not make any adjustments to the controller parameters during this period. The self tuning is finished when
“TunE” no longer flashes in the lower display.
Self tuning will calculate values for:
Proportional band - P
Integral - I
Derivative - d
•
Self tuning cannot be initiated while running a
program.
•
A power failure will cause the AT parameter to
revert back to “OFF”. (Reset tune parameter to
“ON” using the “UP” button).
•
In the case of alarm conditions during tuning,
those conditions will flash alternately with
“TunE.”
The next time you use your furnace, push “SEL” button
until “AT” is displayed, then push “UP” or “DOWN” button
to turn tune “oFF.”
23
Multi-Programmable Models
(8 ramp & 8 dwell)
F6030CM, F6030CM-33, F6030CM-33-60, F6030CM-60,
F6038CM, F6038CM-60
Note
When performing operations with the
controller, if you depress and release
either the SCROLL, Up or DOWN
push button and more than eight seconds elapse before the buttons are
used again, the display screen will
automatically switch back to displaying
set point temperature. If this happens,
you will have to step through each
parameter until you reach the point at
which the interruption occurred, The
parameter values you adjusted earlier,
however, will not be lost or altered.
Note
To change from °C indication to °F
indication, contact
Barnstead|Thermolyne.
Caution
Remember that whenever the power
switch is turned ON, the furnace will
begin to heat at the set point temperature that was previously set in. This
value will remain unchanged for up to
a year without power being applied to
the control.
Controls and Displays
Digital Readout:
The digital readout continuously displays chamber (upper
display) and set point (lower display) temperatures unless
the scroll button is depressed.
If the scroll button is depressed and released, the lower
display will indicate output power (OP) or set point (SP).
This is referred to as the “short scroll.” Continued single
step action of scroll button will cause lower display to alternate between set point (SP) and output power (OP).
To enter the main scroll list (list of all controller parameters that are accessed through front keyboard), the scroll
button should be held depressed. PR1 (program ramp
rate 1) will appear. To progress through the parameter list,
the scroll button must first be released; subsequent single
step depression will advance you through the list. Rapid
progression through the parameter list is achieved by
holding the scroll button depressed.
See Parameters for a list of the controller parameters in
order.
Power Switch
Turn power switch to the “ON” position.
Furnace Power Indicator
Warning
To avoid electrical shock, this furnace
must have the door switch connected
and operating properly. If the furnace
cycle light does not go out while the
door is open, consult the
Troubleshooting section before proceeding.
24
The amber furnace power light will illuminate whenever
the door is closed. This light will go out only when the
door is open or when there is an over-temperature condition.
Door Safety Switch
The door safety switch removes power from the heating
elements when the door is opened. Open and close door
MULTI-PROGRAMMABLE MODELS
Note
The two center push buttons are inactive and not used.
a few times, note that the amber furnace cycle light will
go out while the door is open. If the furnace cycle light
does not go out while the door is open, consult the
Troubleshooting section before proceeding.
Parameters
Pnr - Program Number. The program number of the program you are going to work with. By pushing the up or
down button you can select a program numbered from 1
to 4.
PR1 - Program Ramp Rate. The rate of heat increase or
decrease in °C/minutes. Pushing the up or down button
will give current setting of this ramp.
PL1 - Program Level. The temperature to which the furnace needs to attain. Push up or down button to set.
PD1 - Program Dwell 1. Amount of time in minutes to
hold PL1 program level temperature entered. Push up or
down button to set.
You will use the same descriptions and procedures used
for PR1, PL1, PD1 for the remaining Program Ramp
Rates PR2 - PR8, Program Levels PL2 - PL8, and Program Dwells PD2 - PD8.
Cnt - Continue. Allows linking of programs. You may select Cnt as “y” (yes) or “n” (no) by pushing the up or down
button.
HB - Holdback. Automatically places the programmer
into “Hold” if the measured value deviates more than a
specified amount from programmer set point. When measured value re-enters the holdback band, the timing for
the segment resumes. (Parameter is expressed in °C and
only functions when running a program). Push up or down
button to set.
PLC - Program Loop Count. The number of times a program will be repeated. Push up or down button to set.
SP1 - Set point One. Indicates current set point. Push up
or down button to set.
25
MULTI-PROGRAMMABLE MODELS
SP2 - Set point two. Not configured into control and nonfunctional. Set to “20.”
AT - Adaptive Tune. Analyzes and inputs optimum PID
values when temperature has reached set point. This
function does not have a value; it is either “ON” or “OFF.”
(See Furnace Operation for function of Adaptive Tune).
ATR - Adaptive Tune Range setting. Determines the operational band width of the adaptive tuning function. Self
Tuning automatically determines this setting.
Note
Barnstead|Thermolyne recommends
that you set the value either at maximum operating temperature of the furnace (1100°C = 2012°F) or a value of
20° above your working temperature if
you desire to provide protection for
your workload.
AL1 - Alarm 1. A full scale alarm which protects load and
furnace when temperature exceeds preset value. Furnace
will control temperature at the preset temperature value; it
will not shut off furnace. Push up or down button to set.
The next three parameters - Proportional (PB) Integral
(+i) and Derivative (+d) - are the three control parameters
of a P.l.D. control system. These parameters will be set
when you tune your furnace. (See Self-Adaptive
Tuning.)
Pb - Proportional.
(+i) - Integral.
(+d) - Derivative.
The next two parameters - cutback low (cbl) and cutback
high (cbh) - are to aid the control in preventing temperature overshoots and undershoots. The point from set point
where the power starts “cutting back” is defined as the
cutback value. These values are also automatically
adjusted by the Self Tuning and Adaptive Tuning features.
These values cannot be changed by the user; the controller automatically installs optimum cutback values when
in Self Tuning and Adaptive Tuning.
HL - Output Power limits the average maximum power
that is applied to the heating elements. Normal setting is
100%. If you plan to use the furnace below 260°C (500°F)
the output power may be reduced. This will significantly
shorten the time it takes for stabilization. It will also
reduce drastic temperature overshoots. Contact
Barnstead/Thermolyne Customer Service for advice on
the proper value to use. Remember that this parameter
does not reduce the voltage to the elements. It reduces
the average power to the elements by cycling power on
and off.
26
MULTI-PROGRAMMABLE MODELS
HC - Cycle Time is the rate at which power is supplied to
power control switch. Push up or down button to set.
Sbr - the percent of power that is supplied to the control output terminals if an open thermocouple condition exists. Push up or down button to check. 0.0 will be
displayed. This parameter cannot be changed; if 0.0 is
not displayed, contact Barnstead/Thermolyne. The upper
display will flash “OR” if an open thermocouple condition
exists.
Tuning Your Controller
The programmable control has automatic tuning features
which install optimum tuning parameters to give the best
temperature accuracy. No manual loading of tuning parameters is needed. We highly recommend using these
features to provide the best temperature accuracy the
controller can attain. Perform the following procedures
when you first set up your furnace and each time you
change your load type, operating temperature, or program.
The following procedure is instruction on how to initiate
the SAT Self and Adaptive Tuning feature. This feature
starts the controller in the Self Tune mode then automatically switches over to the Adaptive Tuning Feature. Self
Tuning is a one-time function which permits the user to
retune the instrument control parameters to suit new process conditions. Adaptive tuning takes over when the self
tune is completed and continuously reevaluates the tuned
parameters. Adaptive tuning will then automatically install
new values if a better response could have been attained.
To initiate the tuning feature:
Load your furnace with a load characteristic of those you
intend to heat in it.
Depress scroll button until SAT is displayed. Depress the
up and down buttons simultaneously to start self tuning.
The A-T indicator is then illuminated (upper right hand
comer) and the lower display indicates the set point at
which the self-tune sequence will occur. The “SP” indicator will flash for 1 minute, during which time the set point
may be changed, if it is required to retune at a new set
27
MULTI-PROGRAMMABLE MODELS
point either above or below the process value indicated
on the upper display. (If you will be using the controller as
a single Set point Controller, set the furnace’s set point to
the temperature you intend to use for your application. If
you will be running a multi-step program, set the furnace’s
set point to the value of PL1 (Program Level #1).) At the
end of the minute, the “SP” indicator will stop flashing,
indicating that the set point can no longer be changed.
The A-T indicator will start flashing and continue to flash
until the self tune has completed. Once the self tune is
completed, adaptive tune takes over and the A-T indicator
will remain illuminated.
To stop tuning, function scroll until SAT is displayed and
simultaneously push up and down buttons.
Operating the Controller
Caution
Do not exceed limitations for continuous or intermittent operating temperature shown in the General
Specifications section. Exceeding
these limits will result in severely
reduced heating element life.
Single Set Point Operation
This programmable control can be used as a single set
point control or as a programmable control. To use as a
single set point control, simply push up or down buttons
to choose a specific temperature. Temperature set point
or output power is indicated on lower display; single depression of scroll button will alternate between these two
parameters. The control will cause the furnace chamber
to heat to the chosen temperature and hold it at this temperature until you turn off the power switch or select
another temperature.
1. The set point temperature presently set in the control
will be read out on the lower display.
2. To change this set point, depress the “UP” or
“DOWN” push button until the desired set point value
is displayed then release the button.
3.
At this point the furnace will begin to heat if the new
set point temperature you have chosen is higher than
the present chamber temperature.
4. The upper display indicates the actual furnace temperature.
28
MULTI-PROGRAMMABLE MODELS
Programming Controller
The multi-programmable controller in these units provides
up to 4 separate programs of 8 ramps and 8 dwells each.
This controller also allows you to link programs together,
which allows you to achieve 64 total segments (4 programs X 16 segments). These functions are controlled by
the controller’s first two programming parameters, “Pnr”
and “Cnt.”
A maximum of 8 ramp and 8 dwell segment combinations
are available per program, thus enabling eight different
set point levels to be achieved. Each ramp is programmed by specifying the program level (PL) and the
required ramp rate (PR). The programmer then automatically calculates the time that is required to attain the program level (PL) based on desired ramp rate (PR). Dwell
segments (soak) then can be attached to each program
level (PL) to hold that temperature for a specified time.
To run a program, first determine your ramp rate, dwell
times, program levels. It is helpful to graph your program
out for ease of loading program into controller.
To Select Program Number
Push scroll button until “Pnr 1” is displayed. Push the up
or down button to select a program number from 1 to 4.
Note
Once the desired parameter has been
selected, depressing either the raise or
lower button will cause the parameter
to be replaced with the new value. At
this point, the “top dot” of the least significant digit of the secondary display
will flash on and off. Any further use of
the UP or DOWN buttons will change
the parameter value. In all cases, the
value shown on the display is the current working value of that parameter.
Program Entry
To Link Programs Together
Push scroll button until “Cnt n” is displayed. Press and release the up and down buttons to switch between “Cnt y”
(continue yes) and “Cnt n” (continue no). The effect of
selecting “Cnt y” is to continue the program to the next
program number. For example, if in program #3 you select “Cnt y,” when program #3 is complete, program #4
will run automatically. Setting “Cnt y” in program #4 will
initiate the start of program #1 upon the completion of
program #4. Each program will complete the selected
number of loops before continuing (see Loop Count). If
you do not want to link programs, set Cnt to “Cnt n” (continue no).
29
MULTI-PROGRAMMABLE MODELS
Set Ramp Rates
1. With the programmer not operating, indicated by
the bottom right hand side of the display extinguished, depress scroll button until PR1 is displayed. Push the up or down button to scroll to
the desired value, which is degrees per minute.
Scrolling down below zero will give three other options for
the ramp:
NONE-which will force the program to skip to
the next segment;
END-which will cause the program to stop or restart if loops remaining is not zero;
STEP-which will cause the program to ramp as
quickly as possible to the next temperature
level.
All other ramps in the program are set in a similar fashion
by selecting ‘PR’ followed by the relevant ramp number.
Set Level Temperatures
2. The level to which the first ramp is aiming is
entered by scrolling through the main scroll list
until “PL1” is displayed. By pressing either the
up or down button the present value of this level
is indicated in display units. Using the up or
down button will scroll the present value to the
new value required. All other levels in the program are set in a similar fashion by selecting
‘PL’ followed by the relevant number.
Set Dwell Times
3. To set the dwell time for the first level, scroll
through the main scroll list until “Pd1” is displayed. Pressing the up or down button will
reveal the current value of time in minutes.
Using the up or down button will scroll the present value to the new value required. Scrolling
this value downscale will allow a setting of
“END.” A setting of “END” will terminate the program, or force it to restart if loops remaining are
not zero at the beginning of that dwell.
30
MULTI-PROGRAMMABLE MODELS
All other dwells in the program can be set in a similar
fashion by selecting “PD” followed by the relevant dwell
number.
Set the Number of Times to Repeat the Program
4. Scrolling through the main scroll until the parameter “PLC” is displayed and then depressing the
up or down button will reveal the present setting
of the loop count. This is the number of times
that the entered program will be repeated before
a continuous set point at the last level of the
program is achieved. By pushing the up or down
button the number of loops can be set at any
value from 1 to 999.
Set the Holdback Feature
5. Scroll through the main scroll list until “HB” is
displayed. Push the up or down button to reveal
the current value of holdback. The up or down
button can now be depressed to scroll to the
required value. Holdback is set in display units
and represents the allowable excursion of measured value away from the current set point, either above or below, before the program is
forced into hold. The program will remain in hold
until the measured value comes within holdback
limits. This feature is active the whole time that
the program is running. When hold is forced
onto the program by holdback, the “HOLD’”legend is not illuminated but either the “RAMP” or
“DWELL” legend will flash.
Note
Be sure to select the program number
before pressing “Run/Hold.”
Implementing Programs
Program Execution
Once the program has been entered it can be set running
by depressing the ‘RUN/HOLD’ push button on the front.
With the run initiated, the program will commence and the
legend on the display will indicate if a ramp or dwell is
being performed. While a program is running the short
scroll will contain a third parameter “TIME.” Push scroll
31
MULTI-PROGRAMMABLE MODELS
button once; time remaining for the current segment, either ramp or dwell will be indicated. If the loop counter
has been set to any value other than one, then the above
procedure will be repeated for each loop.
At the end of the complete program, an “E” will appear on
the display.
Parameter Change While Running
The previous parameters can be inspected but not
changed while a program is running. If it is necessary to
alter a parameter while a program is running, the program
must be placed into the hold condition. To put program
into hold, push run/hold button once. After modification of
the parameter, returning the program to the run state will
cause the program to continue with the changed value(s)
installed. Push run/hold button again to restart program.
Loop Count
If the loop count is set to values other than one, then the
number of loops remaining in a running program can be
displayed. To determine which loop is being performed
depress scroll button until LR’ is displayed and by pushing
either the up or down button the remaining number of
loops, excluding the one being executed, is displayed.
Note
The temperature control in these models is a programmble and automatic
single set point device. When the program has ended, the controller will
maintain the chamber temperature at a
value equal to the last programmed
level (PL), until the program is canceled. It will not automatically cool to
ambient unless the last programmed
level (PL) is set at ambient. When a
program is canceled, the controller will
maintain the chamber temperature at a
value equal to the main set point (SP1
or SP). To cancel a program, depress
and release the UP or DOWN push
buttons simultaneously. Be sure single
set point mode is set to 20° or below
as described earlier in this manual.
32
Program Hold
A running program can be forced into hold at any stage
by depressing the “RUN/HOLD” push button on the front.
When a running program is forced into hold, “HOLD” legend will appear on the display together with the segment
type and will be flashing. Pushing “RUN/HOLD” button
again will return the program to a run situation and extinguish the “HOLD” legend.
Program Reset
A running, held or finished program can be reset by depressing the up and down push buttons together.
When the reset has been enabled, the parts of the display
associated with programming will be extinguished and the
controller will operate as a single set point control.
Installation and Operation of
Air Control
Note
Coal ashing furnaces -60 models contain a feature to provide air (or inert
gas) flow within the furnace chamber.
Note
A pressurized air line with a minimum
working pressure range of 0 to 20 psi
is required.
Note
A flow rate of 40 to 45 liters per minute
will provide three air exchanges of the
chamber per minute.
Note
If the furnace is to be used regularly,
the airline regulator may be left open
to 20 psi.
Note
Appropriate exhaust must be provided
to remove smoke and gases proceeding an ashing procedure.
Note
Failure to connect the exhaust port to
an appropriate exhaust system will
result in smoke and gases filling the
work area. Without the connection,
gases and smoke will escape around
the door seal and at the rear of the furnace.
Installation
Compressed Air Hook-Up
1.
At the rear of the furnace is located a 0.250 inch
tube fitting.
2.
Using 0.250 inch I.D. rubber tubing, connect a
length of tubing from this input fitting to a corresponding 0.250 inch fitting located on the regulated side of a pressurized air service line.
3.
Prior to making connections at the regulator,
ensure that the regulator is turned fully closed (0
psi).
4.
Turn flow control valve located at the bottom of
the flow meter (front control panel) fully clockwise to closed position.
5.
Turn regulator to maximum output pressure of
20 psi. Check for any leaks at connection points
of connecting tubing.
6.
Open flow control valve slowly until ball in flow
meter reads between 40 to 45 liters per minute
flow rate.
7.
Open furnace door and check that air is
exhausting from the manifold located at the bottom rear of the chamber.
8.
Turn flow control valve to off (fully clockwise).
Exhaust Tubing Hook-Up
Using accessory stainless steel tubing available from
Barnstead/Thermolyne Corporation (part number
AY408X1A) or equal quality 2.5 inch I.D. stainless steel
tubing, connect flexible tubing from vent port at top of furnace case to an appropriate negative pressure exhaust
system. This exhaust system must be capable of handling
smoke and gases produced in an ashing procedure.
33
INSTALLATION AND OPERATION
OF
AIR CONTROL
Furnace Programming
Refer to “Programmable Models” in this manual to program in the following values for performing ASTM specification D3174.
PR1 (Ramp 1) value is 8°C/minutes
PL1 (Level 1) value is 500°C
PD1 (Dwell 1) value is 0 minutes
PR2 (Ramp 2) value is 6°C/minutes
PL2 (Level 2) value is 750°C
PD2 (Dwell 2) value is 120 minutes
PR3 (Ramp 3) value is END (for 8 ramp & 8
dwell controller)
PLC (Loop Center) value is 1
Included with this furnace are two stainless steel trays
which will hold crucibles of quartz jars. Use the appropriate side for the type of crucible you are using. A removable handle is also provided to use in loading and unloading the trays from the furnace.
Shelf Location
1.
The side walls of the chamber contain twenty
four holes (.250 inch dia.) which allow adjustment of the two perforated shelves at various
heights within the chamber.
2.
Using the eight, .250 inch diameter porcelain
pegs, insert four pegs in the bottom row of
holes.
3.
Next insert the remaining four pegs in fourth row
of holes and insert the two perforated shelves .
4.
Check for proper fit at this point by inserting the
crucible trays.
Operation
34
1.
Insert crucible trays. One tray per shelf.
2.
Close the furnace door.
INSTALLATION AND OPERATION
OF
AIR CONTROL
3.
Ensure the exhaust system is operating.
4.
Set flow control valve so flow indicator reads between 40 and 45 liters per minute. (Check regulator to ensure 20 psi pressure).
5.
Switch power switch to “ON”.
6.
Depress run button. Controller will automatically
step the program through the various steps outlined earlier.
7.
When the program has ended, the controller will
maintain the chamber temperature at a value
equal to the last programmed level (PL) until the
program is cancelled. It will not automatically
cool to ambient unless last programmed level
(PL) is set at ambient. When a program is cancelled the controller will maintain the chamber
temperature at a value equal to the main set
point (SP1 or SP). To cancel a program depress
and release the “UP” and “DOWN” push buttons
simultaneously. Be sure single set point mode is
set to 20 degrees as described earlier in this
manual.
8.
At the end of the program, turn the flow control
valve fully clockwise to the closed position.
35
Furnace Loading
For best results, use only the center two-thirds of the furnace chamber.
Caution
Do not overload your furnace chamber. If the load is to be heated uniformly, it should not occupy more than twothirds of the furnace chamber. Failure
to observe this caution could result in
damage to furnace components.
36
1.
If you are heating a number of small parts,
spread them throughout the center of the furnace chamber.
2.
Keep objects away from thermocouple.
3.
Use insulated tongs and mittens when loading
and unloading furnace.
4.
Always wear safety glasses.
5.
Use Barnstead|Thermolyne hearth plates if you
place load on bottom of chamber. Part #PHX2
(three are required).
Maintenance and Servicing
Warning
This warning is presented for compliance with California
Proposition 65 and other regulatory agencies and only
applies to the insulation in this product. This product contains refractory ceramic, refractory ceramic fiber or fiberglass insulation, which can produce respirable dust or
fibers during disassembly. Dust or fibers can cause irritation and can aggravate preexisting respiratory diseases.
Refractory ceramic and refractory ceramic fibers (after
reaching 1000°C) contain crystalline silica, which can
cause lung damage (silicosis). The International Agency
for Research on Cancer (IARC) has classified refractory
ceramic fiber and fiberglass as possibly carcinogenic
(Group 2B), and crystalline silica as carcinogenic to
humans (Group 1).
Warning
Disconnect from the power supply
prior to maintenance and servicing.
Warning
Refer servicing to qualified personnel.
Warning
Replace fuses with same type and
rating.
Hot Surface
“Caution. Hot Surface.Avoid Contact.”
To avoid burns, this furnace must not
be touched on the exterior or interior
surfaces during use or for a period of
time after use.
The insulating materials can be located in the door, the
hearth collar, in the chamber of the product or under the
hot plate top. Tests performed by the manufacturer indicate that there is no risk of exposure to dust or respirable
fibers resulting from operation of this product under normal conditions. However, there may be a risk of exposure
to respirable dust or fibers when repairing or maintaining
the insulating materials, or when otherwise disturbing
them in a manner which causes release of dust or fibers.
By using proper handling procedures and protective
equipment you can work safely with these insulating
materials and minimize any exposure. Refer to the appropriate Material Safety Data Sheets (MSDS) for information regarding proper handling and recommended protective equipment. For additional MSDS copies, or additional
information concerning the handling of refractory ceramic
products, please contact the Customer Service
Department at Barnstead|Thermolyne Corporation at 1800-553-0039.
Note
Perform only maintenance described in
this manual. Contact an authorized
dealer or our factory for parts and assitance.
37
MAINTENANCE AND SERVICING
Preventative Maintenance
This unit is equipped with a venting system on the top of
the furnace. This is for the removal of fumes from the
chamber of the unit. Contamination is a major cause of element failure, therefore, remove all fume forming material
before heating. (e.g. clean cutting oil from tool steel).
1.
Housekeeping is vital to your electric furnace KEEP IT CLEAN. Run your furnace up to
1600°F empty occasionally to burn off the contamination that may exist on the insulation and
elements. Maintain 1600°F for at least 4 hours
to ensure complete ashing of foreign materials.
2.
Element life is reduced somewhat by repeated
heating and cooling. If the furnace is to be used
again within a few hours, it is best to keep it at
the operating temperature or at a reduced level
such as 500°F (260°C).
3.
Change the thermocouple every six months.
General Cleaning Instructions
Wipe exterior surfaces with lightly dampened cloth containing mild soap solution.
To Replace a Heating Element
38
1.
Disconnect furnace from power supply.
2.
Remove the back terminal cover of the furnace.
(Note placement and connections of wires)
3.
Loosen the nuts on the terminals of the element
to be replaced.
4.
Open the door and pull the defective element
out. (It may be easiest to turn the furnace so
that the element to be removed is on top).
5.
Slide the new element into place, threading the
leads through the insulating porcelain bushing
on the back of the furnace.
MAINTENANCE AND SERVICING
6.
Tighten the nuts securely. Cut off any excess
lead wire.
7.
Replace the back terminal cover.
8.
Reconnect furnace to power supply.
9.
Test operation of furnace.
To Replace a Platinel II
Thermocouple in Programmable
and Automatic Furnaces
1.
Disconnect furnace from power supply.
2.
Remove the back terminal cover of the furnace.
(Note placement and connection of wires).
3.
Remove the screws on the thermocouple terminals and pull the thermocouple straight out.
4.
Insert the new thermocouple into the furnace
with blue and yellow beaded lead connected to
the positive (+) marked terminal and other lead
to negative (-) terminal.
5.
Secure connections with screws removed in
step 3.
6.
Replace the back terminal cover.
7.
Reconnect the furnace to power supply.
8.
Test operation of furnace.
To Replace a Chromel/Alumel
Thermocouple (Basic Automatic
Furnaces)
1.
Disconnect furnace from power supply.
2.
Remove both back covers. (Note placement and
39
MAINTENANCE AND SERVICING
connection of wires).
3.
Remove clip holding thermocouple in place (1
screw) and remove the two screws on the thermocouple terminals.
4.
Remove the thermocouple. Pull thermocouple
straight out of hole in the chamber first to avoid
damage to the insulation.
5.
Guide the looped ends of the new thermocouple
through the plastic bushings with the red (-) lead
to the right as you face the back of the furnace.
6.
Form a 90° bend, towards the furnace, between
the 2" long and 1” long ceramic insulators with
the red (-) lead to the right. Insert the thermocouple straight through the hole in the chamber.
7.
Secure the thermocouple with clip and screw.
Connect the looped ends of the thermocouple to
the terminals with + to + (yellow wire).
Chromel/Alumel thermocouples and lead wire
are easily tested with a magnet. The non-magnetic wire is positive (+) and the magnetic wire
is negative (-).
8.
Replace both back covers.
9.
Reconnect to power supply. Test operation of
furnace.
To Replace Solid State Relay
40
1.
Disconnect furnace from power supply.
2.
Remove back control cover. (Note connection
and placement of wires to relay).
NOTE: For basic automatic control models,
remove both the back cover and the front control panel to provide access to solid state relay.
3.
Disconnect wires from terminals. Identify or
mark wires.
MAINTENANCE AND SERVICING
4.
Remove nuts, washers, and screws from relay,
then remove relay.
5.
Install new relay.
6.
Reconnect the wires identified or marked in step
3.
7.
Replace back control cover.
8.
Reconnect furnace to power supply.
9.
Test operation of furnace.
To Replace Door Switch (Micro
Switch)
1.
Disconnect furnace from power supply.
2.
Remove the four top screws on the front dial
and the four bottom screws on the back cover.
3.
Slide the control section forward. (Do not pull
excessively on the internal wires).
4.
Disconnect the wires from the door switch.
(Note connection and placement of wires to
micro switch). Identify or mark wires.
5.
Remove the two screws and nuts from the micro
switch.
6.
Insert new micro switch and secure with screws
and nuts removed in Step 5.
7.
Reconnect wires identified or marked in Step 4
to new door switch.
8.
To realign door switch see below, steps 5
through 7.
9.
Slide control section back and replace the
screws described in Step 2.
10. Reconnect to power supply.
41
MAINTENANCE AND SERVICING
11. Test operation of door switch. (See below, step
10.).
To Realign Door Switch (Micro
Switch)
1.
Disconnect furnace from power supply.
2.
Remove the four top screws on the front dial
and the four bottom screws on the back cover.
3.
Slide the control section forward. (Do not pull
excessively on the internal wires).
4.
With the door closed loosen the screws on the
microswitch and slide the switch downward, so
that the screws are at the bottom of the slots in
the mounting bracket.
5.
Finger tighten both screws. While holding down
the rear of the micro switch housing, gently push
up on the front of switch until you hear a click.
6.
Open and close the door; the switch should click
when the door is opened approximately 1" and
1/2" to 1" before the door is closed. Slide the
front of the switch up to increase the distance,
down to decrease the distance.
7.
Tighten the two screws to secure the micro
switch. Check the operation of the switch as
described in Step 6 after tightening the screws.
8.
Slide control section back and replace the
screws described in Step 2.
9.
Reconnect to power supply.
10. To test the operation of the door switch: turn the
power switch on, set the control setting high
enough to keep the control from cycling, open
and close the door; the cycle light should turn off
when the door is opened approximately 1" and
on 1/2" to 1" before the door is closed.
42
MAINTENANCE AND SERVICING
To Replace Control Module
Programmable Models
1.
Turn the screw on the control counterclockwise.
2.
As the control module starts to disengage, pull it
straight out of the control sleeve.
Automatic Models
1.
Grasp top and bottom of control, squeeze and
pull straight out.
Basic Automatic Control - PC Board
1.
Disconnect from power supply.
2.
Remove lower back cover and remove screws
from front cover.
3.
Pull control section out to gain access to PC
board.
The Troubleshooting Tips section is intended to aid in defining and correcting possible service problems. When using the chart, select the problem category that resembles
the malfunction. Then proceed to the possible causes category and take necessary corrective action.
43
Troubleshooting
PROBLEM
PROBABLE CAUSE
CORRECTIVE ACTION
The power light does not illuminate.
The furnace is not connected
Check furnace connection
to power supply.
to power source.
ON and OFF power switch is
Replace power switch.
defective.
Fuses blown.
Replace fuses.
Heating elements burned out or
Replace heating elements or
The furnace does not heat,
cycle light illuminated.
improper connections.
The furnace does not heat,
repair connections.
No power.
Check power source and fuses or
Two or more heating elements in
Replace defective elements.
cycle light not illuminated.
breakers.
208V or 240V furnaces are burned
out.
Thermocouple has oxidized and
Replace thermocouple.
opened the circuit. Indicated by:
a) basic automatic control - 1-5
degrees on display
b) automatic control - “OR” on
display.
c) Prog. 2 ramp & 2 dwell “SNB” on display.
d) Prog. 8 ramp & 8 dwell “OR” on display.
Defective electrical hookup.
Repair electrical hookup.
Set point set too low.
Reset set point to a higher value.
High power limit set to a low level.
Reset level to a higher value.
Door switch malfunction.
Re-align or replace door safety
switch.
Replace relay.
Defective mechanical door switch
relay coil or contacts.
44
TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
CORRECTIVE ACTION
No temperature control.
Shorted thermocouple circuit.
Check thermocouple connection
and/or replace thermocouple.
Shorted solid state relay - over
Replace solid state relay.
temperature protection may
be activated.
Defective control - error message
on display may appear.
Slow heat-up.
Return control for repair
or replace.
Thermocouple leads are reversed.
Connect leads correctly (see manual).
One or two heating elements are
burned out.
Replace burned out elements.
Heavy load in chamber.
Lighten load in chamber
to allow heat to circulate.
Low line voltage.
Install line of sufficient size and
proper voltage (isolate furnace
from other electrical loads).
Incorrect parameter setting “HL”
Set “HL” to 100.
high power limit.
Wired improperly.
Check wiring diagram for
correct wiring of your furnace.
Door switch does not cut power
switch.
Wrong heating element.
Install proper element.
Door switch is not functioning.
Re-align or replace door safety
Mechanical relay contacts sticking.
Replace relay.
Chamber improperly loaded.
See loading procedures in start-up
procedure.
Heating harmful materials.
Enclose material in container.
Clean up spills on chamber.
Ventilate chamber by leaving door
cracked slightly open when
heating known harmful reagents.
Overheating furnace.
Keep furnace under maximum
temperature. Closer supervision
of control setting.
to the furnace chamber.
Repeated element burnout.
45
TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
CORRECTIVE ACTION
Repeated element burnout (cont.)
Wrong element.
Install proper element.
Oxidized thermocouple.
Replace thermocouple.
Contamination present from
previous burnout.
Replace insulation material.
Wired improperly.
Check wiring diagram for correct
wiring of your furnace.
Oxidized or contaminated
Replace thermocouple.
Inaccurate temperature display.
thermocouple.
Improper loading.
Use proper loading procedures.
Refer to start-up procedure.
Ambient temperature too high.
Keep ambient temperature under
100°F.
Poor thermocouple connection.
Tighten connections.
Solid state relay malfunction.
Replace solid state relay.
Thermocouple connections
Reconnect thermocouple correctly.
reversed.
Control out of calibration.
46
Contact Barnstead|Thermolyne.
Replacement Parts List
SERIES 1060
Listed below is the common replacement parts for all models of the 6000 furnace. The far left column contains the letter designation found on the circuit diagrams. Be sure to identify the correct part number with
respect to the exact model number found on your furnace.
REPLACEMENT PART
DESCRIPTION
MODELS USED ON
PC750X4A
Control Unit - PC Board
F6018
PC750X2A
Control Unit - PC Board
F6010, F6010-33
CN71X63
Control Unit, Automatic
F6020C, (-33), (-33-60) & (-60), F6028C & (-60)
CN71X56
Multi-Control Unit, Prog.
(16 segment)
PLX82
Pilot Light
All models except F6010, F6010-33, F6018
EL408X1
Heating Element, Top
F6020C , (-33), (-33-60), (-33-80), (-33-60-80),
(-60), (-60-80) & (-80), F6030CM, (-33),
EL408X10`
Heating Element, Top
F6010, F6010-33, F6018
EL408X2
Heating Element, Top
F6028C, (-60), (-60-80) & (-80),
(-33-60) & (-60)
F6038CM & (-60)
EL408X5
Heating Element, bottom
F6020C , (-33), (-33-60), (-33-80), (-33-60-80),
(-60), (-60-80) & (-80), F6030CM, (-33),
EL408X4
Heating Element, bottom
EL408X9
Heating Element, bottom
F6010, F6010-33, F6018
EL205X6
Heating Element, side
F6020C , (-33), (-33-60), (-33-80), (-33-60-80),
(-33-60) & (-60)
F6028C, (-60), (-60-80) & (-80),
F6038CM & (-60)
(-60), (-60-80) & (-80), F6030CM, (-33), (-33-60)
& (-60)
EL408X3
Heating Element, side
F6028C, (-60), (-60-80) & (-80), F6038CM
EL408X11
Heating Element, side
F6010, F6010-33, F6018
FZX28
Fuse, Type ABC, 250 Volt,
F6010-33
& (-60)
15 Amp
RYX57
Relay
All models except F6010, F6010-33, F6018
RYX34
Solid State Relay
All models except F6010, F6010-33, F6018
RYX54
Solid State Relay
F6010, F6010-33, F6018
SWX144
Power Switch
All models
SW356X1A
Micro Switch
All models
TC357X1A
Thermocouple, Type K
F6010, F6010-33, F6018
TC408X1A
Thermocouple, Type F
All models except F6010, F6010-33, F6018
SW745X1A
Push To Set Temp. Switch
F6010, F6010-33, F6018
RS745X1A
Temp. Adjustment Rheostat
F6010, F6010-33, F6018
CAX94
CAX99
Filter, EMI
Filter, EMI
F6010-33
F6020C-33, (-33-60), (-33-60-80) & (-33-80),
F6030CM-33 & (-33-60)
47
48
H3
T1
Wiring Diagram (F6010, F6010-33, F6018)
H2
H1
SWITCH, DOOR
SWITCH, DOOR
SWITCH, SET POINT
TERMINAL BLOCK
THERMOCOUPLE
S2
S3
S4
TB1
TC1
T2
H4
RESISTOR, POT
RESISTOR
RELAY, SOLID STATE
SWITCH, POWER
R1
R2
RY1
S1
GND
L2
L1
FUSE
FILTER
HEATING ELEMENT
HEATING ELEMENT
HEATING ELEMENT
HEATING ELEMENT
F2
FL1
H1
H2
H3
H4
FL1
ONLY
F6010-33
L2
L1
PILOT LIGHT
FUSE
CONTROL
DESCRIPTION
CN1
DS1
F1
NO.
REF.
DIAGRAM COMPONENT LIST
GND
R2
F2
F1
S1
S4
R1
GND
S2
S3
HI
J1
AC
J3
J7
GND
J2
AC
4
LOW
1
J5
RY1
3+
2
+
J9
SSR
J8
CN1
J6
TB1
RED
J4
YEL.
+
DS1
RED
YELLOW
TC1
Wiring Diagrams
S2
TC-
CN1
5
3
+
1
2
4
3
L1
1
T1
H1
RY1
RY2
2
H3
H4
L2
4
6
H2
T2
S1
S2
TC1
RY2
S1
DS1
CYCLE
DOOR SWITCH
THERMOCOUPLE
RELAY, DPST, N.O.
SWITCH
FILTER, EMI
HEATING ELEMENT
HEATING ELEMENT
HEATING ELEMENT
HEATING ELEMENT
SOLID STATE RELAY
FL1
H1
H2
H3
H4
RY1
CONTROL
CURCUIT BREAKER
PILOT LIGHT, NEON
CN1
CB1
DS1
CB1
FL1
LOAD
TC1
TC+
10
9
4
11
8
3
12
7
2
5
6
1
DESCRIPTION
REF.
NO.
DIAGRAM COMPONENT LIST
F6020C-33 &
F6020C-33-60
GND
L2
G
L1
GND
G
L2
L1
LINE
LINE
WIRING DIAGRAMS
LINE
Wiring Diagram (F6020C, -33, -33-60, -60, F6028C & -60)
49
50
S2
9
10
4
5
TC-
CN1
5
3
2
3
+
1
4
L1
1
T1
H1
RY1
RY2
2
H3
H4
L2
4
6
H2
T2
S1
HEATING ELEMENT
HEATING ELEMENT
SOLID STATE RELAY
RELAY, DPST, N.O.
SWITCH
DOOR SWITCH
H2
H3
H4
RY1
RY2
S1
S2
DS1
CYCLE
CB1
THERMOCOUPLE
HEATING ELEMENT
FL1
H1
TC1
FILTER, EMI
HEATING ELEMENT
CB1
DS1
FL1
LOAD
TC1
TC+
8
6
3
12
7
11
2
1
CONTROL
CURCUIT BREAKER
PILOT LIGHT, NEON
CN1
DESCRIPTION
REF.
NO.
DIAGRAM COMPONENT LIST
F6020C-33-80 &
F6020C-33-60-80
GND
L2
G
L1
GND
G
L2
L1
LINE
LINE
WIRING DIAGRAMS
LINE
Wiring Diagram (F6020C-33-60-80, F6020C-33-80,F6020C-60-80, F6020C-80, F6028C-60-80, F6028C-80)
S2
6
5
3
1
18
GND
25
TC-
CN1
5
3
2
3
+
1
4
L1
1
T1
H1
RY1
RY2
2
H3
H4
L2
4
6
H2
T2
S1
DS1
CYCLE
HEATING ELEMENT
HEATING ELEMENT
SOLID STATE RELAY
RELAY, DPST, N.O.
SWITCH
DOOR SWITCH
THERMOCOUPLE
H3
H4
RY1
RY2
CB1
FILTER, EMI
HEATING ELEMENT
HEATING ELEMENT
FL1
H1
H2
S1
S2
TC1
CONTROL
CURCUIT BREAKER
PILOT LIGHT, NEON
CN1
CB1
DS1
FL1
LOAD
TC1
TC+
26
33
31
DESCRIPTION
REF.
NO.
DIAGRAM COMPONENT LIST
F6030CM-33 &
F6030CM-33-60
GND
G
L2
L1
GND
G
L2
L1
LINE
LINE
WIRING DIAGRAMS
LINE
Wiring Diagram (F6030CM, -33,-33-60,-60, F6038CM, -60)
51
Ordering Procedures
Please refer to the Specification Plate for the complete model number, serial number, and series number
when requesting service, replacement parts or in any correspondence concerning this unit.
All parts listed herein may be ordered from the Barnstead|Thermolyne dealer from whom you purchased this
unit or can be obtained promptly from the factory. When service or replacement parts are needed we ask that
you check first with your dealer. If the dealer cannot handle your request, then contact our Customer Service
Department at 319-556-2241 or 800-553-0039.
Prior to returning any materials to Barnstead|Thermolyne Corp., please contact our Customer Service
Department for a “Return Goods Authorization” number (RGA). Material Returned without an RGA number will
be returned.
52
Two Year Limited Warranty
Barnstead|Thermolyne Corporation warrants that if a product manufactured by
Barnstead|Thermolyne and sold by it within the continental United States or Canada
proves to be defective in material or construction, it will provide you, without charge, for a
period of ninety (90) days, the labor, and a period of two (2) years, the parts, necessary to
remedy any such defect. Outside the continental United States and Canada, the warranty
provides, for two (2) years, the parts necessary to remedy any such defect. The warranty
period shall commence either six (6) months following the date the product is sold by
Barnstead|Thermolyne or on the date it is purchased by the original retail consumer,
whichever date occurs first.
All warranty inspections and repairs must be performed by and parts obtained from an
authorized Barnstead|Thermolyne dealer or Barnstead|Thermolyne (at its own discretion). Heating elements, however, because of their susceptibility to overheating and contamination, must be returned to our factory, and if, upon inspection, it is concluded that failure is
not due to excessive high temperature or contamination, warranty replacement will be provided by Barnstead|Thermolyne. The name of the authorized Barnstead|Thermolyne
dealer nearest you may be obtained by calling 1-800-446-6060 (319-556-2241) or writing
to:
Barnstead|Thermolyne
P.O. Box 797
2555 Kerper Boulevard
Dubuque, IA 52004-0797
USA
FAX: (319) 589-0516
E-MAIL ADDRESS: mkt@barnstead.com
Barnstead|Thermolyne’s sole obligation with respect to its product shall be to repair or
(at its own discretion) replace the product. Under no circumstances shall it be liable for incidental or consequential damage.
THE WARRANTY STATED HEREIN IS THE SOLE WARRANTY APPLICABLE TO
Barnstead|Thermolyne PRODUCTS. Barnstead|Thermolyne EXPRESSLY DISCLAIMS
ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR USE.
53
54
55