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LFD SERIES OVEN
WITH PROTOCOL
PLUS
INSTRUCTION MANUAL
™
C-186
PN 143378
REVISION H
3/2009
Notice
Users of this equipment must comply with operating procedures and training of operation personnel as required by the Occupational Safety and Health Act (OSHA) of 1970, Section 6 and relevant safety standards, as well as other safety rules and regulations of state and local governments. Refer to the relevant safety standards in
OSHA and National Fire Protection Association (NFPA), section 86 of 1990.
Caution
Setup and maintenance of the equipment should be performed by qualified personnel who are experienced in handling all facets of this type of system.
Improper setup and operation of this equipment could cause an explosion that may result in equipment damage, personal injury or possible death.
Thank you for choosing Despatch Industries. We appreciate the opportunity to work with you and to meet your heat processing needs. We believe that you have selected the finest equipment available in the heat processing industry.
At Despatch, our service does not end after the purchase and delivery of our equipment. For this reason we have created the Service Products Division within Despatch. The Service Products Division features our Response
Center for customer service. The Response Center will direct and track your service call to ensure satisfaction.
Whenever you need service or replacement parts, contact the Response
Center at 1-800-473-7373: FAX 612-781-5353.
Thank you for choosing Despatch.
Sincerely,
Despatch Industries
PREFACE
This manual is your guide to the Despatch oven. It is organized to give you the information you need quickly and easily.
The INTRODUCTION section provides an overview of the Despatch oven.
The THEORY OF OPERATION section details the
NOTE: function and operation of assemblies and subassemblies on the Despatch oven.
The INSTRUCTIONS section provides directions on unpacking, installing, operating and maintaining the
Read the entire
INTRODUCTION and THEORY
OF OPERATION before installing the oven.
Despatch oven.
The APPENDIX section contains Special Instructions for operating the control instrument, a Troubleshooting Table, a list of Accessories and a Warranty.
An efficient way to learn about the oven would be to read the manual while working with the corresponding
WARNING:
Failure to heed warnings in this instruction manual and on the oven could result in personal injury, property damage or death. oven control system. This will give you practical hands-on experience with information in the manual and the oven.
Before operating the equipment, be sure you understand all of the technical information contained in this manual. Information skipped, not understood or misunderstood could create the possibility of operating the equipment in an unsafe manner. This can cause damage to the oven or personnel or reduce the efficiency of the equipment. i
Revision B: Corrected Sensor Calibration Page instruction
Revision C: Added definitions and sample profile to Program Page description
Revision D: Modified per Rev C Protocol Plus software
Revision E: Update to Protocol Plus software version 4.0.
Revision F: Revised Protocol Plus times. Updated Despatch Address.
Revision G: Updated Warranty
Revision H: Updated Controller Section ii
TABLE OF CONTENTS
iii
iv
INTRODUCTION
This section provides an overview of the Despatch LFD Series forced air oven. The
LFD Series Ovens have the most effective heat distribution and the fastest processing time of any lab oven their size. Air is discharged from the left side wall of the oven and circulates through the chamber.
Special Features
The sturdy construction and three inch insulation of the Despatch LFD Series ovens contribute to excellent temperature uniformity.
Other special features include the following:
Class A design features forced exhaust with airflow switch, pressure relief panel, and purge timer.
Unique Despatch design to combine higher fan volume of forced recirculated air with a system of perforated stainless steel walls for the ultimate in temperature uniformity.
Welded double wall construction and fiberglass insulation to reduce heat loss.
Silicone rubber gaskets further minimize heat leakage.
Rapid response heater.
Scratch-resistant baked enamel exterior and stainless steel interior for easy cleaning.
1
Specifications
Dimensions
Chamber Size in (cm)
Model
Capacity feet
3
(liters)
W D H
LFD 1-42
LFD 2-11
LFD 2-24
20
(50)
38
(96)
48
(122)
18
(46)
20
(50)
24
(61)
20
(51)
26
(66)
36
(91)
4.2
(120)
11.0
(310)
24.0
(680)
W
33
(84)
54
(137)
66
(166)
Overall Size in (cm)
D H
45
(114)
78
(198)
89
(226)
Maximum
Number of
Shelf
Positions
9
6
9
41
(104)
35
(88)
38
(98)
Capacities
LFD 1-42 Model
Maximum Load
Maximum Shelf Load
Exhaust at 177°C (350°F)
Lbs
Lbs
Recirculating Fan
Approximate Weight Net
CFM
HP
CFM
HP
Approximate Shipping Weight Lbs.
KG
Solvent Handling Capabilities at 177°C (350°F)
Lbs.
KG
150
30
25 to 93
1/50
300
1/4
380
173
510
232
0.025 GPH of VM and P
Naptha
LFD 2-11
180
60
38 to 300
1/3
1,000
1
795
361
1,095
498
0.042 GPH of VM and P
Naptha
Exhaust
Dimension inches (cm)
1.75 x 2.75
(4.5 x 7.0)
3.5 x 8.5
(8.9 x 21.6)
3.5 x 8.5
(8.9 x 21.6)
LFD 2-24
300
100
122 to 300
1/3
1,500
2
1,065
484
1,465
666
0.14 GPH of VM and P Naptha
2
Temperature
Model
Time to Temperature
(approximate minutes with no load)
25°C - 100°C
25°C - 200°C
25°C - 343°C
4
10
35
LFD 1-42 LFD 2-11 LFD 2-24
4
10
30
2
10
40
Recovery Time Door Open 1 Min.
(approximate minutes with no load)
Temperature Uniformity at
100°C
200°C
343°C
<1
2
4
100°C*
200°C*
343°C*
±1°C
±2°C
±4°C
<1
3
8
±1°C
±2°C
±4°C
<1
3
7
±1°C
±2°C
±4°C
Minimum Operating Temperature
(Approximate w/20 C ambient) dampers open dampers closed
40°C
50°C
Control Stability
Repeatability
Cooldown Time
(approximate minutes with no load)
±0.3°C
±0.5°C
343 - 50°C dampers open
343 - 75°C dampers closed
46
110
30°C
40°C
±0.3°C
±0.5°C
40
120
30°C
55°C
±0.3°C
±0.5°C
27
85
* Figures are based on actual tests in an empty oven. Uniformity can vary slightly depending on unit and operating conditions.
3
Power
Line voltages may vary in some geographical locations. If your line voltage is much lower than the oven voltage rating, warm up time will be longer and motors may overload or run hot. If your line voltage is higher than name plate rating, the motor may run hot and draw excessive amps.
If the line voltage varies more than 10% from the oven voltage rating, some electrical components such as relays, temperature controls, etc. may operate erratically.
Power Requirements
Model Volts Amps Hertz Phase Heater KW
LFD 1-42
LFD 2-11
LFD 2-24
240*
208
240
480
208
240
480
28.7
39.7
34.9
17.5
76.2
66.8
33.4
50/60
60
60
60
60
60
60
1
3
3
3
3
3
3
6
12
12
12
24
24
24
* Oven designed for 240 volts (see name plate on oven) will operate satisfactorily on a minimum of 208 volts, but with a 25% reduction in heater power. If your power characteristics are lower, contact Despatch Industries. An option is available to regain the full heater power when operating on 208V.
4
THEORY OF OPERATION
This section details the function and operation of assemblies and subassemblies on the
Despatch LFD Series Ovens. These ovens have the most effective heat distribution system and the fastest processing time of any lab ovens their size. They are especially useful for testing, preheating, sterilizing, drying, aging and curing as well as other production applications. Horizontal airflow with precision digital control delivers uniform, fast processing. The overall result is efficient productivity under strenuous conditions.
Fresh
Air
Figure 1. Horizontal Airflow
The unique Despatch computerized design, moves forced convected heat through perforated stainless steel walls. The air is recirculated with a high volume fan.
Despatch LFD Series Ovens employ higher volume fans than any competitive model.
The chamber can be densely loaded without interfering with the process. The LFD series air delivery temperature is within 1/2° C of the number appearing on the digital display. Also, fresh air intake is regulated by a panel-mounted damper control. The exhaust rate is regulated by an adjustable control on the exhaust stack.
5
Damper Control
The oven is equipped with a manually adjustable damper mechanism. The damper control arm is located on the front panel of the oven. The damper adjustment controls the flow of fresh air into the chamber. If the damper is in the full open position, the maximum amount of fresh air is distributed into the chamber. An additional adjustable damper is provided on the exhaust.
In the full closed position of an LFD oven, a pre-determined amount of fresh air is allowed into the chamber due to cutaways provided in the fresh air and exhaust dampers. This minimum amount of fresh air is required by NFPA86 safety guidelines for Class A ovens.
Determining Damper Settings
The optimum setting for the amount of fresh air that should be distributed into the chamber depends on several factors. These factors include ambient environment temperature, load conditions, load distribution, heat up rates, cool down rates, desired temperature uniformity and most importantly the desired operating temperature. To consider all of these variables at any one point in time is not practical and there are engineering tradeoffs that should be considered. Therefore guidelines should be used to determine the fresh air damper setting.
In general, the damper should be set so that the amount of fresh air flowing into the chamber agrees with the desired operating temperature conditions. The following outline shows the considerations involved with various damper position settings.
Full Closed Position
When the fresh air damper is in the full closed position, the chamber will be able to achieve the maximum attainable heat up rates for the chamber. In addition, the chamber will use the minimum amount of power to operate at the desired temperature.
In almost all cases, the fresh air damper should be in the full closed position in order to efficiently operate at the maximum operating temperature for the chamber.
6
Full Open Position
When the fresh air damper is in the full open position, the chamber will operate at its minimum operating temperature.
Friction heat from the air recirculation system builds up in the chamber. This causes chamber temperature to rise slightly even though the heating system is not turned on.
After the recirculation motor has been on for an extended period of time, the chamber will reach a thermal equilibrium temperature.
When the damper is not set to the full open position, the chamber has no way to readily dissipate the heat generated by the friction. With the fresh air damper fully open, the thermal equilibrium temperature is the minimum operating temperature of the chamber.
Other Damper Settings
The damper can be set to several other distinct operating positions. In most cases the damper setting is influenced by two specific performance factors. The two performance factors are uniformity and cool down rates.
The uniformity of the chamber is influenced by the inside chamber pressure of the system. The pressure inside the chamber is dependant on the amount of fresh air flowing into the chamber. When a large volume of fresh air is flowing into the chamber, the chamber becomes slightly pressurized and the overall temperature uniformity improves. The slightly pressurized chamber produces the effect of "pushing" the air to the corners of the chamber. Typically the corners of the chamber will improve with respect to temperature distribution while the core of the chamber will maintain excellent uniformity characteristics regardless of the damper position. Therefore, the pressurization of the chamber typically is a factor when the chamber is loaded heavily.
Adjusting the exhaust damper will aid in pressurizing the chamber. The best uniformity results, with respect to the product, are achieved when no more than two-thirds of any inside chamber dimension are used. The best overall results are achieved when the product(s) are located in the center of the chamber.
7
OVEN INSTRUCTIONS
The INSTRUCTIONS section provides directions for unpacking, installation, operation and maintenance of the LFD Series oven.
Unpacking and Inspection
Remove all packing materials and thoroughly inspect the oven for damage of any kind that could have occurred during shipment.
See whether the carton and plastic cover sheet inside carton are still in good condition.
Look at all outside surfaces and corners of the oven for scratches and dents.
Check the oven controls and indicators for normal movement, bent shafts, cracks, chips or missing parts such as knobs and lenses.
Check the door and latch for smooth operation.
If there is damage that may have occurred during shipment, follow these instructions.
1. Contact the shipper immediately and file a written damage claim.
2. Contact Despatch Industries to report your findings and to order replacement parts for those that were damaged or missing.
3. Send a copy of your filed damage claims to Despatch.
4. Next, check to make sure you have received all the required materials. Your shipment should include:
One (1) Despatch oven,
One (1) Instruction manual,
One (1) Warranty card,
Two (2) Shelves
One (1) Package containing four rubber feet (LFD1-42 only).
5. If any of these items are missing from the packaged contents, contact Despatch
Industries to have the appropriate materials forwarded to you.
6. Finally, to protect the warranty on your new LFD Series Oven, complete the warranty card and mail it to Despatch within 15 days after receipt of the equipment.
8
Set-up
1. Select the location for installing your oven.
If solvents are going to be used in the oven, you must install an exhaust stack to the outside of the building. Go to step 2.
WARNING:
Do not use the oven in wet, corrosive or explosive atmospheres unless this oven is specifically designed for a special atmosphere.
If no exhaust stack is necessary, go to step 3.
2. Install an exhaust stack from the rectangular exhaust fan discharge stack to the outside of the building.
If a round exhaust stack is used, a minimum area greater than the area of the exhaust stack is required.
The flashing through the roof or wall must be capable of handling an exhaust stack temperature up to 343°C (650°F).
All stacks must comply with state and local building codes to insure that surrounding combustible surfaces are below 71°C (160°F).
Design the exhaust stack to limit the amount of restrictions to insure proper airflow. If more than two (2) elbows are used in the stack, over all airflow will be reduced. If airflow is reduced, the amount of solvent that can be safely used with the equipment must also be reduced.
3. Place oven on a bench top or an optional cabinet base, or directly on the floor.
The oven must have a minimum 2 inch clearance in the rear to provide proper ventilation. When placed next to another cabinet, or next to another oven, a 3 inch clearance is required. The doors will still open.
4. Make sure oven is level and plumb; this will assure proper heat distribution and operation of all mechanical components.
5. Identify correct power source indicated on the specification plate.
6. On the larger units, remove the control panel and the filler panel to expose the equipment mounting area.
WARNING:
Do not use the oven in wet, corrosive or explosive atmospheres unless this oven is specifically designed for a special atmosphere.
7. Hardwire the oven directly to the electric supply. On larger units the oven line connection is located on the equipment mounting panel.
9
Operating
Users and operators of this oven must comply with operating procedures and training of operating personnel as required by the Occupational Safety and
Health Act (OSHA) of 1970, Section 5 and relevant safety standards, and other safety rules and regulations of state and local governments. Refer to the relevant safety standards in OSHA and National
Fire Protection Association (NFPA), Section 86 of
1990.
WARNING:
Do not use the oven in wet, corrosive or explosive atmospheres unless this oven is specifically designed for a special atmosphere.
Loading the Oven
Despatch Industries cannot be responsible for either the process or process temperature used, or for the quality of the product being processed. It is the responsibility of the purchaser and operator to see that the product undergoing processing in a Despatch oven is adequately protected from damage.
Carefully following the instructions in this manual will help the purchaser and operator in fulfilling that responsibility.
When loading the oven avoid spills of anything onto the heater elements or onto the floor of the oven. Do not place the load on the oven floor plate. This may cause the load to heat unevenly and the weight may
WARNING:
This equipment is designed for a specific amount of solvent.
Exceeding this amount could result in explosion. cause shorting out of the heater elements. Use the shelves provided.
The two shelves are designed to be pulled out about half way without tipping. The support capacity of the shelves is listed in the Capacities Table in the Specifications section in this manual. Do not overload the shelves.
Distribute the workload evenly so that airflow is not restricted. Do not overfill your oven.
The workload should not take up more than two-thirds of any dimension of the inside cavity.
10
Pre-Startup Checklist
Know the system. Read this manual carefully. Make use of its instructions and explanations. Safe, continuous, satisfactory, trouble-free operation depends primarily on your understanding of the system and your willingness to keep all parts in proper operating condition.
Check line voltage. Voltage must correspond to nameplate requirements of motors and controls. Refer to the section on power connections in the
INTRODUCTION of this manual.
Fresh air and exhaust. Do not be careless about restrictions in and around the fresh air and exhaust openings and stacks. Under no condition permit them to become so filled with dirt that they appreciably reduce the air quantity. The proper ventilation clearances should be fulfilled at all times. Refer to the Set-up instructions in this manual.
Helpful hints
For drying ovens, open vent to prevent buildup of moisture.
For sample heating, close the vent when no ventilation is required.
Startup
For fastest oven heat-up time, close the fresh-air vent. After the desired temperature is reached, the vent may be adjusted as needed.
1. Start Fan. a. Open oven door. b. Press Power switch to the On position. You will hear the exhaust and recirculating fans start. c. Shut oven door. d. Check that the control display turns on.
2. Operate the temperature control as desired by following the control operation instructions that follow.
11
Note that in a Class A oven, the heater can not be energized until the forced exhaust system has brought in a minimum amount of fresh air into the chamber. The purge timer provided prevents the heater from energizing until the oven has had enough time to bring in the amount of fresh air required. The purge timer is energized by the airflow switch which closes when the exhaust system is running.
The pre-determined purge time is two minutes for the LFD1-42 and LFD2-24 and three minutes for the LFD2-11.
12
CONTROL
The special features of the Protocol Plus
TM
control include:
PID tuning
Ramp/Soak programming of up to 64 segments
Segment looping and profile linking
Built-in manual reset high limit control
Built-in process timer
Dedicated LED display for process temperature
Multi-purpose two-line LCD display with backlight
Auto-tuning
Security access
Process temperature retransmission signal
Digital inputs for remote profile control
Real time clock
Optional relay outputs for events, alarms, or end-of-cycle signal
Optional RS232/RS422/RS485 MODBUS communications
Theory of Control Operation
The Protocol Plus is a modular microprocessor based digital temperature controller. The
Protocol Plus operates as a dual functioning controller/high limit instrument. The control portion utilizes a time-proportioning voltage signal to control heating devices with minimal temperature fluctuations.
The high limit portion protects the product and/or the oven from overheating. If the product being processed has a critical high temperature limit, the high limit setpoint should be set to a temperature somewhat below the temperature at which the product could be damaged. If the product does not have a critical high temperature limit, the high limit setpoint should be set 5 to 15 degrees higher than the maximum programmed setpoint at which the oven will operate.
13
Protocol Plus Faceplate and Wiring Diagram
14
Operating Modes
The Protocol Plus control has five modes of operation available:
Stopped Mode: All control and relay outputs are off. Stopped Mode is integrated into each of the following four modes of operation.
Manual Mode:
Control operates as a single setpoint control until Stopped mode is accessed
Timer Mode: Control operates as a single setpoint control until preset time period has expired.
Profile Mode: Control operates as a ramp/soak profiling control until the end of the profile. 8 profiles are available with up to 8 ramp/soak segments in each profile.
Auto Start Mode: Control may automatically start Manual, Timer, or Profile mode based on a preset time and day.
The optional event outputs can be utilized during Manual, Timer, or Profile modes.
Setup Mode
The control has a Setup Mode which provides access to control configuration and programming of profiles. The Setup Mode contains ten separate electronic Pages where the configuration and programming parameters (Menu items) are found. The Setup
Mode Pages are described in detail elsewhere in this manual.
Fast Start Mode
The Protocol Plus control has the ability to automatically start an operating mode when power is applied. This feature may be useful if the same mode of operation is used everyday. The user can turn on the power and the oven will start the desired process automatically. The Fast Start Mode is controlled by the Power-Up Start parameters on the Control page (see Setup Mode).
15
High Limit
The control has an integrated high limit function which will disable the heater output when tripped. If the high limit does trip, the relay will need to be manually reset. When the high limit relay is tripped, the Hi-Limit indicator will be lit. Allow the oven to cool several degrees (or increase the high limit setpoint) and then press the Reset key. The indicator will turn off.
High-Limit temperature readout is provided on LCD Line #2 in all Modes (Stop, Run,
Hold, and Standby) except Setup Mode. High-Limit temperature is displayed for 10 seconds, alternating with current Mode and Status display for 10 seconds.
The control will not allow the high limit setpoint to be set below the current setpoint value.
Indicators
The Protocol Plus control has 12 indicating LEDs that provide operational information to the user.
Power LED: Indicates that power is supplied to the instrument.
Heater LED: Indicates that the heater output is active.
Profile LED: Indicates that the Profile Mode is in operation.
Timer LED: Indicates that the Timer Mode is in operation.
Manual LED: Indicates that the Manual Mode is in operation.
Cycle Complete LED: Indicates that the control is in Stopped mode.
Hi-Limit Alarm LED: Indicates that the high limit relay has tripped
(de-energized).
Soak Alarm LED: Indicates that the guaranteed soak deviation is in alarm condition.
Outputs 1 through 4: Indicate that the optional relay outputs are in the ON state. These outputs may be configured as timed event outputs, process temperature trip point outputs, alarm outputs, or as an end of cycle relay output.
The ON state can be configured as energized or de-energized.
16
Displays
The Protocol Plus control has two displays. A dedicated LED upper display shows the oven temperature. A two-line LCD lower display provides information on control status, high limit temperature, and allows changes to be made to the control settings.
Key Functions
The Protocol Plus control has seven keys that provide operation.
Select key: Press to select mode of operation. In Setup Mode, to select profile number or relay. In Profile/Run Mode, press simultaneously with the UP key to advance a segment.
Run/Hold key: Press to activate a mode of operation. If a Profile (or Timer)
Mode is running, pressing the Run/Hold key will place the Profile (or Timer) in
Hold status. A subsequent press will resume the Profile (Timer).
Stop key: Press to stop any mode of operation.
Page/Reset key: While in Setup Mode, press to access different Pages of configuration, Press this key to silence an alarm if the instrument alarm sounds during operation. In an operating mode, if an alarm or error condition occurs, press this key to return the instrument to normal operation once the condition is cleared.
Menu/View key: While running any operating mode, pressing this key will display the high limit setpoint. While in Setup Mode, pressing this key will provide access to each Menu parameter.
keys: Press these keys to adjust parameter settings. In Profile/Stopped
Mode, press to select profile to run. In Profile/Run Mode, press key simultaneously with the Select key to force the program to advance one segment.
17
Outputs
The Protocol Plus control has seven different outputs available.
Heating output: The control output is a DC voltage open-collector output which is time-proportioned and designed to control a heat control device such as a solid state relay.
High limit: The high limit output is a form C relay which is energized under normal operating conditions. If the control senses a temperature higher than the high limit setpoint, or if there is a sensor error, the high limit relay will de-energize until the condition is cleared and the Reset key is pressed. When the high limit relay is de-energized, the heater is disabled.
Retransmission: The retransmission output is a DC 1 to 5 volt or 4 to 20 ma
(DC) signal that is proportional to the process temperature. The signal can be an input to other devices such as a chart recorder.
Relay (four optional outputs): The four form A dry contact relay outputs can be configured to function as alarms, events, or end of cycle. These outputs can be utilized in Manual, Timer, or Profile Mode.
Layout for Optional Components
18
Relay (Continued)
Use the Relay Card Optional Ay p/n 144562 to add relays to the standard controller.
Each relay card contains two relays (maximum of two cards Ay’s allowed).
Communication
The Protocol Plus control has optional MODBUS communication available which can communicate via RS232, RS422, or RS485 to a computer. See communications option assembly p/n 161957 for board and cable assembly. Please refer to the MODBUS communications manual which comes with this option.
Optional Software
The Protocol Manager program allows the operator to start/stop multiple ovens (32 maximum) from a personal computer. A data log can also be used to record process information (p.n. 140008).
19
INSTRUCTIONS
Start-Up
These instructions are provided as a quick reference for operating the Protocol Plus control. If the Profile Mode is to be used, or the configuration of the control needs to be changed, please refer to the Setup Mode instructions before operating the control. For more detailed operating instructions refer to the Operation instructions for the mode you wish to use.
Upon initial power-up the control is in Manual/Stopped Mode (unless the Autostart or
Fast Start Modes are active). To activate any operating mode from Stopped Mode, press the Select key until the desired mode is displayed, then press the Run key. If the proper Profile number is not displayed when the Profile Mode is accessed, press the or keys until the desired Profile number is displayed, then press the Run key. If no profile numbers can be displayed (display only reads NONE) then no profiles are currently programmed (see Setup Mode).
The Hi-limit thermocouple actual temperature reading is displayed, when the lower LCD display reads HL Temp. Note: This is not a error message.
The temperature setpoint can be adjusted while Manual or Timer Mode is running by pressing the UP or DOWN key.
To momentarily hold the Timer or Profile Mode, press the Hold key. To continue the
Timer or Profile Mode, press the Run key.
To return to Stopped Mode at any time, press the Stop key and the cycle complete LED will illuminate.
Note that the control can be configured to automatically activate Manual, Timer or
Profile Mode when power is applied (power switch turned on). See Control Page in the
Setup Mode to utilize the Fast Start mode.
20
Operation
Manual Mode
Press the Select key until Manual is displayed (note you can press the Run key at any time to activate Manual Mode).
1. Press the Menu key to display the Process Temperature Setpoint (setpt). You can change the Setpoint with the keys.
Note: If the SPChange parameter on the Enable page in Setup Mode has been set to DISABLED, it must be changed to ENABLED before any changes to the process temperature and high limit setpoints can be made.
2. Press the Menu key a second time to display current high limit setpoint (Hi-Lim
SP). The value can be adjusted by pressing the keys. If Band is displayed, the high limit band feature is activated (see Control page) and the high limit can not be adjusted.
3. (optional feature) Press the Menu key a third time to display Event1. Press the key to turn on the event or to turn off the event. Repeat for all events which are enabled (up to 4).
4. To start Manual Mode, press the Run key.
The display will change from Stop to Run. To return to Stopped Mode, press the
Stop key. While in operation, the process setpoint can be adjusted by using the
keys to change the value while the mode is running. Pressing the Menu key will display the High Limit Setpoint (HLSP) setting.
If changes to the high limit setpoint or event output configuration are needed, they must be done from the stopped mode.
21
Timer Mode
1. Press the Select key until Timer is displayed (note you can press the Run key at any time to activate Timer Mode).
2. Press the Menu key to display the Process Temperature Setpoint (Setpt). You can change the Setpoint with the keys.
Note that if the SPChange parameter on the Enable page in Setup Mode has been set to DISABLED, it must be changed to ENABLED before any changes to the process temperature and high limit setpoints can be made.
3. Press the Menu key a second time to display current high limit setpoint (Hi-lim
SP). The value can be adjusted by pressing the keys. If Band is displayed, the high limit band feature is activated (see Control page) and the high limit can not be adjusted.
4. Press the Menu key a third time to display Time Set. You can change the time setting with the keys.
5. (optional feature) Press the Menu key a fourth time to display Event1. Press the
key to turn on the event or to turn off the event. Repeat for all events which are enabled (up to 4).
6. Press the Menu key a fifth time to display the current guaranteed soak band
(TmrGuarSoak) value. If the process temperature deviates from the setpoint by more than this value, the timer is placed in a hold condition. The timer continues when the process temperature falls within range. Reference the Quick
Reference and Default Values section for available settings.
7. To start Timer Mode, press the Run key.
The display will change from Stop to Run and the time remaining will be displayed. To return to Stopped Mode, press the Stop key. While in operation, the process setpoint can be adjusted by using the keys to change the value while the mode is running. Pressing the Menu key will display the High Limit
Setpoint.
Pressing the Run/Hold key while the Timer Mode is in operation will put the control in
Hold status. The Timer LED will flash to indicate the held status. Press the Run/Hold key again to continue timing. The Timer LED will return to lit status.
22
Profile Mode
1.
Press the Select key until Profile is displayed. “None” may be displayed if a profile has not been selected or no profiles entered.
2. Press the key to display the desired profile to run.
3. To start Profile Mode, press the Run key.
The display will change from Stop to Run and the segment time remaining,
Temperature Setpoint, Profile #, along with the current segment number, will be displayed. To return to Stopped Mode, press the Stop key.
Pressing the Run/Hold key while the Profile Mode is in operation will put the control in
Hold status. Press the Run/Hold key again to continue the mode. The Profile LED will flash to indicate the hold status.
To advance to the next segment while running a profile, press the Select and UP arrow keys at the same time.
If Link To is set to Standby in the Program Page, at the End of Program/Profile,
1. Cycle Complete LED indication goes ON.
2. Controller beeps if End of Cycle beep is enabled.
3. Heater/control output keeps controlling oven temperature at last Soak setpoint.
4. All events programmed (if relay cards installed and programmed as an event) for the last Soak Segment stays active.
Note that ramping down too fast may cause the high limit relay to trip unexpectedly if the high limit band feature is used. This can be avoided by using a separate cooling profile that does not utilized the high limit band and then jumping to that profile to perform rapid cooling.
Auto Start Mode
The Auto Start Mode allows the control to start Manual, Timer, or Profile mode automatically at a preset time and day. See the Auto Start Page in Setup Mode for the time, day, and operating mode settings.
To activate the Auto Start Mode,
1. On Auto Start page, Enable is set to Yes.
2. LCD reads Active on line 1 in Auto Start Mode.
3. On Auto Start page Enable set to No, will deactivate Auto Start Mode.
23
Note that once you activate Auto Start, you can continue to use all operating modes as normal. If an operating mode is running at the time of a preset Auto Start function, and
Auto Start is activated, the existing operating mode will override the auto Start function and the Auto Start will not turn on.
Note: All process Set to Run in Auto Start Mode must be at least one minute long for all
Run Modes (Manual, Timer, and Profile).
Setup Mode
Configuration of the control and programming of the ramp/soak profiles must be done in the Setup Mode. To access Setup Mode, the control must first be in Stopped Mode.
1. Press the Select key until Setup is displayed.
2. Press the Page key and Security will be displayed.
3. Press the Menu key and Password will also be displayed. Use the enter the proper password.
keys to
4. Once the proper password is displayed, press the Page key twice to enter the
Setup Mode.
To exit Setup Mode, press and hold the Page key for three seconds.
The control has two levels of password-protected security. Level one provides access only to those menu pages that are enabled on the Enable page. Level two provides access to all menu pages, including the Enable page. The default security password values are 1 for level one and 2 for level two.
If an improper password has been entered, the control will remain at the Security display. To enter the proper password, press the Menu key. To exit Setup Mode, press and hold the Page key for three seconds.
Mapping of the Setup Mode is provided in the following sections. To access each parameter Page, which are described in detail in the following sections, press the Page key until the desired page heading is displayed. Press the Menu key to access each
Menu parameter. Press the keys to change Menu parameter settings.
Refer to the Quick Reference and Default Values section for available settings for each
Menu parameter.
Press the Page key to continue with each Page, or press and hold the Page key for three seconds to exit Setup Mode.
24
Instructions for Setup Mode Pages
Program Page
Programming of the profiles is provided on the Program Page. Eight profiles are available with up to eight ramp and soak segments per profile.
If the optional relay outputs are installed, they must be configured as alarms or events on the Relay Outputs Page before they can be utilized. If configured as event outputs, these relays can be used as time or temperature events.
When entering the Program Page, press the Select key to select the profile you wish to enter/edit, then press the Menu key. The first parameter (Profile #, Segment 1, Ramp
Time) will display. Adjust the time value with the keys. Once the proper value is displayed, press the Menu key to continue. Continue with the Menu key to adjust/view each parameter.
If the ramp time value of the current segment is left at 0:00, the next press of the Menu key will advance the control to the High Limit Setpoint parameter for that profile.
Continue entering / verifying all parameters until you get to the last parameter
(Guaranteed Soak Band). Once all parameters have been properly entered, press the
Page key to return to the top of the Profile Page. You can press the Select key to enter/edit another profile, press the Page key to access another page, or press and hold the Page key to exit Setup mode.
While editing any profile, pressing the Select key will advance the control to the time value for the next segment, until the last segment has been reached. This allows faster editing of the profile rather than pressing the Menu key to advance past each parameter.
If Link To is set to Standby in the Program Page, at the End of Program/Profile,
1. Cycle Complete LED indication goes ON.
2. Controller beeps if End of Cycle beep is enabled.
3. Heater/control output keeps controlling oven temperature at last Soak setpoint.
4. All events programmed (if relay cards installed and programmed as an event) for the last Soak Segment stays active.
To run a profile indefinitely, link the profile to itself.
25
Menu Item
Ramp Time Seg 1
Display
Pro-1 Seg-1 Ramp Time
Event 1 Set Value* Pro-1 Seg-1 Ramp Event 1
Event 2 Set Value* Pro-1 Seg-1 Ramp Event 2
Event 3 Set Value* Pro-1 Seg-1 Ramp Event 3
Event 4 Set Value* Pro-1 Seg-1 Ramp Event 4
Soak Temp Seg 1 Pro-1 Seg 1 Soak Temp
Soak Time Seg 1 Pro-1 Seg 1 Soak Time
Event 1 Set Value* Pro-1 Seg-1 Soak Event 1
Description
Ramp time for segment 1 of profile
Event 1 setting for segment 1 ramp of profile
Event 2 setting for segment 1 ramp of profile
Event 3 setting for segment 1 ramp of profile
Event 4 setting for segment 1 ramp of profile
Soak temperature for segment 1 of profile
Soak time for segment 1 of profile
Event 1 setting for segment 1 soak of profile
Event 2 Set Value* Pro-1 Seg-1 Soak Event 2
Event 3 Set Value* Pro-1 Seg-1 Soak Event 3
Event 4 Set Value* Pro-1 Seg-1 Soak Event 4
Event 2 setting for segment 1 soak of profile
Event 3 setting for segment 1 soak of profile
Event 4 setting for segment 1 soak of profile
(repeat for segments 2-8, until ramp or soak time = 00:00)
High Limit Setpoint Pro-1 Hi-Lim SP High limit setpoint for profile**
Loop From Pro-1 Loop From Seg To start a loop action in a profile
Loop To
Loop Count
Profile Link
Pro-1 Loop To Seg
Pro-1 Loop Number
Pro-1 Link To Pro
To end a loop action in a profile
Number of times to execute loop
To jump from this profile to another
Guaranteed Soak Pro-1 Guar Band Guaranteed soak band for profile
See the definitions on the following pages for parameter ranges.
* only available if optional relay outputs are installed (repeat all for profiles 2-8)
** Set to Band to use the high limit band feature
26
Profile #
There are eight profiles available
.
Segment#
Ramp Time
Recipe segments 1 through 8 may be programmed, each with its own set of events, ramp and soak times, and soak temperature.
The time required to ramp from one setpoint up to another setpoint.
Values between 0 and 99:59 are allowable. In the Protocol Plus controller, the profile ramp and soak times are stored without units.
Units are set as either hours and minutes (HH:MM) or minutes and seconds (MM:SS). The setpoint will automatically increment from the actual temperature to the soak temperature.
EV1 through 4
From 1 to 4 events may be programmed into the ramp time portion of each segment here. These typically involve actuating/disabling relays to close/open valves or perform other relay-controlled functions.
NOTE: These will only actuate when the controller has the relay cards installed and programmed for an event.
Soak Temp.
Soak Time
The temperature setpoint of a particular segment is entered here; it can range from -18 to 540 degrees C (0 to 1000 degrees F).
The duration of soak is entered here; the value can range from 0 to
99:59.
EV1 through 4
From 1 to 4 events may be programmed into the soak portion of each segment here. These typically involve actuating/disabling relays to close/open valves or perform other relay-controlled functions. NOTE:
These will only actuate when the controller has the relay cards installed and programmed for an event.
Hi Limit SP
Loop From
The high limit setpoint may be entered here; if the temperature exceeds this value, the hi-limit will alarm and shut off the heater.
Values are No, Seg-1 to Seg-8.
Loop To
Values are No, Seg-1 to Seg-8.
Loop Number
Values are 0 - 99.
These values enable the operator to jump from a certain step to another step of the recipe a preset number of times.
Profile Link
Values are STANDBY/STOP/HOLD/1 - 8. When the profile ends, the profile can hold the temperature setpoint while keeping the events active, turn the heater off, hold the temperature setpoint at the end of the profile, or jump to another specified profile.
Guaranteed
Soak Band
If the process temperature deviates from the setpoint by more than this value, the soak timer is placed in a hold condition. The timer continues when the process temperature falls within range.
27
Sample Profile
Programming Table
Profile Number____1______
Segment
Time
Ramp
1 2
Events
3
Profile Name__________
4
Temperature
Time
1 01h00 100 01h00
Soak
1 2
Events
3
2 02h00 50 00h01
3 00h00
4
5
6
7
8
High Limit Setpoint
Loop From Seg
Loop To Seg
115
No
No
Loop Number
Link To Pro
Guar Soak Band
0
No
10
4
28
Auto Start Page
The Auto Start Page can be configured to automatically start Manual, Timer or Profile
Mode at a specified time and day. Note that if Auto Start Enable is set to Yes in the
Setup Mode, the Auto Start feature is not turned on - it is available to the operator to be activated in Stopped Mode.
To configure the Auto Start feature:
1. Access the Setup Mode.
2. Press the Page key until Auto Start is displayed.
3. Press the Menu key. If there is no change in the display, the controller may not have the realtime clock option.
4. Set Auto Start Enable to Yes.
5. Using the Menu key, scroll through the options available and use the keys to set the mode desired for each day of the week. You may select from Manual,
Timer, or Profile 1 through 8.
6. When the mode is set press the Menu key.
7. Enter the time of day you wish the mode to activate.
8. Continue through the rest of the week by pressing the Menu key, or press the
Page key when done.
One Auto Start mode can be set for each day of the week. Exit the Setup mode by pressing and holding the Page key for three seconds. Press the Select key until Auto
Start is displayed. Make sure the correct time and day is displayed. If not proper, set it to the correct time on the Real Time Clock Page in the Setup mode.
To activate the Auto Start Mode,
1. On Auto Start page, Enable is set to Yes.
2. LCD reads Active on Line 1 in Auto Start Mode.
3. On Auto Start page Enable set to No, will deactivate Auto Start Mode.
Note that once you activate Auto Start, you can continue to use all operating modes as normal. If an operating mode is running at the time of a preset Auto Start function, and
Auto Start is activated, the existing operating mode will override the Auto Start function and the Auto Start will not turn on.
Note: All process Set to Run in Auto Start Mode must be at least one minute long for all
Run Modes (Manual, Timer, and Profile).
Menu Item Display
Enable
Autostart
Sunday mode
Sunday time
Monday mode
Monday time
Tuesday mode
Tuesday time
Wednesday mode
Wednesday time
Thursday mode
Thursday time
Friday mode
Auto Start Enable
Friday time
Saturday mode
Saturday time
Auto Start Sun
Mode
Auto Start Sun
Time
Auto Start Mon
Mode
Auto Start Mon
Time
Auto Start Tue
Mode
Auto Start Tue
Time
Auto Start Wed
Mode
Auto Start Wed
Time
Auto Start Thu
Mode
Auto Start Thu
Time
Auto Start Fri
Mode
Auto Start Fri
Time
Auto Start Sat
Mode
Auto Start Sat
Time
Description
Enable (yes) or disable (no) the
Autostart function
Range
No, Yes
Set mode on Sunday to activate Off, Manual, Timer, Pro-1 to Pro-8
Set time on Sunday for mode to activate
00:00 to 23:59
Set mode on Monday to activate Off, Manual, Timer, Pro-1 to Pro-8
Set time on Monday for mode to activate
00:00 to 23:59
Set mode on Tuesday to activate Off, Manual, Timer, Pro-1 to Pro-8
Set time on Tuesday for mode to activate
Set mode on Wednesday to activate
Set time on Wednesday for mode to activate
00:00 to 23:59
Off, Manual, Timer, Pro-1 to Pro-8
00:00 to 23:59
Set mode on Thursday to activate Off, Manual, Timer, Pro-1 to Pro-8
Set time on Thursday for mode to activate
00:00 to 23:59
Set mode on Friday to activate
Set time on Friday for mode to activate
Off, Manual, Timer, Pro-1 to Pro-8
00:00 to 23:59
Set mode on Saturday to activate Off, Manual, Timer, Pro-1 to Pro-8
Set time on Saturday for mode to activate
00:00 to 23:59
30
PID Page
The PID Page contains parameters which control the response to the setpoint and process variable input. To access the PID Page, enter the Setup Mode. Press the Page key until PID is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the
keys to change the value.
Menu Item Display Description Range
Display units PID Temp Unit Set display units to °C or °F
Proportional band
PID Prop Band Set proportional band for tuning
°C or °F
1 to 56°C (1 to 100°F)
Integral reset
PID
Reset/Rep/Min
Set integral reset for tuning 0.0 to 100 seconds/repeat
Derivative
Rate
PID Rate In Sec Set derivative rate for tuning 0.0 to 500 seconds
AutoTune PID AutoTune Enable auto tuning function Disable, Enable
The AutoTune parameter disables or enables the AutoTune function. To utilize
AutoTuning:
1. Access the Setup Mode.
2. Press the Page key until the display reads AutoTune. Press the key to enable the AutoTune.
3. Press the Page key for three seconds to exit Setup Mode.
4. Cycle power to the instrument.
5. Set Manual Mode to run. The display will alternately display AutoTune and
Manual.
If the Manual Mode setpoint is less than 50 degrees higher than the actual process temperature, the AutoTune function will create an error condition. This can be cleared by either cooling off the process temperature or increasing the setpoint until there is more than 50 degrees between them. Once the AutoTune function is allowed to complete tuning, the AutoTune parameter will disable by itself.
If you wish to cancel the AutoTune function, press the STOP key, access the PID page in Setup Mode, and set the AutoTune parameter to Disable.
31
Control Page
The Control Page contains various parameters which control miscellaneous functions.
To access the Control Page, enter the Setup Mode. Press the Page key until Control is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the the value.
keys to change
Menu Item Display Description Range
Cycle Time Control Cycle
High limit setpoint
High limit band
Power fail recovery
Recovery time limit
Powerup start enable
Powerup
Start Mode
Time Sec
Control Hi-Lim
SP***
Control Hi-Lim
Band
Set cycle time in seconds for control output
Maximum value for all high limit setpoints
If=0, high limit setpoint= Control
Hi-Lim SP If>0, high limit setpoint= Control SP* + Band
1 to 60 seconds
MinHiLimSP - MaxHiLimSP*
Off, 3°C to 11°C (5°F to 20°F)
Control PwrFRec Controls response to loss of power
Control PFRTime Control aborts to Stopped mode if power is lost for time period longer then set value
ControlPwrUpStrt Allows mode to automatically
Stop, Restart, Hold, Resume
00m00s to 99m59s
Disable, Enable start when power is first applied
Control StrtMode Operating mode for powerup start Off, Manual, Timer, Pro-1 to Pro-8
Hysteresis
1°C to 56°C (1°F to 100°F)
Process out low
Control
Hysteresis
Control
RetOutLo
Hysteresis for all alarms and temperature events
Process value for retransmit output = 1VDC
-73°C to 760°C (-100°F to 1400°F)
-73°C to 760°C (-100°F to 1400°F) Process out high
Control RetOutHi Process value for retransmit
Time scale Control output = 5VDC
Time scale setting for program hh:mm or mm:ss
TimeScale and timer mode**
Key press beep
End of cycle beep
Alarm beep
Control KeyBeep Internal beeper sounds when key is pressed
Control
EOCBeep
Control
On or Off
Internal beeper sounds at end of cycle
On or Off
Internal beeper sounds for alarms On or Off
AlarmBeep
* includes ramping setpoints during profiles and controlled ramps
** power fail recovery time limit is always MM:SS regardless of time scale setting
*** high limit setpoint is a read-only item which is calculated on Enable page
32
Communication Page (optional)
The Communication Page contains parameters for the communications feature. To access the Communications Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Communication is displayed. Press the Menu key.
(NOTE: If there is no change in the display, the controller does not have the communications board installed.) Each parameter can be changed by pressing the
Menu key until the desired parameter is displayed, and then pressing the change the value.
keys to
Menu Item Display Description Range
Address 1 to 247
Mode
Baud Rate
Communication CommAddr Sets address node for control
Communication Mode Turns on/off communications
Communication BaudRate Sets interface speed
OFF, Modbus
Parity Communication Parity Sets parity for interface
2400, 4800, 9600, 19.2K,
38.4K
None, Odd, Even
Real Time Clock Page
The Real Time Clock Page allows the control to be configured to have an operating mode begin automatically at a specific time on a specific day of the week. The real time clock feature is also used for using the Power Failure Recovery mode Time Limit feature (see Control Page). The real time clock is a seven day, 24 hour clock with battery backup.
To access the Real Time Clock Page, enter the Setup Mode. Press the Page key until
Clock is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the to change the value.
keys
Menu Item Display Description Range
Day of the week
Time of day
Reset clock
Clock Day
Clock HH:MM
Clock UP to
Reset CLK*
Setting for current day of the week Sun, Mon, Tue, Wed, Thu, Fri, Sat
Setting for current time of the day 00:00 to 23:59
Press the key to set the clock to entered values
Ready, Done
* If the key is not pressed, the clock values will retain their original values. The display will change to Done if the clock is reset
33
Relay Outputs Page (optional)
The Relay Outputs Page configures the four alarm/event outputs. Each output has a dedicated indicator light and can be configured as a temperature alarm, profile event, or end of cycle output. Temperature alarms can be of type process high, process low, deviation high, deviation low, or deviation band.
To access the Relay Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Relay is displayed. Press the Select key until the desired relay output is selected. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value. To configure a specific relay, press the Select key until the desired relay appears.
NOTE: If Relay 0 appears, then no relays are installed (see relay kit assembly p.n.
144562).
Menu Item Display
Type of relay Relay 1
RelayType
Action of relay Relay 1
RelayAction
Description
Set function of relay
Set coil and contact state of relay
Range
Off, Alarm, Cycl, Ev1 to Ev4
NDE, NE, NDEL, NEL*****
Type of alarm*
Alarm setpoint*
Alarm deviation*
Relay 1
AlarmType
Relay 1 AlmHi/Lo
SP
Relay 1
AlmDevBand
Inhibit alarm* Relay 1
ALMInhibit
Type of event**
Relay 1
EventType
Set alarm type for relay
Setpoint for alarm
Deviation band for alarm
Inhibits alarm until "safe" condition is reached
Set event type for relay
High, Low, Plus, Minus, Band
-73°C to 760°C (-100°F to 1400°F)
1 to 56°C (1 to 100°F)
En or Dis
Time or Temp
Event setpoint***
Relay 1 Event SP Setpoint for temperature event SPLoLim to SPUpLim****
(repeat for relay outputs 2-4, if available)
* appears only for alarm types
** appears only for time or temperature event types
*** appears only for temperature event types
Turning on the Alarm Inhibit function disables the alarm output on power up until the process temperature has reached a non-alarming condition ("safe").
If the relay output has been configured as latching, the RESET key must be pressed to return the output to the non-alarm state once the alarm condition has cleared.
34
Test Page
The Test Page contains parameters which allow manual control of the heat control and optional relay outputs and should be used only for testing the functionality of the control instrument. Do not operate the oven for processes using the Test Page.
To access the Test Page, enter the Setup Mode (see description earlier in this manual).
Press the Page key until Test is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.
Menu Item Display
Test HeatOut
Description
Activate SSR output 100%
Range
On Heater output
High limit relay
Relay 1 output
Test HiLimOut
Test Rly1 Out
Activate high limit alarm
(de-energize relay)
Energize relay output 1
On
On
Test Rly2 Out Energize relay output 2
On
Relay 2 output
Relay 3 output
Relay 4 output
Test Rly3 Out
Test Rly4 Out
Energize relay output 3
Energize relay output 4
On
On
HiLim
Sensor
Test HL Temp
(push and hold up)
Displays sensor reading*
*Push key to refresh display
When the Test Page is entered, all outputs are automatically set to off. When exiting the Test Page, all outputs will return to their previous condition regardless of the Test
Page settings.
35
Zone Calibration Page
The Zone Calibration Page allows adjustment of the displayed temperature versus the actual temperature measured by the control thermocouple. This may be desirable in certain conditions where the center of the oven chamber is not the same temperature as the control thermocouple. This may occur when the oven is not allowed to soak at a constant temperature for long periods of time, or the oven is being used at high temperature.
There is also a Factory Calibration Recovery which will restore the factory calibration values when the control was first shipped by the manufacturer. This may be helpful if the calibration has been lost and a calibration instrument is not readily available. To use the Factory Calibration Recovery feature only, bypass the Zone 1 and Zone 2 calibration parameters by pressing the Menu key.
To access the Zone Calibration Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Zone Cal is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.
Menu Item Display
Zone 1 actual
Zone Cal
Zone1Act
Description
Point at which Zone 1 is set (center of chamber)
Range
-73°C to 760°C (-100°F to 1400°F)
Zone1 displayed
Zone 2 actual
Zone2 displayed
Zone Cal
Zone1Dis
Zone Cal
Zone2Act
Zone Cal
Zone2Dis
Desired displayed value for Zone 1 setting
Point at which Zone 2 is set (center of chamber)
Desired displayed value for Zone 2 setting
-73°C to 760°C (-100°F to 1400°F)
-73°C to 760°C (-100°F to 1400°F)
-73°C to 760°C (-100°F to 1400°F)
Factory calibration*
Zone Cal
FactCal
Restores the factory calibration values
Ready or Done (push- key)
*Only use when no calibration instrument is available, push key to restore factory values.
Press the Page key to exit the Zone Calibration Page.
Two points of display calibration (temperature offset) are available. The Zone 1 Actual and Zone 2 Actual parameters are the two temperature points where the offset is to take effect. These values are adjustable. The Zone 1 and Zone 2 Displayed parameters are the values the user wishes to have displayed at the Actual temperatures, and are also adjustable.
36
As an example, the control is displaying 400°F with the setpoint being 400°F, but the center of the oven chamber is actually 395°F. This can occur due to oven wall losses and product loading variations. The operator may change the zone calibration so that the center of the oven is 400°F when the display reads 400°F. In this case operate the oven in manual mode with a setpoint of 400°F. Record the center of the chamber (as measured with an independent sensor). Access the Zone Calibration Page and enter this measured value as the Zone 2 Actual value, with 400° as the Zone 2 Displayed value.
Zone 1 can be adjusted using the same method at a lower temperature. The instrument will then create a linear offset based on the Zone1 and Zone 2 Actual temperature values. Note that the oven does not have to be heated to adjust the zone parameters if the zone values are known based on prior experience.
37
Sensor Calibration Page
The Sensor Calibration Page has parameters which can change the internal calibration of the temperature sensor input signal. There is a low and high calibration point for both the control sensor and the high limit sensor. To calibrate the instrument, allow the control to warm up for at least 30 minutes.
To access the Sensor Calibration Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Control Sensor is displayed. Press the Menu key.
The control may have the optional process value retransmission output feature. The output is a 1 to 5VDC signal. To calibrate the retransmit signal, the RetOutLo and
RetOutHi values from the Control Page must be known. You may bypass calibrating the control and high limit sensor input to access only the retransmit calibration by pressing the Menu key until RetCalLo is displayed (skip steps 4-17).
To re-calibrate the instrument:
1. Disconnect the control and high limit sensor thermocouples.
2. Connect a calibration instrument with a type J thermocouple output to the control sensor input. Allow the control to warm up at least 30 minutes.
3. Access Setup Mode.
4. Press Page key until -100F is displayed.
5. Press Menu key until Ctrl Sens -100F is displayed.
6. With Ctrl Sens -100F displayed, adjust the calibration instrument to Type J thermocouple, -100 degrees Fahrenheit output.
7. Wait 30 seconds. Press the key.
8. With Ctrl Sens 1400F displayed, adjust the calibration instrument to 1400 degrees Fahrenheit output (Type J thermocouple).
9. Wait 30 seconds. Press the key.
10. When the control displays Ctrl Sens Done, disconnect the calibration instrument from the control sensor input and connect it to the high limit sensor input. Reconnect the control sensor thermocouple.
11. Press the Menu key until HL Sens -100F is displayed.
12. With the control displaying HL Sens -100F, adjust the calibration instrument to -100 degrees Fahrenheit output (Type J thermocouple).
13. Wait 30 seconds. Press the key.
14. With the control displaying HL Sens 1400F, adjust the calibration instrument to 1400 degrees Fahrenheit output (Type J thermocouple).
15. Wait 30 seconds. Press the key.
16. When the control displays HL Sens Done, disconnect the calibration instrument from the high limit sensor input. Re-connect the high limit sensor thermocouple.
17. To skip calibration of the retransmit signal, press the Page key twice to exit the
Sensor Calibration Page.
18. To calibrate the retransmit signal, press the Menu key until RetCalLo is displayed.
38
19. Connect a calibration instrument with a type J thermocouple output to the control sensor input.
20. Connect a voltage measurement device to the retransmit output terminals.
21. Set the calibration instrument output to the temperature value of the RetOutLo parameter from the Control Page.
22. Adjust the RetCalLo * value using the keys until the voltage measurement device reads 1VDC.
23. Press the Menu key.
24. Set the calibration instrument output to the temperature value of the RetOutHi parameter from the Control Page.
25. Adjust the RetCalHi * value using the device reads 5VDC.
keys until the voltage measurement
26. Press the Menu key.
27. Press the Page key to exit the Sensor Calibration Page.
28. Calibration is now complete. Disconnect the calibration instrument and voltage measurement device (if used).
29. Verify that the control and high limit sensor thermocouples are connected.
Menu Item
Control Sensor
Cal
HiLim Sensor
Cal
Display
Ctrl Sens -100F
Ctrl Sens 1400F
Ctrl Sens Done
HL Sens -100F
HL Sens 1400F
HL Sens Done
Retransmit Cal RetCalLo XXXX *
RetCalHi XXXX *
Description
Calibrate Sensor Low End
Calibrate Sensor High End
Control Sensor Cal Complete
Calibrate HiLim Sensor Low
End
Calibrate HiLim Sensor High
End
HiLim Sensor Cal Complete
Calibrate Retransmit Output
Low
Calibrate Retransmit Output
High
Range
-100 to 1400°F
-100 to 1400°F
(read only)
-100 to 1400°F
-100 to 1400°F
(read only)
0 to 4096**
0 to 4096***
*Note that the actual RetCalLo and RetCalHi values displayed are of no importance.
39
Enable Page
The Enable Page controls access to the other Setup Pages. The setpoint minimum and maximum values, and the security passwords are also set on the Enable Page.
To access the Enable Page, enter the Setup Mode using a level 2 access code (see description earlier in this manual). Press the Page key until Enable is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.
NOTE: Changing the enable to “yes” for each page will allow access to the page in
Level 1 security.
Menu Item
Profiles
Autostart
Display
Enable Profile
1-8
Enable Auto
Start
Description Range
Controls access to Program Page Yes or No
Controls access to AutoStart
Page
Yes or No **
PID Enable PID Controls access to PID Page Yes or No
Control Enable Control Controls access to Control Page Yes or No
Communication Enable
Real Time
Clock
Communication
Controls access to
Communication Page
Enable Clock Controls access to Real Time
Clock Page
Relay outputs Enable Relay
1-4
Test Enable Test
Controls access to Relay Page
Controls access to Test Page
Yes or No **
Yes or No **
Yes or No **
Yes or No
Zone
Calibration
Sensor
Calibration
Setpoint lower limit
Setpoint upper limit
High limit overhead
Password level
1
Password level
2
Setpoint
Change
Enable Zone
Cal
Enable Sensor
Cal
Enable
SPLowerLim
Enable
SPUpperLim
Enable
HiLimOH
Enable
Password 1
Enable
Password 2
Enable
SPChange
Controls access to Zone
Calibration Page
Controls access to Sensor
Yes or No
Yes or No
Calibration Page
Sets minimum setpoint allowed -73°C to 759°C (-100°F to 1399°F)
Sets maximum setpoint allowed -73°C to 760°C (-100°F to 1400°F)
Sets maximum high limit setpoint allowed*
3 to 11°C (5 to 20°F)*
Sets password for access level 1 0 to 999
Sets password for access level 2 0 to 999
Set to DISABLE to lock out setpoint and high limit setpoint changes in Manual and Timer
Modes
Sets Analog Output type
Yes or No
Analog Output
Type
Enable Analog
Type
Ctrl or Proc
* Maximum high limit setpoint = SPUpperLim + HiLimOH
** If the controller does not have this feature, “No” is the only option.
40
Digital Inputs (optional)
The Protocol Plus control can be run by external inputs wired to the control from an external source such as a PLC or control panel switches. The external run operation can Run, Hold or Stop profiles 1 through 7 (profile 8 can not be operated externally).
Refer to the table below for the inputs required for the desired operation. NOTE: A profile must be created in the program page before trying to run a profile number.
Input 1
ON
Input 2
OFF
Input 3
OFF
Profile Selected
1
OFF
ON
ON
ON
OFF
OFF
2
3
OFF
ON
OFF
ON
OFF
OFF
OFF
ON
ON
OFF
ON
ON
ON
ON
OFF
To start the selected profile, set Input 1, 2, 3 or 4 to ON.
To hold a profile, set Input 4 to OFF.
To stop a profile, set all inputs to OFF.
4
5
6
7 none
Digital Inputs
41
Error Messages and Alarms
The Alarm Status Hi-limit LED is flashing. This indicates a problem with the thermocouple, or the Hi-limit setpoint has been exceeded. Once the problem has corrected, press the Reset pushbutton.
The Alarm Status Soak LED is flashing. This indicates that the oven temperature has not entered or dropped out of the soak band and the soak timer has stopped.
The top LED Display reads OPEN and the lower LCD display reads CONTROL SENS
ERR. This indicates that the Control thermocouple is disconnected or broken. Repair or replace the thermocouple.
The lower LCD display reads HI-LIM SENS ERR. This indicates that the Hi-limit thermocouple is disconnected or broken. Repair or replace the thermocouple.
The lower LCD display reads HIGH LIMIT ALARM. This indicates that the Hi-limit temperature setpoint has been exceeded. Determine if the setting is set too close to the setpoint, the SSR is defective, or the calibration is incorrect.
Note: The lower LCD display intermittently reads HL Temp. This is not an error message, but the Hi-limit thermocouple temperature reading.
42
Quick Reference and Default Values
Program Page
Menu Item Display Default Range Setting
Ramp Time Seg 1 Pro-1 Seg-1 Ramp Time 00:00
Event 1 Set Value Pro-1 Seg-1 Ramp Event 1 Off
00m00s to
99h59s
Off, On
Event 2 Set Value Pro-1 Seg-1 Ramp Event 2 Off Off, On
Event 3 Set Value Pro-1 Seg-1 Ramp Event 3 Off
Event 4 Set Value Pro-1 Seg-1 Ramp Event 4 Off
Soak Temp Seg 1 Pro-1 Seg 1 Soak Temp
Soak Time Seg 1
Event 1 Set Value
Event 2 Set Value
Pro-1 Seg 1 Soak Time
Pro-1 Seg-1 Soak Event 1
Pro-1 Seg-1 Soak Event 2
Off, On
Off, On
68°F SPLowerLim to
SPUpperLim *
00:00 00m00s to
99h59s
Off Off, On
Off Off, On
Event 3 Set Value Pro-1 Seg-1 Soak Event 3
Event 4 Set Value Pro-1 Seg-1 Soak Event 4
(repeat for segments 2-8)
Off
Off
Off, On
Off, On
High Limit Setpoint Pro-1 Hi-Lim SP
Loop From
Loop To
Loop Count
Profile Link
Pro-1 Loop From XX
Pro-1 Loop To XX
Pro-1 Loop Number
Pro-1 Link To XX
Guaranteed Soak Pro-1 Guar Band
Max
HiLimSP
No
No
0
Stop
Off
MinHiLimSP to
MaxHiLimSP *,
Band **
No, Seg-1 to
Seg-8
No, Seg-1 to
Seg-8
0 to 99
Standby***,
Stop, Hold,
Pro-1 to Pro-8
Off, 1 to 778°C
(1400°F)
(repeat for profiles 2-8)
* See Enable Page
** Band value is set on Control Page
*** If Standby
1. Cycle Complete LED indication goes ON.
2. Controller beeps if End Of Cycle beep is enabled.
3. Heater/control output keeps controlling oven temperature at last Soak setpoint.
4. All events programmed (if relay cards installed and programmed as an event) for the last Soak Segment stays active.
43
Programming Table
Profile Number__________
Profile Name__________
Segment
Time
1
Ramp
Events
2 3
1
2
3
4
5
6
7
8
High Limit Setpoint
Loop From Seg
Loop To Seg
Loop Number
Link To Pro
Guar Soak Band
4
Temperature
Time
Soak
1 2
Events
3 4
44
Autostart
Menu Item
Sunday mode
Sunday time
Monday mode
Monday time
Tuesday mode
Tuesday time
Display
Enable Autostart Auto Start Enable
Default Range
No No, Yes
Auto Start Sun Mode Off
Auto Start Sun Time
Auto Start Mon Mode Off
Auto Start Mon Time
00:00
Auto Start Tue Mode Off
Auto Start Tue Time
00:00
00:00
Off, Manual, Timer, Pro-1 to
Pro-8
00:00 to 23:59
Off, Manual, Timer, Pro-1 to
Pro-8
00:00 to 23:59
Off, Manual, Timer, Pro-1 to
Pro-8
00:00 to 23:59
Wednesday mode
Auto Start Wed Mode Off
Wednesday time Auto Start Wed Time 00:00
Thursday mode Auto Start Thu Mode Off
Thursday time
Friday mode
Friday time
Saturday mode
Auto Start Thu Time 00:00
Auto Start Fri Mode Off
Auto Start Fri Time 00:00
Auto Start Sat Mode Off
Off, Manual, Timer, Pro-1 to
Pro-8
00:00 to 23:59
Off, Manual, Timer, Pro-1 to
Pro-8
00:00 to 23:59
Off, Manual, Timer, Pro-1 to
Pro-8
00:00 to 23:59
Off, Manual, Timer, Pro-1 to
Pro-8
00:00 to 23:59 Saturday time Auto Start Sat Time 00:00
PID
Menu Item
Display units
Display Default
PID Temp Unit °C
Proportional band PID Prop Band 6°C
Integral reset PID Reset 2
Range
°C or °F
1 to 56°C (1 to 100°F)
0 to 100 seconds/repeat
Derivative Rate
AutoTune
PID Rate
PID AutoTune
0
Disable
0 to 500 seconds
Disable, Enable
Setting
Setting
45
Control
Menu Item
Cycle Time
Display
Control Cycle Time
Default
1
Range
1 to 60 seconds
High limit setpoint
High limit band
Power fail recovery
Recovery time limit
Powerup start enable
Powerup Start Mode
Control Hi-Lim SP
Control Hi-Lim Band
Control PwrFRec
Control PwrFTime
Control EPwrStrt
Control StrtMode
Max HiLimSP
Off
Dis
Off
Stop
00m00s
MinHiLimSP - MaxHiLimSP*
Off, 3°C to 11°C (5°F to 20°F)
Stop, Restart, Hold, Resume
00m00s to 99m59s
Dis, En
Off, Manual, Timer, Pro-1 to Pro-8
Hysteresis
Process out low
Process out high
Time scale
Key press beep
End of cycle beep
Alarm beep
Control Hyst
Control RetOutLo
Control RetOutHi
Control TimeScale
Control KeyBeep
Control EOCBeep
Control AlarmBeep
3°C
80°C
On
Off
Off
400°C hh:mm
1°C to 56°C (1°F to 100°F)
-73°C to 760°C (-100°F to 1400°F)
-73°C to 760°C (-100°F to 1400°F) hh:mm or mm:ss
On or Off
On or Off
On or Off
Setting
*see Enable Page
Communication (optional)
Menu Item
Address
Display
Communication CommAddr
Mode
Baud rate
Parity
Communication CommMode
Communication Baud Rate
Communication Parity
Default
1
OFF
None
19.2K
Range
1 to 247
OFF, Modbus
2400, 4800, 9600,
19.2K, 38.4K
None, Odd, Even
Setting
46
Real Time Clock
Menu Item Display
Day of the week Clock Day
Time of day
Reset clock
Clock HH:MM
Default Range
Mon
00:00
Clock UP to Reset CLK* Ready
Sun, Mon, Tue,
Wed, Thu, Fri, Sat
00:00 to 23:59
Ready, Done
Setting
* if the key is not pressed, the clock values will retain their original values, the display will change to Done if the clock is reset
Relay Outputs (optional)
Push Select key to select relay. If Relay 0 appears, no relays are installed
Menu Item
Type of relay
Display
Relay 1 RelayType
Default
Off
Range
Off, Alarm, Cycl, Ev1 to Ev4
Action of relay
Type of alarm*
Alarm setpoint*
Alarm deviation*
Inhibit alarm*
Type of event**
Event setpoint ***
Relay 1 RelayAction
Relay 1 AlarmType
Relay 1 AlmHi/Lo SP
Relay 1 AlmDevBand
Relay 1 ALMInhibit
Relay 1 EventType
Relay 1 Event SP
NDE
High
538°C
3°C
On
Time
SPUpLim
NDE, NE, NDEL, NEL*****
High, Low, Plus, Minus, Band
-73°C to 760°C (-100°F to 1400°F)
1 to 56°C (1 to 100°F)
En or Dis
Time or Temp
SPLoLim to SPUpLim****
(repeat for relay outputs 2-4, if available)
* appears only for alarm types
** appears only for time or temperature event types
*** appears only for temperature event types
**** see enable page
***** Normally de-energized and non-latching, normally energized and non-latching, normally de-energized and latching, normally energized and latching
Table of Settings
Relay Type Action Setpoint Alarm/
Event Type
Alarm
Deviation
Alarm
Inhibit
47
Test
Menu Item
Heater output
High limit relay
Relay 1 output
Display
Test HeatOut
Test HiLimOut
Test Rly1 Out
Default
Off
Off
Off
Range
On
On
On
Relay 2 output
Relay 3 output
Relay 4 output
Test Rly2 Out
Test Rly3 Out
Test Rly4 Out
Off
Off
Off
On
On
On
High Limit Sensor Test HL Temp (sensor reading)
Zone Cal
Menu Item
Zone 1 actual
Zone1 displayed
Zone 2 actual
Zone2 displayed
Factory calibration*
Display Default Range
Zone Cal Zone1Act 38°C -73°C to 760°C (-100°F to
1400°F)
Zone Cal Zone1Dis 38°C -73°C to 760°C (-100°F to
1400°F)
Zone Cal Zone2Act 260°C
Zone Cal Zone2Dis
Zone Cal FactCal
260°C
Ready
-73°C to 760°C (-100°F to
1400°F)
-73°C to 760°C (-100°F to
1400°F)
Ready or Done (push- key)
Setting
Setting
*only use when no calibration instrument is available
Sensor Cal
Menu Item Display
Control Sensor Cal Ctrl Sens 0F
Ctrl Sens 1000F
Ctrl Sens Done
HiLim Sensor Cal HL Sens 0F
HL Sens 1000F
HL Sens Done
Retransmit Cal RetCalLo XXXX *
RetCalHi XXXX *
Default
-100°F
1400°F
Done
-100°F
1400°F
Done
0
4096
Range
-100 to 1400°F
-100 to 1400°F
(read only)
-100 to 1400°F
-100 to 1400°F
(read only)
0 to 4096**
0 to 4096***
Setting
* note that the actual RetCalLo and RetCalHi values displayed are of no importance.
** press keys until retransmission output = 1VDC
*** press keys until retransmission output = 5VDC
48
Enable Page
Menu Item
Profiles
Autostart
PID
Control
Test
Communication
Real Time Clock
Relay outputs
Zone Calibration
Sensor Calibration
Setpoint lower limit
Password level 1
Password level 2
Display
Enable Profile 1-8
Enable Auto Start
Enable PID
Enable Control No
Enable Communication No
Enable Clock No
Default Range
Yes Yes or No
No
Yes
Yes or No **
Yes or No
Yes or No
Yes or No **
Yes or No **
Enable Relay 1-4
Enable Test
Enable Zone Cal
Enable Sensor Cal
Enable SPLowerLim
No
No
No
No
20°C
Setpoint upper limit Enable SPUpperLim
High limit overhead Enable HiLimOH
Manual/Timer mode setpoint change
Analog Output Type
Enable Password 1
Enable Password 2
Enable SPChange
Enable Analog Type
260°C
5°C
1
2
Yes
Proc
Yes or No **
Yes or No
Yes or No
Yes or No
-73°C to 759°C (-100°F to
1399°F)
-73°C to 760°C (-100°F to
1400°F)
3 to 11°C (5 to 20°F)*
0 to 999
0 to 999
Yes or No
Ctrl or Proc
* Maximum high limit setpoint (MaxHiLimSP) = SPUpperLim + HiLimOH
Minimum high limit setpoint (MinHiLimSP) = SPLowerLim + HiLimOH
** If the controller does not have this feature, “No” is the only option.
Setting
49
Technical Specifications
UL, cUL listed: UL file E136675
CE compliance to:
Power supply:
Temperature:
Humidity:
Sensor inputs:
EMC Directive 89-366/EEC
European Standard EN55011/1991
European Standard EN50082-2/1995
100 to 240 VAC +10% -15%, 50-60Hz, 30VA Maximum
12 to 24 VAC/VDC +/-10%, DC to 60Hz, 30VA Maximum
Storage -20 to 60°C
Operating 0 to 50°C
90% or less, non-condensing
Temperature display:
Message display:
Type J thermocouple -73°C to 760°C (-100°F to 1400°F)
Input impedance 1M ohm or greater
Common mode noise rejection of 140db@60Hz
Common mode input voltage of +/-12.0VDC
Sample rate of at least 1 sample per second
Stability of +/- 0.5°C per 5°C change in ambient temperature
Repeatability of +/- 0.5°C, or +/-0.1% of sensed temperature (whichever is greater)
Accuracy (@ 77°F +/-0.2 percent of span (+/-3°F)
Supply Voltage Influence of +/-0.5°C per 10% change in nominal line voltage
1 degree resolution (C or F)
Accuracy after calibration of +/- 1°C, or +/-0.2% of sensed temperature
(whichever is greater) @25°C
Four-digit seven-segment LCD, 0.43 inches high (11mm)
Readout Stability (+/-1°F/10°F Change in ambient temperature)
Two-line, 16 alpha-numeric 5x7 dot matrix characters per line
0.2 inches high (5mm)
+/- 4 seconds accuracy in 24 hours
SSR Drive 24VDC nominal @ 70mA
Time base:
Heat control output:
Relay output: (plug-in module)
Retransmit output:
Communications:
(plug-in module)
Form A dry contact, rated 3 amps @ 24-264VAC
1 to 5 VDC into > 100K ohm load
RS232 Single drop, isolated
RS422 Multi-drop, isolated
RS485 Multi-drop, isolated
Dry-contact closure type with less than 250 ohm ON resistance Remote inputs:
(plug-in module)
Front panel: NEMA 4X (with gasket)
Dimensions:
Panel opening:
3.57H x 7.24W x 2.84D inches (91H x 184W x 72D mm)
3.63H x 7.30W inches (92H x 185W mm)
50
Maintenance
Do not attempt any service on this oven before opening the main power disconnect switch.
Checklist
Keep equipment clean. Gradual dirt accumulation retards air flow. A dirty oven can result in unsatisfactory operation such as unbalanced temperature in the work chamber, reduced heating capacity, reduced production, overheated components, etc. Keep the walls, floor and ceiling of the oven work chamber free of dirt and dust. Floating dust or accumulated dirt may produce unsatisfactory work results. Keep all equipment accessible. Do not permit other materials to be stored or piled against it.
Protect controls against excessive heat. This is particularly true of controls, motors or other equipment containing electronic components. Temperatures greater than 51.5 C (125 F) should be avoided.
Establish maintenance & checkup schedules. Do this promptly and follow the schedules faithfully. Careful operation and maintenance will be more than paid for in continuous, safe and economical operation.
Maintain equipment in good repair. Make repairs immediately. Delays may be costly in added expense for labor and materials and in prolonged shut down.
Practice safety. Make it a prime policy to know what you are doing before you do it. Make CAUTION, PATIENCE, and GOOD JUDGEMENT the safety watchwords for the operation of your oven.
Lubrication, Fan motor bearings are permanently lubricated. All door latches, hinges, door operating mechanisms, bearing or wear surfaces should be lubricated to ensure easy operation.
51
Tests
Tests should be performed carefully and regularly. The safety of personnel as well as the condition of equipment may depend upon the proper operation of any one of the functions of the temperature control. Test the control every 40 hours. Check that the heater LED is cycling on and off, indicating that the heater is working. Also check the high limit function to make sure it is working properly.
To test the high limit:
1. Go to Manual Mode and enter control setpoint value at least 20°F (11°C) lower than the current process temperature.
2. Press the Menu key and lower the high limit setpoint to a value just below the current process temperature.
3. The high limit alarm indicator should flash and a high limit alarm message should be displayed. Verify that the heater relay has been disabled by checking that
2LED on the control panel circuit board is not lit.
4. Return the control setpoint and high limit setpoint values to their original values.
5. Press the Reset key.
The airflow switch and purge timer should also be tested every 40 hours.
To test the airflow switch and purge timer:
1. Allow the oven to stabilize at its minimum operating temperature by turning the heater off. Place all dampers in the closed position.
2. Cycle power to the system.
3. The airflow switch should be closed but the heater relay should remain deenergized until the purge timer times out. This can be verified by monitoring the purge timer.
On the LFD1-42: Indicators 1LED and 2LED should be lit. 3LED should remain off until the purge timer times out.
On the LFD2-11 and 2-24: The purge timer can be visually inspected to determine its state. The contacts can be seen to close when it energizes.
52
Replacement
Parts
To order or return parts, contact the Service Products Division at Despatch. The
Service Products features our Response Center for customer service. When returning parts, a Despatch representative will provide you with an MRA (Material Return
Authorization) number. The MRA number must be attached to the returned part for identification. When you are ordering parts, be sure to give the model number, serial number and the part number. This will expedite the process of obtaining a replacement part.
When you have a service need, contact the Response Center at 1-800-473-7373: FAX
612-781-5353.
WARNING:
Disconnect the main power switch or power cord before attempting any repair or adjustment.
53
Protocol Plus™ Instrument
(Tools needed: 1/4" socket driver with #1 bit, #2 Phillips screwdriver)
1. Disconnect the power.
2. Remove the screws from the control panel and slide it forward.
3. Unplug all terminals on the rear of the control, noting the proper connections.
4. Remove the four retaining clips for the control.
5. Remove the control.
6. Insert the new control into the panel.
7. Fasten the four retaining clips.
8. Re-plug all terminals.
9. Fasten the control panel.
Heater Unit
(Tools needed: 3/8" wrench, square recess driver with #1 bit for LFD1-42, one-quarter inch socket set for LFD2-11 and LFD2-24)
1. Remove the chamber floor plate. a. Remove the screws from the floor plate. b. Lift the floor plate out of the oven.
2. Disconnect the heater leads from heater element with wrench. Note which wires go on which terminals.
3. Unscrew the screws holding the heater frame to the oven body.
4. Remove the heater and discard.
5. Screw down the new heater frame.
6. Attach the heater leads to appropriate terminals.
7. Replace the interior floor and screws.
54
Fan Motor
(Tools needed: Screwdriver, 5/32 inch Allen wrench, one quarter (¼) inch socket set)
1. Remove the chamber floor plate. a. Remove the screws from the floor plate. b. Lift the floor plate out of the oven.
2. Remove the left side wall.
3. Remove the fan inlet plate.
4. Loosen the set screws (2) on fan wheel in middle of oven bottom. You can reach the fan wheel by going through the heater or by disconnecting and removing the heater. Refer to the Heater Unit instructions.
5. Place the oven on its back (LFD1-42 only).
6. Remove the bottom plate on the LFD1-42, or remove the control panel on the
LFD2-11 and 2-24. This will reveal the fan motor.
7. Remove the fan motor. a. Unscrew the screws (4) holding motor mounts to the body. b. Disconnect the motor leads from the terminal strip on the power panel. c. Lift the fan motor from the oven body.
After the fan wheel has run at temperature for awhile, it will stick to the shaft.
Some force may be required to separate the fan wheel from the fan motor shaft.
8. Take the motor mounts off old motor.
9. Put the motor mounts onto new motor.
10. Replace the fan motor. a. Insert the shaft into shaft collar. Put the fan wheel onto shaft from inside oven. b. Reattach the motor mounts to the oven body, making sure grommets are in place.
55
c. Reattach the motor lead wires to the terminal strip.
11. Replace the oven bottom (LFD1-42) or control panel front (LFD2-11 or 2-24).
12. Turn the oven right side up.
13. Adjust the fan wheel for 3/16 inch clearance between the wheel and the inlet ring.
14. Tighten the set screws on the fan wheel.
15. Check that the set screws hit the flats machined into the motor shaft.
16. Replace the chamber floor plate.
56
Troubleshooting
Equipment which operates for long periods of time may develop problems. Below are possible problems and suggested solutions. If you have a problem not listed and do not know what to do, contact Despatch Industries at our toll free Help Line 800-473-7373.
Difficulty Probable Cause
Failure to heat No power
Burned out heater
Protocol™ malfunction
Loose wire connections
Purge timer not timed out or
Slow heat up
Frequent heater element out failed
Heater relay failure
Airflow switch not closed
Door switch failure
Improperly loaded
Low line voltage
Heating element(s) are burned out
240 volt oven is connected to a 208V line (LFD1-42 only)
Fan motor failure
Harmful fumes generated by load
Erratic temp. or inaccurate temp.
Spillage or splattering of material on heater elements
Overheating oven
Protocol™ malfunction
Improper tuning parameters
Protocol™ miscalibration
Hi-limit setting
Improper offset
Suggested Remedy
Check power source and/or oven and wall fuses.
Replace heater (see warranty.)
Replace controller.
Disconnect power and check connections behind control panel.
Wait 3 minutes. If still not heating, replace purge timer.
Replace circuit board.
Check exhaust system for proper operation and ventilation. If airflow switch still does not close, replace switch.
Replace door switch.
Reduce load or redistribute load in chamber.
Supply sufficient power and proper connections.
Check for circuit overload.
Replace burned out element (see warranty statement.)
Raise line voltage to a 240 volt line or modify oven for 208V operation (consult factory).
Replace fan motor.
Increase vent opening or discontinue process.
Disconnect power and clean oven chamber and elements.
Check the Hi-limit.
Replace Protocol™.
Check tuning parameters.
Recalibrate Protocol™ (see section on Calibration mode.)
Hi-limit should be 10-25°C higher than setpoint.
Check zone calibration.
57
Difficulty
Excess surface or door temp.
Probable Cause
Door seal deterioration
Improper airflow Fan motor failure
Fan wheel seated too low on fan shaft
Unbalanced fan wheel
Excessive vibration
Dirty fan wheel
Unbalanced fan wheel
Hi-limit set too low Oven will not control at setpoint Protocol malfunction
SSR malfunction
Air friction of recirculation fan
Heater does not shut down until temp. reaches the Hi-limit setting
Protocol malfunction
SSR malfunction
Suggested Remedy
Replace door seal.
Replace fan motor.
Adjust fan wheel for 3/16" clearance between wheel and inlet ring.
Replace fan wheel.
Clean fan.
Replace fan wheel.
Set the Hi-limit higher
Replace control.
Replace SSR and/or check control output voltage.
Open exhaust air vent. Unit will not control below minimum operating temperature with vent closed.
Replace Protocol
Replace SSR
NOTE: The circuit board mounted on the control panel has three status LED indicators to help troubleshoot if the oven is not heating (LFD1-42 only).
A. If LED 1 is not lit, check 2F and 3F (control fuses), or power switch.
B. If LED 1 and LED 3 are lit but not LED 2, check high limit (and optional door switch, if installed).
C. If all three LEDs are lit, check 1F and 4F (heater fuses), SSR, heater, and heater relays.
58
APPENDIX
Temperature Scale Conversion (C/F)
The Protocol Plus controller can be operated in either C or F. The default setting for the controller is C. Changing from one to the other is as follows:
1. Go into the Setup Mode on the controller.
2. Press the Select Key until Setup is displayed.
3. Press the Page key and Security will be displayed.
4. Press the Menu Key and Password will be displayed. Use the arrow keys to enter the proper password. The default password is 2 for level two.
5. Once the proper password is displayed, press the Page key until PID is displayed.
6. Press the Menu key and Temp Unit along with C or F will be displayed. Use the arrow keys to change the setting.
7. Once the proper setting is displayed, press and hold the Page key for approximately three seconds to exit the Setup Mode.
59
diSP dPOS
EUU **
EUL **
ChUP
ChLO
DFF
* Note:
Optional MRC5000 Recorder Setup
The temperature is retransmitted to the Recorder from the Controller. Set up the
Recorder as follows:
1. Make sure that jumper JU1 is setup for the 5 VDC setting (see MRC Manual).
2. Move the Mode switch to the PROG/TEST/CAL position, and Prog will be displayed.
3. Press the down arrow key twice and Inps will be displayed. Make sure the settings are per the table below.
4. Once all the settings have been changed, move the Mode switch to the RUN position. The display on both the Recorder and controller should read the same.
Parameter Code
Inps
Degrees C
17
Degrees F
17
Icor 0 0
0
1
On
0
400
0
400
0
1
On
0
752
32
800 *
The 0 - 400 chart paper must be changed to the 0 - 800 chart paper. Depending on the equipment, 0 - 600 paper can be used if the maximum temperature is 500 degrees F.
** Note: These values must mach the setting sRetOutLo and RetOutHi on the Control page on the
Protocol Plus controller (example: RetOutLo is 32, then EUL must read 32).
60
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