High Temperature Muffle Furnace

High Temperature Muffle Furnace
BARNSTEAD|THERMOLYNE CORPORATION
High Temperature
Muffle Furnace
OPERATION MANUAL
AND PARTS LIST
Model Numbers
F46110CM
F46110CM-33
F46118CM
F46120CM
F46120CM-33
F46128CM
F46120CM-75
F46120CM-33-75
F46128CM-75
F46230CM
F46230CM-33
F46238CM
F46240CM
F46240CM-33
F46248CM
F46240CM-75
F46240CM-33-75
F46248CM-75
Automatic
Automatic
Automatic
Multi-Programmable
Multi-Programmable
Multi-Programmable
Multi-Programmable
Multi-Programmable
Multi-Programmable
LT1078X2 • 5/9/97
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.
Table of Contents
Safety Information .......................................................................................................................................... 4
Alert Boxes ..................................................................................................................................................... 4
Warnings ........................................................................................................................................................ 5
Description ..................................................................................................................................................... 7
Intended Use ............................................................................................................................................. 7
General Usage ......................................................................................................................................... 7
Principles of Operation .............................................................................................................................. 7
Types of Controllers .................................................................................................................................. 8
General Specifications ................................................................................................................................... 9
General Specifications ................................................................................................................................. 10
Environmental Conditions ........................................................................................................................ 10
Declaration of Conformity ........................................................................................................................ 11
Unpacking .................................................................................................................................................... 12
Installation .................................................................................................................................................... 13
Furnace Connection ................................................................................................................................ 13
Initial heat-up procedure: ......................................................................................................................... 13
General Operation of Furnace ...................................................................................................................... 14
Power Switch ........................................................................................................................................... 14
Cycle Indicator ......................................................................................................................................... 14
Circuit Breaker ......................................................................................................................................... 15
Fans ........................................................................................................................................................ 15
Controllers ............................................................................................................................................... 15
Operation of Automatic Models .................................................................................................................... 16
Control Parameters ................................................................................................................................. 16
Tuning Your Furnace ............................................................................................................................... 17
Single Set Point Operation ................................................................................................................... 18
Program Ramp Rate ................................................................................................................................ 19
Program Ramp Reset .............................................................................................................................. 19
Operation of Programmable Models ............................................................................................................. 20
Control Parameters ................................................................................................................................. 20
Tuning Your Furnace ............................................................................................................................... 22
Operating the Controller ......................................................................................................................... 23
Single Set Point Operation ................................................................................................................... 23
Programming Controller .......................................................................................................................... 23
Multi-Programmable Controller Program Entry (Models F46120CM,
F46120CM-33, F46120CM-33-75, F46120CM-75, F46128CM, F46128CM-75, F46240CM,
F46240CM-33, F46240CM-33-75, F46240CM-75, F46248CM, F46248CM-75) .................................. 24
Program Entry (all models) ...................................................................................................................... 25
Implementing Programs .............................................................................................................................. 27
Program Execution ................................................................................................................................. 27
Parameter Change While Running .......................................................................................................... 27
Loop Count .............................................................................................................................................. 27
Program Hold ........................................................................................................................................ 27
Program Reset ....................................................................................................................................... 28
2
TABLE OF CONTENTS
Furnace Loading: .........................................................................................................................................29
Furnace Atmospheres .............................................................................................................................30
Preventive Maintenance .............................................................................................................................. 31
General Cleaning Instructions ............................................................................................................... 32
Problem Solving Guide ................................................................................................................................. 33
Maintenance and Servicing ..........................................................................................................................34
Wiring Diagram ............................................................................................................................................ 38
Wiring Diagram ............................................................................................................................................. 39
Wiring Diagram ............................................................................................................................................. 40
Wiring Diagram ............................................................................................................................................. 41
Replacement Parts List ............................................................................................................................... 42
Ordering Procedures .................................................................................................................................... 43
Material Safety Data Sheet ..........................................................................................................................44
Warranty ....................................................................................................................................................... 47
3
Safety Information
Safety Information
Your Thermolyne furnace has been designed with function,
reliability, and safety in mind. It is the user’s responsibility to
install it in conformance with local electrical codes. For safe
operation, please pay attention to the alert boxes throughout the manual.
Alert Boxes
Because of the nature of this product, considerably more
care is required in operating and servicing this furnace than
for lower temperature laboratory furnaces. For maximum
safety and longest furnace life, be sure to observe the
WARNING
Warning alerts apply when there is a various cautions and warnings throughout this manual.
possibility of personal injury.
CAUTION
Caution alerts apply when there is a
possibility of
damage to the equipment.
NOTE
Notes alert the manual user 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.
4
SAFETY INFORMATION
WARNING
To avoid electrical shock, this furnace must:
1. Be installed by a competent, qualified electrician who
insures compatibility among furnace specifications,
electrical source and grounding code requirements.
2. Always be disconnected from the electrical supply
prior to maintenance and servicing.
To avoid personal injury:
1. Do not stand directly in front of the chamber without
wearing a heat resistant face shield, gloves and apron.
2. Do not operate or clean furnace without proper eye
protection.
3. Do not use in the presence of flammable or combustible materials; fire or explosion may result. This
device contains components which may ignite such
materials.
4. Refer servicing to qualified personnel.
5. Caution: Hot Surface. Avoid Contact.
6. To AVOID EYE DAMAGE in operating or cleaning
furnace, proper eye protection must be worn.
7. To AVOID BURNS, do not stand directly in front of the
chamber without wearing a heat resistant faceshield,
gloves and apron.
8. To AVOID FIRE, do not place combustible materials
where exposed to heat from open door.
HOT SURFACE
Caution: Hot Surface. Avoid Contact.
5
SAFETY INFORMATION
Please note the following WARNINGS:
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 pre-existing 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) fo 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 1-800-553-0039.
WARNING
REFER SERVICING TO QUALIFIED PERSONNEL.
6
Description
Intended Use
Types 461 and 462 are general purpose laboratory
furnaces
intended for applications requiring temperatures from
800-1700
degrees C.
NOTE
The fans operate continuously, even
when the circuit breaker is OFF, to assure
that the control section and the terminals
of the heating elements are continuously
ventilated. Without ventilation, residual
heat from the furnace chamber can cause
overheating after the furnace is turned off.
CAUTION
Do not completely remove electricity from
the furnace until chamber temperature
falls below 500°C. Do not touch exposed
elements.
General Usage
Do not use this product for anything other than its
intended usage.
Principles of Operation
The chamber section is heated by six (in type F46100
urnaces) or eight (in type F46200 furnaces) Super
Kanthal 33 heating elements suspended in a chamber
made of alumina and silica high temperature refractory
fiber.
This high temperature refractory fiber is in the form of
blocks which line the inside of the chamber. Because of
the
stresses caused by extremely high temperature operation, these blocks will show some surface cracking. This
cracking is not detrimental to the operation of the furnace.
A precious metal type B thermocouple senses the
temperature in the chamber and transmits this information to the temperature control in millivolts.
7
DESCRIPTION
The control section consists of a temperature controller, a
current controller, a transformer, a contactor (relay), a
circuit breaker, and a pilot light.
The temperature controller senses the furnace temperature
(by means of the thermocouple) and adjusts electricity to
the heating elements by means of the current controller.
The current controller controls electricity to the heating
elements by adjusting the magnitude of the electrical
current (rather than turning the electricity completely on or
off). This is the preferred method of controlling electricity to
molybdenum disilicide heating elements.
The transformer supplies the proper electrical voltage to the
heating elements.
The contactor removes electricity from the heating elements
if the furnace temperature equals or exceeds the high limit
set point of the controller
The circuit breaker is used to turn the furnace on and off
and also protects the electrical supply in the event that the
furnace draws too much electrical current.
The pilot light indicates that the circuit breaker is ON and
that the controller is being supplied with electricity.
A fan is provided in each section of the furnace to provide
forced air cooling.
Types of Controllers
1. The automatic (single set point) digital model enables the
user to program a single set point temperature which the
furnace will heat and hold.
2. The 4 program, programmable digital model enables the
operator to program up to 8 ramp segments (heat-up or
cool-down rate) and 8 dwell segments (soak) for applications that require time and temperature relationship for
up to 4 separate or linkable programs.
3. The 15 program, programmable digital model enables
the operator to program up to 8 ramp segments (heat-up
or cool-down rate) and 8 dwell segments (soak) for up to
15 separate or linkable programs.
8
General Specifications
General Specifications
Model#
F46110CM,
F46110CM-33
F46118
F46120CM
F46120CM,-33
F46128
F46120CM-75
F46120CM-33-75
F46128CM-75
Width
28-1/8
(71.4)
28-1/8
(71.4)
28-1/8
(71.4)
28-1/8
(71.4)
28-1/8
(71.4)
28-1/8
(71.4)
Height
18-1/2
(47)
18-1/2
(47)
18-1/2
(47)
18-1/2
(47)
18-1/2
(47)
18-1/2
(47)
Depth
19
(48.3
19
(48.3)
19
(48.3)
19
(48.3)
19
(48.3
19
(48.3)
Width
6
(15.2)
6
(15.2)
6
(15.2)
6
(15.2)
6
(15.2)
6
(15.2)
Height
6-1/2
(16.5)
6-1/2
(16.5)
6-1/2
(16.5)
6-1/2
(16.5)
6-1/2
(16.5)
6-1/2
(16.5)
Depth
6-1/4
(15.9)
6-1/4
(15.9)
6-1/4
(15.9)
6-1/4
(15.9)
6-1/4
(15.9)
6-1/4
(15.9)
LBS.(kg)
156 (70.9)
156 (70.9)
156 (70.9)
156 (70.9)
156 (70.9)
156(70.
Electrical
Volts
240
208
240
208
240
208
Rating
Amps
40*/10.4#
40*/12#
40*/10.4#
40*/12#
40*/10.4#
40*/12#
Watts
9600*
2500#
8320*
2500#
9600*
2500#
8320*
2500#
9600*
2500#
8320*
2500#
Phase
1
1
1
1
1
1
Cont.
1700°C
1700°C
1700°C
1700°C
1700°C
1700°C
Automatic
Automatic
4-Program.
4-Program.
Multi-Prog.
Multi-Prog.
Dimensions
Overall-in
(cm)
Chamberin (cm)
Weight
Temp. Range
Controller
NOTES:*Inrush power and current.
# Power and current required to maintain maximum temperature after stabilization.
The maximum current is determined by the limiting factor set by the current controller. In the event that 40 amperes is not available, the
current controller may be set to limit the current to some smaller value at the expense of a somewhat longer heat-up time.
The variation in current is a result of molybdenum disilicide heating elements
having a large decrease in resistance with increasing temperature.
NOTES: The maximum ramp rates for this furnace for heat-up are: 100°C per minute from 25°C-1000°C and
15°C per minute from 1000°C-1700°C.
9
GENERAL SPECIFICATIONS
Model#
F46230CM,
F46230CM-33
F46238
F46240CM
F46240CM,-33
F46248
F46240CM-75
F46240CM-33-75
F46248CM-75
Width
34-1/8
(86.7)
34-1/8
(86.7)
34-1/8
(86.7)
34-1/8
(86.7)
34-1/8
(86.7)
34-1/8
(86.7)
Height
22-1/2
(57.2)
22-1/2
(57.2)
22-1/2
(57.2)
22-1/2
(57.2)
22-1/2
(57.2)
22-1/2
(57.2)
Depth
23
(58.4)
23
(58.4)
23
(58.4)
23
(58.4)
23
(58.4)
23
(58.4)
Width
10
(25.4)
10
(25.4)
10
(25.4)
10
(25.4)
10
(25.4)
10
(25.4)
Height
10-1/4
(26)
10-1/4
(26)
10-1/4
(26)
10-1/4
(26)
10-1/4
(26)
10-1/4
(26)
Depth
9-3/4
(24.8)
9-3/4
(24.8)
9-3/4
(24.8)
9-3/4
(24.8)
9-3/4
(24.8)
9-3/4
(24.8)
LBS.(kg)
234 (106.3)
234 (106.3)
234 (106.3)
234 (106.3)
234 (106.3)
234 (106.3)
Electrical
Volts
240
208
240
208
240
208
Rating
Amps
40*/20.8#
40*/24#
40*/20.8#
40*/24#
40*/20.8#
40*/24#
Watts
9600*
5000#
8320*
5000#
9600*
5000#
8320*
5000#
9600*
5000#
8320*
5000#
Phase
1
1
1
1
1
1
Cont.
1700°C
1700°C
1700°C
1700°C
1700°C
1700°C
Automatic
Automatic
4-Program.
4-Program.
Multi-Prog.
Multi-Prog.
Dimensions
Overall-in
(cm)
Chamberin (cm)
Weight
Temp. Range
Controller
# Power and current required to maintain maximum temperature after stabilization.
The maximum current is determined by the limiting factor set by the current controller. In the event that 40 amperes is not available, the
current controller may be set to limit the current to some smaller value at the expense of a somewhat longer heat-up time.
The variation in current is a result of molybdenum disilicide heating elements
having a large decrease in resistance with increasing temperature.
NOTES: The maximum ramp rates for this furnace for heat-up are: 100°C per minute from 25°C-1000°C and
15°C per minute from 1000°C-1700°C.
Environmental Conditions
Operating:17°C-27°C; 20% to 80% relative humidity,
non-condensing. Installation Category II (overvoltage) in accordance with IEC 664.
Pollution
Degree 2 in accordance with IEC 664. Altitude limit:
2,000
meters.
Storage: -25°C to 65°C; 20% to 80% relative humidity.
10
Declaration of Conformity
Declaration of Conformity
(-33 models only)
NOTE
The Type 46100 and 46200 furnaces do
not come with an electrical cord because
current requirements are too great to be
handled by ordinary electrical cords and
standard wall electrical outlets.
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 Compatability
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:
European Manager
Barnstead|Thermolyne
Saarbrückener Str. 248
D-38116 Braunschweig
Germany
Copies of the Declaration of Conformity are available
upon request.
11
Unpacking
Unpacking
CAUTION
Be sure ambient temperature does
not exceed 104°F (40°C). Ambient
temperatures above 104°F (40°C)
may result in damage to the controller.
Allow at least six inches (15 cm) of
space between the furnace on all
sides and the top. This permits the
heat from the furnace case to escape.
WARNING
To avoid electrical shock, this furnace
must be installed by a competent,
qualified electrician who insures
compatibility among furnace specifications, electrical source and grounding code requirements. Ensure unit is
properly grounded.
CAUTION
For supply connections, use 8 AWG or
larger wires suitable for at least 90°C.
Failure to observe this caution could
result in damage to furnace.
12
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. A hearth plate is supplied with the furnace to
be placed on bottom of furnace chamber.
Retain the original packaging material if re-shipment is
foreseen or required.
Installation
Installation
Site Selection: Install furnace on a sturdy surface and
allow space for ventilation.
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 46100 or 46200 furnace to your electrical
supply, be sure the front circuit breaker is in the OFF
position.
Furnace Connection
Remove cover plate for access to the electrical connections. Connect electricity to the three terminals found
behind this plate; one side of the 208 or 240 volt service
to the top terminal, L1; the other side of the 208 or 240
volt service to the bottom terminal, L2, and the ground
(usually green wire) to the center terminal marked GND.
For 220 volt service,connect the neutral to the top
terminal (marked L1); the 220 volt line to the bottom
terminal, L2, and the ground to the center terminal
marked GND. Electricity must be brought to the furnace
through an appropriate conduit system, through the hole
in the back panel at the bottom left rear of the furnace,
and connected as described. Be sure to observe local
wiring codes in connecting.
Initial heat-up procedure:
The elements may bend slightly sideways due to electromagnetic forces generated between the element shanks.
To prevent this bending, heat the furnace up to 1650°C
for 10-20 minutes. Then let furnace cool to ambient
temperature. See Operation for your particular controller
for information on setting temperature setpoints.
13
General Operation of Furnace
General Operation of Furnace
Observe these Warnings before operating your furnace:
WARNING
CAUTION
Remember that when the power switch
is turned “ON”, the furnace will begin to
heat to the set point temperature that
was previously set in the controller. This
value will remain unchanged for up to a
year without electricity being supplied to
the controller.
CAUTION
If the electrical supply must be disconnected from the furnace at any time, be
sure the chamber temperature is 500°C
or less before doing so.
To avoid electrical shock, this furnace must:
1. Be installed by a competent, qualified electrician who
insures compatibility among furnace specifications, electrical source and grounding code requirements.
2. Always be disconnected from the electrical supply
prior to maintenance and servicing.
To avoid personal injury:
1. Do not stand directly in front of the chamber without
wearing a heat resistant faceshield, gloves and apron.
2. Do not operate or clean furnace without proper eye
protection.
3. Do not use in the presence of flammable or combustible
materials; fire or explosion may result. This device contains
components which may ignite such materials.
4. Refer servicing to qualified personnel.
5. Caution: Hot Surface. Avoid Contact.
6. To AVOID EYE DAMAGE in operating or cleaning
furnace, proper eye protection must be worn.
7. To AVOID BURNS, do not stand directly in front of the
chamber without wearing a heat resistant faceshield, gloves
and apron.
8. To AVOID FIRE, do not place combustible materials
where exposed to heat from open door.
HOT SURFACE
Caution: Hot Surface. Avoid Contact.
Power Switch
Controls power to the furnace. Switch to the “ON” position
to energize the elements and the controller.
Cycle Indicator
The amber cycle light will illuminate when electricity is
being supplied to the elements.
14
GENERAL OPERATION
OF
FURNACE
Circuit Breaker
A double pole circuit breaker is located at the bottom of
the control section. It serves to turn electricity ON and
OFF and to protect the electrical circuit.
Fans
NOTE
When performing operations on the
controller, remember that if you depress
and release either the “scroll”, “up”, or
“down” push buttons and more than 8
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
Due to the High Temperature design of
the thermocouple, the controller will
indicate a temperature of 70°-90°C at
ambient temperature.
The fans, located in the rear of the heating section and
the control section, will run continuously as long as
electricity is supplied to the furnace, even when the
furnace panel circuit breaker is OFF. This serves to
remove residual heat after the furnace is turned OFF so
the heat does not cause damage to the controls.
Controllers
Your furnace’s controller consists of a microprocessor
based three-mode (Proportional, Integral, Derivative),
programmablecontrol with overtemperature 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 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 depression 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. On the Automatic
Models, PR (program ramp rate) will appear. On the
Programmable Models, 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 Control Parameters for your particular controller for a list of parameters.)
15
Operation of Automatic
Controls
Operation of Automatic Models
(Models F46110CM, F46110CM-33, F46118CM,
F46230CM, F46230CM-33, F46238CM)
Control Parameters
NOTE
Thermolyne recommends that you set
the value of AL 1 either at 1710°C
(3092°F) or at a value of 20 degrees
above your working temperature if you
desire to provide protection for your
workload.
NOTE
“OR” will be displayed if an open thermocouple condition exists.
NOTE
To change from °C indication to °F
indication, contact Barnstead/
Thermolyne.
NOTE
The automatic 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 recommend that you tune the
furnace to your specific application to
obtain the best
results. To provide the best temperature
accuracy possible, use these features
when you install yourfurnace and
whenever you change your application
orprocedure.
16
PR = program ramp rate, the rate of heat increase or
decrease in °C/minute. Pushing the up or down button will
give the current setting of this ramp. Push up or down
button to set.
SP2. SP2 is not configured into control and nonfunctional.
Set to 20.
ST = Self-tune automatically loads PID values on initial
start up. This function does not have a value, it is
either “ON” or “OFF”. (See Furnace Operation for
function of Self-tune).
AT = Adaptive Tune, which 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).
SAT = Self-Adaptive Tune when engaged starts controller in
self-tune mode then automatically switches to Adaptive
Tune (AT). 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.
AL1 = Alarm 1 is 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.
The next five parameters: proportional (PB), integral (+i),
derivative (+d), cutback low (cbl) and cut back high (cbh)
are for high accuracy control. These parameters are set
during Self-Adaptive Tune. (See Tuning Your Furnace.)
OPERATION OF AUTOMATIC CONTROLS
NOTE
The self-tune feature will be inactive if you
implement a ramp to setpoint. If your
implement a ramp to setpoint, the adaptive
tune feature will be active only after you
reach your setpoint. See Program Ramp
Rate for more information on ramping to
setpoint.
CAUTION
Minimize operation of furnace under
800°C. Element life is reduced when
operating below 800°C because the
protective layer of silica glass takes
longer to form.
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 up or down
buttons will change parameter value. In all
cases, the value shown on the display is
the current working
NOTE
The two center push buttons are nonfunctional.
NOTE
The program ramp rate is designed to
reduce the heat-up rate or cooling rate
that the furnace normally exhibits. When
not using this feature, the furnace will
operate at its maximum heating and
cooling capability.
HL = Output Power limits the average maximum percentage
of electricity that is applied to the heating elements.
Depress and release up or down button, if 100 is not
displayed, contact Barnstead/Thermolyne.
Sbr = the power that is required to indicate an open
thermocouple condition exists. Push up or down button, if
0.0 is not displayed, contact Barnstead/Thermolyne.
Tuning Your Furnace
The SAT Self and Adaptive Tuning feature starts the
controller in the Self-tune mode, then automatically
switches over to the Adaptive Tuning mode. Self-Tuning
is a one-time function which permits the user to tune the
instrument control parameters to suit new process
conditions.
Adaptive tuning takes over when the self-tune is completed and continuously evaluates tuning parameters.
Adaptive tuning automatically installs new values if better
accuracy is
possible.
To Tune Your Furnace:
1. Load your furnace with a load characteristic of those
you intend to heat in it.
2. Depress scroll button until SAT is displayed. Depress
the up and down buttons simultaneously to start selftuning.
During Tuning, the A-T indicator is illuminated (upper
right hand corner) 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 (use temperature set point that
your application requires). At the end of one 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 is
completed. After the self-tune is completed, adaptive
tune takes over and the A-T indicator will remain illuminated.
17
OPERATION OF AUTOMATIC CONTROLS
3. To stop tuning function, scroll until SAT is displayed
and simultaneously push up and down buttons.
Single Set Point Operation
The automatic control is used as a single set point control,
which includes one ramp to set point capability. To use as a
single set point control, simply push up or down buttons to
choose a specific temperature. The control will cause the
furnace chamber to heat to the chosen temperature and
hold it at this temperature until you turn off the front circuit
breaker switch or select another temperature.
NOTE
When the program ramp has ended or
has been reset, the furnace will
continue to maintain set point temperature. It will not cool to ambient
temperature unless set point is set to
ambient temperature.
18
To operate the control:
1. Turn power switch to the “ON” position. The set point
temperature presently set in the control will appear 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. 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 actual chamber temperature.
OPERATION OF AUTOMATIC CONTROLS
Program Ramp Rate
If you desire to ramp to the set temperature at a specified
rate, depress scroll button until “PR” appears. (“PR” =
program ramp rate, which is the rate of heat increase or
decrease in °C/minutes). Depress up or down button to
give current setting of ramp rate. Depress up or down
button again until you achieve desired setting.
To start the temperature ramp, push the run button. With
the run initiated, the program will commence and the
legend on the display will indicate “RAMP”. While a
program is running, the short scroll will contain three
parameters. SP = set point. OP = output power. Time =
time remaining in program ramp to reach set point
temperature. Single depression of the scroll button will
allow you to view each of these parameters.
When the program ramp has ended, an “E” will appear
on the display.
Program Ramp Reset
A running or finished program can be reset by depressing the run/hold button.
After depressing the run/hold button, the parts of the
display associated with programming will be extinguished
and the controller will operate as a single set point
control as described before.
19
Operation of Programmable
Models
Operation of Programmable Models
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 up or down buttons will
change parameter value. In all cases,
the value shown on the display is the
current working value of that parameter
MODELS F46120CM, F46120CM-33,
F46120CM-33-75, F46120CM-75,
F46128CM, F46128CM-75,
F46240CM, F46240CM-33,
F46240CM-33-75, F46240CM-75,
F46248CM, F46248CM-75
NOTE
These models have two additional
parameters at the beginning of the
parameter list;
Pnr is the program number selected.
By pushing the up or down button,
you can select a program from 1 to
15. On the F46120CM, F46120CM33, F46128CM, F46240CM,
F46240CM-33 and F46248CM
models, this is selected between 1-4.
Cnt is used to allow linking of programs. Cnt (continued) may be
selected as “y” (yes) or “n” (no) by
pushing the up or down button. The
remaining parameters will follow in the
sequence listed.
20
(F46120CM, F46120CM-33, F46120CM-33-75, F46120CM75, F46128CM,
F46128CM-75, F46240CM, F46240CM-33, F46240CM-3375, F46240CM-75,
F46248CM, F46248-75)
Control Parameters
PR1 = program ramp rate is the rate of heat increase or
decrease in °C/minute. Pushing the up or down button to
set.
PL1 = program level is the temperature which the furnace
needs to attain. Push up or down button to set.
PD1 = program dwell “1” is amount of time, in minutes, to
hold the PL1 program temperature level entered. Push up
or down button to set.
The remaining Program Ramp Rates PR2 - PR8, Program
Levels PL2 - PL8, and Program Dwells PD2 - PD8 follow in
the same manner as PR1, PL1 and PD1. (After PD8).
HB = “Holdback” automatically places the programmer into
“Hold” if the measured value deviates more than a specified
amount from programmer setpoint. 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 is the number of times a
program will be repeated. Push up or down button to set.
SP1 = setpoint one which indicates current setpoint. Push
up or down button to set.
SP2=Setpoint two. Not configured into control and
nonfunctional. Set to 20.
OPERATION OF PROGRAMMABLE MODELS
ST = Self Tune automatically loads PID values on initial
start up. This function does not have a value, it is either
ON or OFF. (See Furnace Operation for function of Self
Tune.)
AT = Adaptive Tune analyzes and inputs optimum PID
values when temperature has reached setpoint. This
function does not have a value, it is either “ON” or “OFF”.
(See Furnace Operation for function of Adaptive Tune).
NOTE
Barnstead|Thermolyne recommends
that you set the value of AL1 either at
maximum operating temperature of the
furnace or at a value of 20 degrees
above your working temperature if you
desire to provide protection for your
workload.
SAT = Self Adaptive Tune when engaged starts controller
off in self-tune mode, then automatically switches to
Adaptive Tune (AT). 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
The upper display will flash “OR” if an
open thermocouple condition exists.
AL1 = Alarm 1 is 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.
NOTE
To change from °C indication to °F
indication, contact Barnstead/
Thermolyne.
The next five parameters, proportional (PB), integral (+i),
derivative (+d), cutback low (cbl) and cutback high (cbh),
are for high accuracy control. These values cannot be
changed by the user; the controller automatically installs
optimum values when in Self and Adaptive Tuning.(See
Tuning Your Furnace for more information.).
HL = Output Power limits the average maximum percentage of electricity that is applied to the heating elements.
Depress and release up or down button. If “100” is not
displayed, contact Barnstead/Thermolyne.
Sbr = the percent of power that is supplied to the control
output terminals if an open thermocouple condition
exists.
Push up or down button. This parameter cannot be
changed, if 0.0 is not displayed, contact Barnstead/
Thermolyne.
21
OPERATION OF PROGRAMMABLE MODELS
Tuning Your Furnace
NOTE
The automatic 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 recommend that you tune
the furnace to your specific application
to obtain the best results. To provide
the best temperature accuracy possible, use these features when you
install your furnace and whenever you
change your application or
procedure.
NOTE
The self-tune feature is inactive while
running a program. The adaptive tune
feature is active only in the dwell segments of a program.
The SAT Self and Adaptive Tuning feature starts the
controller in the Self Tune mode, then automatically
switches over to the Adaptive Tuning mode. Self Tuning is a
one-time function which permits the user to tune the
instrument control parameters to suit new process conditions.
Adaptive tuning takes over when the self tune is completed
and continuously evaluates the tuned parameters. Adaptive
tuning automatically install new values if better accuracy is
possible.
To Tune Your Furnace:
1. Load your furnace with a load characteristic of those
you intend to heat in it.
2. Depress scroll button until SAT is displayed. Depress
the up and down buttons simultaneously to start self-tuning.
During Tuning, the A-T indicator is illuminated (upper right
hand corner) 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 you will be using the controller as a single
Setpoint Controller, set the furnace’s setpoint to the temperature you intend to use for your application. If you will be
running a multi-step program, set the furnace’s setpoint to
the value of PL1 (Program Level #1).) At the end of one
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 is
completed. After the self-tune is completed, adaptive tune
takes over and the A-T indicator will remain illuminated.
4. To stop tuning function, scroll until SAT is displayed
and simultaneously push up and down buttons.
5. Operate your controller normally as described in
Operating the Controller.
22
OPERATION OF PROGRAMMABLE MODELS
Operating the Controller
The programmable control can be used as a single
CAUTION
setpoint control or as a programmable control.
Minimize operation of furnace under 800°C.
Element life is reduced when operating below
800°C because the protective layer of silica
glass takes longer to form.
Single Set Point Operation
To use as a single set point control simply push up or
down
buttons to choose a setpoint temperature.
NOTE
Temperature setpoint 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 front circuit breaker
switch or select another temperature.
CAUTION
Remember that whenever the power switch
is turned “ON”, the furnace will begin to
heat to the setpoint temperature that was
previously programmed. This value will
remain unchanged for up to a year without
electricity being applied to the control.
NOTE
The two center push buttons are non-functional.
To operate the control as a single set point control:
1. Turn front circuit breaker switch to the “ON” position.
The setpoint temperature presently set in the control
will appear on the lower display.
2. To change this set point, depress the “UP” or
“DOWN” push button until the desired setpoint 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 actual chamber temperature.
Programming Controller
To run a program, first determine your ramp rate, dwell
times, program levels. It is helpful to graph your program
for ease of loading program into controller. Observe
maximum ramp rates (heat up time) on the general
specifications page before programming ramp rates.
A maximum of 8 ramp and 8 dwell segment combinations
are available, thus enabling eight different setpoint levels
to be achieved. Each ramp is programmed by specifying
the program level (PL) and the required ramp rate (PR).
The control automatically calculates the time that is
required to attain the program level (PL) based on
23
OPERATION OF PROGRAMMABLE MODELS
desired ramp rate (PR). Dwell segments (PD) can be
attached to each program level (PL) to hold that temperature for a specified number of minutes.
Multi-Programmable Controller Program Entry
(Models F46120CM, F46120CM-33, F46120CM-33-75,
F46120CM-75, F46128CM, F46128CM-75, F46240CM,
F46240CM-33, F46240CM-33-75, F46240CM-75,
F46248CM, F46248CM-75)
The multi-programmable controller in the F46120CM-75,
F46128CM-75, F46240CM-75 and F46248CM-75 units
provides up to 15 separate programs of 8 ramps and 8
dwells each. The F46120CM, 46128CM, F46240CM and
F46248CM models have four separate programs These
controllers allow you to link programs together. These
functions are governed by the controller’s first two programming parameters, “Pnr” and Cnt.”
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 15. On
the F46120CM, F46120CM-33, F46128CM, F46240CM,
F46240CM-33 and F46248CM models, this is selected
between 1-4.
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 #15 will initiate the
start of program #1 upon the completion of program
#15.Each program will complete the selected number of
loops before continuing (see Loop Count).
These two parameters (“Pnr” and “Cnt”) are the only ones
that differ from the single program 8 ramp and 8 dwell
control. Program entry for the multi-programmable models
continues with the following instructions, which are applicable to both the multi-programmable and single programmable models.
24
OPERATION OF PROGRAMMABLE MODELS
Program Entry (all models)
Set Ramp Rates
1. With the controller 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.
NOTE
Be sure to select the program number
before pressing “Run/Hold.” (Models
F46120CM, F46120CM-33,
F46120CM-33-75, F46120CM-75,
F46128CM, F46128CM-75,
F46240CM, F46240CM-33,
F46240CM-33-75, F46240CM-75,
F46248CM and F46248CM-75)
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; STEPwhich 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.
25
OPERATION OF 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 setpoint 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.
NOTE
The temperature control in these
models is a programmable “and”
automatic single setpoint 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 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 setpoint (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 or below
degrees as described earlier in this
manual.
26
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 setpoint, 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.
Implementing Programs
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
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.
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
27
IMPLEMENTING PROGRAMS
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 setpoint control.
28
Furnace Loading
Furnace Loading:
Be sure to use care in loading and unloading the furnace
chamber. Molybdenum disilicide heating elements are
extremely fragile and can crack or break with just a slight
bump. Be sure not to block the flow of radiant heat from
the heating elements to the thermocouple. The thermocouple must be able to respond directly to the heating
elements. Failure to observe this will permit the heating
elements to overheat and possibly burn out. Poor
temperature control can also result from improper
loading.
Because of the possibility of erosion of the insulation on
the floor of the furnace chamber, a separate hearth plate
should be used when possible.
In general, space should be left on all sides of a load or
on all sides of individual components of a load so that
heat can penetrate through the surfaces. The load should
not occupy more than two-thirds of the inside dimensions
of the chamber.
The extent to which a furnace may be loaded depends
upon such factors as operating temperature, desired
accuracy, and type of material. A furnace may be loaded
more heavily at lower temperatures, if highest accuracy
is not needed, and if the material of the load absorbs
heat easily.
29
FURNACE LOADING
Furnace Atmospheres
This furnace is designed to be used to 1700°C in pure air
only. It may be used with nitrogen, argon, or helium
atmospheres to 1600°C. Reducing atmospheres are not
recommended.
The heating elements in this furnace are attacked by
fluorine, chlorine, sodium and potassium compounds and
also by molten metals. This furnace may be used for metal
melting if care is taken not to splash molten metal on the
heating elements.
30
Preventive Maintenance
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 pre-existing 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 1-800-553-0039.
WARNING
To avoid electrical shock, this furnace must always be
disconnected from the electrical supply prior to
maintenance and servicing.
Do not clean furnace without proper eye protection.
Refer servicing to qualified personnel.
31
PREVENTIVE MAINTENANCE
General Cleaning Instructions
Wipe exterior surfaces with lightly dampened cloth containing mild soap solution.
A few simple procedures will help insure that your furnace
will give you long service.
1. Keep the chamber clean; this furnace is capable of
achieving temperatures which will cause vaporization
of many materials. In turn, these vapors can react with the
heating elements, the insulation, or other materials you
have placed in the chamber. In many instances this
reaction is detrimental to operation.
2. Clean exterior surfaces with lightly dampened cloth
containing mild soap solution.
3. Occasionally check the electrical connections in the
control section. Repeated heating and cooling can cause
terminals to loosen.
4. The type B thermocouple used in this furnace is
matched to the temperature controller. It is possible that its
calibration can drift, particularly when operated near
the upper temperature limit, and especially in the
presence of contaminants. It is a good idea to inspect it
at regular intervals or when its accuracy is suspect.
5. Check the cooling fans at regular intervals to be sure
they are functioning properly and are not obstructed.
32
Probelm Solving Guide
The following pages are intended to help you resolve functional problems with your furnace.
Thermolyne is always available to assist you with problems. If this guide does not direct you to your specific
problem, call or write Barnstead/Thermolyne at (1-800-553-0039).
PROBLEM
Inaccurate temperatures.
Repeated element burn-out.
POSSIBLE CAUSES
CORRECTIVE ACTION
Contaminated themocouple.
Replace thermocouple.
Continuous operation
below 800°C.
Do not continuously
operate below 800°C.
Contact Barnstead/Thermolyne
Heating element
contamination.
“OR” displayed.
Slow heat-up.
Building or laboratory
main fuses blow or
circuit breakers trip.
CH. C, CH.. H, Err-r
displayed.
Open thermocouple.
Replace thermocouple.
Operating 240V furnace
on 208V supply.
Increase voltage to
proper level.
Furnace chamber overloaded.
Lighten load.
Fuses or breakers not
properly rated to
furnace electrical
requirements.
Install service line of sufficient
size to match furnace
electrical requirements. Contact
Barnstead|Thermolyne for
assistance.
Contact
Barnstead/Thermolyne
33
Maintenance and Servicing
WARNING
To avoid electrical shock, this furnace must always be disconnected from the electrical supply prior to
maintenance and servicing. Refer servicing to qualified personnel.
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 pre-existing 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 1-800-553-0039.
CAUTION
To avoid breakage of a replacement heating
element, be sure that the slot into which the
replacement heating element slides is free of all
debris so that the element goes in very easily.
Forcing an element into a slot, however slightly,
can result in its breakage.
34
MAINTENANCE AND SERVICING
To avoid premature burnout of a replacement heating
element, be sure that the insulation tail supplied with the
replacement element is inserted between the two legs of
the element as shown in the drawing. Also be sure that
the heating element projects sufficiently into the chamber. Insert element until welded portion (where large
diameter meets small diameter) projects approximately
1/4" into inside of furnace chamber.
To replace a heating element: (refer to Fig. 1A).
a. Remove top cover from heating chamber side of
furnace.
b. Remove the clips holding the connector cable (4) to
the defective heating element. Unwrap the connector
cable from the element.
c. Slide the heating element with element ceramic holder
attached upward, out of the slot in the insulation.
Save the blanket insulation for reuse.
d. Remove the element ceramic holder, noting its exact
position on the heating element.
e. Fasten the element ceramic holder on the new element in exactly the same position it was on the old
element.
f. Begin inserting the new element with element ceramic
holder attached into the slot in the insulation; stop
when there is just enough room left to insert the new
element insulation.
g. Continue sliding the element with the element insulation tail into the slot. DO NOT FORCE - even slight
pressure can fracture the heating element.
h. When the element ceramic holder is nearly seated
against the main insulation, check the top of the
element insulation tail. In its final position, the top
should be about 1/8 inch below the surface of the
main insulation.
i. Position the blanket insulation piece from step c in the
cavity over the insulation tail. Complete insertion of
35
MAINTENANCE AND SERVICING
the heating element until the element ceramic holder
rests on top the main insulation. Check the heating
element on the inside of the chamber. The large diameter
section of the element must be flush with or slightly
projecting from the surface of the insulation (if not,
reposition element ceramic holder). Carefully wrap the
connector cable around the element ends; fasten with
clips. Replace top cover.
To replace thermocouple:
a. Remove top cover from the heating chamber side of
furnace.
b. Loosen diagonal screw holding ceramic connection
block.
c. Lift connection block.
d. Loosen connection block screws holding thermocouple;
noting which side of block the side of the
thermocouplewith the colored bead is connected to.
e. Remove thermocouple.
f. Install new thermocouple with colored bead in same
position.
g. With thermocouple through the hole in the insulation,
replace block in its holder and retighten diagonal screw.
h. Turn furnace ON for a few minutes; check to be sure the
temperature displays upscale.
i. Replace cover.
36
Figure 1A Element Replacement
37
38
CONTROLLER, TEMPERATURE
CONTROLLER, CURRENT
CIRCUIT BREAKER
FAN
FAN
CONTACTOR, MECHANICAL
TRANSFORMER
THERMOCOUPLE
INDICATOR LAMP
CN1
CN2
CB1
B1
B2
K1
T1
TC1
DS1
DOOR SWITCH
SW1
FUSE AND FUSE HOLDER ARE
SUPPLIED WITH CURRENT CONTROLLER.
NOTES:
HEATING ELEMENT
HR6
HR1 to
DESCRIPTION
PART NO.
1
2
3
7
CONNECTOR
O
B
W
R
17
13
15
2
CONTROLLER
INTERNAL COMMUNICATION CABLE WIRING
DIAGRAM COMPONENT LIST
HR1
T1
HR2
240 VOLTS
208 VOLTS
K1
SW1
4
6
5
HR4
27
26
25
SERIES ELEMENTS
HR3
3
2
1
18
17
8
9
16
14
13
12
11
10
7
6
5
4
3
2
1
CN2
-
+
FUSE
CN1
HR5
33
32
31
30
29
28
HR6
DS1
RED
CB1
BLACK
B1
TC1
L1
B2
GND
L2
Wiring Diagram
Wiring DiagramWiring Diagram
F46110CM, F46118CM, F46120CM, F46128CM, F46120CM-75, F46128CM-75
CONTROLLER, TEMPERATURE
CONTROLLER, CURRENT
CIRCUIT BREAKER
FAN
FAN
CONTACTOR, MECHANICAL
TRANSFORMER
THERMOCOUPLE
INDICATOR LAMP
CN1
CN2
CB1
B1
B2
K1
T1
TC1
DS1
DOOR SWITCH
SW1
SUPPLIED WITH CURRENT CONTROLLER.
FUSE AND FUSE HOLDER ARE
NOTES:
HEATING ELEMENT
HR6
HR1 to
EMI LINE FILTER
DESCRIPTION
C
PART NO.
1
2
3
7
CONNECTOR
O
B
W
R
17
13
15
2
CONTROLLER
INTERNAL COMMUNICATION CABLE WIRING
DIAGRAM COMPONENT LIST
HR1
T1
HR2
208 VOLTS
240 VOLTS
K1
SW1
4
5
6
HR4
27
26
25
SERIES ELEMENTS
HR3
3
2
1
18
17
8
9
16
14
13
7
6
5
4
12
11
2
3
10
1
CN2
-
+
FUSE
CN1
HR5
33
32
31
30
29
28
HR6
DS1
RED
CB1
BLACK
B1
TC1
L1
C
B2
GND
L2
GND
WIRING DIAGRAM
Wiring DiagramWiring Diagram
F46110CM-33, F46120CM-33, F46120CM-33-75
39
40
CONTROLLER, CURRENT
CIRCUIT BREAKER
FAN
FAN
CONTACTOR, MECHANICAL
TRANSFORMER
THERMOCOUPLE
INDICATOR LAMP
CN2
CB1
B1
B2 & 3
K1
T1
TC1
DS1
SUPPLIED WITH CURRENT CONTROLLER.
FUSE AND FUSE HOLDER ARE
DOOR SWITCH
SW1
NOTES:
HEATING ELEMENT
HR8
HR1 to
CONTROLLER, TEMPERATURE
DESCRIPTION
CN1
PART NO.
1
2
3
7
CONNECTOR
O
B
W
R
17
13
15
2
CONTROLLER
INTERNAL COMMUNICATION CABLE WIRING
DIAGRAM COMPONENT LIST
HR1
T1
HR2
208 VOLTS
240 VOLTS
K1
SW1
6
5
4
HR4
18
17
16
14
13
12
11
10
SERIES ELEMENTS
HR3
3
2
1
9
8
7
6
5
4
3
2
1
27
26
25
CN2
-
+
CN1
HR5
33
32
31
30
29
28
HR6
FUSE
RED
BLACK
HR7
DS1
CB1
TC1
HR8
B1
B2
L1
GND
B3
L2
WIRING DIAGRAM
Wiring Diagram Wiring Diagram
F46230CM, F46238CM, F46240CM, F46248CM, F46240CM-75, F46248CM-75
CONTROLLER, TEMPERATURE
CONTROLLER, CURRENT
CIRCUIT BREAKER
FAN
FAN
CONTACTOR, MECHANICAL
TRANSFORMER
THERMOCOUPLE
INDICATOR LAMP
CN1
CN2
CB1
B1
B2 & 3
K1
T1
TC1
DS1
SUPPLIED WITH CURRENT CONTROLLER.
FUSE AND FUSE HOLDER ARE
DOOR SWITCH
SW1
NOTES:
HEATING ELEMENT
HR8
HR1 to
EMI LINE FILTER
DESCRIPTION
C
PART NO.
1
2
3
7
CONNECTOR
O
B
W
R
17
13
15
2
CONTROLLER
INTERNAL COMMUNICATION CABLE WIRING
DIAGRAM COMPONENT LIST
HR1
T1
HR2
208 VOLTS
240 VOLTS
K1
SW1
6
5
4
HR4
18
17
16
14
13
12
11
10
SERIES ELEMENTS
HR3
3
2
1
9
8
7
6
5
4
3
2
1
27
26
25
CN2
-
+
CN1
HR5
33
32
31
30
29
28
HR6
FUSE
RED
BLACK
HR7
DS1
CB1
TC1
HR8
B1
B2
L1
C
GND
B3
L2
GND
WIRING DIAGRAM
Wiring Diagram Wiring Diagram
F46230CM-33, F46240CM-33, F46240CM-33-75
41
Replacement Parts List
Description
(Chamber)
Circuit breaker switch
Connector cable 30" long
Connector cable 36" long
Current controller
Elements
Element ceramic holder
Element connector clips
Element connector cable 4" lg
Element connector cable 10" Ig
Element connector cable 14" lg
Element connector cable 19" lg
Element Insulation tail
Fans
Fuse, Thyristor, Fast Blow, 250V, 45 Amp
Fuse Holder
Hearth Plate
Injection Port w/plug
Insulation - door
Insulation Kit - chamber
Multi-programmable control
(8 ramp & 8 dwell, 15 programs, -75 models)
Relay
Temperature Control Automatic
Temperature Control Programmable
(8 ramp and 8 dwell 4 program)
Thermocouple
Thermocouple terminal block
Transformer
SERIES 1077
Small (Models)
(6"X6"X6")
SWX54
CE557X1 (2 req’d)
CNX125
EL461X1 (6 req’d)
HRX2 (6 req’d)
CEX135 (12 req’d)
CE461X1 (4 req’d)
CE461X3
JN461X8 (6 req’d)
FAX7 (2 req’d)
FZX42
FZX62
PH461X1
JC633x1
& JC633X2 (plug)
JN461X3
JN461X9A
CN71X46
(F46120CM-75,
F46120CM-33-75,
F46128CM-75)
RYX62
CN71X59
(F46110CM,
F46110CM-33,
F46118CM)
CN71X59
(F46120CM,
F46120CM-33,
F46128CM)
TCX5
TRX137
TNX79
SERIES 1078
Large (Models)
(10"X10"X10")
SWX54
CE557X1 (1 req’d)
CE558X1 (1 req’d)
CNX125
EL462X1 (8 req’d)
HRX2 (8 req’d)
CEX135 (16 req’d)
CE461X1 (6 req’d)
CE462X1
CE462X2
JN461X8 (8 req’d)
FAX7 (3 req’d)
FZX42
FZX62
PH462X1
JC633x1
& JC633X2 (plug)
JN462X4
JN462X7A
CN71X46
(F46240CM-75,
F46240CM-33-75,
F46248CM-75)
RYX62
CN71X59
(F46230CM,
F46230CM-33,
F46238CM)
CN71X59
(F46240CM,
F46240CM-33,
F46248CM)
TCX5
TRX137
TNX80
NOTE: Service on control units - contact Barnstead/Thermolyne Corp (1-800-553-0039).
42
Ordering Procedures
WARNING
Replace fuses with the same type and rating.
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 319-5562241 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 a
RGA number will be refused.
43
Material Safety Data Sheet
Thermal Ceramics
Material Safety Data Sheet
Date Revised:
7/2/91
PRODUCT IDENTIFICATION
Trade Name(s):
Generic Name:
Chemical Name:
Manufacturer:
Address:
City:
CERAFIBER
REFRACTORY CERAMIC FIBER INSULATION
ALUMINA SILICA
Thermal Ceramics
P.0. BOX 923, 2102 Old Savannah Road
Augusta
State:
Georgia
Zip: 30903
CAS #:
Formula:
Telephone:
65997-17-3
MIXTURE
(404) 796-4200
PRODUCT INGREDIENTS
INGREDIENT NAME
REFRACTORY CERAMIC FIBER
CAS NUMBER
%
PEL and TLV (except as noted)
65997-17-3
100
EXPOSURE GUIDELINE
5mg/M- NUISANCE RESPIRABLE - OSHA
1 FIBER/CC
10mg/M- NUISANCE TOTAL - ACGIH
CRYSTALLINE SILICA (CRISTOBALITE) WILL FORM “AFTER SERVICE” AT TEMPERATURES >1000°C.
14464-46-1
>20
0.05 mg/M- OSHA Respirable Dust
PHYSICAL DATA
Appearance and Odor:
Boiling Point:
Vapor Pressure:
Water Solubility (%):
Vapor Density (Air= l):
WHITE FIBER-NO ODOR.
NA
NA
NIL
NA
Evaporation Rate (NA = 1):
Specific Gravity (water = 1 ):
Melting Point:
% Volatile by Volume:
NA
2.6
>3000°F
0
FIRE AND EXPLOSION DATA
Flash Point (Method):
NONFLAMMABLE
NFPA Flammable/Combustible Liquid Classification:
NA Flammable Limits: LEL: NA %
UEL:
NA %
Auto-Ignition Temperature:
NA
HEALTH HAZARDS
Summary/Risks
Summary: EXPOSURE TO DUST FROM THIS PRODUCT SHOULD BE MINIMIZED. ANIMAL INHALATION AND ARTIFICIAL IMPLANTATION STUDIES HAVE REPORTED THE DEVELOPMENT OF TUMORS. BASED ON PRELIMINARY RESULTS, A NOTICE OF
SUBSTANTIAL RISK HAS BEEN FILED WITH THE EPA ACCORDING TO SECTION 8(e) OF THE TOXIC SUBSTANCES CONTROL
ACT. BASED ON ANIMAL STUDIES, IARC HAS CLASSIFIED RCF AS POSSIBLY CARCINOGENIC FOR HUMANS (2B). DATA
FROM HUMAN EPIDEMIOLOGICAL STUDIES IS INSUFFICIENT. THIS SUBSTANCE OR MIXTURE HAS NOT BEEN CLASSIFIED
A CARCINOGEN BY NTP OR OSHA.
Medical conditions which may be aggravated: AS WITH ANY DUST, PRE-EXISTING UPPER RESPIRATORY AND LUNG DISEASES
44
MATERIAL SAFETY DATA SHEET
MAY BE AGGRAVATED.
Target Organ(s): LUNGS, SKIN AND EYES .
Acute Health Effects: PRODUCT IS A MECHANICAL IRRITANT TO SKIN, EYES AND UPPER RESPIRATORY SYSTEM.
Chronic Health Effects: EXCESSIVE EXPOSURE TO RCF DUSTS AND AFTER SERVICE FIBERS MAY CAUSE LUNG DAMAGE (FIBROSIS). IARC STATES THERE IS SUFFICIENT EVIDENCE IN ANIMALS AND LIMITED EVIDENCE IN HUMANS TO CLASSIFY
CRYSTALLINE SILICA AS A PROBABLE CARCINOGEN (2A) AND RCF AS A POSSIBLE CARCINOGEN (2B).
Primary Entry Route(s): INHALATION, SKIN AND EYE CONTACT.
Signs/Symptoms of Overexposure
Inhalation: IRRITATION OR SORENESS IN THROAT & NOSE. IN EXTREME EXPOSURES SOME CONGESTION MAY OCCUR.
Skin Contact: TEMPORARY IRRITATION OR RASH.
Skin Absorption: NA
Ingestion: NOT HAZARDOUS WHEN INGESTED. MAY CAUSE TEMPORARY IRRITATION TO GI TRACT.
Eyes: TEMPORARY IRRITATION OR INFLAMMATION
First Aid/Emergency Procedures
Inhalation: REMOVE TO FRESH AIR. DRINK WATER TO CLEAR THROAT AND BLOW NOSE TO EVACUATE FIBERS.
Skin Contact: WASH AFFECTED AREAS GENTLY WITH SOAP AND WARM WATER.
Skin Absorption: NA
Ingestion: NA
Eyes: FLUSH EYES WITH COPIOUS QUANTITIES OF WATER. IF IRRITATION PERSISTS CONSULT A PHYSICIAN.
REACTIVITY DATA
MATERIAL IS STABLE.
Chemical Incompatibilities: HYDROFLUORIC ACID
Conditions to Avoid: NONE IN DESIGNED USE.
Hazardous Decomposition Products: NONE
HAZARDOUS POLYMERIZATION CANNOT OCCUR.
SPILL OR LEAK PROCEDURES
Procedures for Spill/Leak: VACUUM CLEAN DUST WITH EQUIPMENT FITTED WITH HEPA FILTER. IF SWEEPING IS NECESSARY
USE A DUST SUPPRESSANT.
Waste Management: WASTES ARE NOT HAZARDOUS AS DEFINED BY RCRA (40 CFR PART 261 ) . COMPLY WITH FEDERAL,
STATE & LOCAL REGULATIONS. METHOD OF DISPOSAL - LANDFILL. RQ - N/A.
SPECIAL PROTECTION INFORMATION
Goggles: GOGGLES OR SAFETY GLASSES WITH SIDE SHIELDS ARE RECOMMENDED.
Gloves: GLOVES ARE RECOMMENDED.
Respirator: <1 F/CC, USE 3M 9900; <10 F/CC, USE MSA COMFO II WITH H FILTER; <50 F/CC, USE MSA ULTRA-TWIN H FILTER; OR
EQUIVALENTS. SEE SECTION IX-OTHER.
Ventilation: USE SUFFICIENT NATURAL OR MECHANICAL VENTILATION TO KEEP DUST LEVEL TO BELOW PEL/TLV/WEG (WORKPLACE EXPOSURE GUIDELINE) USE DUST COLLECTION WHEN TEARING OUT.
Other: WEAR LOOSE FITTING, LONG SLEEVED CLOTHING. WASH EXPOSED AREAS WITH SOAP & WARM WATER AFTER HANDLING. WASH WORK CLOTHES SEPARATELY FROM OTHER CLOTHING; RINSE WASHER THOROUGHLY.
Special Considerations for repair/maintenance of contaminated equipment: CRISTOBALITE RESPIRATOR: <10X PEL, USE 3M
9900; <100X PEL, USE MSA ULTRA-TWIN H FILTER; OR EQUIV. SEE SEC IX-OTHER.
45
MATERIAL SAFETY DATA SHEET
SPECIAL PRECAUTIONS
*** ALWAYS SEGREGATE MATERIALS BY MAJOR HAZARD CLASS ***
THIS PRODUCT CONTAINS A CHEMICAL KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER.
Storage Segregation Hazard Classes: IRRITANT
Special Handling/Storage: KEEP MATERIAL DRY.
Special Workplace Engineering Controls: ADEQUATE VENTILATION TO KEEP DUST LEVEL TO BELOW PEL/TLV/WEG (WORKPLACE
EXPOSURE GUIDELINE).
Other: ADDITIONAL INFORMATION ON THE HEALTH AND SAFETY ASPECTS OF REFRACTORY CERAMIC FIBERS IS AVAILABLE.
† Copyright© 1980, National Fire Protection Assoc., Quincy, MA 02269. This reprinted material is not the complete and official position of
the NFPA on the referenced subject, which is represented only by the standard in its entirety.
MSSM/226-21:26/00030
As of the date of preparation of this document, the foregoing information is believed to be accurate and is provided in good faith to comply
with applicable federal and state law(s). However, no warranty or representation with respect to such information is intended or given.
MSDS/MSD3 FORM REV. 7/2/91
46
One 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 one (1) year, the parts, necessary to
remedy any such defect. Outside the continental United States and Canada, the warranty
provides, for one (1) year, 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. 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 or writing to:
Barnstead|Thermolyne
P.O. Box 797
2555 Kerper Boulevard
Dubuque, IA 52004-0797
USA
FAX: (319) 556-0695
Barnstead|Thermolyne’s sole obligation with respect to its product shall be to repair
or 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.
Special Two Warranty on Control Module
There are no other warranties, expressed or implied, made in connection with the sales
of this product. Barnstead|Thermolyne expressly disclaims any implied warranty of merchantability or fitness for specific use.
47
Barnstead Thermolyne
2555 Kerper Blvd.
P.O. Box 797
Dubuque, IA 52004-0797 USA
PHONE: 319-556-2241 • 800-553-0039
FAX: 319-556-0695
Web Address: http://www.barnsteadthermolyne.com
48
a subsidiary of
ISO
9001
REGISTERED
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