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Type 30400Thermolyne Furnace
OPERATION MANUALAND PARTS LIST
Series 1262
Single Setpoint Models F30420C, F30420C-33, F30428C
8 Segment Programmable F30420C-33-80, F30420-33-60-80Models with
OTP F30420C-60-80, F30420C-80
F30428C-60-80, F30428C-80
4 X 16 Segment F30430CM, F30430CM-33,Programmable Models
F30430CM-33-60, F30430CM-60with OTP F30438CM, F30438CM-60
LT1262X1 10/8/04
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IMPORTANT INFORMATIONThis manual contains important operating
and safety information. You must carefully read and understand the
contents of this manual prior to the use of this equipment.
Safety Information
..............................................................................................................................................4
Alert
Signals..................................................................................................................................................4
Warnings
......................................................................................................................................................4
General Specifications
........................................................................................................................................6
Environmental Conditions
............................................................................................................................6
Declaration of Conformity
............................................................................................................................7
Introduction..........................................................................................................................................................8
Intended Use
................................................................................................................................................8General
Usage..............................................................................................................................................8
Principles of Operation
................................................................................................................................9
Unpacking
........................................................................................................................................................10
Installation
........................................................................................................................................................11
Site Selection
..............................................................................................................................................11Electrical
Connections
................................................................................................................................11
Operation, All Models
........................................................................................................................................12Power
Switch
..............................................................................................................................................12Cycle
Light
..................................................................................................................................................12Door
Safety Switch
....................................................................................................................................12
Single Setpoint Models with OTP
....................................................................................................................13Basic
Operation
..........................................................................................................................................13Buttons
and Indicators
................................................................................................................................13To
View or Change the Setpoint
................................................................................................................14To
View the Display Units
..........................................................................................................................14To
View the % Output
Power......................................................................................................................14Controller
Parameters
................................................................................................................................14Alarms
........................................................................................................................................................15Sensor
Break Protection
............................................................................................................................16Over
Temperature Protection (OTP)
..........................................................................................................16Tuning
........................................................................................................................................................17
Single Ramp and Dwell
....................................................................................................................................18Functions
....................................................................................................................................................18Program
Overview
......................................................................................................................................18Program
Setup............................................................................................................................................19Running
the
Program..................................................................................................................................20Stopping
the Program
................................................................................................................................20Clearing
the Flashing End
..........................................................................................................................20Switching
from Manual Mode to Automatic Mode
......................................................................................20Verifying
a Running
Program......................................................................................................................20
8 Segment & 4x16 Segment Programmable Models
w/OTP............................................................................21Basic
Operation
..........................................................................................................................................21To
Change the Setpoint
..............................................................................................................................21To
View the Display Units
..........................................................................................................................22To
View the % Output
Power......................................................................................................................22Buttons
and Indicators
................................................................................................................................22Controller
Parameters
................................................................................................................................23Alarms
........................................................................................................................................................26
2
Table of Contents
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Sensor Break Protection
............................................................................................................................26Over
Temperature
Protection......................................................................................................................27To
Operate the Controller as a Single Setpoint Controller
........................................................................27Programming
Controller..............................................................................................................................27Creating
a New Program or Editing an Existing
Program..........................................................................28Setting
the Target Setpoint
........................................................................................................................28Running
a Program
....................................................................................................................................34Holding
a
Program......................................................................................................................................35Cancelling
a Program
................................................................................................................................35Tuning
Your Furnace
..................................................................................................................................35Gain
Scheduling
........................................................................................................................................36
Installation and Operation of Air Control
..........................................................................................................38Installation
..................................................................................................................................................38
Furnace Loading
..............................................................................................................................................39
Preventative Maintenance
................................................................................................................................40
General Cleaning Instructions
....................................................................................................................40
Problem Solving
................................................................................................................................................41
Maintenance and Servicing
..............................................................................................................................44
Warning
......................................................................................................................................................44
To Replace a Heating Element
..................................................................................................................44
To Replace a Platinel II Thermocouple
......................................................................................................45
To Replace Solid State Relay
....................................................................................................................46
To Replace Door Switch (Microswitch)
......................................................................................................46
To Realign Door Strike
......................................................................................................................................47
To Replace Control Module
..............................................................................................................................48
Replacement Parts List
....................................................................................................................................49
Ordering Procedures
........................................................................................................................................51Wiring
DIagrams................................................................................................................................................52
Two Year Limited Warranty
..............................................................................................................................56
3
TABLE OF CONTENTS
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Your Barnstead Thermolyne furnace has been designedwith
function, reliability and safety in mind. It is your
re-sponsibility to install it in conformance with local
electricalcodes. For safe operation, please pay attention to
thealert signals throughout the manual.
To avoid electrical shock, this furnace must:1. Use a properly
grounded electrical outlet of cor-
rect voltage and current handling capacity.
2. Disconnect from the power supply prior to main-tenance and
servicing.
3. Have the door switch operating properly.
To avoid burns, this furnace must:1. Not be touched on the
exterior or interior sur-
faces during use or for a period of time afteruse.
To avoid personal injury:1. Do not use in the presence of
flammable or
combustible materials; fire or explosion mayresult. This device
contains components whichmay ignite such material.
2. Refer servicing to qualified personnel.
WarningPlease note the following WARNINGS:
This warning is presented for compliance with
CaliforniaProposition 65 and other regulatory agencies and
onlyapplies to the insulation in this product. This product
contains refractory ceramic, refractory ceramic fiber orfiberglass
insulation, which can produce respirable dust orfibers during
disassembly. Dust or fibers can cause irritation and can aggravate
preexisting respiratory diseases. Refractory ceramic and refractory
ceramicfibers (after reaching 1000C) contain crystalline
silica,which can cause lung damage (silicosis). The Internation-al
Agency for Research on Cancer (IARC) has classifiedrefractory
ceramic fiber and fiberglass as possibly
4
Safety Information
Hot SurfaceHot surfaces alert you to a possibility of personal
injury if youcome in contact with a surface duringuse or for a
period of time after use.
CautionCautions alert you to a possibility ofdamage to the
equipment.
WarningWarnings alert you to a possibility ofpersonal
injury.
NoteNotes alert you to pertinent facts andconditions.
Alert Signals
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carcinogenic (Group 2B), and crystalline silica as carcino-genic
to humans (Group 1).
The insulating materials can be located in the door, thehearth
collar, in the chamber of the product or under thehot plate top.
Tests performed by the manufacturer indi-cate that there is no risk
of exposure to dust or respirablefibers resulting from operation of
this product under nor-mal conditions. However, there may be a risk
of exposureto respirable dust or fibers when repairing or
maintainingthe insulating materials, or when otherwise
disturbingthem in a manner which causes release of dust or
fibers.By using proper handling procedures and protectiveequipment
you can work safely with these insulatingmaterials and minimize any
exposure. Refer to the appro-priate Material Safety Data Sheets
(MSDS) for informa-tion regarding proper handling and recommended
protec-tive equipment. For additional MSDS copies, or
additionalinformation concerning the handling of refractory
ceramicproducts, please contact the Customer ServiceDepartment at
Barnstead International(1-800-553-0039).
5
SAFETY INFORMATION
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Models F30420C, (-33), F30428C, (-60-80)(-33-60-80), (-33-80),
& (-80)(-60-80) & (-80) F30438CM & (-60)F30430CM,
(-33),(-33-60) & (-60)
Overall Dimensions Width 21 1/2 (55) 21 1/2 (55)IN. (CM) Height
29 1/2 (75) 29 1/2 (75)
Depth 25 1/2 (65) 25 1/2 (65)
Chamber Dimensions Width 14 (35) 14 (35)IN. (CM Height 14 (35)
14 (35)
Depth 14 5/8 (37) 14 5/8 (37)
Weight Lbs. (KG) 188 (86) 188 (86)
Electrical Ratings Volts 240 208Amps 22.9 26.4Watts 5500
5500Freq. 50/60 50/60Phase 1 1
Temperature Ratings Cont. 400F-1800F* 400F-1800F*F (C)
(204C)-(982C) (204C)-(982C)
Intermittent 1800F-2000F 1800F-2000F(982C)-(1093C)
(982C)-(1093C)
* The maximum continuous temperature for ashing furnaces (-60
models) is 1787F (975C).
Environmental Conditions Operating: 17C - 27C; 20% to 80%
relative humidity, non-condensing. Installation Category II
(over-voltage) in accordance with IEC 664. Pollution Degree 2 in
accordance with IEC 664. Altitude limit: 2,000 meters.Storage: -25C
to 65C; ; 10% to 85% relative humidity.
6
General Specifications
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Declaration of Conformity (for 230 volt CE models only)Barnstead
International hereby declares under its sole responsibility that
this product conforms with the tech-nical requirements of the
following standards:
EMC: EN 61000-3-2 Limits for harmonic current emissionsEN
61000-3-3 Limits for voltage fluctuations and flickerEN 61326-1
Electrical equipment for measurement, control, and laboratory use;
Part I:
Generic Requirements
Safety: EN 61010-1 Safety requirements for electrical equipment
for measurement, control, and laboratory use; Part I: General
Requirements
EN 61010-2-010 Part II: Particular requirements for laboratory
equipment for the heating of materials
per the provisions of the Electromagnetic Compatibility
Directive 89/336/EEC, as amended by 92/31/EEC and93/68/EEC, and per
the provisions of the Low Voltage Directive 73/23/EEC, as amended
by 93/68/EEC.
The authorized representative located within the European
Community is:
Electrothermal Engineering, Ltd.419 Sutton RoadSouthend On
SeaEssex SS2 5PHUnited Kingdom
Copies of the Declaration of Conformity are available upon
request.
7
GENERAL SPECIFICATIONS
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Intended Use1. The Type 30400 Automatic and Programmable
furnaces are general laboratory and heat treat-ing furnaces. For
optimum element life,Barnstead Thermolyne recommends these
fur-naces for applications requiring temperaturesfrom 400F (204C)
to 1800F (982C) for con-tinuous use, or temperatures from
1800F(982C) to 2000F (1093C) for intermittent use.Continuous use is
operating the furnace formore than 3 hours and intermittent use is
oper-ating the furnace for less than 3 hours.
2. The unit consists of 1) a heating chamber; 2) anautomatic
proportioning digital set, digital readcontrol with overtemperature
protection and 3) adoor interlock relay for user safety.
3. The Type 30400 Programmable furnace isdesigned to control a
programmed temperatureprofile. The profile is in the format of
ramps anddwell segments. The first ramp, RAMP 1, startsat the
initial measured furnace temperature. Thisramp is positive going at
a programmed rateuntil the programmed level is reached. The
set-point will stay at this level for a period deter-mined by the
setting of DWELL 1. Additionalpositive or negative going ramps are
now initiat-ed starting at the level at the end of DWELL 1.When the
second ramp reaches the second pro-grammed level, the setpoint
stays at that levelfor the duration of the segment. Dependingupon
the model ordered, additional ramp anddwell segments may be added.
See specificmodel number in proceeding chart for total num-ber of
program segments.
4. The Type 30400 Automatic furnace is designedas a single set
point controller which reachesand maintains one temperature
value.
General UsageDo not use this product for anything other than its
intend-ed usage.
8
Introduction
NoteWhen in the program RUN mode, theprogrammable controller
serves to pro-vide a programmed temperature pro-file as described
earlier. When in thesingle setpoint automatic mode, theunit serves
as an automatic tempera-ture controller.
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9INTRODUCTION
Principles of Operation1. Furnace: The furnace chamber is heated
by four
electric resistance heaters which are embedded in arefractory
material. The chamber is insulated with aceramic fiber insulation.
The temperature is con-trolled by an automatic proportioning
controller usinga platinel thermocouple to feed back information.
Thecontrol is located under the furnace chamber and iswell
insulated from the heat generated in the furnacechamber. The
temperature is controlled by one ofthree types of controllers.
MODEL NUMBER DIGITAL COMMUM. TOTAL NUMBER OF NUMBER
OFPROGRAMMABLE STORED
SEGMENTS PROGRAMSF30420C-33-80 NO 8F30420-33-60-80 NO
8F30420C-60-80 NO 8F30420C-80 NO 8F30428C-60-80 NO 8F30428C-80 NO
8F30430CM YES 64 16 Segment ProgramsF30430CM-33 YES 64 16 Segment
ProgramsF30430CM-33-60 YES 64 16 Segment ProgramsF30430CM-60 YES 64
16 Segment ProgramsF30438CM YES 64 16 Segment ProgramsF30438CM-60
YES 64 16 Segment Programs
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10
1. Visually check for any physical damage to theshipping
container.
2. Inspect the equipment surfaces that are adja-cent to any
damaged area.
3. Open the furnace door and remove the packingmaterial from
inside the furnace chamber.
4. Vacuum the chamber prior to use to remove theinsulation dust
due to shipment.
5. Retain the original packaging material if reship-ment is
foreseen or required.
Unpacking
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11
Installation
CautionBe sure ambient temperature does notexceed 40C (104F).
The recommendedambient temperature is 17C - 27C.Ambients above this
level may result indamage to the controller.
WarningTo avoid electrical shock, this furnacemust always use a
properly groundedoutlet of correct voltage and current han-dling
capacity.
CautionAllow at least six inches of spacebetween the furnace and
any combustiblesurface. This permits the heat from thefurnace case
to escape so as not to cre-ate a possible fire hazard.
Site SelectionInstall furnace on a sturdy surface and allow
adequatespace for ventilation.
Electrical ConnectionsThe electrical ratings are located on the
specificationplate on the back of the furnace.
ConsultBarnstead/Thermolyne if your electrical service is
dif-ferent than those listed on the specification plate. Besure the
front power switch is in the OFF positionbefore connecting the
furnace to your electrical supply.
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12
Operation, All Models
WarningTo avoid personal injury do not use in thepresence of
flammable or combustiblechemicals; fire or explosion may
result.This device contains components whichmay ignite such
materials.
Hot SurfaceCaution: Avoid Contact. To avoid burns,this furnace
must not be touched on theexterior or interior surfaces during use
orfor a period of time after use.
WarningTo avoid electrical shock, the door safetyswitch must be
operating properly.
WarningAlways wear safety glasses or a safetyshield and high
temperature gloves whenloading or unloading the furnace.
Longsleeved, fire retardant clothing and a fireretardant apron is
also recommended.
Power SwitchBoth the ON/OFF power switch and the digital
displaywill illuminate when power is switched ON. The furnacewill
begin to heat to its controller's current setpoint.(See the
instructions for your type of controller for infor-mation on
checking and setting the setpoint.)
Cycle LightThe amber cycle light will illuminate whenever
thepower is being applied to the heating elements. Thecycle light
will turn on and off as the furnace reachesthe setpoint.
Door Safety SwitchThe door safety switch removes power from the
heat-ing elements when the door is opened. Open andclose the door a
few times; note that the amberCYCLE light will switch off when the
door is opened. Ifthis condition is not true, consult the
Troubleshootingsection before proceeding. This check must be
donewhen the furnace is heating and the cycle light is
illumi-nated.
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13
Single Setpoint Models
Output 1
Manual
UP ARROW Button
Temperature Display
Display Window
DOWN ARROWButton
PAGE Button
SCROLLButton
Output 2
MAN
Single Setpoint Models w/OTP
NoteIf at any time you want to return to theHOME DISPLAY,
simultaneously pressthe PAGE and SCROLL buttons.
The single setpoint model w/ OTP furnace controlleris a single
setpoint controller which provides a singledigital display to
indicate the current chamber tempera-ture or setpoint temperature.
This temperature con-troller features sensor break protection,
self-tuningcapability and over temperature protection (OTP) withan
additional OTP relay device.
Basic OperationWhen the controller is turned ON it will perform
a shortself-test and then display the measured value (processvalue)
in the HOME DISPLAY.
Buttons and IndicatorsOP1 (Output 1): Illuminates when the logic
output isON.
OP2 (Output 2): Illuminates when the relay output isON (will go
out during an alarm situation).
PAGE button: Allows you to select a new list ofparameters.
SCROLL button: Allows you to select a parameterwithin a list of
parameters.
DOWN button: Allows you to decrease a value.
UP button: Allows you to increase a value.
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14
SINGLE SETPOINT MODELS W/OTP
To View or Change the SetpointTo view the setpoint, press and
release the UP or DOWNbuttons. If you want to change the setpoint,
continue press-ing until the desired setpoint value is displayed
and thenrelease the button. A few seconds after the button
isreleased, the controller will accept the new value and revertto
the HOME DISPLAY.
To View the Display UnitsFrom the HOME DISPLAY press the SCROLL
button. Thedisplay will show the temperature units in C/F/K and
thenreturn to the HOME DISPLAY. (Call Customer Service if
yourequire a different temperature unit.)
To View the % Output PowerFrom the HOME DISPLAY press the SCROLL
button twice.Press and release the UP or DOWN button to view the
%output power. This value is a read-only value and cannot
bechanged.
Controller Parameters
Home displayC: Temperature units in Celsius. Temperature units
can notbe changed without entering the configuration.
ContactCustomer Service if a different temperature unit is
required.
OP: % output power demand.
IdHi: Deviation high alarm.
Al ListIdHi: Deviation high alarm.
Atun ListtunE: One-shot autotune enable.
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15
SINGLE SETPOINT MODELS W/OTP
NoteThe following alarm messages arefactory default settings and
may varyif you have changed the configurationof your
controller:
IDHi: = 50C2FSH = 1118C
Pid ListPb: Proportional band (in display units).
ti: Integral time in seconds.
td: Derivative time in seconds.
ACCS List Code: Access code (Code needed to enter orchange the
other configuration parameters which are notnormally accessible.)
Not accessable.
AlarmsThe controller will flash an alarm message in the
homedisplay if an alarm condition is detected.
2FSH: Measured value full scale high alarm.
IdHi: Measured value deviation high alarm.
S.br: Sensor break: check that sensor is connected
cor-rectly.
L.br: Loop break: check that the heating circuits are work-ing
properly.
Ld.F: Heater Circuit fault: indication of either an open orshort
solid sate relay, a blown fuse, missing supply oropen circuit
heater.
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16
Sensor Break ProtectionThis controller provides sensor break
protection in theevent the thermocouple opens. If an open
thermocou-ple condition occurs, the digital display will blink
S.brand the power to the heating element will be shut OFF(Cycle
light will extinguish).
Over-Temperature Protection(OTP)The OTP will be in effect during
any alarm conditionwhen the temperature of the furnace has
deviatedbeyond the limit. The Deviation High alarm is the onlyalarm
value which can be changed. To change it, pressthe SCROLL button
until IdHi appears on the display.Press the UP or DOWN button to
select the OTP valueyou desire. We recommend a value of 20 above
yourworking temperature to provide protection for yourworkload.
In addition to over-temperature protection, units con-taining a
single setpoint controller w/OTP feature amechanical OTP relay
device which disconnects powerfrom the elements in an alarm
condition (only in fur-naces with OTP relay). See models listed on
frontpage.
SINGLE SETPOINT MODELS W/OTP
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17
NoteFurnace must be at ambient temperature before starting a
tune.
NoteTune has completed when tunEstops flashing on display.
SINGLE SETPOINT MODELS W/OTP
TuningThis controller incorporates a self-tuning feature
whichdetermines the optimum control parameters for thebest
temperature accuracy with your load and setpoint.Use this feature
the first time you use your furnace andeach time you change either
your setpoint or the typeof load you are heating.
Barnstead|Thermolyne recom-mends you use this feature to provide
the best temper-ature accuracy the controller can attain. To use
the tun-ing feature:
1. Adjust the setpoint to your desired value.
2. Press the PAGE button until display reads,Atun.
3. Press the SCROLL button. Display will read,tunE.
4. Press the UP or DOWN button to select, on.
5. Simultaneously press the PAGE andSCROLL buttons to return to
the HOME DIS-PLAY. The display will alternately flashbetween tunE
and the HOME DISPLAYwhile tuning is in progress.
6. The controller will then turn the heating onand off to induce
an oscillation. When themeasured value reaches the required
setpointthe first cycle will end.
7. Tuning will be complete after two oscillationcycles and then
the tuner will turn itself off.
8. Normal control function will resume after thecontroller
calculates tuning parameters.
NoteStat and Sp.rr in Sp list must beset to OFF or tunE will not
initiate.
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18
Single Ramp & DwellNoteThese instructions are used with the
Single Setpoint models with OTP only(See models listed on front
page).
FunctionsThis type of controller has single ramp and dwell
program-ming capabilities. The Ramp and Dwell can be configuredto
five different modes.
1. Mode 1 (Opt. 1) is a Ramp (if needed) to theSetpoint
temperature, a Dwell, and then a cooldown.
2. Mode 2 (Opt. 2) is the same as mode 1, exceptthe controller
continues to heat at the Setpointafter the Dwell has completed.
(This mode doesnot cool down.)
3. Mode 3 (Opt. 3) is the same as mode 1, exceptthe Dwell time
includes the Ramp (if needed).
4. Mode 4 (Opt. 4) is the same as mode 2, exceptthe Dwell time
includes the Ramp (if needed).
5. Mode 5 (Opt. 5) is a Dwell (delay time) before thecontroller
Ramps (if needed) to the Setpoint tem-perature.
Program Overview A program mode can be set by changing the
tm.OP variable to Opt. 1, Opt. 2, Opt. 3, Opt. 4,or Opt. 5.
A Ramp rate may be set by changing the SPrrvariable to a value.
The Ramp rate units are indegrees per minute.
The Dwell time can be set by changing thedwEll variable to the
desired value. Dwell timeunits are in minutes.
The program Status can be set by changing theStAt variable to
run or oFF. This variable willstart or stop the program.
Mode 1 (Opt. 1)
Mode 2 (Opt. 2)
Mode 3 (Opt. 3)
Mode 4 (Opt. 4)
Mode 5 (Opt. 5)
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19
SINGLE RAMP & DWELL CONTROLLER
NoteThe program must be stopped andthe controller must be
displaying theactual temperature before beginningthe Setup.
Program Setup1. Press the PAGE button until the SP is
displayed.
2. Press the SCROLL button once, SPrr (Ramp Rate)will be
displayed, set the desired Ramp rate with theUP or DOWN buttons, if
the ramp to setpoint feature isneeded. If the Ramp rate is not
needed, then set toOFF with the UP or DOWN buttons.
3. Press the SCROLL button once, tm.OP (Ramp &Dwell mode)
will be displayed, select the desiredmode with the UP or DOWN
buttons. (Opt. 1, Opt. 2,Opt. 3, Opt. 4, Opt. 5)
4. Press the SCROLL button once, dwEll will be dis-played, set
the desired Dwell time with the UP orDOWN buttons. (Dwell in
minutes.)
5. Press the PAGE button until the Actual temperature
isdisplayed.
Running the Program1. Press the SCROLL button until StAt is
displayed, set
to run with the UP or DOWN buttons.
2. Press the PAGE button to display Actual temperature.
Stopping the ProgramPress the SCROLL button until StAt is
displayed, set to oFFwith the UP or DOWN buttons.
Clearing the Flashing EndPress the PAGE and SCROLL buttons at
the same time.
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20
Verifying a Running ProgramPress the SCROLL button until StAt is
displayed.The display will show run if the program is running,
oroFF if it is not running. Press the PAGE button to dis-play
Actual temperature.
SINGLE RAMP & DWELL CONTROLLER
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21
8 Segment & 4x16 SegmentProgrammable Models w/OTP
Output 1
PAGE Button
AUTO/MAN Button
Display Window
Upper Display
Lower Display
RUN/HOLD Button
UP ARROW Button
DOWN ARROWButton
SCROLLButton
NoteThe controller will return to the HOMEDISPLAY if left idle
for more than a fewseconds.
NoteOnce the desired parameter has beenselected, depressing
either the UP orDOWN button will change the parametervalue. In all
cases, the value shown onthe display is the current working value
ofthat parameter.
4x16 & 8 Segment Programmable Models with OTP
The 8 segment programmable controller consists ofa
microprocessor based three-mode PID(Proportional, Integral,
Derivative), programmabletemperature controller with
over-temperature protec-tion and appropriate output switching
devices to con-trol the furnace. The digital readout continuously
dis-plays chamber (upper display) and setpoint (lowerdisplay)
temperatures unless the SCROLL or PAGEbutton is depressed. The
programmable controller canbe used as a single setpoint controller
or as a pro-grammable controller. The 8 segment digital
modelenables eight segments of programming.
The 4x16 segment programmable controller con-sists of a
microprocessor based three-mode PID(Proportional, Integral,
Derivative), programmabletemperature controller with
over-temperature protec-tion and appropriate output switching
devices to con-trol the furnace. The digital readout continuously
dis-plays chamber (upper display) and setpoint (lowerdisplay)
temperatures unless the SCROLL or PAGEbutton is depressed. The
programmable controller canbe used as a single setpoint controller
or as a pro-grammable controller. The 4 program controller hasfour
16 segment programs.
Basic OperationWhen the controller is turned ON, it will perform
ashort self-test and then change to the HOME DIS-PLAY. The HOME
DISPLAY shows the measuredtemperature (process value) in the upper
display andthe desired value (setpoint) in the lower display.
To Change the SetpointIf you want to change the setpoint, press
the UP orDOWN button until the desired setpoint value is dis-played
in the lower display and then release the but-ton.
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22
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
To View Display UnitsFrom the HOME DISPLAY press the SCROLL
button. Thedisplay will briefly show the temperature units in
C/F/Kand then return to the HOME DISPLAY. (If you require
adifferent temperature unit call Barnstead|ThermolyneCustomer
Service.)
To View the % Output PowerFrom the HOME DISPLAY press the SCROLL
buttontwice. This value is a read-only value and cannot
bechanged.
Buttons and IndicatorsOP1 (Output 1): illuminates when the
heating output ofthe temperature controller is on.
AUTO/MAN: (Auto/Manual Mode): when the controller isin the
automatic mode the output automatically adjusts tokeep the
temperature or process value at the setpoint.The AUTO light will
illuminate. The manual mode hasbeen disabled through factory
configuration. CallCustomer Service for further information.
RUN/HOLD (Run/Hold button): Starts a program when pressed
onceRUN
light illuminates.
Holds a program when pressed againHOLDlight illuminates.
Cancels hold and continues running whenpressed againHOLD light
is off and RUN lightilluminates.
Exits a program when the button is held downfor two secondsRUN
and HOLD lights are off.
At the end of a program the RUN light will flash.
During holdback the HOLD light will flash.
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8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
PAGE button: allows you to choose a parameter from alist of
parameters.
SCROLL button: allows you to choose a parameter withina list of
parameters.
UP button: allows you to increase the value in the
lowerdisplay.
DOWN button: allows you to decrease the value in thelower
display.
Controller ParametersHome DisplayC: measured temperature in
Celsius. Temperature unitscan not be changed without entering the
configuration.Contact Customer Service if a different temperature
unit isrequired.
OP: % output power demand; displayed in lower display(cannot be
changed).
C.id: Controller identification number.
PrG: Program number (displayed when a program is run-ning; 4x16
programmable models only.)
IdHi: Deviation High Alarm
tunE: One-shot autotune enable.
run LiSt (Program Run List)PrG: Currently running program (only
used on 4x16 pro-grammable models)
StAt: Displays the program status [OFF, run (runningactive
program), hoLd (program on hold), HbAc (waiting forprocess to catch
up), End (program completed)] in thelower display. The controller
will default to OFF.
FASt: Fast run through program (no/YES). The controllerwill
default to no.
SEG.d: Flash active segment type in the lower display ofthe home
display (no/YES). The controller will default tono.
23
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24
ProG LiSt (Program Edit List)PrG.n: Press the UP or DOWN ARROW
to select theprogram number (program number will be displayed
inlower display on 4x16 programmable models only.)
Hb: Press the UP or DOWN ARROW to select theholdback type [OFF
(disables holdback), Lo (deviationlow holdback), Hi (deviation high
holdback) or bAnd(deviation band holdback)] for the entire program.
Thecontroller will default to OFF.
Hb.U: Press the UP or DOWN ARROW to select theholdback value (in
display units).
rmP.U: Press the UP or DOWN ARROW to togglebetween ramp units
(SEc, min or Hour). Controller willdefault to SEc.
dwL.U: Press the UP or DOWN ARROW to togglebetween dwell units
(SEc, min or Hour). Controller willdefault to SEc.
Cyc.n: Press the UP or DOWN ARROW to set thenumber of program
cycles (1 to 999 or cont). The con-troller will default to
cont.
SEG.n: Press the UP or DOWN ARROW to select thesegment number
(1-8 in 8 segment models, 1-16 in4x16 models).
tYPE: Press the UP or DOWN ARROW to select thesegment type [End
(end of program), rmP.r = ramp rate(ramp to a specified setpoint at
a set rate), rmp.t =ramp time (ramp to a specified temperature in a
settime), dwEll (to maintain a constant temperature for aset time),
StEP (climb instantaneously from current tospecified temperature),
cALL (to call a program as asubroutine, available only on 4x16
programmable mod-els)]. The controller will default to End. Other
parame-ters used with tYPE include; tGt target setpoint), Rate(rate
of temperature increase) and dur (time to targetsetpoint or time to
dwell).
End.t: End segment type: dwELL (dwell continuous),rSEt (reset)
and S OP (End Segment Output powerlevel.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
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25
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
AL LiSt (Alarm List)IdHi: Deviation High Alarm.
Atun LiSt: (Autotune List)tunE: One-shot autotune enable.drA:
Adaptive tune enable.
drA.t: Adaptive tune trigger level in display units.Range = 1
9999.
Pid LiStG.SP (Gain Setpoint): Is the temperature at which
thecontroller switches from the (SEt1) PID values to the(SEt 2) PID
values.
Pb: Proportional band in display units. (SEt 1)
ti: Integral time in seconds. (SEt 1)
td: Derivative time in seconds. (SEt 1)
Pb2: Proportional band. (SEt 2)
ti2: Integral time in seconds. (SEt 2)
td2: Derivative time in seconds. (SEt 2)
ACCS LiSt (Access List)Access Code (Code needed to enter or
change theother configuration parameters which are not
normallyaccessible.) Not accessable.
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26
NoteThe following alarm messages are factorydefault settings and
may vary if you havechanged the configuration of your
controller:
IDHi: = 50C2FSH = 1118C (all models
except -60)2FSH = 1000C (-60 models only)
AlarmsThe controller will flash an alarm message in the
homedisplay if an alarm condition is detected.
IdHi: PV deviation high alarm.
2FSH: PV full scale high alarm.
LCr: load current low alarm.
HCr: load current high alarm.
S.br: Sensor break: check that sensor is connectedcorrectly.
L.br: Loop Break: Check that the heating circuits areworking
properly.
Ld.F: Heater Circuit Fault: indication of either an openor short
solid sate relay, a blown fuse, missing supplyor open circuit
heater.
SSr.F: Solid state relay failure indications in a solidstate
relay: indicates either an open or short circuit inthe SSR.
Htr.F: Heater failure: Indication that there is a fault inthe
heating circuit: indicates either a blown fuse, miss-ing supply or
open circuit heater.
Sensor Break ProtectionThis controller provides sensor break
protection in theevent the thermocouple opens. If an open
thermocou-ple condition occurs, the digital display will Blink
S.brand the power to the heating element will be shut OFF(Cycle
light will extinguish).
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
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27
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
Over-Temperature Protection(OTP)The OTP will be in effect during
any alarm conditionwhen the temperature of the furnace has
deviatedbeyond the limit. The Deviation High alarm is the onlyalarm
value which can be changed. To change it, pressthe SCROLL button
until idHi appears on the display.Press the UP or DOWN button to
select the OTP valueyou desire. We recommend a value of 20 above
yourworking temperature to provide protection for yourworkload.
To Operate the Controller as aSingle Setpoint Controller
1. Switch the circuit breaker to the ON posi-tion. The setpoint
temperature presently set inthe controller will appear in the lower
display.(The upper display indicates the actual cham-ber
temperature.)
2. To change the setpoint, press the UP orDOWN button until the
desired setpoint valueis displayed; then release the button.
3. The furnace will begin to heat if the new set-point
temperature is higher than the presentchamber temperature.
Programming the ControllerThe controller is capable of varying
temperature orprocess value with time through programming. A
pro-gram is stored as a series of segments and can be runonce,
repeated a set number of times or run continu-ously. To create a
customized program using the con-troller parameters listed under
Controller Parametersat the beginning of this section, follow the
proceduresoutlined in the proceeding sections of this manual.
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28
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
Creating a New Program or Editing anExisting Program (4x16
SegmentProgrammable Models Only)The same steps are used when
creating a new pro-gram and editing an existing program with the
excep-tion being that a new program starts with all its seg-ments
set to End in the tYPE parameter. Temporarychanges can be made to
these parameters when theprogram is in the hold state but permanent
changesmust be made in the reset state. Follow the stepsbelow to
create or edit a program.
1. Press the PAGE button until you reach theprogram list (ProG
LiSt).
2. Press the SCROLL button until display reads,PrG.n.
3. Press the UP or DOWN button to select anumber for a new
program or to edit an exist-ing program.
Hb: HoldbackHoldback consists of a value and a type. If the
meas-ured value lags behind the setpoint by an undesirableamount
during a ramp or dwell, the holdback featurecan be used to freeze
the program at its current state(the HOLD light will flash). The
program will resumewhen the error comes within the holdback
value.
OFF: holdback is disabled.
Lo (Deviation Low Holdback): holds the programback when process
variable deviates below the set-point by more than the holdback
value.
Hi (Deviation High Holdback): holds the programback when process
variable deviates above the set-point by more than the holdback
value.
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8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
bAnd (Deviation Band Holdback): combines the fea-tures of the
high and low deviation holdback in that itholds the program back
when the process variabledeviates above or below the setpoint by
more than theholdback value.
To set the holdback type:1. Press the PAGE button until you
reach the
program list (ProG LiSt).
2. Press the SCROLL button until display reads,Hb.
3. Press the UP or DOWN button to togglebetween bAnd, Hi, Lo and
OFF.
Hb U: Holdback ValueTo set the holdback value:
1. Press the PAGE button until you reach theprogram list (ProG
LiSt).
2. Press the SCROLL button until display reads,Hb.U.
3. Press the UP or DOWN button to enter aholdback value.
rmP.U: Setting Ramp UnitsRamp units are time units which are
used in rmP.rsegments (ramp to a setpoint at degrees per
second,minute or hour) and rmP.t segments (ramp to setpointin a
specific amount of time). See Setting theSegment Type for an
explanation on how to set aramp segment.
1. Press the PAGE button until you reach theprogram list (ProG
LiSt).
2. Press the SCROLL button until display reads,rmP.U.
3. Press the UP or DOWN button to togglebetween seconds, minutes
and hours.
NoteThe value set in this parameter is alwaysfor the entire
program.
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8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
dwL.U: Setting Dwell UnitsDwell units are time units which are
used in dwELL seg-ments (amount of time to remain at a specific
temperature). See Setting the Segment Type for an explanation onhow
to set a dwell segment.
1. Press the PAGE button until you reach the pro-gram list (ProG
LiSt).
2. Press the SCROLL button until display reads,dwL.U.
3. Press the UP or DOWN button to toggle betweenseconds, minutes
and hours.
CYC.n: Setting the Number of CyclesSet the number of times a
group of segments or programsare to be repeated by following the
steps listed below.
1. Press the PAGE button until you reach the pro-gram list (ProG
LiSt).
2. Press the SCROLL button until displayreads,CYC.n.
3. Press the UP or DOWN button to select the num-ber of cycles
you want to run or, press the DOWNbutton to select cont. so the
program will runcontinuously.
Setting the Segment TypeThere are five segment types. Proceed
with the followingsteps according to the type of segment you have
selected.
rmP.r (Ramp)To ramp linearly at a set rate to a specified
temperature:
1. Press the PAGE button until you reach the pro-gram list (ProG
LiSt).
2. Press the SCROLL button until displayreads,tYPE.
3. Press the UP or DOWN button until displayreads, rmP.r.
NoteThe program ramp rate is designed toreduce the heatup rate
or cooling ratethat the furnace normally exhibits.When not using
this feature, the fur-nace will operate at its maximumheating and
cooling capability.
NoteWhen the program ramp has endedor has been reset, the
furnace willcontinue to maintain setpoint temper-ature. It will not
cool to ambient tem-perature unless the setpoint is set toambient
temperature by the programor by the operator.
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31
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
Steps 4 and 5 are used in the 4 program model only. Ifyou are
using an 8 segment program, skip to step 6.
4. Press the SCROLL button until display readsHb.
5. Press the UP or DOWN button to togglebetween bAnd, Hi, Lo and
OFF.
6. Press the SCROLL button until display reads,tGt.
7. Press the UP or DOWN button to set a targetsetpoint.
8. Press the SCROLL button until displayreads,rAtE.
9. Press the UP or DOWN button to select avalue in ramp units
(seconds, minutes orhours; set in the rmP.U parameter).
rmP.tTo ramp to a specified temperature at a set time:
1. Press the PAGE button until you reach theprogram list (ProG
LiSt).
2. Press the SCROLL button until display reads,tYPE.
3. Press the UP or DOWN button until displayreads, rmP.t.
4. Press the SCROLL button until display reads,tGt.
5. Press the UP or DOWN button to set a targetsetpoint.
6. Press the SCROLL button until display reads,dur.
7. Press the UP or DOWN button to select atime in ramp units
(seconds, minutes orhours; set in the rmP.U parameter.
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32
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
dwEllTo maintain a constant temperature for a specified
time:
1. Press the PAGE button until you reach the pro-gram list (ProG
LiSt).
2. Press the SCROLL button until display reads,tYPE.
3. Press the UP or DOWN button until displayreads, dwEll.
4. Press the SCROLL button until display reads,dur.
5. Press the UP or DOWN button to select a time indwell units
(seconds, minutes or hours; set in thedwL.U parameter).
StEPTo climb instantaneously from the current temperature to
aspecified temperature.
1. Press the PAGE button until you reach the pro-gram list (ProG
LiSt).
2. Press the SCROLL button until display reads,tYPE.
3. Press the UP or DOWN button until the displayreads, StEP.
4. Press the SCROLL button until display reads,tGt.
5. Press the UP or DOWN button to set a target set-point.
cALL (Running Multiple Programs; 4x16 SegmentProgrammable Models
Only)To call a program as a subroutine:If you want to run multiple
programs, you can program thecontroller to call or link one program
to another. Thismakes it possible to run one program at any time
duringanother program and also return to the original program
ifdesired.
1. Press the PAGE button until you reach the pro-gram list (ProG
LiSt).
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33
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
2. Press the SCROLL button until display reads,tYPE.
3. Press the UP or DOWN button until displayreads, cALL.
4. Press the SCROLL button until display reads,PrG.n.
5. Press the UP or DOWN button to select a pro-gram number to be
linked.
6. Press the SCROLL button until display reads,CYC.n.
7. Press the UP or DOWN button to select thenumber of cycles the
linked program is to berun.
EndTo end or repeat a program:
1. Press the PAGE button until you reach the pro-gram list (ProG
LiSt).
2. Press the SCROLL button until display reads,tYPE.
3. Press the UP or DOWN button until displayreads, End.
4. Press the SCROLL button until display reads,End.t.
5. Press the UP or DOWN button to togglebetween dwEll (an
indefinite dwell), S OP(End Segment Output Power) and
rSET(reset).
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34
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
Setting the Target Setpoint (4x16Segment Programmable Models
Only)
1. Press the PAGE button until you reach theprogram list (ProG
LiSt).
2. Press the SCROLL button until display reads,tGt.
3. Press the UP or DOWN button to set the tar-get setpoint
temperature.
Running a Program (8Segment ProgrammableModels)To run a program,
press the RUN/HOLD button. (TheRUN light will illuminate.)
Running a Program (4x16Segment ProgrammableModels)To run a
program, press the RUN/HOLD button. (TheRUN light will illuminate)
or:
1. Press the PAGE button until you reach the runlist (run
LiSt).
2. Press the SCROLL button until display reads,PrG.
3. Press the UP or DOWN button to select theprogram number you
want to run.
4. Press the RUN/HOLD button once to start theprogram. (The RUN
light will illuminate.)
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35
Holding a ProgramTo put a running program on hold, press the
RUN/HOLDbutton. (The HOLD light will illuminate.)
Cancelling a ProgramTo cancel a program, hold the RUN/HOLD
button downuntil the RUN and HOLD lights go off.
Tuning your FurnaceThe purpose of tuning your furnace is to
match the char-acteristics of your controller to the
characteristics of theprocess being controlled. Good control is
evidenced by:stable, straight-line control of the setpoint
temperaturewith no fluctuations; No overshoot or undershoot of
thesetpoint temperature; rapid restoration of the
setpointtemperature when external disturbances cause deviationsfrom
the setpoint.
This controller has automatic tuning features which
installoptimum tuning parameters to give the best
temperatureaccuracy. No manual loading of tuning parameters
isneeded. We recommend that you tune the furnace to yourspecific
application to obtain the best results. To providethe best
temperature accuracy possible, use these fea-tures when you install
your furnace and whenever youchange your application or
procedure.
Tuning ErrorThe display will flash tu.ER if an error occurs
during tun-ing. To clear the error and restart tuning,
simultaneouslypress the PAGE and SCROLL buttons and follow thesteps
outlined in Autotuning.
NoteDisplay will flash tu.ER if an erroroccurs during tuning. To
clear theerror and restart tuning, simultane-ously press the PAGE
and SCROLLbuttons and follow the steps outlinedin Autotuning.
NoteTo stop the tuning function, simulta-neously press the PAGE
andSCROLL buttons.
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36
Gain Scheduling
G.SP: Gain SchedulingGain scheduling is the automatic transfer
of controlbetween two sets of PID values. The 2416 controllerdoes
this at a presettable process value. Gain schedul-ing is used for
difficult control processes which showlarge changes in their
response time or sensitivity athigh or low temperatures, or when
heating or cooling.
The G.SP gain schedule setpoint is factory set at 700C. The G.SP
must be adjusted to 200C from thedesired setpoint temperature when
tuning.
Setting the Transfer Point If gain scheduling has been enabled,
G.SP will appearat the top of the PID list. This sets the value at
whichthe transfer will occur. When the process value isbelow this
level, PID1 will be active and when it isabove, Pid2 will be
active. Set a value between thecontrol regions that show the
greatest change toachieve the best point of transfer.
TuningThe two sets of PID values can be manually set
orautomatically tuned. To tune automatically you musttune above and
below the transfer point G.SP. If theprocess value is below the
transfer point G.SP, the cal-culated values will automatically be
inserted into the(SEt 1) set and if the process value is above
G.SP, thecalculated values will automatically be inserted into
the(SEt 2).
AutotuningThe Autotune feature automatically sets up the PID
val-ues in the control parameters to suit new process con-ditions.
To tune your furnace using autotuning:
1. Load your furnace with a load similar to yournormal load and
close the door.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
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37
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP
2. Set the setpoint temperature.
3. Press the PAGE button until the display reads,Atun LiSt.
4. Press the SCROLL button until tunE OFF isdisplayed.
5. Press the UP or DOWN button to select on.
6. Simultaneously press the PAGE and SCROLLbuttons to return to
the HOME DISPLAY. Thedisplay will flash tunE while tuning is
inprogress.
Adaptive TuningAdaptive tuning continuously evaluates tuning
parame-ters. Adaptive tuning automatically installs new values
ifbetter accuracy is possible. Adaptive tuning should beused when
the characteristics of a process change due toload or setpoint
changes or, in a process that can nothandle the oscillation caused
by a one-shot tune.
To tune your furnace using adaptive tuning:1. Load your furnace
with a load characteristic of
those you intend to heat in it.
2. Press the PAGE button until display reads, AtunLiSt.
3. Press the SCROLL button until drA OFF is dis-played.
4. Press the UP or DOWN button to select on.
5. Press the SCROLL button until drA.t is dis-played.
6. Press the UP or DOWN button until the desiredtrigger value is
achieved.
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38
Installation and Operation ofAir Control
NoteAshing furnaces -60 models contain afeature to provide air
(or inert gas)flow within the furnace chamber.
NoteA pressurized air line with a minimumworking pressure range
of 0 to 40 psiis required.
NoteIf furnace is to be used regularly, theairline regulator may
be left open to 30psi.
NoteAppropriate exhaust must be providedto remove smoke and
gases producedin an ashing procedure.
Models F30420-33-60-80, F30420C-60-80,F30428C-60-80,
F30430CM-33-60, F30430CM-60, F30438CM-60
Installation
Compressed air hook-up1. A 0.250 inch tube fitting is located at
the rear of
the furnace.
2. Using 0.250 inch I.D. rubber tubing, connect alength of
tubing from this input fitting to a corre-sponding 0.250 inch
fitting located on the regulat-ed side of a pressurized air service
line.
3. Prior to making connections at the regulator,insure that the
regulator is turned fully closed (0psi).
4. Turn flow control valve located at the bottom ofthe flow
meter (front control panel) fully clockwiseto closed position.
5. Turn regulator to maximum output pressure of 30psi. Check for
any leaks at connection points ofconnecting tubing.
6. Open flow control valve slowly until ball in flowmeter reads
between 40 to 45 liters per minuteflow rate.
7. Open furnace door and check that air is exhaust-ing from the
manifold located at the bottom rearof the chamber.
8. Turn flow control valve to off (fully clockwise).
Exhaust tubing hook-upUsing accessory tubing available from
Barnstead
International (part number AY408X1A for furnace temper-atures
less than 975C, part number AY718X1 for furnacetemperatures of 975C
or greater) or equal quality 2.5" I.D.tubing appropriate for the
temperatures at which you willoperate your furnace, connect
flexible tubing from vent portat top of furnace case to an
appropriate negative pressureexhaust system. This exhaust system
must be capable ofhandling smoke and gases produced in an ashing
proce-dure.
-
39
Furnace Loading
NoteFailure to connect the exhaust port toan appropriate exhaust
system will re-sult in smoke and gases filling thework area.
Without the connection,gases and smoke will escape aroundthe door
seal and at the rear of thefurnace.
CautionDo not overload your furnace cham-ber. If the load is to
be heated uniform-ly it should not occupy more than two-thirds of
the furnace chamber. Failureto observe this caution could result
indamage to furnace components.
For best results, use only the center two-thirdsof the furnace
chamber.
Use Hearth plate to elevate load when placingon bottom heating
element. This prevents bot-tom heating element from overheating and
burn-ing out. (Part Numbers PHX1 & PHX2)
If you are heating a number of small parts,spread them
throughout the center of the fur-nace chamber.
Keep objects away from thermocouple.
Use insulated tongs and mittens when loadingand unloading
furnace.
Always wear safety glasses.
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40
Preventative Maintenance
This unit is equipped with a venting system on the top ofthe
furnace. This is for the removal of fumes from thechamber of the
unit. Contamination is a major cause of el-ement failure,
therefore, remove all fume forming materialbefore heating. (e.g.
clean cutting oil from tool steel).
Housekeeping is vital to your electric furnace - KEEP ITCLEAN.
Run your furnace up to 1600F empty occasion-ally to burn off the
contamination that may exist on the in-sulation and elements.
Maintain 1600F for at least 4hours to insure complete ashing of
foreign materials.Element life is reduced somewhat by repeated
heatingand cooling. If the furnace is to be used again within afew
hours, it is best to keep it at the operating tempera-ture or at a
reduced level such as 500F (260C).
General Cleaning InstructionsWipe exterior surfaces with lightly
dampened cloth con-taining mild soap solution.
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41
Problem Solving
The Problem Solving section is intended to aid in defining and
correcting possible service problems. Whenusing the chart, select
the problem category that resembles the malfunction. Then proceed
to the possiblecauses category and take necessary corrective
action.
Problem Probable Causes Corrective Action
The cycle light does The furnace is not connected to Check
furnace connection not illuminate. power supply. to power
source.
ON and OFF power switch is Replace power switch.defective.Door
switch defective. Realign door strike or
replace door safety switch.
Incorrect power source. Check power source.Defective circuit
breaker. Replace circuit breaker.
The furnace does not heat. No power. Check power source and
fuses or breakers.
Defective electrical hookup. Repair electrical
hookup.Thermocouple has oxidized Replace thermocouple.and opened
the circuit.Controller malfunction. Contact customer service.
Two or more heating elements Replace defective elements.burned
out.
Door switch malfunction. Realign door strike or replace
doorsafety switch.
Defective safety relay. Replace safety repay.Defective solid
state relay (SSR) Replace SS relay.
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42
PROBLEM SOLVING
Problem Probable Causes Corrective Action
Slow heatup. Low line voltage. Install line of sufficient size
and proper voltage (Isolatefurnace from other electrical
loads).
Heavy load in chamber. Lighten load in chamberto allow heat to
circulate.
Wrong heating element Install proper element.
One or more heating Replace burned out elements.elements are
burned out.
Wired improperly. Check wiring diagram forcorrect wiring of your
furnace.
Door switch does not cut Door switch is not functioning. Realign
door strike or power to the furnace chamber. replace door safety
switch.
Safety relay malfunction. Replace safety relay.Repeated element
burnout. Overheating furnace. Do not exceed the maximum
operating temperature offurnace or recommended continuous
intermittent usevalues.
Heating harmful materials. Enclose material in container.Clean
up spills on chamber. Ventilate chamber by leaving door cracked
slightly open when heatingknown harmful reagents.
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43
PROBLEM SOLVING
Problem Probable Causes Corrective Action
Contamination present from Clean and/or replace
insulationprevious burnout. material.
Wired improperly. Check wiring diagram forcorrect wiring of your
furnace.
Inaccurate. Oxidized or contaminated Replace
thermocouple.thermocouple.
Poor thermocouple connections. Tighten connections.Improper
loading. Use proper loading procedures.Poor ventilation of base.
Clear area around furnace base.Control out of calibration. Contact
customer service.
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44
Maintenance and Servicing
WarningRefer servicing to qualified personnel.
WarningReplace fuses with same type and rating.
WarningThis product contains refractoryceramic, refractory
ceramic fiber orfiberglass insulation, which can pro-duce
respirable dust or fibers duringdisassembly. Dust or fibers can
cause irritation and can aggravate preexistingrespiratory diseases.
Refractoryceramic and refractory ceramic fibers(after reaching
1000C) contain crys-talline silica, which can cause lungdamage
(silicosis). The InternationalAgency for Research on Cancer(IARC)
has classified refractory ceram-ic fiber and fiberglass as possibly
carcinogenic (Group 2B), and crys-talline silica as carcinogenic
tohumans (Group 1).
WarningTo avoid electrical shock, this furnacemust always be
disconnected from thepower supply prior to maintenanceand
service.
Perform only maintenance describedin this manual. Contact an
authorizeddealer or our factory for parts and as-sistance.
WarningPlease note the following WARNINGS:
This warning is presented for compliance with
CaliforniaProposition 65 and other regulatory agencies and
onlyapplies to the insulation in this product. This product
contains refractory ceramic, refractory ceramic fiber orfiberglass
insulation, which can produce respirable dust orfibers during
disassembly. Dust or fibers can cause irritation and can aggravate
preexisting respiratory diseases. Refractory ceramic and refractory
ceramicfibers (after reaching 1000C) contain crystalline
silica,which can cause lung damage (silicosis). The Internation-al
Agency for Research on Cancer (IARC) has classifiedrefractory
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, thehearth
collar, in the chamber of the product or under thehot 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 productunder normal conditions. However, there may be a
risk ofexposure to respirable dust or fibers when repairing
ormaintaining the insulating materials, or when otherwisedisturbing
them in a manner which causes release of dustor fibers. By using
proper handling procedures and protective equipment you can work
safely with these insulating materials and minimize any exposure.
Refer tothe appropriate Material Safety Data Sheets (MSDS)
forinformation regarding proper handling and recommendedprotective
equipment. For additional MSDS copies, oradditional information
concerning the handling of refracto-ry ceramic products, please
contact the Customer ServiceDepartment at Barnstead International
at 1-800-553-0039.
To Replace a Heating Elementa. Disconnect furnace from power
supply.
b. Remove the back terminal cover of the furnace(Note placement
and connections of wires).
c. Loosen the screws and nuts on the terminals of
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MAINTENANCE AND SERVICING
c. Loosen the screws and nuts on the terminals ofthe element to
be replaced.
d. Open the door and pull the defective elementout.
e. Slide the new element into place, threading theleads through
the insulating porcelain bushing onthe back of the furnace.
f. Cut off any excess lead wire. Be careful not tonick element
lead wires. Reinstall terminal con-nections and tighten screws and
nuts securely.
g. Replace the back terminal cover.
h. Reconnect furnace to power supply.
i. Test operation of furnace.
To Replace a Platinel IIThermocouple
a. Disconnect furnace from power supply.
b. Remove the back terminal cover of the furnace.(Note placement
and connection of T/C leadwires).
c. Remove the screws on the thermocouple termi-nals and pull the
thermocouple straight out.
d. Insert the new thermocouple into the furnacewith colored
beaded lead connected to the posi-tive (+) marked terminal and
other lead to nega-tive (-) terminal.
e. Secure connections with screws removed earlier.
f. Replace the back terminal cover.
g. Reconnect the furnace to power supply.
h. Test operation of furnace.
45
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MAINTENANCE AND SERVICING
To Replace Solid State Relay:a. Disconnect furnace from power
supply.
b. Remove the screws on the front dial and thescrews on the
lower back cover.
c. Remove the upper back cover.
d. Disconnect the element lead wires and oneground wire from
back of furnace. Also, discon-nect T/C lead wire from terminal
block. (Noteplacement and connection of wires).
e. Slide control section forward and disconnect twowires from
door switch. (Note placement andconnection of wires).
f. Control section can now be removed from fur-nace housing.
g. Disconnect the wires from the relay and removerelay. (Note
placement and connection of wires).
h. Install new relay.
i. Reverse steps a - e to reassemble furnace.
j. Test operation of furnace.
To Replace Door Switch(Microswitch)
a. Disconnect furnace from power supply.
b. Remove the screws on the front dial and thescrews on the
lower back cover.
c. Remove the upper back cover.
d. Disconnect the element lead wires and oneground wire from
back of furnace. Also, discon-nect the lead wire from terminal
block (noteplacement and location of wires).
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MAINTENANCE AND SERVICING
e. Slide the control section forward.
f. Disconnect the wires from the door switch.(Note connection
and placement of wires toMicroswitch).
g. Control section can now be removed from fur-nace housing.
h. Remove the two screws and nuts from theMicroswitch.
i. Insert new Microswitch and secure with screwsand nuts removed
in Step h.
j. Slide control section back and replace the wireson the door
switch.
k. Reverse steps b, c, d and e to reassemble fur-nace.
l. Reconnect to power supply.
m. Test operation of door switch. (To realign doorstrike, see To
Realign Door Strike).
To Realign Door Strikea. Disconnect furnace from power
supply.
b. Loosen the screws which retain the door strikeon the bottom
left side of the door.
c. Move the bracket closer to the furnace to makestrike engage
sooner. Move bracket furtheraway to make strike engage later.
(Lightly tight-en screws between each adjustment to holdbracket
while you test the strike.)
d. The door switch should click when the door isapproximately 1
from being completely closed.
e. Tighten screws when bracket is positioned cor-rectly.
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MAINTENANCE AND SERVICING
f. Reconnect to power supply.
g. To test the operation of the door strike: turn thepower
switch on, set the control to a setting highenough to keep the
control from cycling, openand close the door; the cycle light
should switchon when the door is approximately 1 from
beingclosed.
To Replace Control Module
a. Gently pry the retaining tabs on both sides out,then pull the
control straight out of the sleeves.Install the new controller to
the sleeve.
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Replacement PartsSingle Setpoint ModelsF30420C, F30420C-33,
F30428C
Part Number Description Quantity NotesCAX99 Line filter 1 -33
model onlyCA1249X1 Capacitor 1 -33 model onlyCN71X88 Controller 1
All modelsEL412X1 Element 1 208V modelEL412X2 Element 1 208V
modelEL412X3 Element 2 208V modelEL412X4 Element 1 240 V
modelEL412X5 Element 1 240 V modelEL412X6 Element 2 240 V
modelFA1262X1 Fan 1 All modelsPLX82 Pilot light 1 All modelsRYX37
S.S. relay 1 All modelsRYX62 Mechanical relay 1 All modelsSWX103
Circuit breaker 1 All modelsSWX144 Power switch 1 All modelsSWX163
Door switch 1 All modelsTC412X119 Thermocouple 1 All modelsTRX96
Terminal block 1 All modelsTRX178 Terminal block 1 All models
F30420C-33-80, F30420-33-60-80, F30420C-60-80, F30420C-80,
F30428C-60-80,F30428C-80
Part Number Description Quantity NotesCAX98 Line Filter 1 -33
model onlyCA1249X1 Capacitor 1 -33 model onlyCN71X89 Controller 1
F30420C-38-80, F30420C-80, F30428C-80CN71X91 Controller 1
F30420-33-60-80, F30420C-60-80,
F30428C-60-80EL412X1 Element 1 208V model
EL412X2 Element 1 208V modelEL412X3 Element 2 208V modelEL412X4
Element 1 240 V modelEL412X5 Element 1 240 V modelEL412X6 Element 2
240 V modelFA1262X1 Fan 1 All modelsSWX103 Circuit breaker 1 All
modelsPLX82 Pilot light 1 All modelsRYX37 S.S. relay 1 All
models
8 Segment Programmable Models with OTP
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50
REPLACEMENT PARTS
4X16 Segment Programmable Models with OTPF30430CM, F30430CM-33,
F30430CM-33-60, F30430CM-60, F30438CM, F30438CM-60
Part Number Description Quantity NotesCAX99 Line Filter 1 -33
model onlyCA1249X1 Capacitor 1 -33 model onlyCN71X90 Controller 1
F30430CM, F30430CM-33, F30438CMCN71X92 Controller 1 F30430CM-33-60,
F30430CM-60,
F30438CM-60EL412X1 Element 1 208V modelEL412X2 Element 1 208V
modelEL412X3 Element 2 208V modelEL412X4 Element 1 240 V
modelEL412X5 Element 1 240 V modelEL412X6 Element 2 240 V
modelFA1262X1 Fan 1 All modelsSWX103 Circuit breaker 1 All
modelsPLX82 Pilot light 1 All modelsRYX37 S.S. relay 1 All
modelsRYX62 Mechanical relay 1 All modelsSWX144 Power switch 1 All
modelsSWX163 Door switch 1 All modelsTRX96 Terminal block 1 All
modelsTRX178 Terminal Block 1 All modelsTC412X1A Thermocouple 1 All
models
RYX62 Mechanical relay 1 All modelsSWX144 Power switch 1 All
modelsSWX163 Door switch 1 All modelsTRX96 Terminal block 1 All
modelsTRX178 Terminal Block 1 All modelsTC412X1A Thermocouple 1 All
models
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51
Please refer to the Specification Plate for the complete
modelnumber, serial number, and series number when
requestingservice, replacement parts or in any correspondence
concern-ing this unit.All parts listed herein may be ordered from
the BarnsteadInternational dealer from whom you purchased this unit
or canbe obtained promptly from the factory. When service
orreplacement parts are needed we ask that you check first withyour
dealer. If the dealer cannot handle your request, then con-tact our
Customer Service Department at 563-556-2241 or800-553-0039.Prior to
returning any materials to Barnstead International,please contact
our Customer Service Department for a ReturnGoods Authorization
number (RGA). Material returned withouta RGA number will be
refused.
Ordering Procedures
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52
Wiring DiagramsSINGLE SETPOINT CONTROL
WIRING DIAGRAM
-
53
WIRING DIAGRAMS
SEGMENT PROGRAMMABLE CONTROL
WIRING DIAGRAM
-
54
WIRING DIAGRAMS
4X16 SEGMENT PROGRAMMABLE CONTROL
WIRING DIAGRAM
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55
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56
Two Year Limited WarrantyBARNSTEAD INTERNATIONAL (BARNSTEAD)
warrants that a product manufactured by Barnstead shall befree of
defects in materials and workmanship for two (2) year from the
first to occur of (i) the date the productis sold by BARNSTEAD or
(ii) the date the product is purchased by the original retail
customer (theCommencement Date). Except as expressly stated above,
BARNSTEAD MAKES NO OTHER WARRANTY,EXPRESSED OR IMPLIED, WITH
RESPECT TO THE PRODUCTS AND EXPRESSLY DISCLAIMS ANY ANDALL
WARRANTIES, INCLUDING BUT NOT LIMITED TO, WARRANTIES OF DESIGN,
MERCHANT ABILITYAND FITNESS FOR A PARTICULAR PURPOSE.
An authorized representative of BARNSTEAD must perform all
warranty inspections. In the event of a defectcovered by BARNSTEADs
warranty, BARNSTEAD shall, as its sole obligation and exclusive
remedy, providefree replacement parts to remedy the defective
product. In addition, for products sold by BARNSTEAD withinthe
continental United States or Canada, BARNSTEAD shall provide
provide free labor to repair the productswith the replacement
parts, but only for a period of ninety (90) days from the
Commencement Date.
BARNSTEADs warranty provided hereunder shall be null and void
and without further force or effect if thereis any (i) repair made
to the product by a party other than BARNSTEAD or its duly
authorized service repre-sentative, (ii) misuse (including use
inconsistent with written operating instructions for the product),
mishan-dling, contamination, overheating, modification or
alteration of the product by any customer or third party or(iii)
use of replacement parts that are obtained from a party who is not
an authorized dealer of BARNSTEAD.
Heating elements, because of their susceptibility to overheating
and contamination, must be returned to theBARNSTEAD factory and if,
upon inspection, it is concluded that failure is due to factors
other than excessivehigh temperature or contamination, BARNSTEAD
will provide warranty replacement. As a condition to thereturn of
any product, or any constituent part thereof, to BARNSTEADs
factory, it shall be sent prepaid and aprior written authorization
from BARNSTEAD assigning a Return Goods Number to the product or
part shallbe obtained.
IN NO EVENT SHALL BARNSTEAD BE LIABLE TO ANY PARTY FOR ANY
DIRECT, INDIRECT, SPECIAL,INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OR
FOR ANY DAMAGES RESULTING FROM LOSS OFUSE OR PROFITS, ANTICIPATED
OR OTHERWISE, ARISING OUT OF OR IN CONNECTION WITH THESALE, USE OR
PERFORMANCE OF ANY PRODUCTS, WHETHER SUCH CLAIM IS BASED ON
CON-TRACT, TORT (INCLUDING NEGLIGENCE), ANY THEORY OF STRICT
LIABILITY OR REGULATORYACTION.
The name of the authorized Barnstead International dealer
nearest you may be obtained by calling 1-800-446-6060
(563-556-2241) or writing to:
2555 Kerper BoulevardP.O. Box 797Dubuque, Iowa 52001-0797Phone:
563-556-2241 or 800-553-0039Fax: 563-589-0516E-mail:
[email protected]