thermolyne 30400 muffle furnace manual

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

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

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Table of Contents

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

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TABLE OF CONTENTS

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

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

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.

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General Specifications

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.

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GENERAL SPECIFICATIONS

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.

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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.

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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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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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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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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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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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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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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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.


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NoteFurnace must be at ambient temperature before starting a tune.

NoteTune has completed when tunEstops flashing on display.


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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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)

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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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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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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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.


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

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.


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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.

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).


27


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.

28


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.

29


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:


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.


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.

30


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.


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:


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.

31


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:


2. Press the SCROLL button until display reads,tYPE.

3. Press the UP or DOWN button until displayreads, rmP.t.


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.

32


dwEllTo maintain a constant temperature for a specified time:



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.



3. Press the UP or DOWN button until the displayreads, StEP.


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.


33



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:



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).

34


Setting the Target Setpoint (4x16Segment Programmable Models Only)



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.)

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.

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.


37


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.

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.

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.

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.

42

PROBLEM SOLVING


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.

43

PROBLEM SOLVING


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.

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

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

46


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).

47


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.

48


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.

49

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

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

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

52

Wiring DiagramsSINGLE SETPOINT CONTROL

WIRING DIAGRAM

53

WIRING DIAGRAMS

SEGMENT PROGRAMMABLE CONTROL

WIRING DIAGRAM

54

WIRING DIAGRAMS

4X16 SEGMENT PROGRAMMABLE CONTROL

WIRING DIAGRAM

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]

thermolyne 30400 muffle furnace manual

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otp f30420c

programmable models

segment f30430cm

single setpoint models

otp f30438cm

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