Types F79300 & F79400 Tube Furnaces ma… · Types F79300 & F79400 Tube Furnaces OPERATION MANUAL AND PARTS LIST SERIES 1080 & 1081 ... Thank you for buying this Thermolyne tube furnace

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Types F79300 & F79400Tube Furnaces

OPERATION MANUALAND PARTS LIST

SERIES 1080 & 1081

LT1080X1 • 5/7/97

Model Voltage Heating Zone ControlF79320 240 12" (30.48 cm) Single Set Point AutoF79320-33 240 12" (30.48 cm) Single Set Point AutoF79325 120 12" (30.48 cm) Single Set Point AutoF79328 208 12" (30.48 cm) Single Set Point AutoF79330-70 240 12" (30.48 cm) Program. 2 ramp/2 dwellF79330-33-70 240 12" (30.48 cm) Program. 2 ramp/2 dwellF79335-70 120 12" (30.48 cm) Program. 2 ramp/2 dwellF79338-70 208 12" (30.48 cm) Program. 2 ramp/2 dwellF79340 240 12" (30.48 cm) Multi-programmableF79340-33 240 12" (30.48 cm) Multi-programmableF79345 120 12" (30.48 cm) Multi-programmableF79348 208 12" (30.48 cm) Multi-programmableF79420 240 24" (60.96 cm) Single Set Point AutoF79420-33 240 24" (60.96 cm) Single Set Point AutoF79428 208 24" (60.96 cm) Single Set Point AutoF79430-70 240 24" (60.96 cm) Program. 2 ramp/2 dwellF79330-33-70 240 24" (60.96 cm) Program. 2 ramp/2 dwellF79438-70 208 24" (60.96 cm) Program. 2 ramp/2 dwellF79440 240 24" (60.96 cm) Multi-programmableF79440-33 240 24" (60.96 cm) Multi-programmableF79448 208 24" (60.96 cm) Multi-programmable

BARNSTEAD|THERMOLYNE CORPORATION

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Thank you for buying this Thermolyne tube furnace. We believe that you will find it to be thebest furnace of its kind available. Please note that this manual contains important operatingand safety information. You must carefully read and understand the contents of this manualprior to the use of this furnace.

SideLatch

SideLatch

Front Latch

Controller

HEAT Light

HEAT Switch

POWER Switch

Figure 1 F79300 Tube Furnace (F79400 Tube Furnace is similar, with two Front Latches)

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Table of Contents

Safety Information ............................................................................................................................................5Alert Boxes ....................................................................................................................................................5Warnings ........................................................................................................................................................5

Introduction ......................................................................................................................................................7Intended Use..................................................................................................................................................7General Usage ..............................................................................................................................................7Principles of Operation ..................................................................................................................................7

General Specifications ......................................................................................................................................8Materials of Construction ..............................................................................................................................8Weight ............................................................................................................................................................8Dimensions ....................................................................................................................................................8Electrical ........................................................................................................................................................8Operating Characteristics for F79300............................................................................................................8Operating Parameters (Recommended)........................................................................................................9Environmental Conditions..............................................................................................................................9Declaration of Conformity ..............................................................................................................................9

Installation ......................................................................................................................................................10Unpacking ....................................................................................................................................................10Site Selection ..............................................................................................................................................10Electrical Connections ................................................................................................................................10Process Tubes ............................................................................................................................................11

Installing Tubes ........................................................................................................................................11Remote Operation of Furnace ....................................................................................................................12

Single Setpoint Temperature Control (Automatic) ........................................................................................16Controls and Displays..................................................................................................................................16

Power Switch: ..........................................................................................................................................16Furnace Power Indicator: ........................................................................................................................16Door Safety Switch: ................................................................................................................................16Control Buttons: ......................................................................................................................................17Digital Readout: ........................................................................................................................................17

Adjusting Furnace Set Point Temperature ..................................................................................................17Tuning: ........................................................................................................................................................17

To tune your furnace:................................................................................................................................18Setting Control Parameters ........................................................................................................................18

Changing Temperature Indication ............................................................................................................18High Alarm (Over-Temperature Protection OTP): ....................................................................................18

2 Ramp & 2 Dwell Programmable Models ....................................................................................................20Controls and Displays..................................................................................................................................20

Digital Readout ........................................................................................................................................20Power Switch............................................................................................................................................21Furnace Power Indicator ..........................................................................................................................21Door Safety Switch ..................................................................................................................................21

Parameters ..................................................................................................................................................21Tuning Your Controller ................................................................................................................................23

To Initiate the Self Tune Feature ..............................................................................................................23Operating the Controller ..............................................................................................................................24

Single Set Point Operation ......................................................................................................................24Programming Controller ..........................................................................................................................25

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TABLE OF CONTENTS

Implementing Programs ..........................................................................................................................278 Ramp & 8 Dwell Multi-Programmable Models ............................................................................................29

Controls and Displays..................................................................................................................................29Digital Readout ........................................................................................................................................29Parameters ..............................................................................................................................................30

Tuning Your Controller ................................................................................................................................33To Initiate the Tuning Feature ..................................................................................................................33

Operating the Controller ..............................................................................................................................34Single Set Point Operation ......................................................................................................................34Programming Controller ..........................................................................................................................35

Implementing Programs ..............................................................................................................................39Furnace Atmospheres and Furnace Loading..................................................................................................41Preventative Maintenance ..............................................................................................................................42Troubleshooting Tips ......................................................................................................................................43Maintenance and Servicing ............................................................................................................................45

Element Replacement..................................................................................................................................45Element Check ........................................................................................................................................46Replacing The Bottom Element................................................................................................................46Replacing The Top Element ....................................................................................................................48

Replacing The Thermocouple......................................................................................................................50Replacement Parts List ..................................................................................................................................52Ordering Procedures ......................................................................................................................................53Wiring Diagrams for F79300 ..........................................................................................................................54Wiring Diagrams for F79400 ..........................................................................................................................57Exploded Views for F79300 ............................................................................................................................60Exploded View Key (F79300) ........................................................................................................................62Exploded Views for F79400 ............................................................................................................................63One Year Limited Warranty ............................................................................................................................68

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Safety Information

Alert Boxes

Warning Warning alerts apply whenthere is a possibility of per-sonal injury.

Caution Caution alerts apply whenthere is a possibility of dam-age to the equipment.

Note Notes alert you to pertinentfacts and conditions.

Your Thermolyne Type F79300 or F79400 TubeFurnace has been designed with function, reliability,and safety in mind. It is your responsibility to install itin conformance with local electrical codes. For safeoperation, please pay attention to the alert boxesthroughout the manual.

WarningsTo avoid electrical shock, this furnace must:1. Be connected to electrical service by a quali-

fied electrician who ensures compatibilitybetween wiring, furnace electrical require-ments, electrical service and electricalcodes.

2. Be disconnected from the power supply priorto maintenance and servicing.

3. Have the furnace safety switch operatingproperly.

4. Always use a properly sized combustiontube.

To avoid personal injury:1. Do not use in the presence of flammable or

combustible materials; fire or explosion mayresult. This device contains componentswhich may ignite such material.

2. "Caution: Hot Surface - Avoid Contact." Toavoid burns, do not touch the exterior orinterior surfaces of this furnace during use orfor a period of time after use.

3. Do not open furnace until it has cooled suffi-ciently to cease to radiate dangerousamounts of heat.

4. Refer servicing to qualified personnel.

Hot SurfaceHot surfaces alert you to apossibility of personal injury ifyou come in contact with a sur-face during use or for a periodof time after use.

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SAFETY INFORMATION

PLEASE NOTE THE FOLLOWING WARNINGS:

WARNING

This warning is presented for compliance with California Proposition 65 and other regulatoryagencies and only applies to the insulation in this product. This product contains refractoryceramic, refractory ceramic fiber or fiberglass insulation, which can produce respirable dustor fibers during disassembly. Dust or fibers can cause irritation and can aggravate pre-exist-ing respiratory diseases. Refractory ceramic and refractory ceramic fibers (after reaching1000°C) contain crystalline silica, which can cause lung damage (silicosis). TheInternational Agency for Research on Cancer (IARC) has classified refractory ceramic fiberand fiberglass as possibly carcinogenic (Group 2B), and crystalline silica as carcinogenic tohumans (Group 1).

The insulating materials can be located in the door, the hearth collar, in the chamber of theproduct or under the hot plate top. Tests performed by the manufacturer indicate that thereis no risk of exposure to dust or respirable fibers resulting from operation of this productunder normal conditions. However, there may be a risk of exposure to respirable dust orfibers when repairing or maintaining the insulating materials, or when otherwise disturbingthem in a manner which causes release of dust or fibers. By using proper handling proce-dures and protective equipment you can work safely with these insulating materials andminimize any exposure. Refer to the appropriate Material Safety Data Sheets (MSDS) forinformation regarding proper handling and recommended protective equipment. For addi-tional MSDS copies, or additional information concerning the handling of refractory ceramicproducts, please contact the Customer Service Department at Barnstead|ThermolyneCorporation at 1-800-553-0039.

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Intended UseThe Type F79300 and F79400 furnaces are highquality, split, hinged furnaces ideally suited forschool, chemical and industrial laboratories. Theyare intended for applications requiring tempera-tures up to 1200°C. See specification sheet forcontinuous and intermittent operating tempera-tures.

General usageDo not use this product for anything other than itsintended usage.

Principles of OperationThe furnace chamber is heated by heating ele-ments embedded in a refractory material, with aportion of the elements exposed for maximum heatup and cool down. The split tube design providesease of loading process tubes and allows a fastcool down. The furnace chamber is supported bythe control base, which also houses the electricalconnections. Three types of temperature controlsare used.

Introduction

Caution Do not exceed limitations forcontinuous or intermittentoperating temperatureshown in the GeneralSpecifications. Exceedingthese limits will result inseverely reduced heatingelement life.

"Caution: Hot Surface -Avoid Contact." To avoidburns, do not touch the exte-rior or interior surfaces ofthis furnace during use or fora period of time after use.

Do not open furnace until ithas cooled sufficiently tocease to radiate dangerousamounts of heat.

Hot Surface

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Materials of ConstructionAluminum inner shell, painted steel outer shell

WeightShipping..................105 lbs (47.6 kg) (12" models)................................111 lbs (50.3 kg) (12", -33 models)................................150 lbs (68 kg) (24" models)................................156 lbs (70.8 kg) (24", -33 models)Operational ............70 lbs (31.7 kg) (12" models)................................76 lbs (34.5 kg) (12", -33 models)................................115 lbs (52.3 kg) (24" models)................................121 lbs (55.1 kg) (24", -33 models)

DimensionsW H D

12" models 22.875" X 23.125" X 18.875"(58.1 cm) (58.7 cm) (47.9 cm)

24" models 34.875" X 23.125" X 18.875"(88.6 cm) (58.7 cm) (47.9 cm)

Electrical12" models

V W Hz I120 2880 50/60 24.0208 2880 50/60 13.8240 2880 50/60 12.0

24" modelsV W Hz I

240 5760 50/60 24.0208 5760 50/60 27.6

Operating Characteristics for F79300Temperature Range 100°C to 1200°CTemperature Stability ±0.5°CTemperature Uniformity ±0.6°C over center 3"

±3.0°C over center 6"

General Specifications

3"Center

±0.6°C

Process Tube

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Operating Parameters (Recommended)Ambient Temperature ........24°CRelative Humidity ..............80% (non-condensing)

Environmental ConditionsOperating: 17°C - 27°C; 20% - 80% relative humidity, non-condensing. Installation

Category II (over-voltage) in accordance with IEC 664. Pollution Degree 2 in accordance with IEC 664. Altitude limit: 2,000 meters.

Storage: -25°C - 65°C; 10% - 85% relative humidity.

Declaration of Conformity (-33 models only)Barnstead|Thermolyne hereby declares under its sole responsibility that this product con-forms with the technical requirements of the following standards:

EMC: EN50081-1 Generic Emission Standard; EN 50082-1 Generic Immunity Standard.

Safety: IEC 1010-1-92 Safety requirements for electrical equipment for measurement, control and laboratory use; Part I: General RequirementsIEC 1010-2-010 Part II: Particular requirements for laboratory equipment for the heating of materials

per the provisions of the Electromagnetic Compatability Directive 89/336/EEC, as amendedby 92/31/EEC and 93/68/EEC, and per the provisions of the Low Voltage Directive73/23/EEC, as amended by 93/68/EEC.

The authorized representative located within the European Community is:European ManagerBarnstead|ThermolyneSaarbrückener Str. 248D-38116 BraunschweigGermany

Copies of the Declaration of Conformity are available upon request

GENERAL SPECIFICATIONS

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Installation

Caution Be sure ambient tempera-ture does not exceed 104°F(40°C). Ambients above thislevel may result in damageto the controller.

Allow at least six inches ofspace between the furnaceand any combustible sur-face. This permits the heatfrom the furnace case toescape so as not to create apossible fire hazard.

Warning To avoid electrical shock,this furnace must be con-nected to electrical serviceby a qualified electrician whoensures compatibilitybetween wiring, furnaceelectrical requirements, elec-trical service and electricalcodes.

UnpackingVisually check for any physical damage to the ship-ping container. Inspect the equipment surfaces thatare adjacent to any damaged area.

Unpack furnace from box and remove packingmaterial from inside furnace chamber. Furnacedoes not contain a refractory process tube.

Retain the original packaging material if re-ship-ment is foreseen or required.

Site SelectionInstall furnace on a sturdy surface and allow ade-quate space for ventilation.

Electrical ConnectionsThe F79300 or F79400 must be wired to an electri-cal box by a qualified electrician. The connectionsmust be made with 10 AWG wires for 24 & 27.6Amp models or 14 AWG for 12 & 13.8 Amp mod-els, suitable for temperatures of 90°C. The electri-cal specifications are located on the specificationplate on the back of the furnace. ConsultBarnstead|Thermolyne if your electrical service isdifferent than those listed on the specification plate.Be sure the front power switch is in the OFF posi-tion before connecting the furnace to your electricalsupply.

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Process TubesThis furnace can be used with tubes of 1", 2" or 3"diameter. Each size tube requires two tube collarsof corresponding size to hold it in position in thefurnace. Tubes are not supplied with the furnace.Contact Barnstead|Thermolyne for suppliers ofprocess tubes. Three sets of collars (one set ofeach size) are supplied with your furnace. For addi-tional collars, see the Ordering Procedures forordering information and the Replacement PartsList for part numbers.

Installing T ubes1. Unlatch and open the furnace chamber.

2. Carefully slide your tube into the roundside of an appropriately sized tube collar,inserting the tube until it is flush with thesurface of the square side of the collar.

Figure 2 Tube Installation

Tube CollarTube Collar

ProcessTube

INSTALLA TION

Note If your process tube is muchlonger than the width of yourfurnace, you might notesome degradation in the per-formance of the heatingzone of the furnace.

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3. Slide the other end of your tube into theround side of another appropriately sizedtube collar, again inserting the tube until itis flush with the surface of the square sideof the collar.

4. Carefully place the tube/collar assemblyinto the lower half of the furnace, beingsure to seat the square sides of the col-lars fully into the furnace case.

5. Close and latch the furnace chamber.

Note In some cases, your processtube may be longer than thefurnace chamber. In thiscase, carefully center theprocess tube in the furnacechamber.

INSTALLA TION

Note Your F79300 or F79400 canalso be operated in a verticalposition. If you wish to oper-ate your furnace in a verticalposition, contactBarnstead|Thermolyne toorder a Vertical SupportStand, part numberAY793X1.

Remote Operation of FurnaceThe furnace section of the F79300 or F79400 TubeFurnace can be removed from the control section,allowing you to operate your furnace from a dis-tance. The furnace is supplied with 5 foot cords,allowing you to place your furnace up to 5 feet fromthe control base. For applications requiring agreater separation between the furnace and thecontrol section, 10 foot remote operation extensioncords are also available from Thermolyne (orderpart number AY793X2 for 208V and 220/240V,AY793X3 for 120V).

To operate your F79300 or F79400 from a dis-tance:

1. Disconnect the unit from the power supply.

13Figure 3 Furnace Back - Connections

ThermocoupleSignal Wire

Power Cord

INSTALLA TION

2. Disconnect the power cord from the backof the control section:

a. Turn the power cord plug counter-clockwise until it unlocks

b. Pull the plug straight out.

3. Disconnect the door switch cord and thethermocouple wire from the back of thecontrol section. If you will be using the 10foot remote operation extension cords,also disconnect the door switch cordfrom the back of the furnace section.

4. Unlatch the two latches holding the fur-nace section onto the control section.

5. Carefully lift the furnace section off thecontrol section. Place the furnace sectionin its new, remote location.

6. If you are installing the 10 foot remoteoperation extension cords:

Door Switch Cord

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a. Insert the power cord plug into theplug receptacle on the extensionpower cord and turn the power cordplug clockwise until it locks.

b. Connect the extension thermocouplewire to the thermocouple wire, beingcareful to insert the thermocouplewire plug into the receptacle on theextension thermocouple wire so thatthe "+" prong on the plug is insertedinto the "+" hole on the receptacle.

7. Connect the power cord to the back of thecontrol section

a. Insert the power cord plug into theplug receptacle on the back of thecontrol section

b. Turn the power cord plug clockwiseuntil it locks.

8. Connect the door switch cord to the backof the control section. If you are using the10 foot remote operation extension cords,connect the door switch and the two doorswitch extension cords together. Connect

Figure 4 Remote Operation

INSTALLA TION

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INSTALLA TION

the unattached end to the back of the fur-nace section.

9. Connect the thermocouple extension wireto the back of the control section, beingcareful to insert the thermocouple wireplug into the receptacle on the back of thecontrol section so that the "+" prong onthe plug is inserted into the top hole onthe receptacle.

10. Reconnect the unit to the powersupply.Single Setpoint TemperatureControl (Automatic) Operation

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Controls and Displays

Power SwitchSwitch power switch to the “ON” position. TheCONTROLLER will illuminate when power is on.

Furnace Power IndicatorThe amber furnace power light will illuminate when-ever the door is closed. This light will go out onlywhen the door is open or when there is an over-temperature condition.

Door Safety SwitchThe door safety switch removes power from theheating elements when the door is opened. Openand close the door a few times, note that theamber furnace power light will go out while thedoor is open. If the furnace power light does not goout while the door is open, consult theTroubleshooting section before proceeding.

The temperature control inthese models is a single set-point device. By using the “UP”or “DOWN” buttons a specifictemperature can be chosen.The control will cause the fur-nace chamber to heat to thechosen temperature and hold itat this temperature until youturn off the power switch orselect another temperature.

To avoid electrical shock, thisfurnace must have the doorswitch connected and operat-ing properly. If the furnacepower light does not go outwhile the door is open, consultthe Troubleshooting sectionbefore proceeding.

Note

Warning

Figure 5 Single Setpoint Controller

Furnace Chamber Temperature

Temperature Setpoint

Alarm Indicator

Cycle Light

Down Button

Scroll Button

Secret Key

Up Button

Single Setpoint TemperatureControl (Automatic)Operation

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Control ButtonsTo illuminate the “DOWN” button, “SCROLL” but-ton, and “UP” button, touch anywhere on the frontpanel.

Digital ReadoutThe Digital Readout continuously displays chamber(upper display) and setpoint (lower display) temper-atures unless the “SCROLL” button is depressed.

Startup DisplayWhen the power switch is turned on, the controllerwill perform a self-test to make sure controller isoperating properly. (If all four 1’s do not light up orfail to go to “8888”, contact Thermolyne.)

Adjusting Furnace Set Point

Temperature To illuminate the “DOWN” button, “SCROLL” but-ton, and “UP” button, touch anywhere on the frontpanel.

Push the “UP” button or the “DOWN” button tomodify the temperature setpoint (lower digital dis-play).

TuningThis control incorporates a self tuning featurewhich determines the optimum control parametersfor the best temperature accuracy. We recommendthat you tune the furnace to your specific applica-tion to obtain the best results. Perform the followingprocedures when you first set up your furnace andeach time you change your load type or operatingtemperature.

When performing operationswith the controller, rememberthat if more than eight to tenseconds elapse before the but-tons are used again, the dis-play screen will automaticallyswitch back to displayingchamber temperature. If thishappens, light up the frontpanel again and step througheach parameter until you reachthe point at which the interrup-tion occurred. The parametervalues you adjusted earlier,however, will not be lost oraltered. Holding down on the“SCROLL” button allows longerviewing time.

Note

Do not exceed limitations forcontinuous or intermittent oper-ating temperature shown in theGeneral Specifications.Exceeding these limits willresult in severely reducedheating element life.

Caution

SINGLE SETPOINT TEMPERATURE CONTROL (AUTOMATIC)OPERATION

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To tune your furnace:Load your furnace with a load characteristic ofthose you intend to heat in it.

Set the furnace’s setpoint to the temperature youintend to use for your application.

Push the “SCROLL” button until "tunE” appears.To start the tuning function, push the “UP” button.

When the tuning process is started, the lowerdisplay will flash "tunE” along with the furnace tem-perature setpoint. During tuning, the temperaturesetpoint cannot be changed. To change tempera-ture setpoint "tunE” must be turned “OFF.” (To stopthe tuning function, push the “DOWN” button.)

Setting Controller Parameters

Changing T emperature IndicationPush “SCROLL” button once, “°C” will appear. Thisindicates temperature measurement. (ContactThermolyne if control needs to be changed to °F.)

Setting the High Alarm T emperature

(Over Temperature Protection OTP)Push “SCROLL” button until “AL.SP” (AlarmSetpoint) appears.

If the power to furnace is“turned off” or interrupted whilein “tuning,” upon returningpower to furnace, the controllerdisplay will indicate “LinE FAIL”because sampled data couldbe questionable. To restart tun-ing, refer to “Tuning” proce-dure.

If the controller cannot main-tain temperature setpoint,“tunE FAIL” will appear on dis-play. First, correct the problemresponsible for not maintainingthe temperature setpoint, thenrestart the “tuning” procedure.

Note


Do not open furnace until ithas cooled sufficiently andceased to radiate dangerousamounts of heat.

Hot Surface


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Depress either the “UP” or “DOWN” button toselect the OTP value you desire. Thermolyne rec-ommends that you set the value either at the maxi-mum operating temperature of the furnace or avalue of 20 degrees above your working tempera-ture if you desire to provide protection for yourworkload.HIAL- HIGH ALARM. (over-

temperature protection, OTP)

The controller is fitted with amechanical relay which is de-energized in the alarm mode.This relay, when de-energized,removes power from the heat-ing elements. If the primarycontrol circuit fails, the OTPwill control the furnace temper-ature at the preset value youhave entered. It does not shutoff the furnace, but will main-tain the chamber temperatureat that value.

Note


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Digital ReadoutThe digital readout continuously displays chamber(upper display) and setpoint (lower display) temper-atures unless the PAR (parameter) button isdepressed.

If a program is in either run, Hb or Hold, pressing“PAR” once causes the lower display to indicate thecurrent segment of the program (r1, d1, r2, d2, orHb) along with °C or °F. If the program is currentlyin either d1 and d2, the value shown below theseparameters (d1 or d2) reflects the time remaining inthe segment.

While the program is in run, Hold or Hb, the setpoint shown on the bottom display is the currentworking set point.

When the controller is in idle, depressing PARshows each parameter and its current value in turnon the display. The parameter value can either bemodified with the “up” or “down” push buttons orleft unmodified.

Operation of 2 Ramp & 2Dwell Programmable Models

In the event of a thermocouplebreak (open circuit), thenumeric display increasesrapidly upscale, then displays“Sn b” (sensor break), and mayalternatively flash “HiAL” (highalarm) and/or dAL (deviationalarm) and the sensor breakpower value.

A reversed thermocouple con-nection or incorrect thermocou-ple will cause the display toread “ur” (underrange) and thecontrol will maintain the sensorbreak power output valueselected.

Note



Hot Surface

Furnace Chamber Temperature (At startup, displays software ver-sion number)

Scroll Button ofAdjustable Parameters

Down Button

Nonfunctional

Temperature SetpointOutput Power Indicator

Nonfunctional

Up Button

Screw retaining instrument in sleeve

Figure 6 Programmable Control (2 ramp & 2 dwell)

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Note

See Parameters for a list of the controller para-meters in order.

Power SwitchSet power switch to the “ON” position. The CON-TROLLER will illuminate when power is on.


Door Safety SwitchThe door safety switch removes power from theheating elements when the door is opened. Openand close the door a few times, note that theamber furnace power light will go out while thedoor is open. If the furnace power light does not goout while the door is open, consult theTroubleshooting section before proceeding.

ParametersPROG - program options . By pushing up ordown buttons, three options can be chosen: run -to start program; idle - to end program; hold - tohold program until further action. SP - set point temperature. When running a pro-gram, it is the last temperature value attained.Push up or down button to set. TUNE - self-tuning feature. Push up or down but-ton to set. LC - loop count . The number of times the programis repeated. Push up or down button to set.

Remember that whenever thepower switch is turned “ON,”the furnace will begin to heatat the setpoint temperaturethat was previously set. Thisvalue will remain unchangedfor up to a year without powerbeing applied to the control.


Pushbutton “A/M” and light“OP2” are inactive and notused.

Warning

Note

OPERATION OF 2 RAMP & 2 DWELL PROGRAMMABLE MODELS

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Note

Warning

r1 - ramp rate #1. The rate of heat increase ordecrease in °/minute. Push up or down button toset. L1 - temp level #1. The temp level that r1 willattain. Push up or down button to set. d1 - dwell (soak) time #1. The amount of time inminutes to hold L1 temp level #1. Push up or downbutton to set. r2 - ramp rate #2. The rate of heat increase ordecrease in °C/minute. Push up or down button toset. L2 - temp level #2. The temperature level r2 willattain. Push up or down button to set. d2 - dwell (soak) time #2. The amount of time inminutes to hold L2 temperature level #2. Push upor down button to set. Hb - “holdback.” Automatically places the pro-grammer into “HOLD” if the measured value devi-ates more than a specified amount from program-mer setpoint. When measured value reenters theholdback band, the timing for the segmentresumes. (Parameter is expressed in °C and onlyfunctions when running a program). Push up ordown button to set. HiAL - high alarm (over temperature protection).Push up or down button to set. Thermolyne recom-mends that you set the value either at the maxi-mum operating temperature of the furnace or avalue of 20 degrees above your working tempera-ture if you desire to provide protection for yourworkload.

The next three parameters - Proportional Band,Integral and Derivatives - are the three controlparameters of a P.l.D. control system. These para-meters will be set when you tune your furnace.(See Tuning .)Prop - Proportional Band.In.t - Integral T ime.dEr.t - Derivative T ime.HPl - High Power Limit (%) This parameter limitsthe average maximum power that is applied to the

When performing operationswith the controller, if youdepress and release either the“PAR,” scroll “up,” or scroll“down” push buttons and morethan 6 seconds elapse beforethe buttons are used again, thedisplay screen will automatical-ly switch to displaying chambertemperature. If this happens,you will have to step througheach parameter until you reachthe point at which the interrup-tion occurred. The parametervalues you adjusted earlier,however, will not be lost oraltered. Holding down on“PAR” allows longer viewingtime.

The controller is fitted with amechanical relay which is de-energized in the alarm mode.This relay, when de-energized,removes power from the heat-ing elements. If the primarycontrol circuit fails, the OTPwill control the furnace temper-ature at the preset value youhave entered. It does not shutoff the furnace but will maintainthe chamber temperature atthat value.


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heating elements. Remember that this parameterdoes not reduce the voltage to the elements. Itreduces the average power to the elements bycycling power on and off. C/F - Centigrade/Fahrenheit. Choose the desiredtemperature unit by depressing the “UP” or“DOWN” pushbutton.

Tuning Your ControllerThis programmable control has an automatic tuningfeature which installs optimum tuning parametersto give the best temperature accuracy. No manualloading of tuning parameters is needed. We highlyrecommend using this feature to provide the besttemperature accuracy the controller can attain.Perform the following procedures when you first setup your furnace and each time you change yourload type, operating temperature, or program.

To initiate the self tune featureLoad your furnace with a load characteristic ofthose you intend to heat in it.

If you will be using the controller as a singleSetpoint Controller, set the furnace’s setpoint to thetemperature you intend to use for your application.

If you will be running a multi-step program, setthe furnace’s setpoint to the value of L1 (templevel #1).

Push “PAR” button until TUNE is displayed, thenpush “UP” or “DOWN” button to turn tune “ON.”

All temperature dependentparameters are automaticallyconverted when the tempera-ture unit (C or F) is changed.

Note


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During the operation, TUNE flashes in the lowerdisplay. Do not make any adjustments to the con-troller parameters during this period. The self tun-ing is finished when TUNE no longer flashes in thelower display.

Self tuning will calculate values for: Proportional band - propIntegral time - Int.tDerivative time - der.t• Self tuning cannot be initiated while run-

ning a program.

• A power failure will cause the TUNE para-meter to revert back to NO. (Reset tuneparameter to YES).

• If there are alarm conditions during selftuning, they flash alternately with TUNE.

Operating the Controller

Single Set Point OperationThe programmable control can be used as a singlesetpoint control or as a programmable control. Touse as a single set point control simply push the“UP” or “DOWN” buttons to choose a specific tem-perature. The control will cause the furnace cham-ber to heat to the chosen temperature and hold thistemperature until the power switch is set to "OFF"or another temperature is selected.

a. The setpoint temperature presently set inthe control will be read out on the lowerdisplay.

Caution



Do not exceed limitations forcontinuous or intermittent oper-ating temperature shown in theGeneral Specifications (in fur-nace manual). Exceeding theselimits will result in severelyreduced heating element life.

Hot Surface


25

b. To change this set point, depress the “UP”or “DOWN” push button until the desiredsetpoint value is displayed, then releasethe button.

c. At this point the furnace will begin to heat,if the new set point temperature you havechosen is higher than the present cham-ber temperature.

Programming ControllerTo run a program, first determine your ramp rate,dwell times and program levels. It is helpful tograph your program for ease of loading the pro-gram into controller.

A maximum of 2 ramp and 2 dwell segment com-binations are available, thus enabling 2 different setpoint levels to be achieved. Each ramp is pro-grammed by specifying the temperature level (L1)and the required ramp rate (r1). The programmerthen automatically calculates the time that isrequired to attain the temperature level (L1) basedon the desired ramp rate (r1). Dwell segments (d1)then can be attached to each temperature level(L1) to hold that temperature for a specifiedamount of time.

Make sure the PROG parameter is set to idle (tostop program) when entering program values. (SeeParameters .)

Push “PAR” until “r1” is displayed. Push “UP” or“DOWN” buttons and set ramp rate “r1” (heatincrease or decrease) in °C/minute.

Push “PAR” until “L1” is displayed. Push “UP” or“DOWN” buttons and set temperature level “L1.”This is the target temperature for the first ramp.

Push “PAR” until “d1” is displayed. Push “UP” or“DOWN” buttons and set dwell (soak) time “d1” inminutes.

Graphing a New Program


26

Push “PAR” until “r2” is displayed. Push “UP” or“DOWN” buttons and set ramp rate “r2” in °C/minutes.

Push “PAR” until “L2” is displayed. Push “UP” or“DOWN” buttons and set temperature level “L2.”This is the target temperature for the second ramp.

Push ‘PAR’’ until “d2” is displayed. Push “UP” or“DOWN” buttons and set dwell (soak) time “d2” inminutes.

Push “PAR” until “SP” is displayed. Push “UP” or“DOWN” buttons and modify set point temperature.After “d2” dwell time has expired, thus ending theprogram, the last temperature level to be attainedwill be equal to “SP” temperature. For example, ifafter your program has been completed, you wantthe furnace to cool to ambient, set “SP” to 20. Thiswill be the last temperature level attained.

Push “PAR” until “LC” is displayed. Push “UP” or“DOWN” buttons and set “LC” (loop count - numberof times program is repeated).

Skipping SegmentsIf you desire to skip a ramp or dwell segment, fol-low this procedure:

• for a dwell segment, enter a setting of “0”minutes.

• for a ramp segment, enter a high valuesuch as 100°/min. This will cause con-troller to skip to the next segment as fastas the furnace is capable.

Setting the Holdback FeatureThis controller features a holdback (Hb) function toensure programmed parameter values are adheredto. Holdback is set in display units (degrees C or F)


27

and represents the allowable excursion of mea-sured value away from the current set point, eitherabove or below, before the program is forced intohold (clock stops).

The program will remain in hold until the mea-sured value comes within holdback band (clockstarts). This feature is active the whole time thatthe program is running. (Holdback functions onlywhile running a program).

Push PAR until “Hb” is displayed. Select desiredholdback setting - a setting of 20° is recommended.

If a running program is forced into holdback, theilluminated dot below the “R” symbol on controllerwill flash and the PROG parameter will indicate“Hb.” When the program is in “holdback,” it effec-tively lengthens the time of the program - if theholdback band “Hb” is set too low, the program willnever escape the holdback band, thus the programwill never be completed. If you do not want to usethe holdback function, set “Hb” to an extremelylarge value.

Implementing ProgramsWhen you have finished programming and areready to run your program, push “PAR” until PROGis displayed. Pushing the “UP” or “DOWN” buttons,you have three options: “Run” (to start program),“idle” (to stop program), “hold” (to hold program) -parameter values can be changed when hold ischosen.

Program ExecutionWhen “run” is selected, the program will start fromthe actual furnace temperature at that point in time.The dot under “R” on the control will illuminate toindicate the program is running.

Parameter values r1, L1, D1,r2, L2, D2 and LC cannot beadjusted while running a pro-gram.

Note


28

Program HoldTo adjust parameters while running a program, youmust put control into “Hold.” Push “PAR” until“prog” is displayed. Push “UP” or “DOWN” buttonsuntil Hold is displayed. When the dot underneath“R” on controller flashes and “Hold” is indicated atthe “prog” parameter, the controller is in Hold. Nowyou are able to adjust all parameters. To restart theprogram, set “prog” to “run” again.

Program IdleTo stop program, push “PAR” button until “prog” isdisplayed. Push “UP” or “DOWN” buttons until“idle” is displayed. This will terminate a running pro-gram.


29


Digital Readout:The digital readout continuously displays chamber(upper display) and setpoint (lower display) temper-atures unless the scroll button is depressed.

If the scroll button is depressed and released,the lower display will indicate output power (OP) orsetpoint (SP). This is referred to as the “shortscroll.” Continued single step action of scroll buttonwill cause lower display to alternate between set-point (SP) and output power (OP).

To enter the main scroll list (list of all controllerparameters that are accessed through front key-board), the scroll button should be held depressed.PR1 (program ramp rate 1) will appear. To progressthrough the parameter list, the scroll button mustfirst be released; subsequent single step depres-sion will advance you through the list. Rapid pro-gression through the parameter list is achieved byholding the scroll button depressed.

When performing operationswith the controller, if youdepress and release either the“scroll,” “up,” or “down” pushbuttons and more than 8 sec-onds elapse before the buttonsare used again, the displayscreen will automatically switchback to displaying setpointtemperature. If this happens,you will have to step througheach parameter until you reachthe point at which the interrup-tion occurred. The parametervalues you adjusted earlier,however, will not be lost oraltered.

Note

8 Ramp & 8 Dwell Multi-Programmable Models

Figure 7 Multi-Programmable Control (8 ramp & 8 dwell)

Alarm Active Temperature Setpoint

Screw Retaining Instrument in Sleeve

Furnace ChamberTemperature(At Startup, DisplaysSoftware VersionNumber)DigitalCommunications

Condition of Program,Ramp or Dwell and ifProgram is Held, RampDwell Segment CurrentlyRunningUp Button

Run/Hold Button

Down Button

Parameter Selected onSecondary Display:SP = SetpointOP = Output PowerTime = Time Remaining inProgram

Adaptive or SelfTune Selected (AT)

Scroll Button

Nonfunctional

30

See Parameters for a list of the controller para-meters in order.

Power SwitchTurn power switch to the “ON” position.


Door Safety Switch: The door safety switch removes power from theheating elements when the door is opened. Openand close door a few times, note that the amberfurnace power light will go out while the door isopen. If the furnace power light does not go outwhile the door is open, consult the Troubleshootingsection before proceeding.

ParametersPnr - Program Number . The program number ofthe program you are are going to work with. Bypushing the up or down button you can select aprogram numbered from 1 to 4. PR1 - Program Ramp Rate . The rate of heatincrease or decrease in °C/minutes. Pushing the upor down button will give current setting of thisramp. PL1 - Program Level. The temperature to whichthe furnace needs to attain. Push up or down but-ton to set. PD1 - Program Dwell 1. Amount of time in minutesto hold PL1 program level temperature. Push up ordown button to set.


The two center push buttonsare inactive and not used.

Remember that whenever thepower switch is turned “ON,”the furnace will begin to heatat the setpoint temperaturethat was previously set in. Thisvalue will remain unchangedfor up to a year without powerbeing applied to the control.

To change from °C indicationto °F indication, contactBarnstead/Thermolyne.

Note

Caution

Warning

Note

8 RAMP & 8 DWELL MULTI-PROGRAMMABLE MODELS

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You will use the same descriptions and proceduresused for PR1, PL1, PD1 for the remaining ProgramRamp Rates PR2 - PR8, Program Levels PL2 -PL8, and Program Dwells PD2 - PD8.Cnt - Continue. Allows linking of programs. Youmay select Cnt as “y” (yes) or “n” (no) by pushingthe up or down button. HB - Holdback. Automatically places the program-mer into “Hold” if the measured value deviatesmore than a specified amount from programmersetpoint. When measured value re-enters the hold-back band, the timing for the segment resumes.(Parameter is expressed in °C and only functionswhen running a program). Push up or down buttonto set. PLC - Program Loop Count. The number of timesa program will be repeated. Push up or down but-ton to set. SP1 - Setpoint One. Indicates current setpoint.Push up or down button to set. SP2 - Setpoint two. Not configured into controland nonfunctional. Set to “20”.AT - Adaptive T une. Analyzes and inputs optimumPID values when temperature has reached set-point. This function does not have a value; it iseither “ON” or “OFF.” (See Furnace Operation forfunction of Adaptive Tune).ATR - Adaptive T une Range setting. Determinesthe operational band width of the adaptive tuningfunction. Self Tuning automatically determines thissetting.AL1 - Alarm 1. A full scale alarm which protectsload and furnace when temperature exceeds pre-set value. Furnace will control temperature at thepreset temperature value; it will not shut off fur-nace. Push up or down button to set.

Thermolyne recommends thatyou set the AL1 value either atmaximum operating tempera-ture of the furnace (1100°C =2012°F) or a value of 20degrees above your workingtemperature if you desire toprovide protection for yourworkload.

Note


32

The next three parameters - Proportional (PB)Integral (+i) and Derivative (+d) - are the three con-trol parameters of a P.l.D. control system. Theseparameters will be set when you tune your furnace.(See Self-Adaptive T uning .)Pb - Proportional.(+i) - Integral.(+d) - Derivative.

The next two parameters - cutback low (cbl) andcutback high (cbh) - are to aid the control in pre-venting temperature overshoots and undershoots.The point from setpoint where the power starts“cutting back” is defined as the cutback value.These values are also automatically adjusted bythe Self Tuning and Adaptive Tuning features.These values cannot be changed by the user; thecontroller automatically installs optimum cutbackvalues when in Self Tuning and Adaptive Tuning.HL - Output Power limits the average maximumpower that is applied to the heating elements.Normal setting is 100%. If you plan to use the fur-nace below 260°C (500°F) the output power maybe reduced. This will significantly shorten the time ittakes for stabilization. It will also reduce drastictemperature overshoots. ContactBarnstead/Thermolyne Customer Service foradvice on the proper value to use. Remember thatthis parameter does not reduce the voltage to theelements. It reduces the average power to the ele-ments by cycling power on and off.HC - Cycle T ime is the rate at which power is sup-plied to power control switch. Push up or down but-ton to set.Sbr - the percent of power that is supplied tothe control output terminals if an open thermo -couple condition exists. Push up or down buttonto check. 0.0 will be displayed. This parameter can-not be changed; if 0.0 is not displayed, contactBarnstead/Thermolyne. The upper display will flash“OR” if an open thermocouple condition exists.


33

Tuning Your Controller The programmable control has automatic tuningfeatures which install optimum tuning parametersto give the best temperature accuracy. No manualloading of tuning parameters is needed. We highlyrecommend using these features to provide thebest temperature accuracy the controller can attain.Perform the following procedures when you first setup your furnace and each time you change yourload type, operating temperature, or program.

The following procedure is instruction on how toinitiate the SAT Self and Adaptive Tuning feature.This feature starts the controller in the Self Tunemode, then automatically switches over to theAdaptive Tuning Feature. Self Tuning permits youto retune the instrument control parameters to suitnew process conditions. Adaptive tuning takes overwhen the self tune is completed and continuouslyreevaluates the tuned parameters. Adaptive tuningwill then automatically install new values if a betterresponse could have been attained.

To initiate the tuning featureLoad your furnace with a load characteristic ofthose you intend to heat in it.

Depress the scroll button until SAT is displayed.Depress the up and down buttons simultaneouslyto start self tuning. The A-T indicator is then illumi-nated (upper right hand comer) and the lower dis-play indicates the setpoint at which the self-tunesequence will occur. The “SP” indicator will flash for


34

1 minute, during which time the setpoint may bechanged, if it is required to retune at a new setpointeither above or below the process value indicatedon the upper display. (If you will be using the con-troller as a single Setpoint Controller, set the fur-nace’s setpoint to the temperature you intend touse for your application. If you will be running amulti-step program, set the furnace’s setpoint to thevalue of PL1 (Program Level #1). At the end ofthe minute, the “SP” indicator will stop flashing,indicating that the setpoint can no longer bechanged. The A-T indicator will start flashing andcontinue to flash until the self tune has completed.Once the self tune is completed, adaptive tunetakes over and the A-T indicator will remain illumi-nated.

To stop tuning, function scroll until SAT is dis-played and simultaneously push up and down but-tons.

Operating the Controller

Single Set Point OperationThis programmable control can be used as a singlesetpoint control or as a programmable control. Touse as a single set point control, simply the pushup or down buttons to choose a specific tempera-ture. Temperature setpoint or output power is indi-cated on lower display; single depression of thescroll button will alternate between these two para-meters. The control will cause the furnace chamberto heat to the chosen temperature and hold it atthis temperature until you turn off the power switchor select another temperature.

Do not exceed limitations forcontinuous or intermittent oper-ating temperature shown in theGeneral Specifications.Exceeding these limits willresult in severely reducedheating element life.

Caution



Hot Surface


35

a. The setpoint temperature presently set inthe control will be read out on the lowerdisplay.

b. To change this set point, depress the “UP”or “DOWN” push button until the desiredsetpoint value is displayed then releasethe button.

c. At this point the furnace will begin to heatif the new set point temperature you havechosen is higher than the present cham-ber temperature.

The upper display indicates the actual furnace tem-perature.

Programming ControllerThe multi-programmable controller in these unitsprovides up to 4 separate programs of 8 ramps and8 dwells each. This controller also allows you tolink programs together, which allows you to achieve64 total segments (4 programs X 16 segments).These functions are controlled by the controller’sfirst two programming parameters, “Pnr” and “Cnt.”

A maximum of 8 ramp and 8 dwell segment com-binations are available per program, thus enablingeight different setpoint levels to be achieved. Eachramp is programmed by specifying the programlevel (PL) and the required ramp rate (PR). Theprogrammer then automatically calculates the timethat is required to attain the program level (PL)based on desired ramp rate (PR). Dwell segments(soak) then can be attached to each program level(PL) to hold that temperature for a specified time.


36

To run a program, first determine your ramp rate,dwell times and program levels. It is helpful tograph your program for ease of loading programinto controller.

Program EntryTo Select Program Number

Push scroll button until “Pnr 1” is displayed. Pushthe up or down button to select a program numberfrom 1 to 4.

To Link Programs TogetherPush scroll button until “Cnt n” is displayed. Pressand release the up and down buttons to switchbetween “Cnt y” (continue yes) and “Cnt n” (contin-ue no). The effect of selecting “Cnt y” is to continuethe program to the next program number. Forexample, if in program #3 you select “Cnt y,” whenprogram #3 is complete, program #4 will run auto-matically. Setting “Cnt y” in program #4 will initiatethe start of program #1 upon the completion of pro-gram #4. Each program will complete the selectednumber of loops before continuing (see LoopCount). If you do not want to link programs, set Cntto “Cnt n” (continue no).

Set Ramp Rates1. With the programmer not operating, indi-

cated by the bottom right hand side of thedisplay extinguished, depress scroll buttonuntil PR1 is displayed. Push the up ordown button to scroll to the desired value,which is degrees per minute.

Scrolling down below zero will give three otheroptions for the ramp:

NONE-which will force the program to skipto the next segment;

Once the desired parameterhas been selected, depressingeither the raise or lower buttonwill cause the parameter to bereplaced with the new value. Atthis point, the “top dot” of theleast significant digit of thesecondary display will flash onand off. Any further use of upor down buttons will changeparameter value. In all cases,the value shown on the displayis the current working value ofthat parameter.

Note


37

END-which will cause the program to stopor restart if loops remaining is not zero;

STEP-which will cause the program toramp as quickly as possible to the nexttemperature level.

All other ramps in the program are set in a simi-lar fashion by selecting ‘PR’ followed by the rele-vant ramp number.

Set Level Temperatures2. The level to which the first ramp is aiming

is entered by scrolling through the mainscroll list until “PL1” is displayed. Bypressing either the up or down button, thepresent value of this level is indicated indisplay units. Using the up or down buttonwill scroll the present value to the newvalue required. All other levels in the pro-gram are set in a similar fashion by select-ing ‘PL’ followed by the relevant number.

Set Dwell Times3. To set the dwell time for the first level,

scroll through the main scroll list until“Pd1” is displayed. Pressing the up ordown button will reveal the current valueof time in minutes. Using the up or downbutton will scroll the present value to thenew value required. Scrolling this valuedownscale will allow a setting of “END.” Asetting of “END” will terminate the pro-gram, or force it to restart if loops remain-ing are not zero at the beginning of thatdwell.

All other dwells in the program can be set in asimilar fashion by selecting “Pd” followed by therelevant dwell number.


38

Set the Number of Times to Repeat the Program4. Scrolling through the main scroll until the

parameter “PLC” is displayed and thendepressing the up or down button willreveal the present setting of the loopcount. This is the number of times that theentered program will be repeated before acontinuous setpoint at the last level of theprogram is achieved. By pushing the up ordown button, the number of loops can beset at any value from 1 to 999.

Set the Holdback Feature5. Scroll through the main scroll list until

“HB” is displayed. Push the up or downbutton to reveal the current value of hold-back. The up or down button can now bedepressed to scroll to the required value.Holdback is set in display units and repre-sents the allowable excursion of mea-sured value away from the current set-point, either above or below, before theprogram is forced into hold. The programwill remain in hold until the measuredvalue comes within holdback limits. Thisfeature is active the whole time that theprogram is running. When hold is forcedonto the program by holdback, the“HOLD’”legend is not illuminated but eitherthe “RAMP” or “DWELL” legend will flash.


39

Implementing Programs

Program ExecutionOnce the program has been entered it can be setrunning by depressing the ‘RUN/HOLD’ push but-ton on the front.

With the run initiated, the program will com-mence and the legend on the display will indicate ifa ramp or dwell is being performed. While a pro-gram is running, the short scroll will contain a thirdparameter “TIME.” Push the scroll button once;time remaining for the current segment, either rampor dwell, will be indicated. If the loop counter hasbeen set to any value other than one, then theabove procedure will be repeated for each loop.

At the end of the complete program, an “E” willappear on the display.

Parameter Change While RunningThe parameters can be inspected but not changedwhile a program is running. If it is necessary toalter a parameter while a program is running, theprogram must be placed into the hold condition. Toput a program into hold, push the run/hold buttononce. After modification of the parameter, returningthe program to the run state will cause the programto continue with the changed value(s) installed.Push run/hold button again to restart program.

Loop CountIf the loop count is set to values other than one,then the number of loops remaining in a runningprogram can be displayed. To determine whichloop is being performed depress the scroll buttonuntil LR’ is displayed and, by pushing either the upor down button, the remaining number of loops,excluding the one being executed, is displayed.

Be sure to select the programnumber before pressing“Run/Hold.”

Note


40

Program HoldA running program can be forced into hold at anystage by depressing the “RUN/HOLD” push buttonon the front. When a running program is forced intohold, the “HOLD” legend will appear on the displaytogether with the segment type and will be flashing.Pushing “RUN/HOLD” button again will return theprogram to a run situation and extinguish the“HOLD” legend.

Program ResetA running, held or finished program can be reset bydepressing the up and down push buttons together.

When the reset has been enabled, the parts ofthe display associated with programming will beextinguished and the controller will operate as asingle setpoint control.

The temperature control inthese models is a programma-ble “and” automatic single set-point device. When the pro-gram has ended, the controllerwill maintain the chamber tem-perature at a value equal tothe last programmed level (PL)until the program is cancelled.It will not automatically cool toambient unless last pro-grammed level (PL) is set atambient. When a program iscancelled, the controller willmaintain the chamber tempera-ture at a value equal to themain setpoint (SP1 or SP). Tocancel a program, depress andrelease the “UP” and “DOWN”push buttons simultaneously.Be sure single set point modeis set to 20 degrees or belowas described earlier in thismanual.

Note


41

These furnaces are designed to be used to 1200°Cin a respirable atmosphere only. When injectingatmospheres into the process tube, use proper pro-cedures to avoid leakage which may contaminatethe heating elements.

The heating elements in these furnaces areattacked by fluorine, chlorine, sodium and potassi-um compounds and also by molten metals.

Furnace Atmospheres andFurnace Loading

For best results, use only the center two-thirds ofthe furnace chamber.

Keep objects away from the thermocouple.Use insulated tongs and mittens when loading

and unloading the furnace.Always wear safety glasses.Never come into contact with the heating ele-

ments. Hitting the elements with tongs or laying theload against them will cause the elements to burnout.

42

Preventative Maintenance

Housekeeping is vital to your electric furnace –KEEP IT CLEAN. Occasionally run your furnace upto 1600°F (871°C) empty to burn off the contamina-tion that may exist on the insulation and elements.Maintain 1600°F (871°C) for at least 4 hours toinsure complete ashing of foreign materials. This isonly necessary if contaminants build up on theheating elements or the insulation.

Element life is reduced somewhat by repeatedheating and cooling. If the furnace is to be usedagain within a few hours, it is best to keep it at theoperating temperature or at a reduced level suchas 500°F (260°C).

Thermolyne highly recommends that you replacethe thermocouple periodically (once every sixmonths) to ensure temperature accuracy.

General cleaning instructionsWipe exterior surfaces with a dampened cloth con-taining a mild soap solution.

43

Troubleshooting Tips

The Troubleshooting Tips section is intended to aid in defining and correcting possible ser-vice problems. When using the chart, select the problem category that resembles the mal-function. Then proceed to the possible causes category and take necessary correctiveaction. If difficulties persist, call Barnstead|Thermolyne customer service at 1-800-553-0039.

Problem Possible Causes Solutions

The power switch does notilluminate.

The furnace is notconnected to powersupply.

Check furnace connectionto power supply.

The furnace does not heat. No power. Check power source andfuses or breakers.

Thermocouple is open orthermocouple leads arereversed.

Replace thermocouple orcheck thermocoupleconnections.

One of the elements isburned out.

Replace the burned outelement.

Heat switch not turned"On."

Turn on Heat switch.

Slow heatup. Low line voltage. Install line of sufficient sizeand proper voltage.(Isolate furnace from otherelectrical loads.)

Heavy load in chamber. Lighten loan in chamber toallow heat to circulate.

Low ramp rate setting. Increase setting.

Repeated element burnout. Control malfunction. Replace control.Oxidized thermocoupleleading to inaccuratereading.

Replace thermocouple.

Heating elementcontamination.

ContactBarnstead|Thermolyne.


The power switch does notilluminate.

The furnace is notconnected to powersupply.

Check furnace connectionto power supply.

The furnace does not heat. No power. Check power source andfuses or breakers.

Thermocouple is open. Replace thermocouple. One of the elements isburned out.

Replace the burned outelement.

Heat switch not turned"On."

Turn on Heat switch.

Slow heatup. Low line voltage. Install line of sufficient sizeand proper voltage.(Isolate furnace from otherelectrical loads.)

Heavy load in chamber. Lighten loan in chamber toallow heat to circulate.

Low ramp rate setting. Increase setting.

Repeated element burnout. Control malfunction. Replace control.Thermocouple leads arereversed.

Check thermocoupleconnections.

Oxidized thermocoupleleading to inaccuratereading.


Heating elementcontamination.

ContactBarnstead|Thermolyne.

44

TROUBLESHOOTING TIPS


Inaccurate temperaturereadout.

Oxidized or contaminatedthermocouple.


Poor thermocoupleconnection.

Tighten connections.

Improper loadingprocedures

Use proper loadingprocedures.

Thermocouple connectionsreversed.

Reconnect thermocouplecorrectly.

Control out of calibration. ContactBarnstead|Thermolyne.

P.I.D. values invalid. Retune control.Control malfunction. Verify and correct all

parameter andconfiguration values.

Main fuses blow or circuitbreakers trip.

Fuses or breakers notproperly rated to furnacepower requirements.

Install service line ofsufficient size to matchfurnace powerrequirement. Contactqualified electrician forassistance.

45

Maintenance and Servicing

Warning To avoid electrical shock,this furnace must always bedisconnected from the powersupply prior to maintenanceand service.

Perform only maintenancedescribed in this manual.Contact an authorized dealeror our factory for parts andassistance.

Refer servicing to qualifiedpersonnel.

Element ReplacementThe F79300 Tube Furnace contains two heatingelements, one in the bottom half of the furnacesection and the other in the top half. Becausethese elements are wired serially, if one burns out,the other will not receive power. Therefore, eventhough the furnace will not heat and the amber"Heat" light will not light when the "Heat" button ispressed, you may need to replace only one ele-ment.

The F79400 Tube Furnace contains four heatingelements, two in the bottom half of the furnace andtwo in the top half. The elements are wired seriallyon each side (i.e. the left top and bottom are wiredtogether and the right top and bottom are wiredtogether). Therefore, when one element burns out,that side of your furnace will not heat. The otherside of the furnace will continue to operate and the"Heat" light will still light. Your load will showuneven heating, since the temperature in theunheated half of the furnace will be considerablylower than in the heated half. In most (but not nec-essarily all) instances, the furnace chamber tem-perature will never reach your setpoint.

Terminal Cover

Figure 8 Terminal Cover Location

46

MAINTENANCE AND SERVICING

Element CheckTo determine which of the heating elements is burned out:

1. Disconnect the power from the furnace.

2. Remove the terminal cover from the back of thebottom half of the furnace section.

3. With an ohmmeter, check the continuity of theelements. The element which returns an open orinfinite reading must be replaced.

On an F79300 : Test the top elementbetween the top of terminal T1 and the top of ter-minal T3. Test the bottom element between thetop of terminal T2 and the bottom of terminal T3.

On an F79400 : Test the top right elementbetween the top of terminal T1 and the top of ter-minal T3. Test the top left element between thetop of terminal T1 and the top of terminal T4.Test the bottom right element between the top ofterminal T2 and the bottom of terminal T3. Testthe bottom left element between the top of termi-nal T2 and the bottom of terminal T4.

Replacing The Bottom Element1. Disconnect the element leads for the burned out

element from the terminals specified in ElementCheck step #3. At the same time, disconnect theground wire from the grounding bolt located tothe right of the terminal block.

2. Remove the side covers from the bottom furnacesection. (Seven black sheet metal screws secureeach side cover.)

3. Remove the brackets (one on each side) secur-ing the element assembly. (Four pointed screwssecure each bracket.)

Note On an F79400 furnace,you only need toremove the cover,brackets, etc. from thefurnace side on whichthe element is burnedout.

47


4. Remove the six flat end screws securing the innershield to the outer shell.

5. Remove the inner shield from the outer shell.

6. Locate the screws on the bottom of the inner shieldthat secure the element support brackets. Loosenthese screws.

7. Slide the burned out element (and an end insula-tion piece) out of the inner shield. Handle the insu-lation carefully.

8. Note the difference in length between the two ele-ment lead wires and the location of each wire'sconnection to the element. Remove the elementleads with their protective sleeves from the ele-ment.

9. Connect the element leads to your replacementelement. Be sure to attach each lead in the sameposition that it was attached to the old element.

10. Slide the new element (and the end insulationpiece) into the inner shell, routing the element leadwires through the notches in the inner shell.

11. Center the element(s) and the two end insulationpieces in the element support brackets.

12. Tighten the screws securing the element supportbrackets until the element(s) is (are) secure.

13. Replace the inner shield in the outer shell, routingthe element lead wires and the ground wirethrough the bushing in the outer shell to the termi-nal block.

14. Replace the six flat end screws securing the innershield to the outer shell.

48


15. Replace the brackets securing the elementassembly. (Four pointed screws secure eachbracket.)

16. Replace the end plates. (Seven black sheetmetal screws secure each side cover.)

17. Connect the element lead wires to the terminalsspecified in Element Check step #3. Reconnectthe ground wire to the grounding bolt located tothe right of the terminal blocks.

18. Replace the terminal block cover. Reconnect thefurnace to the power supply and test the furnace.

Replacing The T op Element1. Remove the thermocouple using steps 2-4 of

"Replacing the Thermocouple."

2. Disconnect the element leads for the burned outelement from the terminals specified in ElementCheck step #3. At the same time, disconnect theground wire from the grounding bolt located tothe right of the terminal blocks. Remove the pro-tective sleeve covering the wires between the topand bottom sections of the furnace.

3. Remove the side covers from the top furnacesection. (Seven black sheet metal screws secureeach side cover.)

4. Remove the two brackets (one each side) secur-ing the element assembly. (Four pointed screwssecure each bracket.)

5. Remove the six flat end screws securing theinner shield to the outer shell.

6. Remove the inner shield from the outer shell.

49


7. Locate the screws on the top of the inner shieldthat secure the element support brackets. Loosenthese screws.

8. Slide the element (and an end insulation piece) outof the inner shield. Handle the insulation carefully.

9. Note the difference in length between the two ele-ment lead wires and the location of each wire'sconnection to the element. Remove the elementleads with their protective sleeves from the ele-ment.

10. Connect the element leads to your replacementelement. Be sure to attach each lead in the sameposition that it was attached to the old element.

11. Slide the new element (and the end insulationpiece) into the inner shell, routing the element leadwires through the notches in the inner shell.

12. Center the element(s) and the two end insulationpieces in the element support brackets.

13. Tighten the screws securing the element supportbrackets until the element(s) is (are) secure.

14. Replace the inner shield in the outer shell, routingthe element lead wires and the ground wirethrough the bushing in the outer shell.

15. Replace the six screws securing the inner shield tothe outer shell.

16. Replace the brackets securing the element assem-bly. (Four pointed screws secure each bracket.)

17. Replace the end plates. (Seven black sheet metalscrews secure each side cover.)

50


18. Replace the protective sleeve over the wiresbetween the two furnace sections. Route thewires to the terminal block.

19. Connect the element lead wires to the terminalsspecified in Element Check step #3. Reconnectthe ground wire to the grounding bolt located tothe right of the terminal block. Replace the termi-nal block cover.

20. Create a hole for the thermocouple in the newelement.

a. Place a 4" (10 cm) long, 1/4" (6 mm) drill bitinto the thermocouple hole in the innershield (reached through the access hole onthe top of the upper section.)

b. Carefully press the drill bit straight down intothe furnace chamber.

21. Reinstall the thermocouple using steps 6-8 of"Replacing the Thermocouple."

22. Reconnect the furnace to the power supply andtest the furnace.

Replacing The Thermocouple1. Disconnect the furnace from the power supply.

2. Remove the four black screws securing the ther-mocouple access panel on the top of the upperfurnace section. Remove the access panel.

3. Locate the thermocouple terminal block in thecompartment beneath the access panel.Disconnect the thermocouple lead wires and thethermocouple signal wires from the terminalblock.

51


4. Carefully pull the thermocouple straight out of thefurnace. The ceramic thermocouple bushing willcome out with the thermocouple.

5. Move the ceramic thermocouple bushing to the newthermocouple.

6. Carefully insert the new thermocouple fully into thefurnace. Ensure that the thermocouple tip protrudesinto the furnace chamber.

7. Connect the thermocouple signal wires and the leadwires of the new thermocouple to the thermocoupleterminal block.

a. Connect the yellow thermocouple signal wireand the yellow beaded thermocouple lead wireto the "+" terminal.

b. Connect the red thermocouple signal wire andthe thermocouple lead wire with only whiteceramic beads to the "-" terminal.

8. Replace the thermocouple access panel and rese-cure it with the four screws.

9. Reconnect the furnace to the power supply and test.

52

Replacement Parts ListF79300 F79400

Circuit Breaker 220/240 V SWX164 SWX103(-33 models) (-33 models)

Element 220/240 V EL793X2A120 V EL793X1A208 V EL793X3A

End Insulation Left Side JC793X4Right Side JC793X5

Electronic Control Single Setpoint CN71X512R/2D CN71X408R/8D CN71X56

Thermocouple TC408X1AMechanical Relay 220/240 V RYX62

208 V RYX62120 V RYX63

F79300 F79400Power Cordset 220/240 V CR793X2 CR794X2

208 V CR793X2 CR794X2120 V CR793X1 N/A

Door Switch Cordset CR793X3Solid State Relay 220/240 V RYX34

208 V RYX34120 V RYX37

Cycle Light (Amber) 220/240 V PLX104208 V PLX104120 V PLX103

ON/OFF Power Switch 220/240 V SWX138208 V SWX138120 V SWX137

HEAT Switch SWX108Furnace Safety Switch 04246

AccessoriesVertical Support Stand AY793X1Insulation Collars 1" I.D. JC793X1

2" I.D. JC793X23" I.D. JC793X3

10 Foot Remote Operation Extension PackageIncludes: 1 power cordset, 10 feet long; 1 thermocouple cordset, 10 feet long; and 2 door switchcords, each 5 feet long. Order the appropriate package for you furnace voltage.

220/240 V AY793X2120 V AY793X3208 V AY793X2

53

Ordering Procedures

Please refer to the Specification Plate for the com-plete model number, serial number, and seriesnumber when requesting service, replacementparts or in any correspondence concerning thisunit.

All parts listed herein may be ordered from theBarnstead|Thermolyne dealer from whom youpurchased this unit or can be obtained promptlyfrom the factory. When service or replacementparts are needed we ask that you check first withyour dealer. If the dealer cannot handle yourrequest, then contact our Customer ServiceDepartment at 319-556-2241 or 800-553-0039.

Prior to returning any materials toBarnstead|Thermolyne Corp ., please contact ourCustomer Service Department for a “Return GoodsAuthorization” number (RGA). Material returnedwithout a RGA number will be refused. Minimuminvoice: $25.

54

Wiring Diagrams for F79300

Single Setpoint Controller Models

55

WIRING DIAGRAMS FOR F79300

2 Ramp/2 Dwell Controller Models

56



57

Wiring Diagrams for F79400

Single Setpoint Controller Models

58



59



60

Exploded Views for F79300

Bottom Furnace Section

Top Furnace Section

1

32

4

5

6

7 8

9

1

3

2

4

5

8

11

5

8

5

8

61

EXPLODED VIEWS

Final Assembly

Control Section

12

13

14

15

1617 20

18

11

19

21

See Detail A

10

DETAIL A

62

Exploded View Key (F79300)

Key # Quantity Part # Description1 2 JC793X4 End Insulation2 2 JC793X5 End Insulation3 2 EL793X1A Heating Element, 120 Volt

2 EL793X2A Heating Element, 240 Volt2 EL793X3A Heating Element, 208 Volt

4 4 CS793X1 Element Retaining Bracket5 4 BC793X5 End Bracket6 1 TRX183 Thermocouple Terminal Block7 1 TC408X1A Thermocouple8 4 PT793X3A End Panel9 1 HN480X1A Handle10 1 04246 Furnace Safety Switch11 1 04206 Terminal Block12 1 * Electronic Control13 1 SWX138 Switch14 1 SWX108 Switch15 1 PLX104 Pilot Light16 1 RYX34 Relay17 1 RYX62 Relay18 1 CEX205 Connector19 1 CEX206 Connector20 1 CE1080X1A Connector21 3 FCX89 Latch

*Electronic Control Single Setpoint CN71X512R/2D CN71X408R/8D CN71X56

63

Exploded Views for F79400

Top Furnace Section

1

3

2

4

5

6

7

8

9

4

5

8

64

EXPLODED VIEWS

Bottom Furnace Section

1

3

2

4

5

8

22

4

8

5

65

EXPLODED VIEWS

Control Section

*Electronic Control Single Setpoint CN71X512R/2D CN71X408R/8D CN71X56

11

18

17

16

13

14

12

19

15

20

66Final Assembly

EXPLODED VIEWS

21

See Detail A

10

DETAIL A

67

Exploded View Key (F79400)

Key # Quantity Part # Description1 2 JC793X4 End Insulation2 2 JC793X5 End Insulation3 4 EL793X2A Heating Element, 240 Volt

4 EL793X3A Heating Element, 208 Volt4 8 CS793X1 Element Retaining Bracket5 4 BC793X5 End Bracket6 1 TRX183 Thermocouple Terminal Block7 1 TC408X1A Thermocouple8 4 PT793X3A End Panel9 1 HN480X1A Handle10 1 04246 Furnace Safety Switch11 3 04150 Terminal Block

1 04151 Terminal Block12 1 * Electronic Control13 1 SWX138 Switch14 1 SWX108 Switch15 1 PLX104 Pilot Light16 1 RYX37 Relay17 1 RYX62 Relay18 1 CEX205 Connector19 1 CEX229 Connector20 1 CE1080X1A Connector21 3 FCX89 Latch22 4 04150 Terminal Block

1 04151 Terminal Block*Electronic Control Single Setpoint CN71X51

2R/2D CN71X408R/8D CN71X56

68

Barnstead|Thermolyne Corporation warrants that if a product manufactured byBarnstead|Thermolyne and sold by it within the continental United States or Canadaproves to be defective in material or construction, it will provide you, without charge, for aperiod of ninety (90) days, the labor, and a period of one (1) year, the parts, necessary toremedy any such defect. Outside the continental United States and Canada, the warrantyprovides, for one (1) year, the parts necessary to remedy any such defect. The warrantyperiod shall commence either six (6) months following the date the product is sold byBarnstead|Thermolyne or on the date it is purchased by the original retail consumer,whichever date occurs first.

All warranty inspections and repairs must be performed by and parts obtained froman authorized Barnstead|Thermolyne dealer or Barnstead|Thermolyne (at its own dis -cretion) . Heating elements, however, because of their susceptibility to overheating and con-tamination, must be returned to our factory, and if, upon inspection, it is concluded that fail-ure is not due to excessive high temperature or contamination, warranty replacement will beprovided by Barnstead|Thermolyne . The name of the authorized Barnstead|Thermolynedealer nearest you may be obtained by calling 1-800-446-6060 or writing to:

Barnstead|ThermolyneP.O. Box 797

2555 Kerper BoulevardDubuque, IA 52004-0797

USAFAX: (319) 589-0516

E-Mail: [email protected]|Thermolyne’ s sole obligation with respect to its product shall be to repair

or replace the product. Under no circumstances shall it be liable for incidental or conse-quential damage.

THE WARRANTY STATED HEREIN IS THE SOLE WARRANTY APPLICABLE TOBarnstead|Thermolyne PRODUCTS. Barnstead|Thermolyne EXPRESSLY DISCLAIMSANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WAR-RANTIES OF MERCHANTABILITY OR FITNESS FOR USE.

One Year Limited Warranty

Barnstead Thermolyne2555 Kerper Blvd.P.O. Box 797Dubuque, IA 52004-0797 USAPHONE: 319-556-2241 • 800-553-0039FAX: 319-589-0516E-Mail: [email protected]

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Types F79300 & F79400 Tube Furnaces ma… · Types F79300 & F79400 Tube Furnaces OPERATION MANUAL AND PARTS LIST SERIES 1080 & 1081 ... Thank you for buying this Thermolyne tube furnace