Type 30400 Thermolyne Furnace OPERATION MANUAL AND PARTS LIST Series 1262 Single Setpoint Models F30420C, F30420C-33, F30428C 8 Segment Programmable Models with OTP F30420C-33-80, F30420-33-60-80 F30420C-60-80, F30420C-80 F30428C-60-80, F30428C-80 4 X 16 Segment Programmable Models with OTP F30430CM, F30430CM-33, F30430CM-33-60, F30430CM-60 F30438CM, F30438CM-60 LT1262X1 • 10/8/04
Table of Contents IMPORTANT INFORMATION This 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................................................................................................................................
TABLE OF CONTENTS Sensor Break Protection ............................................................................................................................26 Over Temperature Protection......................................................................................................................27 To Operate the Controller as a Single Setpoint Controller ........................................................................27 Programming Controller.....................................
Safety Information Alert Signals Warning Warnings alert you to a possibility of personal injury. Caution Cautions alert you to a possibility of damage to the equipment. Note Notes alert you to pertinent facts and conditions. Hot Surface Hot surfaces alert you to a possibility of personal injury if you come in contact with a surface during use or for a period of time after use. Your Barnstead Thermolyne furnace has been designed with function, reliability and safety in mind.
SAFETY INFORMATION carcinogenic (Group 2B), and crystalline silica as carcinogenic to humans (Group 1). The insulating materials can be located in the door, the hearth collar, in the chamber of the product or under the hot plate top. Tests performed by the manufacturer indicate that there is no risk of exposure to dust or respirable fibers resulting from operation of this product under normal conditions.
General Specifications Models F30420C, (-33), (-33-60-80), (-33-80), (-60-80) & (-80) F30428C, (-60-80) & (-80) F30438CM & (-60) F30430CM, (-33), (-33-60) & (-60) Overall Dimensions IN. (CM) Width Height Depth 21 1/2 (55) 29 1/2 (75) 25 1/2 (65) 21 1/2 (55) 29 1/2 (75) 25 1/2 (65) Chamber Dimensions IN. (CM Width Height Depth 14 (35) 14 (35) 14 5/8 (37) 14 (35) 14 (35) 14 5/8 (37) Weight Lbs. (KG) 188 (86) 188 (86) Electrical Ratings Volts Amps Watts Freq. Phase 240 22.
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 technical requirements of the following standards: EMC: EN 61000-3-2 EN 61000-3-3 EN 61326-1 Safety: EN 61010-1 EN 61010-2-010 Limits for harmonic current emissions Limits for voltage fluctuations and flicker Electrical equipment for measurement, control, and laboratory use; Part I: Generic Requirements Safety requirement
Introduction Intended Use 1. The Type 30400 Automatic and Programmable furnaces are general laboratory and heat treating furnaces. For optimum element life, Barnstead Thermolyne recommends these furnaces for applications requiring temperatures from 400°F (204°C) to 1800°F (982°C) for continuous use, or temperatures from 1800°F (982°C) to 2000°F (1093°C) for intermittent use. Continuous use is operating the furnace for more than 3 hours and intermittent use is operating the furnace for less than 3 hours.
INTRODUCTION MODEL NUMBER DIGITAL COMMUM. F30420C-33-80 F30420-33-60-80 F30420C-60-80 F30420C-80 F30428C-60-80 F30428C-80 F30430CM F30430CM-33 F30430CM-33-60 F30430CM-60 F30438CM F30438CM-60 NO NO NO NO NO NO YES YES YES YES YES YES TOTAL NUMBER OF PROGRAMMABLE SEGMENTS 8 8 8 8 8 8 64 16 64 16 64 16 64 16 64 16 64 16 NUMBER OF STORED PROGRAMS Segment Segment Segment Segment Segment Segment Programs Programs Programs Programs Programs Programs Principles of Operation 1.
Unpacking 10 1. Visually check for any physical damage to the shipping container. 2. Inspect the equipment surfaces that are adjacent to any damaged area. 3. Open the furnace door and remove the packing material from inside the furnace chamber. 4. Vacuum the chamber prior to use to remove the insulation dust due to shipment. 5. Retain the original packaging material if reshipment is foreseen or required.
Installation Site Selection Caution Be sure ambient temperature does not exceed 40°C (104°F). The recommended ambient temperature is 17°C - 27°C. Ambients above this level may result in damage to the controller. Caution Allow at least six inches of space between the furnace and any combustible surface. This permits the heat from the furnace case to escape so as not to create a possible fire hazard. Install furnace on a sturdy surface and allow adequate space for ventilation.
Operation, All Models Warning To avoid personal injury do not use in the presence of flammable or combustible chemicals; fire or explosion may result. This device contains components which may ignite such materials. Power Switch Both the ON/OFF power switch and the digital display will illuminate when power is switched ON. The furnace will begin to heat to its controller's current setpoint. (See the instructions for your type of controller for information on checking and setting the setpoint.
Single Setpoint Models w/OTP Output 2 Output 1 Temperature Display Manual The single setpoint model w/ OTP furnace controller is a single setpoint controller which provides a single digital display to indicate the current chamber temperature or setpoint temperature. This temperature controller features sensor break protection, self-tuning capability and over temperature protection (OTP) with an additional OTP relay device.
SINGLE SETPOINT MODELS W/OTP To View or Change the Setpoint To view the setpoint, press and release the UP or DOWN buttons. If you want to change the setpoint, continue pressing until the desired setpoint value is displayed and then release the button. A few seconds after the button is released, the controller will accept the new value and revert to the HOME DISPLAY. To View the Display Units From the HOME DISPLAY press the SCROLL button.
SINGLE SETPOINT MODELS W/OTP Pid List Pb: Proportional band (in display units). ti: Integral time in seconds. td: Derivative time in seconds. ACCS List Code: Access code (Code needed to enter or change the other configuration parameters which are not normally accessible.) Not accessable.
SINGLE SETPOINT MODELS W/OTP Sensor Break Protection This controller provides sensor break protection in the event the thermocouple opens. If an open thermocouple condition occurs, the digital display will blink “S.br” and 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 condition when the temperature of the furnace has deviated beyond the limit.
SINGLE SETPOINT MODELS W/OTP Tuning Note Furnace must be at ambient temperature before starting a tune. Note “Stat” and “Sp.rr” in Sp list must be set to OFF or “tunE” will not initiate. This controller incorporates a self-tuning feature which determines the optimum control parameters for the best temperature accuracy with your load and setpoint. Use this feature the first time you use your furnace and each time you change either your setpoint or the type of load you are heating.
Single Ramp & Dwell Note These instructions are used with the Single Setpoint models with OTP only (See models listed on front page). Functions This type of controller has single ramp and dwell programming capabilities. The Ramp and Dwell can be configured to five different modes. 1. Mode 1 (Opt. 1) is a Ramp (if needed) to the Setpoint temperature, a Dwell, and then a cool down. 2. Mode 2 (Opt.
SINGLE RAMP & DWELL CONTROLLER Program Setup Note The program must be stopped and the controller must be displaying the actual temperature before beginning the Setup. 1. 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 the UP or DOWN buttons, if the ramp to setpoint feature is needed. If the Ramp rate is not needed, then set to “OFF” with the UP or DOWN buttons. 3.
SINGLE RAMP & DWELL CONTROLLER Verifying a Running Program Press the SCROLL button until “StAt” is displayed. The display will show “run” if the program is running, or “oFF” if it is not running. Press the PAGE button to display Actual temperature.
8 Segment & 4x16 Segment Programmable Models w/OTP Note The controller will return to the HOME DISPLAY if left idle for more than a few seconds. Note Once the desired parameter has been selected, depressing either the UP or DOWN button will change the parameter value. In all cases, the value shown on the display is the current working value of that parameter.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP To View Display Units From the HOME DISPLAY press the SCROLL button. The display will briefly show the temperature units in °C/F/K and then return to the HOME DISPLAY. (If you require a different temperature unit call Barnstead|Thermolyne Customer Service.) To View the % Output Power From the HOME DISPLAY press the SCROLL button twice. This value is a read-only value and cannot be changed.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP PAGE button: allows you to choose a parameter from a list of parameters. SCROLL button: allows you to choose a parameter within a list of parameters. UP button: allows you to increase the value in the lower display. DOWN button: allows you to decrease the value in the lower display. Controller Parameters Home Display °C: measured temperature in Celsius. Temperature units can not be changed without entering the configuration.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP ProG LiSt (Program Edit List) PrG.n: Press the UP or DOWN ARROW to select the program number (program number will be displayed in lower display on 4x16 programmable models only.) Hb: Press the UP or DOWN ARROW to select the holdback type [OFF (disables holdback), Lo (deviation low holdback), Hi (deviation high holdback) or bAnd (deviation band holdback)] for the entire program. The controller will default to “OFF.” Hb.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP AL LiSt (Alarm List) IdHi: Deviation High Alarm. Atun LiSt: (Autotune List) tunE: One-shot autotune enable. drA: Adaptive tune enable. drA.t: Adaptive tune trigger level in display units. Range = 1 9999. Pid LiSt G.SP (Gain Setpoint): Is the temperature at which the controller 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.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP Alarms Note The following alarm messages are factory default settings and may vary if you have changed the configuration of your controller: The controller will flash an alarm message in the home display if an alarm condition is detected. IdHi: PV deviation high alarm. 2FSH: PV full scale high alarm. IDHi: = 50°C 2FSH = 1118°C (all models except -60) 2FSH = 1000°C (-60 models only) LCr: load current low alarm. HCr: load current high alarm. S.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP Over-Temperature Protection (OTP) The OTP will be in effect during any alarm condition when the temperature of the furnace has deviated beyond the limit. The “Deviation High” alarm is the only alarm value which can be changed. To change it, press the SCROLL button until “idHi” appears on the display. Press the UP or DOWN button to select the OTP value you desire.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP Creating a New Program or Editing an Existing Program (4x16 Segment Programmable Models Only) The same steps are used when creating a new program and editing an existing program with the exception being that a new program starts with all its segments set to End in the tYPE parameter. Temporary changes can be made to these parameters when the program is in the hold state but permanent changes must be made in the reset state.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP bAnd (Deviation Band Holdback): combines the features of the high and low deviation holdback in that it holds the program back when the process variable deviates above or below the setpoint by more than the holdback 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 toggle between “bAnd, Hi, Lo and OFF.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP dwL.U: Setting Dwell Units Dwell units are time units which are used in “dwELL” segments (amount of time to remain at a specific temperature ). See “Setting the Segment Type” for an explanation on how to set a dwell segment. 1. Press the PAGE button until you reach the program list (ProG LiSt). 2. Press the SCROLL button until display reads, “dwL.U.” 3. Press the UP or DOWN button to toggle between seconds, minutes and hours. CYC.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP Steps 4 and 5 are used in the 4 program model only. If you are using an 8 segment program, skip to step 6. 4. Press the SCROLL button until display reads “Hb.” 5. Press the UP or DOWN button to toggle between “bAnd, Hi, Lo and OFF.” 6. Press the SCROLL button until display reads, “tGt.” 7. Press the UP or DOWN button to set a target setpoint. 8. Press the SCROLL button until display reads,”rAtE.” 9.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP dwEll To maintain a constant temperature for a specified time: 1. Press the PAGE button until you reach the program list (ProG LiSt). 2. Press the SCROLL button until display reads, “tYPE.” 3. Press the UP or DOWN button until display reads, “dwEll.” 4. Press the SCROLL button until display reads, “dur.” 5. Press the UP or DOWN button to select a time in dwell units (seconds, minutes or hours; set in the “dwL.U” parameter).
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP 2. Press the SCROLL button until display reads, “tYPE.” 3. Press the UP or DOWN button until display reads, “cALL.” 4. Press the SCROLL button until display reads, “PrG.n.” 5. Press the UP or DOWN button to select a program number to be linked. 6. Press the SCROLL button until display reads, “CYC.n.” 7. Press the UP or DOWN button to select the number of cycles the linked program is to be run. End To end or repeat a program: 1.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP Setting the Target Setpoint (4x16 Segment Programmable Models Only) 1. Press the PAGE button until you reach the program list (ProG LiSt). 2. Press the SCROLL button until display reads, “tGt.” 3. Press the UP or DOWN button to set the target setpoint temperature. Running a Program (8 Segment Programmable Models) To run a program, press the RUN/HOLD button. (The RUN light will illuminate.
Holding a Program To put a running program on hold, press the RUN/HOLD button. (The HOLD light will illuminate.) Cancelling a Program To cancel a program, hold the RUN/HOLD button down until the RUN and HOLD lights go off. Note Display will flash “tu.ER” if an error occurs during tuning. To clear the error and restart tuning, simultaneously press the PAGE and SCROLL buttons and follow the steps outlined in “Autotuning.” Note To stop the tuning function, simultaneously press the PAGE and SCROLL buttons.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP Gain Scheduling G.SP: Gain Scheduling Gain scheduling is the automatic transfer of control between two sets of PID values. The 2416 controller does this at a presettable process value. Gain scheduling is used for difficult control processes which show large changes in their response time or sensitivity at high or low temperatures, or when heating or cooling. The G.SP gain schedule setpoint is factory set at 700° C. The G.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP 2. Set the setpoint temperature. 3. Press the PAGE button until the display reads, “Atun LiSt.” 4. Press the SCROLL button until “tunE OFF” is displayed. 5. Press the UP or DOWN button to select “on.” 6. Simultaneously press the PAGE and SCROLL buttons to return to the HOME DISPLAY. The display will flash “tunE” while tuning is in progress. Adaptive Tuning Adaptive tuning continuously evaluates tuning parameters.
Installation and Operation of Air Control Models F30420-33-60-80, F30420C-60-80, F30428C-60-80, F30430CM-33-60, F30430CM60, F30438CM-60 Installation Note Ashing furnaces -60 models contain a feature to provide air (or inert gas) flow within the furnace chamber. Note A pressurized air line with a minimum working pressure range of 0 to 40 psi is required. Note If furnace is to be used regularly, the airline regulator may be left open to 30 psi.
Furnace Loading Note Failure to connect the exhaust port to an appropriate exhaust system will result in smoke and gases filling the work area. Without the connection, gases and smoke will escape around the door seal and at the rear of the furnace. Caution Do not overload your furnace chamber. If the load is to be heated uniformly it should not occupy more than twothirds of the furnace chamber. Failure to observe this caution could result in damage to furnace components.
Preventative Maintenance This unit is equipped with a venting system on the top of the furnace. This is for the removal of fumes from the chamber of the unit. Contamination is a major cause of element failure, therefore, remove all fume forming material before heating. (e.g. clean cutting oil from tool steel). Housekeeping is vital to your electric furnace - KEEP IT CLEAN. Run your furnace up to 1600°F empty occasionally to burn off the contamination that may exist on the insulation and elements.
Problem Solving The Problem Solving section is intended to aid in defining and correcting possible service problems. When using the chart, select the problem category that resembles the malfunction. Then proceed to the possible causes category and take necessary corrective action. Problem Probable Causes Corrective Action The cycle light does not illuminate. The furnace is not connected to power supply. Check furnace connection to power source. ON and OFF power switch is defective.
PROBLEM SOLVING Problem Probable Causes Corrective Action Slow heatup. Low line voltage. Install line of sufficient size and proper voltage (Isolate furnace from other electrical loads). Heavy load in chamber. Lighten load in chamber to allow heat to circulate. Wrong heating element Install proper element. One or more heating elements are burned out. Replace burned out elements. Wired improperly. Check wiring diagram for correct wiring of your furnace. Door switch is not functioning.
PROBLEM SOLVING Problem Inaccurate. Probable Causes Corrective Action Contamination present from previous burnout. Clean and/or replace insulation material. Wired improperly. Check wiring diagram for correct wiring of your furnace. Oxidized or contaminated thermocouple. Replace 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.
Maintenance and Servicing Warning Refer servicing to qualified personnel. Warning Replace fuses with same type and rating. Warning This product contains refractory ceramic, refractory ceramic fiber or fiberglass insulation, which can produce respirable dust or fibers during disassembly. Dust or fibers can cause irritation and can aggravate preexisting respiratory diseases.
MAINTENANCE AND SERVICING c. Loosen the screws and nuts on the terminals of the element to be replaced. d. Open the door and pull the defective element out. e. Slide the new element into place, threading the leads through the insulating porcelain bushing on the back of the furnace. f. Cut off any excess lead wire. Be careful not to nick element lead wires. Reinstall terminal connections and tighten screws and nuts securely. g. Replace the back terminal cover. h.
MAINTENANCE AND SERVICING To Replace Solid State Relay: a. Disconnect furnace from power supply. b. Remove the screws on the front dial and the screws on the lower back cover. c. Remove the upper back cover. d. Disconnect the element lead wires and one ground wire from back of furnace. Also, disconnect T/C lead wire from terminal block. (Note placement and connection of wires). e. Slide control section forward and disconnect two wires from door switch. (Note placement and connection of wires). f.
MAINTENANCE AND SERVICING e. Slide the control section forward. f. Disconnect the wires from the door switch. (Note connection and placement of wires to Microswitch). g. Control section can now be removed from furnace housing. h. Remove the two screws and nuts from the Microswitch. i. Insert new Microswitch and secure with screws and nuts removed in Step h. j. Slide control section back and replace the wires on the door switch. k. Reverse steps b, c, d and e to reassemble furnace. l.
MAINTENANCE AND SERVICING f. Reconnect to power supply. g. To test the operation of the door strike: turn the power switch on, set the control to a setting high enough to keep the control from cycling, open and close the door; the cycle light should switch on when the door is approximately 1” from being closed. To Replace Control Module a. 48 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.
Replacement Parts Single Setpoint Models F30420C, F30420C-33, F30428C Part Number CAX99 CA1249X1 CN71X88 EL412X1 EL412X2 EL412X3 EL412X4 EL412X5 EL412X6 FA1262X1 PLX82 RYX37 RYX62 SWX103 SWX144 SWX163 TC412X119 TRX96 TRX178 Description Line filter Capacitor Controller Element Element Element Element Element Element Fan Pilot light S.S.
REPLACEMENT PARTS RYX62 SWX144 SWX163 TRX96 TRX178 TC412X1A Mechanical relay Power switch Door switch Terminal block Terminal Block Thermocouple 1 1 1 1 1 1 All All All All All All models models models models models models 4X16 Segment Programmable Models with OTP F30430CM, F30430CM-33, F30430CM-33-60, F30430CM-60, F30438CM, F30438CM-60 Part Number CAX99 CA1249X1 CN71X90 CN71X92 Description Line Filter Capacitor Controller Controller Quantity 1 1 1 1 EL412X1 EL412X2 EL412X3 EL412X4 EL412X5 EL412X6
Ordering Procedures Please refer to the Specification Plate for the complete model number, serial number, and series number when requesting service, replacement parts or in any correspondence concerning this unit. All parts listed herein may be ordered from the Barnstead International dealer from whom you purchased this unit or can be obtained promptly from the factory. When service or replacement parts are needed we ask that you check first with your dealer.
Wiring Diagrams SINGLE SETPOINT CONTROL WIRING DIAGRAM 52
WIRING DIAGRAMS SEGMENT PROGRAMMABLE CONTROL WIRING DIAGRAM 53
WIRING DIAGRAMS 4X16 SEGMENT PROGRAMMABLE CONTROL WIRING DIAGRAM 54
Two Year Limited Warranty BARNSTEAD INTERNATIONAL (“BARNSTEAD”) warrants that a product manufactured by Barnstead shall be free of defects in materials and workmanship for two (2) year from the first to occur of (i) the date the product is sold by BARNSTEAD or (ii) the date the product is purchased by the original retail customer (the “Commencement Date”).
