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Type F6000 Furnace

OPERATION MANUALAND PARTS LIST

Series 1249

Single Setpoint Models F6010, F6018

Single Setpoint Models F6020C, F6020C-33, F6020C-33-60, F6020C-60, F6028C, F6028C-60with OTP

8 Segment Programmable F6020C-33-60-80, F6020C-33-80, F6020C-60-80, F6020C-80, Models with OTP F6028C-60-80, F6028C-80

4 X 16 Segment F6030CM, F6030CM-33, F6030CM-33-60, F6030CM-60, F6038CM, Programmable Models F6038CM-60with OTP & RS232Communication

(-60 Models) - Ashing furnace

LT1249X1 • 1/29/03

Important InformationThis manual contains important operating and safety information. The user must carefully

read and understand the contents of this manual prior to the use of this equipment.

Safety Information ..............................................................................................................................................3 Alert Signals..................................................................................................................................................3 Warnings ......................................................................................................................................................3

Introduction..........................................................................................................................................................5Intended Use ................................................................................................................................................5General Usage..............................................................................................................................................5 Principles of Operation ................................................................................................................................5

General Specifications ........................................................................................................................................6Environmental Conditions ............................................................................................................................6 Declaration of Conformity ............................................................................................................................7

Unpacking ..........................................................................................................................................................8 Installation ..........................................................................................................................................................9

Site Selection................................................................................................................................................9Electrical Connections ..................................................................................................................................9

Operation, All Models ........................................................................................................................................10 Power Switch ..............................................................................................................................................10Cycle Light ..................................................................................................................................................10Door Safety Switch ....................................................................................................................................10

Single Setpoint Models and Single Setpoint Models w/OTP ............................................................................11Single Ramp & Dwell ........................................................................................................................................168 Segment & 4X16 Segment Programmable Models w/OTP ..........................................................................20 Installation and Operation of Air Control ..........................................................................................................40

Installation ..................................................................................................................................................40Operation ....................................................................................................................................................42

Furnace Loading ..............................................................................................................................................43Maintenance and Servicing ..............................................................................................................................44

Preventive Maintenance ............................................................................................................................44General Cleaning Instructions ....................................................................................................................44To Replace a Heating Element ..................................................................................................................44To Replace a Platinel II Thermocouple ......................................................................................................45To Replace a Chromel/Alumel Thermocouple ............................................................................................46To Replace a Solid State Relay..................................................................................................................47To Replace a Door Switch ..........................................................................................................................47To Realign Door Switch ..............................................................................................................................48To Replace Controller ................................................................................................................................48

Troubleshooting ................................................................................................................................................50 Replacement Parts List ....................................................................................................................................52 Wiring Diagrams................................................................................................................................................53 Ordering Procedures ........................................................................................................................................57 Two Year Limited Warranty ..............................................................................................................................60

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Table of Contents

Your Barnstead Thermolyne Type F6000 Furnacehas been designed with function, reliability andsafety in mind. It is your responsibility to install itin conformance with local electrical codes. Forsafe operation, please pay attention to the alertsignals throughout the manual.

This manual contains important operating andsafety information. You must carefully read andunderstand the contents of this manual prior tothe use of this furnace.

WarningsTo avoid electrical shock, this furnace must:

1. Use a properly grounded electrical outletof correct voltage and current handlingcapacity.

2. Be disconnected from the power supplyprior to maintenance and servicing.

3. Have the door switch operating properly.

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

or combustible materials; fire or explosionmay result. This device contains compo-nents which may ignite such material.

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

3. Always wear safety glasses or a safetyshield and high temperature gloves whenloading or unloading the furnace. Longsleeved, fire retardant clothing and a fireretardant apron is also recommended.

4. Refer servicing to qualified personnel. 3

Safety Information

WarningWarnings alert you to a possibility of personal injury.

CautionCautions alert you to a possibility of damage to the equip-ment.

NoteNotes alert you to pertinent facts andconditions.

Hot SurfaceHot surfaces alert you to a possibility of personal injury if youcome in contact with a surface duringuse or for a period of time after use.

Alert Signals

WarningThis warning is presented for compliance withCalifornia Proposition 65 and other regulatoryagencies and only applies to the insulation inthis product. This product contains refractoryceramic, refractory ceramic fiber or fiberglassinsulation, which can produce respirable dust orfibers during disassembly. Dust or fibers cancause irritation and can aggravate pre-existingrespiratory diseases. Refractory ceramic andrefractory ceramic fibers (after reaching 1000°C)contain crystalline silica, which can cause lungdamage (silicosis). The International Agency forResearch on Cancer (IARC) has classifiedrefractory ceramic fiber and fiberglass as possi-bly carcinogenic (Group 2B), and crystalline sili-ca as carcinogenic to humans (Group 1).

The insulating materials can be located in thedoor, the hearth collar, in the chamber of theproduct or under the hot plate top. Tests per-formed by the manufacturer indicate that thereis no risk of exposure to dust or respirable fibersresulting from operation of this product undernormal conditions. However, there may be a riskof exposure to respirable dust or fibers whenrepairing or maintaining the insulating materials,or when otherwise disturbing them in a mannerwhich causes release of dust or fibers. By usingproper handling procedures and protectiveequipment you can work safely with these insu-lating materials and minimize any exposure.Refer to the appropriate Material Safety DataSheets (MSDS) for information regarding properhandling and recommended protective equip-ment. For additional MSDS copies, or additionalinformation concerning the handling of refracto-ry ceramic products, please contact theCustomer Service Department at BarnsteadInternational at 1-800-553-0039.4

SAFETY INFORMATION

Intended UseThe Type F60000 furnaces are general purposelaboratory and heat treating furnaces. For opti-mum element life, Barnstead International rec-ommends observing these temperature ranges:from 100°C (212°F) to 1093°C (2000°F) contin-uous use or from 1093°C (2000°F) to 1200C(2192°F) for intermittent use. (-60) Ashing mod-els continuous temperature range is 100°C(212°F) to 975°C (1787°F). Continuous use isoperating the furnace for more than 3 hours andintermittent use is operating the furnace for lessthan 3 hours.

All furnaces consist of: 1) a vented heatingchamber; 2) a temperature controller; and 3) adoor safety switch for operator safety.

General UsageDo not use this product for anything other thanits intended usage.

Principles of OperationThe furnace chamber is heated by electricresistance elements and is insulated withceramic fiber insulation. The controller is locatedunder the furnace chamber and is well insulatedfrom the heat generated in the furnace cham-ber. A door safety switch removes power to theheating elements whenever the furnace door isopened. The temperature is controlled by one ofthree types of controllers. The (-60) modelsoperate the same as the other models except ata lower temperature and can inject gas into thechamber.

5

Introduction

CautionDo not exceed operating temperatures shown in “GeneralSpecifications.” Exceeding these limitswill result in severely reduced elementlife.

6

General SpecificationsFor F6000 FurnaceModel #

F6020C F6028C F6010 F6018F6020C-33 F6028C-60F6020C-33-60 F6028C-60-80F6020C-33-60-80 F6028C-80F6020C-33-80 F6038CMF6020C-60 F6038CM-60F6020C-60-80F6020C-80F6030CMF6030CM-33-60F6030CM-33-60F6030CM-60

Dimensions Overall Width 19.25(48.9) 19.25(48.9) 19.25(48.9) 19.25(48.9)in. (cm) Height 21 (53.3) 21 (53.3) 21 (53.3) 21 (53.3)

Depth 20 (50.8) 20 (50.8) 20 (50.8) 20 (50.8)Chamber Width 12.75 (32.4) 12.75 (32.4) 12.75 (32.4) 12.75 (32.4)

Height 6.75 (17.1) 6.75 (17.1) 6.75 (17.1) 6.75 (17.1)Depth 10 (25.4) 10 (25.4) 10 (25.4) 10 (25.4)

Weight LBS. 9kg) 96 (43.5) 96 (43.5) 96 (43.5) 96 (43.5)Electrical Volts 220-240 208 220-240 208Ratings Amps 18.3 19.2 12.9 11.2

Watts 4400 4000 3095 2325Freq. 50/60 50/60 50/60 50/60Phase 1 1 1 1

Oper. Temp.Range °F (°C) 212-2192°F 212-2192°F 212-2192°F 212-2192°F

(100-1200°C) (100-1200°C) (100-1200°C) (100-1200°C)*212-1787°F *212-1787°F(*100-975°C) (*100-975°C)

Notes: The maximum ramp rates for this furnace for heat up are: 12°C (22°F) per min. from 25°C-537°C (75°F-1000°F), 10°C (18°F) per min. from 537°C-1093°C (1000°F-2000°F).

*(-60) coal-ashing furnaces

Environmental ConditionsOperating: 17°C to 27°C; 20% to 80% relative humidity, non-condensing. Installation Category II (overvoltage) in accordance with IEC 664. Pollution degree 2 in accordance withIEC 664. Altitude Limit: 2,000 meters.Storage: -25°C to 65°C; 20% to 85% relative humidity

Declaration of ConformityBarnstead International hereby declares under its sole responsibility that this product con-forms with the technical requirements of the following standards (-33 Models Only):

EMC: EN 61000-3-2 Limits for Harmonic Current EmissionsEN 61000-3-3 Limits for Voltage Fluctuations and FlickerEN 61326-1 Electrical Equipment for Measurement, Control and Laboratory

Use; Part I: General Requirements

Safety: EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use; Part I: General Requirements

EN 61010-2-010 Part II: Particular Requirements for Laboratory Equipment for the Heating of Materials

per the provisions of the Electromagnetic Compatibility Directive 89/336/EEC, as 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:

Electrothermal Engineering Ltd.419 Sutton RoadSouthend On SeaEssex SS2 5PHUnited Kingdom

Copies of the Declaration of Conformity are available upon request.

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GENERAL SPECIFICATIONS

1. Visually check for any physical damageto the shipping container.

2. Inspect the equipment surfaces that areadjacent to any damaged area.

3. Open the furnace door and remove thepacking material from inside the furnacechamber.

4. Vacuum the chamber prior to use toremove the insulation dust due to ship-ment. (The Type 48000 furnace is sup-plied with one ceramic shelf.)

5. Retain the original packaging material ifreshipment is foreseen or required.

8

Unpacking

Note(-60) models are supplied with twostainless steel trays, handle andporcelain pegs.

NoteThe Type 6000 furnaces do not comewith a power cord because currentrequirements are too great to be han-dled by ordinary power cords andstandard wall supply. (F6010 andF6018 are supplied with cord andplug).

Site SelectionInstall furnace on a sturdy surface and allowspace for ventilation.

Electrical Connections1. The electrical specifications are located

on the specification plate on the back ofthe furnace. Consult BarnsteadInternational if your electrical service isdifferent than those listed on the specifi-cation plate. Prior to connecting yourType 6000 furnace to your electricalsupply, be sure the front power switch isin the OFF position.

2. Your 6000 furnace may be wired eitherdirectly through a conduit system or byusing a power cord and plug which con-forms to the National Electrical Codesand electrical code requirements of yourarea. The terminal block to be used inwiring is located on the lower rear of thefurnace.

NOTE: Please observe the alert signals onthe lefthand side of this page before operat-ing your furnace.

Models F6010, F6010-33, F6018

9

Installation

CautionBe sure ambient temperature does notexceed 104°F (40°C). Ambients abovethis level may result in damage to thecontroller.

Allow at least six inches of spacebetween the furnace and any verticalsurface. This permits the heat from fur-nace case to escape so as not to cre-ate a possible fire hazard.

WarningTo avoid electrical shock, this furnacemust be installed by a competent,qualified electrician who ensures com-patibility among furnace specifications,power source and grounding coderequirements. (Disregard Step 2 if youhave Model F6010 or F6018.).

CautionFor supply connections, use 10 AWGor larger wires suitable for at least90°C. Failure to observe this cautioncould result in damage to furnace.

Hot Surface“Caution: Hot Surface. Avoid Contact.”To avoid burns, this furnace must notbe touched on the exterior or interiorsurfaces during use or for a period oftime after use.

WarningDo not use in the presence of flamma-ble or combustible materials; fire orexplosion may result. This device con-tains components which may ignitesuch material.

Power SwitchBoth the ON/OFF power switch and the digitaldisplay will illuminate when power is switchedON. The furnace will begin to heat to its con-troller's current setpoint. (See the instructionsfor your type of controller for information onchecking and setting the setpoint.)

Cycle LightThe amber cycle light will illuminate wheneverthe power is being applied to the heating ele-ments. The cycle light will turn on and off as thefurnace reaches the setpoint.

Door Safety SwitchThe door safety switch removes power from theheating elements when the door is opened.Open and close the door a few times; note thatthe amber CYCLE light will switch off when thedoor is opened. If this condition is not true, con-sult the Troubleshooting section before proceed-ing. This check must be done when the furnaceis heating and the cycle light is illuminated.

10

Operation, All Models

WarningTo avoid personal injury do not use inthe presence of flammable or com-bustible chemicals; fire or explosionmay result. This device contains com-ponents which may ignite such materi-als.

Hot SurfaceCaution: Avoid Contact. To avoid burns,this furnace must not be touched onthe exterior or interior surfaces duringuse or for a period of time after use.

WarningTo avoid electrical shock, the doorsafety switch must be operating properly.

WarningAlways wear safety glasses or a safetyshield and high temperature gloveswhen loading or unloading the furnace.Long sleeved, fire retardant clothingand a fire retardant apron is also rec-ommended.

The single setpoint model furnace controlleris a single setpoint controller which provides asingle digital display to indicate the currentchamber temperature or setpoint temperature.This temperature controller features sensorbreak protection and self-tuning capability.

The single setpoint model w/ OTP furnacecontroller is a single setpoint controller whichprovides a single digital display to indicate thecurrent chamber temperature or setpoint tem-perature. This temperature controller featuressensor break protection, self-tuning capabilityand over temperature protection (OTP) withan additional OTP relay device.

Basic OperationWhen the controller is turned ON it will per-form a short self-test and then display themeasured value (process value) in the HOMEDISPLAY.

Buttons and IndicatorsOP1 (Output 1): Illuminates when the logicoutput is ON.

OP2 (Output 2): Illuminates when the relayoutput is ON (will go out during an alarm situ-ation).

PAGE button: Allows you to select a new listof parameters.

SCROLL button: Allows you to select aparameter within a list of parameters.

DOWN button: Allows you to decrease avalue.

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Single Setpoint Models & Single Setpoint Models w/OTP

Output 1

UP ARROW Button

Temperature Display

Display Window

DOWN ARROWButton

PAGE Button

SCROLLButton

Output 2

NoteIf at any time you want to return to theHOME DISPLAY, simultaneously pressthe PAGE and SCROLL buttons.

Single Setpoint Models

UP button: Allows you to increase a value.

To View or Change the SetpointTo view the setpoint, press and release the UPor DOWN buttons. If you want to change thesetpoint, continue pressing until the desired set-point value is displayed and then release thebutton. A few seconds after the button isreleased, the controller will accept the newvalue and revert to the HOME DISPLAY.

To View the Display UnitsFrom the HOME DISPLAY press the SCROLLbutton. The display will show the temperatureunits in °C/F/K and then return to the HOMEDISPLAY. (Call Customer Service if you requirea different temperature unit.)

To View the % Output PowerFrom the HOME DISPLAY press the SCROLLbutton twice. Press and release the UP orDOWN button to view the % output power. Thisvalue is a read-only value and cannot bechanged.

Controller Parameters

Home display°C: Temperature units in Celsius. Temperatureunits can not be changed without entering theconfiguration. Contact Customer Service if a dif-ferent temperature unit is required.

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SINGLE SETPOINT MODELS & SINGLE SETPOINT MODELS W/OTP

OP: % output power demand.

IdHi: Deviation high alarm.

Al ListIdHi: Deviation high alarm.

Atun ListtunE: One-shot autotune enable.

Pid ListPb: Proportional band (in display units).

ti: Integral time in seconds.

td: Derivative time in seconds.

ACCS List Code: Access code (Code neededto enter or change the other configurationparameters which are not normally accessible.)Not accessible.

AlarmsThe controller will flash an alarm message inthe home display if an alarm condition is detect-ed.

2FSH: Measured value full scale high alarm.

IdHi: Measured value deviation high alarm.

S.br: Sensor break: check that sensor is con-nected correctly.

L.br: Loop break: check that the heating circuitsare working properly.

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NoteThe following alarm messages arefactory default settings and may vary ifyou have changed the configuration ofyour controller:

IDHi: = 50°C2FSH = 1225°C (All modelsexcept -60)2FSH = 1000°C (-60 models)

Ld.F: Heater Circuit fault: indication of either anopen or short solid sate relay, a blown fuse,missing supply or open circuit heater.

Sensor Break ProtectionThis controller provides sensor break protectionin the event the thermocouple opens. If an openthermocouple condition occurs, the digital dis-play will blink “S.br” and the power to the heat-ing element will be shut OFF (Cycle light willextinguish).

Over-Temperature Protection(OTP)The OTP will be in effect during any alarm con-dition when the temperature of the furnace hasdeviated beyond the limit. The “Deviation High”alarm is the only alarm value which can bechanged. To change it, press the SCROLL but-ton until “IdHi” appears on the display. Press theUP or DOWN button to select the OTP valueyou desire. We recommend a value of 20°above your working temperature to provide pro-tection for your workload.

In addition to over-temperature protection, unitscontaining a single setpoint controller w/OTPfeature a mechanical OTP relay device whichdisconnects power from the elements in analarm condition (only in furnaces with OTPrelay). See models listed on front page.

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TuningThis controller incorporates a self-tuning featurewhich determines the optimum control parame-ters for the best temperature accuracy with yourload and setpoint. Use this feature the first timeyou use your furnace and each time you changeeither your setpoint or the type of load you areheating. Barnstead International recommendsyou use this feature to provide the best temper-ature accuracy the controller can attain. To usethe tuning feature:

1. Adjust the setpoint to your desiredvalue.

2. Press the PAGE button until displayreads, “Atun.”

3. Press the SCROLL button. Display willread, “tunE.”

4. Press the UP or DOWN button to select,“on.”

5. Simultaneously press the PAGE andSCROLL buttons to return to the HOMEDISPLAY. The display will alternatelyflash between “tunE” and the HOMEDISPLAY while tuning is in progress.

6. The controller will then turn the heatingon and off to induce an oscillation.When the measured value reaches therequired setpoint the first cycle will end.

7. Tuning will be complete after two oscilla-tion cycles and then the tuner will turnitself off.

8. Normal control function will resume afterthe controller calculates tuningparameters.

15


NoteFurnace must be at ambient temperature before starting a tune.

NoteTune has completed when “tunE”stops flashing on display.

FunctionsThis type of controller has single ramp anddwell programming capabilities. The Ramp andDwell 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. 2) is the same as mode 1,except the controller continues to heatat the Setpoint after the Dwell has com-pleted. (This mode does not cooldown.)

3. Mode 3 (Opt. 3) is the same as mode 1,except the Dwell time includes theRamp (if needed).

4. Mode 4 (Opt. 4) is the same as mode 2,except the Dwell time includes theRamp (if needed).

5. Mode 5 (Opt. 5) is a Dwell (delay time)before the controller Ramps (if needed)to the Setpoint temperature.

Setting Variables• The Manual or Automatic modes can be

set by changing “m-A” variable to “mAn”or “Auto.” (The Manual mode will keepthe controller from heating without set-ting the Setpoint temperature below theActual temperature. The Automaticmode will allow the controller to heat tothe Setpoint temperature. (The con-troller should be left in the Automaticmode except when programming.)

16

Single Ramp & Dwell

Mode 1 (Opt. 1)

Mode 2 (Opt. 2)

Mode 3 (Opt. 3)

Mode 4 (Opt. 4)

Mode 5 (Opt. 5)

NoteThese instructions are used with the Single Setpoint models with OTP only(See models listed on front page).

• A program mode can be set by chang-ing the “tm.OP” variable to “Opt. 1, Opt.2, Opt. 3, Opt. 4, or Opt. 5.

• A Ramp rate may be set by changingthe “SPrr” variable to a value. TheRamp rate units are in degrees perminute.

• The Dwell time can be set by changingthe “dwEll” variable to the desired value.Dwell time units are in minutes.

• The program Status can be set bychanging the “StAt” variable to “run” or“oFF.” This variable will start or stop theprogram.

Program Setup1. Press the SCROLL button until “m-A” is

displayed, then set to “mAn” with the UPor DOWN buttons.

2. Press the PAGE button once, set thedesired Setpoint temperature with theUP or DOWN buttons.

3. Press the PAGE button until the “SP” isdisplayed.

4. Press the SCROLL button once, “SPrr”(Ramp Rate) will be displayed, set thedesired Ramp rate with the UP orDOWN buttons, if the ramp to setpointfeature is needed. If the Ramp rate isnot needed, then set to “OFF” with theUP or DOWN buttons.

17

SINGLE RAMP & DWELL CONTROLLER

NoteThe program must be stopped andthe controller must be displaying theactual temperature before beginningthe Setup.

5. Press the SCROLL button once,“tm.OP” (Ramp & Dwell mode) will bedisplayed, select the desired mode withthe UP or DOWN buttons. (Opt. 1, Opt.2, Opt. 3, Opt. 4, Opt. 5)

6. Press the SCROLL button once, “dwEll”will be displayed, set the desired Dwelltime with the UP or DOWN buttons.(Dwell in minutes.)

7. Press the PAGE button until the Actualtemperature is displayed.

18


Running the Program1. Press the SCROLL button until “StAt” is

displayed, set to “run” with the UP orDOWN buttons.

2. Press the PAGE button to display Actualtemperature.

Stopping the Program

Press the SCROLL button until “StAt” is dis-played, set to “oFF” with the UP or DOWN but-tons.

Clearing the Flashing End

Press the PAGE and SCROLL buttons at thesame time.

Switching from Manual Mode toAuto Mode

Press the SCROLL button until “m-A” is dis-played. Press the UP or DOWN buttons to setto “Auto.” Press PAGE button to display Actualtemperature.

Verifying a Running Program

Press the SCROLL button until “StAt” is dis-played. The display will show “run” if the pro-gram is running, or “oFF” if it is not running.Press the PAGE button to display Actual tem-perature.

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The 8 segment programmable controller con-sists of a microprocessor based three-mode PID(Proportional, Integral, Derivative) programma-ble temperature controller with over-temperatureprotection and appropriate output switchingdevices to control the furnace. The digital read-out continuously displays chamber (upper dis-play) and setpoint (lower display) temperaturesunless the SCROLL or PAGE button isdepressed. The programmable controller can beused as a single setpoint controller or as a pro-grammable controller. The 8 segment digitalmodel enables eight segments of programming.

The 4x16 segment programmable controllerconsists of a microprocessor based three-modePID (Proportional, Integral, Derivative) program-mable temperature controller with over-tempera-ture protection and appropriate output switchingdevices to control the furnace. The digital read-out continuously displays chamber (upper dis-play) and setpoint (lower display) temperaturesunless the SCROLL or PAGE button isdepressed. The programmable controller can beused as a single setpoint controller or as a pro-grammable controller. The 4 program controllerhas four 16 segment programs.

Basic OperationWhen the controller is turned ON, it will performa short self-test and then change to the HOMEDISPLAY. The HOME DISPLAY shows themeasured temperature (process value) in theupper display and the desired value (setpoint) inthe lower display.

20

8 Segment & 4x16 SegmentProgrammable Models w/OTP

4x16 & 8 Segment Programmable Models with OTP

Output 1

PAGE Button

AUTO/MAN Button

Display Window

Upper Display

Lower Display

RUN/HOLD Button

UP ARROW Button

DOWN ARROWButton

SCROLLButton

NoteThe controller will return to the HOMEDISPLAY if left idle for more than afew seconds.

NoteOnce the desired parameter has beenselected, depressing either the UP orDOWN button will change the parame-ter value. In all cases, the valueshown on the display is the currentworking value of that parameter.

21

8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP

• Holds a program when pressed again—HOLD light illuminates.

• Cancels hold and continues runningwhen pressed again—HOLD light is offand RUN light illuminates.

• Exits a program when the button is helddown for two seconds—RUN and HOLDlights are off.

• At the end of a program the RUN lightwill flash.

• During holdback the HOLD light willflash.

PAGE button: allows you to choose a parame-ter from a list of parameters.

SCROLL button: allows you to choose aparameter within a list of parameters.

UP button: allows you to increase the value inthe lower display.

DOWN button: allows you to decrease thevalue in the lower display.

Controller ParametersHome Display°C: measured temperature in Celsius.Temperature units can not be changed withoutentering the configuration. Contact CustomerService if a different temperature unit isrequired.

OP: % output power demand; displayed inlower display (cannot be changed).

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C.id: Controller identification number.

PrG: Program number (displayed when a pro-gram is running; 4x16 programmable modelsonly.)

IdHi: Deviation High Alarm

tunE: One-shot autotune enable.

run LiSt (Program Run List)PrG: Currently running program (only used on4x16 programmable models)

StAt: Displays the program status [OFF, run(running active program), hoLd (program onhold), HbAc (waiting for process to catch up),End (program completed)] in the lower display.The controller will default to “OFF.”

FASt: Fast run through program (no/YES). Thecontroller will default to “no.”

SEG.d: Flash active segment type in the lowerdisplay of the home display (no/YES). The con-troller will default to “no.”

ProG LiSt (Program Edit List)PrG.n: Press the UP or DOWN ARROW toselect the program number (program numberwill be displayed in lower display on 4x16 pro-grammable models only.)

Hb: Press the UP or DOWN ARROW to selectthe holdback type [OFF (disables holdback), Lo(deviation low holdback), Hi (deviation highholdback) or bAnd (deviation band holdback)]for the entire program. The controller will defaultto “OFF.”

23


Hb.U: Press the UP or DOWN ARROW toselect the holdback value (in display units).

rmP.U: Press the UP or DOWN ARROW to tog-gle between ramp units (SEc, min or Hour).Controller will default to “SEc.”

dwL.U: Press the UP or DOWN ARROW to tog-gle between dwell units (SEc, min or Hour).Controller will default to “SEc.”

Cyc.n: Press the UP or DOWN ARROW to setthe number of program cycles (1 to 999 orcont). The controller will default to “cont.”

SEG.n: Press the UP or DOWN ARROW toselect the segment number (1-8 in 8 segmentmodels, 1-16 in 4x16 models).

tYPE: Press the UP or DOWN ARROW toselect the segment type [End (end of program),rmP.r = ramp rate (ramp to a specified setpointat a set rate), rmp.t = ramp time (ramp to aspecified temperature in a set time), dwEll (tomaintain a constant temperature for a set time),StEP (climb instantaneously from current tospecified temperature), cALL (to call a programas a subroutine, available only on 4x16 pro-grammable models)]. The controller will defaultto “End.” Other parameters used with tYPEinclude; tGt target setpoint), Rate (rate of tem-perature increase) and dur (time to target set-point or time to dwell).

End.t: End segment type: dwELL (dwell contin-uous), rSEt (reset) and S OP (End SegmentOutput power level.

AL LiSt (Alarm List)IdHi: Deviation High Alarm.

24


Atun LiSt: (Autotune List)

tunE: One-shot autotune enable.

drA: Adaptive tune enable.

drA.t: Adaptive tune trigger level in displayunits. Range = 1 9999.

Pid LiStG.SP (Gain Setpoint): Is the temperature atwhich 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. (SEt 1)

Pb2: Proportional band. (SEt 2)

ti2: Integral time in seconds. (SEt 2)

td2: Derivative time in seconds. (SEt 2)

ACCS LiSt (Access List)Access Code (Code needed to enter or changethe other configuration parameters which arenot normally accessible.) Not accessible.

AlarmsThe controller will flash an alarm message inthe home display if an alarm condition is detect-ed.

IdHi: PV deviation high alarm.

2FSH: PV full scale high alarm.

25


NoteThe following alarm messages are factorydefault settings and may vary if you havechanged the configuration of your controller:

IDHi: = 50°C2FSH = 1225°C (All models except -60)2FSH = 1000°C (-60 models)

LCr: load current low alarm.

HCr: load current high alarm.

S.br: Sensor break: check that sensor is con-nected correctly.

L.br: Loop Break: Check that the heating cir-cuits are working properly.

Ld.F: Heater Circuit Fault: indication of eitheran open or short solid sate relay, a blown fuse,missing supply or open circuit heater.

SSr.F: Solid state relay failure indications in asolid state relay: indicates either an open orshort circuit in the SSR.

Htr.F: Heater failure: Indication that there is afault in the heating circuit: indicates either ablown fuse, missing supply or open circuitheater.

Sensor Break ProtectionThis controller provides sensor break protectionin the event the thermocouple opens. If an openthermocouple condition occurs, the digital dis-play will Blink “S.br” and the power to the heat-ing element will be shut OFF (Cycle light willextinguish).

Over-Temperature Protection(OTP)The OTP will be in effect during any alarm con-dition when the temperature of the furnace hasdeviated beyond the limit. The “Deviation High”

26


alarm is the only alarm value which can bechanged. To change it, press the SCROLL buttonuntil “idHi” appears on the display. Press the UP orDOWN button to select the OTP value you desire.We recommend a value of 20° above your workingtemperature to provide protection for your work-load.

To Operate the Controller as aSingle Setpoint Controller

1. Switch the circuit breaker to the “ON” posi-tion. The setpoint temperature presently setin the controller will appear in the lower dis-play. (The upper display indicates the actualchamber temperature.)

2. To change the setpoint, press the UP orDOWN button until the desired setpointvalue is displayed; then release the button.

3. The furnace will begin to heat if the newsetpoint temperature is higher than thepresent chamber temperature.

Programming the ControllerThe controller is capable of varying temperature orprocess value with time through programming. Aprogram is stored as a series of segments and canbe run once, repeated a set number of times or runcontinuously. To create a customized programusing the controller parameters listed under“Controller Parameters” at the beginning of thissection, follow the procedures outlined in the pro-ceeding sections of this manual.

27


Creating a New Program orEditing an Existing Program(4x16 Segment ProgrammableModels Only)

The same steps are used when creating a newprogram and editing an existing program withthe exception being that a new program startswith all its segments set to End in the tYPEparameter. Temporary changes can be made tothese parameters when the program is in thehold state but permanent changes must bemade in the reset state. Follow the steps belowto create or edit a program.

1. Press the PAGE button until you reachthe program list (ProG LiSt).

2. Press the SCROLL button until displayreads, “PrG.n.”

3. Press the UP or DOWN button to selecta number for a new program or to editan existing program.

Hb: HoldbackHoldback consists of a value and a type. If themeasured value lags behind the setpoint by anundesirable amount during a ramp or dwell, theholdback feature can be used to freeze the pro-gram at its current state (the HOLD light willflash). The program will resume when the errorcomes within the holdback value.

OFF: holdback is disabled.

Lo (Deviation Low Holdback): holds the pro-gram back when process variable deviates

28


below the setpoint by more than the holdbackvalue.

Hi (Deviation High Holdback): holds the pro-gram back when process variable deviatesabove the setpoint by more than the holdbackvalue.

bAnd (Deviation Band Holdback): combinesthe features of the high and low deviation hold-back in that it holds the program back when theprocess variable deviates above or below thesetpoint 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 displayreads, “Hb.”

3. Press the UP or DOWN button to togglebetween “bAnd, Hi, Lo and OFF.”

Hb U: Holdback ValueTo set the holdback value:


2. Press the SCROLL button until displayreads, “Hb.U.”

3. Press the UP or DOWN button to entera holdback value.

rmP.U: Setting Ramp UnitsRamp units are time units which are used in“rmP.r” segments (ramp to a setpoint at degreesper second, minute or hour) and “rmP.t” seg-ments (ramp to setpoint in a specific amount of

29


time). See “Setting the Segment Type” for anexplanation on how to set a ramp segment.


2. Press the SCROLL button until displayreads, “rmP.U.”

3. Press the UP or DOWN button to togglebetween seconds, minutes and hours.

dwL.U: Setting Dwell UnitsDwell units are time units which are used in“dwELL” segments (amount of time to remain ata specific temperature ). See “Setting theSegment Type” for an explanation on how to seta dwell segment.


2. Press the SCROLL button until displayreads, “dwL.U.”

3. Press the UP or DOWN button to togglebetween seconds, minutes and hours.

CYC.n: Setting the Number of CyclesSet the number of times a group of segments orprograms are to be repeated by following thesteps listed below.


2. Press the SCROLL button until displayreads,”CYC.n.”

3. Press the UP or DOWN button to selectthe number of cycles you want to run or,press the DOWN button to select “cont.”so the program will run continuously.

30


Setting the Segment TypeThere are five segment types. Proceed with thefollowing steps according to the type of segmentyou have selected.

rmP.r (Ramp)To ramp linearly at a set rate to a specified tem-perature:


2. Press the SCROLL button until displayreads,”tYPE.”

3. Press the UP or DOWN button until dis-play reads, “rmP.r.”

Steps 4 and 5 are used in the 4 program modelonly. If you are using an 8 segment program,skip to step 6.

4. Press the SCROLL button until displayreads “Hb.”

5. Press the UP or DOWN button to togglebetween “bAnd, Hi, Lo and OFF.”

6. Press the SCROLL button until displayreads, “tGt.”

7. Press the UP or DOWN button to set atarget setpoint.

8. Press the SCROLL button until displayreads,”rAtE.”

9. Press the UP or DOWN button to selecta value in ramp units (seconds, minutesor hours; set in the “rmP.U” parameter).

31


NoteThe program ramp rate is designedto reduce the heatup rate or coolingrate that the furnace normallyexhibits. When not using this fea-ture, the furnace will operate at itsmaximum heating and coolingcapability.

NoteWhen the program ramp has endedor has been reset, the furnace willcontinue to maintain setpoint temper-ature. It will not cool to ambient tem-perature unless the setpoint is set toambient temperature by the programor by the operator.

rmP.tTo ramp to a specified temperature at a settime:


2. Press the SCROLL button until displayreads, “tYPE.”

3. Press the UP or DOWN button until dis-play reads, “rmP.t.”



6. Press the SCROLL button until displayreads, “dur.”

7. Press the UP or DOWN button to selecta time in ramp units (seconds, minutesor hours; set in the “rmP.U” parameter.

dwEllTo maintain a constant temperature for a speci-fied time:



3. Press the UP or DOWN button until dis-play reads, “dwEll.”

4. Press the SCROLL button until displayreads, “dur.”

5. Press the UP or DOWN button to selecta time in dwell units (seconds, minutesor hours; set in the “dwL.U” parameter).

32


StEPTo climb instantaneously from the current tem-perature to a specified temperature.


2. Press the SCROLL button until displayreads, tYPE.”

3. Press the UP or DOWN button until thedisplay reads, “StEP.”



cALL (Running Multiple Programs; 4x16Segment Programmable Models Only)To call a program as a subroutine:If you want to run multiple programs, you canprogram the controller to “call” or link one pro-gram to another. This makes it possible to runone program at any time during another pro-gram and also return to the original program ifdesired.



3. Press the UP or DOWN button until dis-play reads, “cALL.”

4. Press the SCROLL button until displayreads, “PrG.n.”

5. Press the UP or DOWN button to selecta program number to be linked.

33


6. Press the SCROLL button until displayreads, “CYC.n.”

7. Press the UP or DOWN button to selectthe number of cycles the linked programis to be run.

EndTo end or repeat a program:



3. Press the UP or DOWN button until dis-play reads, “End.”

4. Press the SCROLL button until displayreads, “End.t.”

5. Press the UP or DOWN button to togglebetween “dwEll” (an indefinite dwell), “SOP” (End Segment Output Power) and“rSET” (reset).

Setting the Target Setpoint (4x16Segment Programmable Models Only)



3. Press the UP or DOWN button to setthe target setpoint temperature.

34


Running a Program (8 SegmentProgrammable Models)

To run a program, press the RUN/HOLD button.(The RUN light will illuminate.)

Running a Program (4x16Segment ProgrammableModels)

To run a program, press the RUN/HOLD button.(The RUN light will illuminate) or:

1. Press the PAGE button until you reachthe run list (run LiSt).

2. Press the SCROLL button until displayreads, “PrG.”

3. Press the UP or DOWN button to selectthe program number you want to run.

4. Press the RUN/HOLD button once tostart the program. (The RUN light willilluminate.)

35


Holding a ProgramTo put a running program on hold, press theRUN/HOLD button. (The HOLD light will illumi-nate.)

Cancelling a ProgramTo cancel a program, hold the RUN/HOLD but-ton down until the RUN and HOLD lights go off.

Tuning your FurnaceThe purpose of tuning your furnace is to matchthe characteristics of your controller to the char-acteristics of the process being controlled. Goodcontrol is evidenced by: stable, straight-line con-trol of the setpoint temperature with no fluctua-tions; No overshoot or undershoot of the set-point temperature; rapid restoration of the set-point temperature when external disturbancescause deviations from the setpoint.

This controller has automatic tuning featureswhich install optimum tuning parameters to givethe best temperature accuracy. No manual load-ing of tuning parameters is needed. We recom-mend that you tune the furnace to your specificapplication to obtain the best results. To providethe best temperature accuracy possible, usethese features when you install your furnaceand whenever you change your application orprocedure.

Tuning ErrorThe display will flash “tu.ER” if an error occursduring tuning. To clear the error and restart tun-ing, simultaneously press the PAGE andSCROLL buttons and follow the steps outlinedin “Autotuning.”

36


NoteDisplay will flash “tu.ER” if an erroroccurs during tuning. To clear theerror and restart tuning, simultane-ously press the PAGE and SCROLLbuttons and follow the steps outlinedin “Autotuning.”

NoteTo stop the tuning function, simulta-neously press the PAGE andSCROLL buttons.

Gain Scheduling

G.SP: Gain SchedulingGain scheduling is the automatic transfer ofcontrol between two sets of PID values. The2416 controller does this at a presettableprocess value. Gain scheduling is used for diffi-cult control processes which show largechanges in their response time or sensitivity athigh or low temperatures, or when heating orcooling.

The G.SP gain schedule setpoint is factory setat 700° C. The G.SP must be adjusted to 200°Cfrom the desired setpoint temperature when tun-ing.

Setting the Transfer Point If gain scheduling has been enabled, “G.SP willappear at the top of the PID list. This sets thevalue at which the transfer will occur. When theprocess value is below this level, PID1 will beactive and when it is above, Pid2 will be active.Set a value between the control regions thatshow the greatest change to achieve the bestpoint of transfer.

TuningThe two sets of PID values can be manually setor automatically tuned. To tune automaticallyyou must tune above and below the transferpoint G.SP. If the process value is below thetransfer point G.SP, the calculated values willautomatically be inserted into the (SEt 1) setand if the process value is above G.SP, the cal-culated values will automatically be inserted intothe (SEt 2).

37


AutotuningThe Autotune feature automatically sets up thePID values in the control parameters to suit newprocess conditions. To tune your furnace using autotuning:

1. Load your furnace with a load similar toyour normal load and close the door.

2. Set the setpoint temperature.

3. Press the PAGE button until the displayreads, “Atun LiSt.”

4. Press the SCROLL button until “tunEOFF” is displayed.

5. Press the UP or DOWN button to select“on.”

6. Simultaneously press the PAGE andSCROLL buttons to return to the HOMEDISPLAY. The display will flash “tunE”while tuning is in progress.

Adaptive TuningAdaptive tuning continuously evaluates tuningparameters. Adaptive tuning automaticallyinstalls new values if better accuracy is possi-ble. Adaptive tuning should be used when thecharacteristics of a process change due to loador setpoint changes or, in a process that can nothandle the oscillation caused by a one-shottune.

To tune your furnace using adaptive tuning:1. Load your furnace with a load character-

istic of those you intend to heat in it.

2. Press the PAGE button until display

38


reads, “Atun LiSt.”

3. Press the SCROLL button until “drAOFF” is displayed.

4. Press the UP or DOWN button to select“on.”

5. Press the SCROLL button until “drA.t” isdisplayed.

6. Press the UP or DOWN button until thedesired trigger value is achieved.

39


Installation

Compressed Air Hook-Up1. A 0.250 inch tube fitting is located at the

rear of the furnace.

2. Using 0.250 inch I.D. rubber tubing,connect a piece of tubing from this inputfitting to a corresponding 0.250 inch fit-ting located on the regulated side of apressurized air service line.

3. Prior to making connections at the regu-lator, ensure that the regulator is com-pletely closed (0 psi).

4. Turn flow control valve located at thebottom of the flow meter (front controlpanel) clockwise to closed positions.

5. Turn regulator to maximum output pres-sure of 20 psi. Check for any leaks atconnection points of connecting tubing.

6. Open flow control valve slowly until ballin flow meter reads between 40-45 litersper minute flow rate.

7. Open furnace door and check that air isexhausting from the manifold located atthe bottom rear of the chamber.

8. Turn flow control to off (clockwise).

Exhaust Tubing Hook-Up

Using accessory stainless steel tubing availablefrom Barnstead International (part number

40

Installation and Operation ofAir Control

NoteCoal ashing furnaces -60 models con-tain a feature to provide air (or inertgas) flow within the furnace chamber.

NoteA pressurized air line with a minimumworking pressure range of 0 to 20 psiis required.

NoteA flow rate of 40 to 45 liters per minutewill provide three air exchanges of thechamber per minute.

NoteIf the furnace is to be used regularly,the airline regulator may be left opento 20 psi.

NoteAppropriate exhaust must be providedto remove smoke and gases proceed-ing an ashing procedure.

NoteFailure to connect the exhaust port toan appropriate exhaust system willresult in smoke and gases filling thework area. Without the connection,gases and smoke will escape aroundthe door seal and at the rear of the fur-nace.

AY408X1A) or equal quality 2.5 inch I.D. stain-less steel tubing, connect flexible tubing fromvent port at top of furnace case to an appropri-ate negative pressure exhaust system. Thisexhaust system must be capable of handlingsmoke and gases produced in an ashing proce-dure.

Furnace ProgrammingRefer to “Programmable Models” in this manualto program in the following values for perform-ing ASTM specification D3174.

(Ramp 1) value is 8°C/minuteTarget SP value is 500°C(Dwell 1) value is 0 minute(Ramp 2) value is 6°C/minuteTarget SP value is 750°C(Dwell 2) value is 120 minute(Ramp 3) value is END (4 program models)Cycles value is 1

Included with this furnace are two stainlesssteel trays which will hold crucibles of quartzjars. Use the appropriate side for the type ofcrucible you are using. A removable handle isalso provided to use in loading and unloadingthe trays from the furnace.

Shelf Location1. The side walls of the chamber contain

twenty four holes (.250 inch dia.) whichallow adjustment of the two perforatedshelves at various heights within thechamber.

2. Using the eight, .250 inch diameterporcelain pegs, insert four pegs in thebottom row of holes.

41

INSTALLATION AND OPERATION OF AIR CONTROL

NoteAppropriate exhaust must be providedto remove smoke and gases proceed-ing an ashing procedure.

NoteFailure to connect the exhaust port toan appropriate exhaust system willresult in smoke and gases filling thework area. Without the connection,gases and smoke will escape aroundthe door seal and at the rear of the fur-nace.

3. Next insert the remaining four pegs infourth row of holes and insert the two perfo-rated shelves .

4. Check for proper fit at this point by insertingthe crucible trays.

Operation1. Insert crucible trays. One tray per shelf.

2. Close the furnace door.

3. Ensure the exhaust system is operating.

4. Set flow control valve so flow indicatorreads between 40 and 45 liters per minute.(Check regulator to ensure 20 psi pres-sure).

5. Switch power switch to “ON”.

6. Depress run button. The controller will auto-matically step the program through the vari-ous steps outlined earlier.

7. When the program has ended, the con-troller will maintain the chamber tempera-ture at a value equal to the last pro-grammed Target SP until the program iscancelled. It will not automatically cool toambient unless last programmed Target SPis set at ambient. When a program is can-celled the controller will maintain the cham-ber temperature at a value equal to themain set point . To cancel a programdepress and hold the run button until the“run” light extinguishes.

8. At the end of the program, turn the flowcontrol valve fully clockwise to the closedposition.

42

INSTALLATION AND OPERATION OF AIR CONTROL

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

• If you are heating a number of smallparts, spread them throughout the cen-ter of the furnace chamber.

• Keep objects away from thermocouple.

• Use insulated tongs and mittens whenloading and unloading furnace.

• Always wear safety glasses.

• Use Barnstead|Thermolyne hearthplates if you place load on bottom ofchamber. Part #PHX2 (three arerequired).

43

Furnace Loading

CautionDo not overload your furnace cham-ber. If the load is to be heated uniform-ly, it should not occupy more than two-thirds of the furnace chamber. Failureto observe this caution could result indamage to furnace components.

Preventative MaintenanceThis unit is equipped with a venting system onthe top of the furnace. This is for the removal offumes from the chamber of the unit.Contamination is a major cause of element fail-ure, therefore, remove all fume forming materialbefore heating. (e.g. clean cutting oil from toolsteel).

Housekeeping is vital to your electric furnace -KEEP IT CLEAN. Run your furnace up to 871°C(1600°F) empty occasionally to burn off the con-tamination that may exist on the insulation andelements. Maintain 871°C (1600°F) for at least4 hours to ensure complete ashing of foreignmaterials.

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 atthe operating temperature or at a reduced levelsuch as 260°C (500°F).

Change the thermocouple every six months.

General Cleaning InstructionsWipe exterior surfaces with lightly dampenedcloth containing mild soap solution.

To Replace a Heating Element1. Disconnect furnace from power supply.

2. Remove the back terminal cover of thefurnace. (Note placement and connec-tions of wires)

3. Loosen the nuts on the terminals of theelement to be replaced.

44

Maintenance and Servicing

WarningDisconnect from the power supplyprior to maintenance and servicing.

WarningRefer servicing to qualified personnel.

WarningReplace fuses with same type and rating.

Hot Surface“Caution. Hot Surface.Avoid Contact.”To avoid burns, this furnace must notbe touched on the exterior or interiorsurfaces during use or for a period oftime after use.

NotePerform only maintenance described inthis manual. Contact an authorizeddealer or our factory for parts andassistance.

4. Open the door and pull the defective el-ement out. (It may be easiest to turn thefurnace so that the element to be re-moved is on top).

5. Slide the new element into place,threading the leads through the insulat-ing porcelain bushing on the back of thefurnace.

6. Tighten the nuts securely. Cut off anyexcess lead wire.

7. Replace the back terminal cover.

8. Reconnect furnace to power supply.

9. Test operation of furnace.

To Replace a Platinel IIThermocouple

1. Disconnect furnace from power supply.

2. Remove the back terminal cover of thefurnace. (Note placement and connec-tion of wires).

3. Remove the screws on the thermocou-ple terminals and pull the thermocouplestraight out.

4. Insert the new thermocouple into thefurnace with yellow beaded lead con-nected to the positive (+) marked termi-nal and other lead to negative (-) termi-nal.

5. Secure connections with screws re-moved in step 3.

45

MAINTENANCE AND SERVICING

6. Replace the back terminal cover.

7. Reconnect the furnace to power supply.


To Replace a Chromel/AlumelThermocouple

1. Disconnect furnace from power supply.

2. Remove both back covers. (Note place-ment and connection of wires).

3. Remove clip holding thermocouple inplace (1 screw) and remove the twoscrews on the thermocouple terminals.

4. Remove the thermocouple. Pull thermo-couple straight out of hole in the cham-ber first to avoid damage to the insula-tion.

5. Guide the looped ends of the new ther-mocouple through the plastic bushingswith the red (-) lead to the right as youface the back of the furnace.

6. Insert the thermocouple straight throughthe hole in the chamber.

7. Secure the thermocouple with clip andscrew. Connect the looped ends of thethermocouple to the terminals with + to+ (yellow wire). Chromel/Alumel thermo-couples and lead wire are easily testedwith a magnet. The non-magnetic wireis positive (+) and the magnetic wire isnegative (-).

46

MAINTENANCE AND SERVICINGTITLE

8. Replace both back covers.

9. Reconnect to power supply. Test opera-tion of furnace.

To Replace Solid State Relay1. Disconnect furnace from power supply.

2. Remove back control cover. (Note con-nection and placement of wires torelay). Remove the front control panelscrews to provide access to solid staterelay. Slide control section forward.

3. Disconnect wires from terminals. Identifyor mark wires.

4. Remove nuts, washers, and screwsfrom relay, then remove relay.

5. Install new relay.

6. Reconnect the wires identified ormarked in step 3.

7. Replace covers.

8. Reconnect furnace to power supply.


To Replace Door Switch 1. Disconnect furnace from power supply.

2. Remove the four top screws on the frontdial and the four bottom screws on theback cover.

47


3. Slide the control section forward. (Donot pull excessively on the internalwires).

4. Disconnect the wires from the doorswitch. (Note connection and placementof wires to micro switch). Identify ormark wires.

5. Remove the two screws and nuts fromthe door switch(es).

6. Insert new door switch(es) and securewith screws and nuts removed in Step5.

7. Reconnect wires identified or marked inStep 4 to new door switch(es).

8. To realign door switch see “To RealignDoor Switch” section.

9. Slide control section back in and replacethe screws described in Step 2.

10. Reconnect to power supply.

11. Test operation of door switch. (See “ToRealign Door Switch” section.)

To Realign Door Switch 1. Disconnect furnace from power supply.

2. Remove the four top screws on the frontdial and the four bottom screws on theback cover.

3. Slide the control section forward. (Donot pull excessively on the internalwires).

48


4. With the door closed loosen the screwson the microswitch and slide the switchdownward, so that the screws are at thebottom of the slots in the mountingbracket.

5. Finger tighten both screws. While hold-ing down the rear of the micro switchhousing, gently push up on the front ofswitch until you hear a click.

6. Open and close the door; the switchshould click approximately 1" to 1.5"before the door is closed.

7. Tighten the two screws to secure themicro switch. Check the operation ofthe switch as described in Step 6 aftertightening the screws.

8. Slide control section back and replacethe screws described in Step 2.

9. Reconnect to power supply.

10. To test the operation of the door switch:turn the power switch on, set the controlsetting high enough to keep the controlfrom cycling, open and close the door;the cycle light should turn off approxi-mately 1" to 1.5” before the door isclosed.

To Replace the ControllerThe controller plugs into a panel mountingsleeve which should be left permanentlyinstalled in the furnace housing. To remove thecontroller, release the side clips and slide thecontroller out. Do not attempt to dismantle thisunit further.

49


50

TroubleshootingPROBLEM PROBABLE CAUSE CORRECTIVE ACTION

The power switch does not The furnace is not connected Check furnace connectionilluminate. to power supply. to power source.

ON and OFF power switch is Replace power switch.defective.

Fuses blown. Replace fuses.

The furnace does not heat,cycle light illuminated. Heating elements burned out or Replace heating elements or

improper connections. repair connections.

The furnace does not heat. No power. Check power source and fuses orbreakers.

Two or more heating elements in Replace defective elements.208V or 240V furnaces are burnedout.Thermocouple has oxidized and Replace thermocouple.opened the circuit. Defective electrical hookup. Repair electrical hookup.

Door switch malfunction. Re-align or replace door safety switch.Defective mechanical relay coil Replace relay.or contacts.

No temperature control. Shorted thermocouple circuit. Check thermocouple connectionand/or replace thermocouple.

Shorted solid state relay - over Replace solid state relay.temperature protection maybe activated.Defective control - error message Return control for repairon display may appear. or replace.Thermocouple leads are reversed. Connect leads correctly (see manual).

Slow heat-up. One or two heating elements are Replace burned out elements.burned out.Heavy load in chamber. Lighten load in chamber

to allow heat to circulate.

Low line voltage. Install line of sufficient size andproper voltage (isolate furnacefrom other electrical loads).

Wrong heating elements. Install proper elements.

51

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Door switch does not cut power Door switch is not functioning. Re-align or replace door safety to the furnace chamber. switch.

Mechanical relay contacts sticking. Replace relay.

Repeated element burnout. Chamber improperly loaded. See loading procedures in start-up procedure.

Heating harmful materials. Enclose material in container. Clean up spills on chamber. Ventilate chamber by leaving door cracked slightly open when heating known harmful reagents.

Overheating furnace. Keep furnace under maximumtemperature. Closer supervisionof control setting.

Repeated element burnout (cont.)Wrong element. Install proper element.

Oxidized thermocouple. Replace thermocouple.

Contamination present from Replace insulation material.previous burnout.

Wired improperly. Check wiring diagram for correctwiring of your furnace.

Inaccurate temperature display. Oxidized or contaminated Replace thermocouple.

thermocouple.

Improper loading. Use proper loading procedures.

Refer to start-up procedure.

Poor thermocouple connection. Tighten connections.

Solid state relay malfunction. Replace solid state relay.

Thermocouple connections Reconnect thermocouple correctly.

Listed below is the common replacement parts for all models of the 6000 furnace. The far left column con-tains the letter designation found on the circuit diagrams. Be sure to identify the correct part number withrespect to the exact model number found on your furnace.

REPLACEMENT PART DESCRIPTION MODELS USED ON

CN71X82 Controller F6010, F6018

CN71X93 Controller F6020C, (-33), F6028C

CN71X85 Controller F6020C-33-60, F6020C-60, F6028C-60

CN71X83 Controller F6020C-33-80, F6020C-80, F6028C-80

CN71X86 Controller F6020C-60-80, F6020C-33-60-80, F6028C-60-80

CN71X84 Controller F6030CM, F6030CM-33, F6038CM

CN71X87 Controller F6030CM-33-60, F6030CM-60, F6038CM-60

PLX82 Pilot Light All models

EL408X1 Heating Element, Top F6020C , (-33), (-33-60), (-33-80), (-33-60-80),(-60), (-60-80) & (-80), F6030CM, (-33),

(-33-60) & (-60)

EL408X10 Heating Element, Top F6010, F6018

EL408X2 Heating Element, Top F6028C, (-60), (-60-80) & (-80),

F6038CM & (-60)

EL408X5 Heating Element, bottom F6020C , (-33), (-33-60), (-33-80), (-33-60-80), (-60), (-60-80) & (-80), F6030CM, (-33),

(-33-60) & (-60)

EL408X4 Heating Element, bottom F6028C, (-60), (-60-80) & (-80),

F6038CM & (-60)

EL408X9 Heating Element, bottom F6010, F6018

EL205X6 Heating Element, side F6020C , (-33), (-33-60), (-33-80), (-33-60-80),

(-60), (-60-80) & (-80), F6030CM, (-33), (-33-60) & (-60)

EL408X3 Heating Element, side F6028C, (-60), (-60-80) & (-80), F6038CM

& (-60)

EL408X11 Heating Element, side F6010, F6010-33, F6018

RYX57 Relay All models except F6010, F6010-33, F6018

RYX34 Solid State Relay All models

SWX144 Power Switch All models

SW1172X1 Micro Switch All models except F6010, F6018,

SWX163 Micro Switch (2) F6010, F6018

TC1249X1 Thermocouple, Type K F6010, F6018

TC327X1 Thermocouple, Platinel All models except F6010, F6018

CAX99 Filter, EMI -33 models

FZX26 Fuse Holder F6010, F6018 only

2-58147 Fuse F6010, F6018 only

52

Replacement Parts List

53

Wiring DiagramsSingle Setpoint Control w/OTP

54

WIRING DIAGRAMS

Single Setpoint Control w/OTP

55

WIRING DIAGRAMS

8 Segment Programmable Control

56

WIRING DIAGRAMS

4 X 16 Segment Programmable Control

57

Ordering Procedures

Please refer to the Specification Plate for the complete model number, serial number, and series numberwhen 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 thisunit or can be obtained promptly from the factory. When service or replacement parts are needed we ask thatyou check first with your dealer. If the dealer cannot handle your request, then contact our Customer ServiceDepartment at 563-556-2241 or 800-553-0039.

Prior to returning any materials to Barnstead International, please contact our Customer Service Departmentfor a “Return Materials Authorization” number (RMA). Material Returned without an RMA number will bereturned.

Two Year Limited Warranty

BARNSTEAD INTERNATIONAL (“BARNSTEAD”) warrants that if a product manufactured by Barnstead shallbe free of defects in materials and workmanship for two (2) year from the first to occur of (i) the date the prod-uct is sold by BARNSTEAD or (ii) the date the product is purchased by the original retail customer (the“Commencement Date”). Except as expressly stated above, BARNSTEAD MAKES NO OTHER WARRANTY,EXPRESSED OR IMPLIED, WITH RESPECT TO THE PRODUCTS AND EXPRESSLY DISCLAIMS ANY ANDALL WARRANTIES, INCLUDING BUT NOT LIMITED TO, WARRANTIES OF DESIGN, MERCHANT ABILITYAND FITNESS FOR A PARTICULAR PURPOSE.

An authorized representative of BARNSTEAD must perform all warranty inspections. In the event of a defectcovered by BARNSTEAD’s warranty, BARNSTEAD shall, as its sole obligation and exclusive remedy, providefree replacement parts to remedy the defective product. In addition, for products sold by BARNSTEAD withinthe continental United States or Canada, BARNSTEAD shall provide provide free labor to repair the productswith the replacement parts, but only for a period of ninety (90) days from the Commencement Date.

BARNSTEAD’s warranty provided hereunder shall be null and void and without further force or effect if thereis any (i) repair made to the product by a party other than BARNSTEAD or its duly authorized service repre-sentative, (ii) misuse (including use inconsistent with written operating instructions for the product), mishan-dling, contamination, overheating, modification or alteration of the product by any customer or third party or(iii) use of replacement parts that are obtained from a party who is not an authorized dealer of BARNSTEAD.

Heating elements, because of their susceptibility to overheating and contamination, must be returned to theBARNSTEAD factory and if, upon inspection, it is concluded that failure is due to factors other than excessivehigh temperature or contamination, BARNSTEAD will provide warranty replacement. As a condition to thereturn of any product, or any constituent part thereof, to BARNSTEAD’s factory, it shall be sent prepaid and aprior written authorization from BARNSTEAD assigning a Return Goods Number to the product or part shallbe obtained.

IN NO EVENT SHALL BARNSTEAD BE LIABLE TO ANY PARTY FOR ANY DIRECT, INDIRECT, SPECIAL,INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OR FOR ANY DAMAGES RESULTING FROM LOSS OFUSE OR PROFITS, ANTICIPATED OR OTHERWISE, ARISING OUT OF OR IN CONNECTION WITH THESALE, USE OR PERFORMANCE OF ANY PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CON-TRACT, TORT (INCLUDING NEGLIGENCE), ANY THEORY OF STRICT LIABILITY OR REGULATORYACTION.

The name of the authorized Barnstead International dealer nearest you may be obtained by calling 1-800-446-6060 (563-556-2241) or writing to:

2555 Kerper BoulevardP.O. Box 797Dubuque, Iowa 52001-0797 Phone: 563-556-2241 or 800-553-0039 Fax: 563-589-0516E-mail: [email protected]

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