LT1262X1(new) 30400 Mufla Thermolyne F30400 Manual Operacion

User Manual: 30400

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Type 30400

Thermolyne Furnace

OPERATION MANUAL

AND PARTS LIST

Series 1262

Single Setpoint Models F30420C, F30420C-33, F30428C

8 Segment Programmable F30420C-33-80, F30420-33-60-80

Models with OTP F30420C-60-80, F30420C-80

F30428C-60-80, F30428C-80

4 X 16 Segment F30430CM, F30430CM-33,

Programmable Models F30430CM-33-60, F30430CM-60

with OTP F30438CM, F30438CM-60

LT1262X1 • 10/8/04

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..................................................................................................................................................4

Warnings ......................................................................................................................................................4

General Specifications ........................................................................................................................................6

Environmental Conditions ............................................................................................................................6

Declaration of Conformity ............................................................................................................................7

Introduction..........................................................................................................................................................8

Intended Use ................................................................................................................................................8

General Usage..............................................................................................................................................8

Principles of Operation ................................................................................................................................9

Unpacking ........................................................................................................................................................10

Installation ........................................................................................................................................................11

Site Selection ..............................................................................................................................................11

Electrical Connections ................................................................................................................................11

Operation, All Models ........................................................................................................................................12

Power Switch..............................................................................................................................................12

Cycle Light..................................................................................................................................................12

Door Safety Switch ....................................................................................................................................12

Single Setpoint Models with OTP ....................................................................................................................13

Basic Operation ..........................................................................................................................................13

Buttons and Indicators................................................................................................................................13

To View or Change the Setpoint ................................................................................................................14

To View the Display Units ..........................................................................................................................14

To View the % Output Power......................................................................................................................14

Controller Parameters ................................................................................................................................14

Alarms ........................................................................................................................................................15

Sensor Break Protection ............................................................................................................................16

Over Temperature Protection (OTP) ..........................................................................................................16

Tuning ........................................................................................................................................................17

Single Ramp and Dwell ....................................................................................................................................18

Functions ....................................................................................................................................................18

Program Overview......................................................................................................................................18

Program Setup............................................................................................................................................19

Running the Program..................................................................................................................................20

Stopping the Program ................................................................................................................................20

Clearing the Flashing End ..........................................................................................................................20

Switching from Manual Mode to Automatic Mode ......................................................................................20

Verifying a Running Program......................................................................................................................20

8 Segment & 4x16 Segment Programmable Models w/OTP............................................................................21

Basic Operation ..........................................................................................................................................21

To Change the Setpoint..............................................................................................................................21

To View the Display Units ..........................................................................................................................22

To View the % Output Power......................................................................................................................22

Buttons and Indicators................................................................................................................................22

Controller Parameters ................................................................................................................................23

Alarms ........................................................................................................................................................26

Table of Contents

Sensor Break Protection ............................................................................................................................26

Over Temperature Protection......................................................................................................................27

To Operate the Controller as a Single Setpoint Controller ........................................................................27

Programming Controller..............................................................................................................................27

Creating a New Program or Editing an Existing Program..........................................................................28

Setting the Target Setpoint ........................................................................................................................28

Running a Program ....................................................................................................................................34

Holding a Program......................................................................................................................................35

Cancelling a Program ................................................................................................................................35

Tuning Your Furnace ..................................................................................................................................35

Gain Scheduling ........................................................................................................................................36

Installation and Operation of Air Control ..........................................................................................................38

Installation ..................................................................................................................................................38

Furnace Loading ..............................................................................................................................................39

Preventative Maintenance ................................................................................................................................40

General Cleaning Instructions ....................................................................................................................40

Problem Solving ................................................................................................................................................41

Maintenance and Servicing ..............................................................................................................................44

Warning ......................................................................................................................................................44

To Replace a Heating Element ..................................................................................................................44

To Replace a Platinel II Thermocouple ......................................................................................................45

To Replace Solid State Relay ....................................................................................................................46

To Replace Door Switch (Microswitch) ......................................................................................................46

To Realign Door Strike ......................................................................................................................................47

To Replace Control Module ..............................................................................................................................48

Replacement Parts List ....................................................................................................................................49

Ordering Procedures ........................................................................................................................................51

Wiring DIagrams................................................................................................................................................52

Two Year Limited Warranty ..............................................................................................................................56

TABLE OF CONTENTS

Your Barnstead Thermolyne furnace has been designed

with function, reliability and safety in mind. It is your re-

sponsibility to install it in conformance with local electrical

codes. For safe operation, please pay attention to the

alert signals throughout the manual.

To avoid electrical shock, this furnace must:

1. Use a properly grounded electrical outlet of cor-

rect voltage and current handling capacity.

2. Disconnect from the power supply prior to main-

tenance and servicing.

3. Have the door switch operating properly.

To avoid burns, this furnace must:

1. Not be touched on the exterior or interior sur-

faces during use or for a period of time after

use.

To avoid personal injury:

1. Do not use in the presence of flammable or

combustible materials; fire or explosion may

result. This device contains components which

may ignite such material.

2. Refer servicing to qualified personnel.

Warning

Please note the following WARNINGS:

This warning is presented for compliance with California

Proposition 65 and other regulatory agencies and only

applies to the insulation in this product. 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. Refractory ceramic and refractory ceramic

fibers (after reaching 1000°C) contain crystalline silica,

which can cause lung damage (silicosis). The Internation-

al Agency for Research on Cancer (IARC) has classified

refractory ceramic fiber and fiberglass as possibly

Safety Information

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.

Caution

Cautions alert you to a possibility of

damage to the equipment.

Warning

Warnings alert you to a possibility of

personal injury.

Note

Notes alert you to pertinent facts and

conditions.

Alert Signals

carcinogenic (Group 2B), and crystalline silica as carcino-

genic 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 indi-

cate that there is no risk of exposure to dust or respirable

fibers resulting from operation of this product under nor-

mal conditions. However, there may be a risk of exposure

to respirable dust or fibers when repairing or maintaining

the insulating materials, or when otherwise disturbing

them in a manner which causes release of dust or fibers.

By using proper handling procedures and protective

equipment you can work safely with these insulating

materials and minimize any exposure. Refer to the appro-

priate Material Safety Data Sheets (MSDS) for informa-

tion regarding proper handling and recommended protec-

tive equipment. For additional MSDS copies, or additional

information concerning the handling of refractory ceramic

products, please contact the Customer Service

Department at Barnstead International

(1-800-553-0039).

SAFETY INFORMATION

Models F30420C, (-33), F30428C, (-60-80)

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

(-60-80) & (-80) F30438CM & (-60)

F30430CM, (-33),

(-33-60) & (-60)

Overall Dimensions Width 21 1/2 (55) 21 1/2 (55)

IN. (CM) Height 29 1/2 (75) 29 1/2 (75)

Depth 25 1/2 (65) 25 1/2 (65)

Chamber Dimensions Width 14 (35) 14 (35)

IN. (CM Height 14 (35) 14 (35)

Depth 14 5/8 (37) 14 5/8 (37)

Weight Lbs. (KG) 188 (86) 188 (86)

Electrical Ratings Volts 240 208

Amps 22.9 26.4

Watts 5500 5500

Freq. 50/60 50/60

Phase 1 1

Temperature Ratings Cont. 400°F-1800°F* 400°F-1800°F*

°F (°C) (204°C)-(982°C) (204°C)-(982°C)

Intermittent 1800°F-2000°F 1800°F-2000°F

(982°C)-(1093°C) (982°C)-(1093°C)

* The maximum continuous temperature for ashing furnaces (-60 models) is 1787°F (975°C).

Environmental Conditions

Operating: 17°C - 27°C; 20% to 80% relative humidity, non-condensing. Installation Category II

(over-voltage) in accordance with IEC 664. Pollution Degree 2 in accordance with IEC 664.

Altitude limit: 2,000 meters.

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

General Specifications

Declaration of Conformity

(for 230 volt CE models only)

Barnstead International hereby declares under its sole responsibility that this product conforms with the tech-

nical requirements of the following standards:

EMC: EN 61000-3-2 Limits for harmonic current emissions

EN 61000-3-3 Limits for voltage fluctuations and flicker

EN 61326-1 Electrical equipment for measurement, control, and laboratory use; Part I:

Generic Requirements

Safety: EN 61010-1 Safety requirements for electrical equipment for measurement, control, and

laboratory use; Part I: General Requirements

EN 61010-2-010 Part II: Particular requirements for laboratory equipment for the heating of

materials

per the provisions of the Electromagnetic Compatibility Directive 89/336/EEC, as amended by 92/31/EEC and

93/68/EEC, and per the provisions of the Low Voltage Directive 73/23/EEC, as amended by 93/68/EEC.

The authorized representative located within the European Community is:

Electrothermal Engineering, Ltd.

419 Sutton Road

Southend On Sea

Essex SS2 5PH

United Kingdom

Copies of the Declaration of Conformity are available upon request.

GENERAL SPECIFICATIONS

Intended Use

1. The Type 30400 Automatic and Programmable

furnaces are general laboratory and heat treat-

ing furnaces. For optimum element life,

Barnstead Thermolyne recommends these fur-

naces for applications requiring temperatures

from 400°F (204°C) to 1800°F (982°C) for con-

tinuous 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 oper-

ating the furnace for less than 3 hours.

2. The unit consists of 1) a heating chamber; 2) an

automatic proportioning digital set, digital read

control with overtemperature protection and 3) a

door interlock relay for user safety.

3. The Type 30400 Programmable furnace is

designed to control a programmed temperature

profile. The profile is in the format of ramps and

dwell segments. The first ramp, RAMP 1, starts

at the initial measured furnace temperature. This

ramp is positive going at a programmed rate

until the programmed level is reached. The set-

point will stay at this level for a period deter-

mined by the setting of DWELL 1. Additional

positive or negative going ramps are now initiat-

ed starting at the level at the end of DWELL 1.

When the second ramp reaches the second pro-

grammed level, the setpoint stays at that level

for the duration of the segment. Depending

upon the model ordered, additional ramp and

dwell segments may be added. See specific

model number in proceeding chart for total num-

ber of program segments.

4. The Type 30400 Automatic furnace is designed

as a single set point controller which reaches

and maintains one temperature value.

General Usage

Do not use this product for anything other than its intend-

ed usage.

Introduction

Note

When in the program RUN mode, the

programmable controller serves to pro-

vide a programmed temperature pro-

file as described earlier. When in the

single setpoint automatic mode, the

unit serves as an automatic tempera-

ture controller.

INTRODUCTION

Principles of Operation

1. Furnace: The furnace chamber is heated by four

electric resistance heaters which are embedded in a

refractory material. The chamber is insulated with a

ceramic fiber insulation. The temperature is con-

trolled by an automatic proportioning controller using

a platinel thermocouple to feed back information. The

control is located under the furnace chamber and is

well insulated from the heat generated in the furnace

chamber. The temperature is controlled by one of

three types of controllers.

MODEL NUMBER DIGITAL COMMUM. TOTAL NUMBER OF NUMBER OF

PROGRAMMABLE STORED

SEGMENTS PROGRAMS

F30420C-33-80 NO 8

F30420-33-60-80 NO 8

F30420C-60-80 NO 8

F30420C-80 NO 8

F30428C-60-80 NO 8

F30428C-80 NO 8

F30430CM YES 64 16 Segment Programs

F30430CM-33 YES 64 16 Segment Programs

F30430CM-33-60 YES 64 16 Segment Programs

F30430CM-60 YES 64 16 Segment Programs

F30438CM YES 64 16 Segment Programs

F30438CM-60 YES 64 16 Segment Programs

1. Visually check for any physical damage to the

shipping container.

2. Inspect the equipment surfaces that are adja-

cent 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 reship-

ment is foreseen or required.

Unpacking

Installation

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.

Warning

To avoid electrical shock, this furnace

must always use a properly grounded

outlet of correct voltage and current han-

dling capacity.

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 cre-

ate a possible fire hazard.

Site Selection

Install furnace on a sturdy surface and allow adequate

space for ventilation.

Electrical Connections

The electrical ratings are located on the specification

plate on the back of the furnace. Consult

Barnstead/Thermolyne if your electrical service is dif-

ferent than those listed on the specification plate. Be

sure the front power switch is in the OFF position

before connecting the furnace to your electrical supply.

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.

Hot Surface

Caution: Avoid Contact. To avoid burns,

this furnace must not be touched on the

exterior or interior surfaces during use or

for a period of time after use.

Warning

To avoid electrical shock, the door safety

switch must be operating properly.

Warning

Always wear safety glasses or a safety

shield and high temperature gloves when

loading or unloading the furnace. Long

sleeved, fire retardant clothing and a fire

retardant apron is also recommended.

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 infor-

mation on checking and setting the setpoint.)

Cycle Light

The amber cycle light will illuminate whenever the

power is being applied to the heating elements. The

cycle light will turn on and off as the furnace reaches

the setpoint.

Door Safety Switch

The door safety switch removes power from the heat-

ing elements when the door is opened. Open and

close the door a few times; note that the amber

CYCLE light will switch off when the door is opened. If

this condition is not true, consult the Troubleshooting

section before proceeding. This check must be done

when the furnace is heating and the cycle light is illumi-

nated.

Single Setpoint Models

Output 1

Manual

UP ARROW

Button

Temperature

Display

Window

DOWN ARROW

Button

PAGE

Button SCROLL

Button

Output 2

MAN

Single Setpoint Models w/OTP

Note

If at any time you want to return to the

HOME DISPLAY, simultaneously press

the PAGE and SCROLL buttons.

The single setpoint model w/ OTP furnace controller

is a single setpoint controller which provides a single

digital display to indicate the current chamber tempera-

ture or setpoint temperature. This temperature con-

troller features sensor break protection, self-tuning

capability and over temperature protection (OTP) with

an additional OTP relay device.

Basic Operation

When the controller is turned ON it will perform a short

self-test and then display the measured value (process

value) in the HOME DISPLAY.

Buttons and Indicators

OP1 (Output 1): Illuminates when the logic output is

ON.

OP2 (Output 2): Illuminates when the relay output is

ON (will go out during an alarm situation).

PAGE button: Allows you to select a new list of

parameters.

SCROLL button: Allows you to select a parameter

within a list of parameters.

DOWN button: Allows you to decrease a value.

UP button: Allows you to increase a value.

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 press-

ing 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. The

display will show the temperature units in °C/F/K and then

return to the HOME DISPLAY. (Call Customer Service if you

require a different temperature unit.)

To View the % Output Power

From the HOME DISPLAY press the SCROLL button twice.

Press and release the UP or DOWN button to view the %

output power. This value is a read-only value and cannot be

changed.

Controller Parameters

Home display

°C: Temperature units in Celsius. Temperature units can not

be changed without entering the configuration. Contact

Customer Service if a different temperature unit is required.

OP: % output power demand.

IdHi: Deviation high alarm.

Al List

IdHi: Deviation high alarm.

Atun List

tunE: One-shot autotune enable.

SINGLE SETPOINT MODELS W/OTP

Note

The following alarm messages are

factory default settings and may vary

if you have changed the configuration

of your controller:

IDHi: = 50°C

2FSH = 1118°C

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.

Alarms

The controller will flash an alarm message in the home

display if an alarm condition is detected.

2FSH: Measured value full scale high alarm.

IdHi: Measured value deviation high alarm.

S.br: Sensor break: check that sensor is connected cor-

rectly.

L.br: Loop break: check that the heating circuits are work-

ing properly.

Ld.F: Heater Circuit fault: indication of either an open or

short solid sate relay, a blown fuse, missing supply or

open circuit heater.

Sensor Break Protection

This controller provides sensor break protection in the

event the thermocouple opens. If an open thermocou-

ple 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. 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. We recommend a value of 20° above your

working temperature to provide protection for your

workload.

In addition to over-temperature protection, units con-

taining a single setpoint controller w/OTP feature a

mechanical OTP relay device which disconnects power

from the elements in an alarm condition (only in fur-

naces with OTP relay). See models listed on front

page.

SINGLE SETPOINT MODELS W/OTP

Note

Furnace must be at ambient

temperature before starting a tune.

Note

Tune has completed when “tunE”

stops flashing on display.

SINGLE SETPOINT MODELS W/OTP

Tuning

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. Barnstead|Thermolyne recom-

mends you use this feature to provide the best temper-

ature accuracy the controller can attain. To use the tun-

ing feature:

1. Adjust the setpoint to your desired value.

2. Press the PAGE button until display reads,

“Atun.”

3. Press the SCROLL button. Display will read,

“tunE.”

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

5. Simultaneously press the PAGE and

SCROLL buttons to return to the HOME DIS-

PLAY. The display will alternately flash

between “tunE” and the HOME DISPLAY

while tuning is in progress.

6. The controller will then turn the heating on

and off to induce an oscillation. When the

measured value reaches the required setpoint

the first cycle will end.

7. Tuning will be complete after two oscillation

cycles and then the tuner will turn itself off.

8. Normal control function will resume after the

controller calculates tuning parameters.

Note

“Stat” and “Sp.rr” in Sp list must be

set to OFF or “tunE” will not initiate.

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 program-

ming 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. 2) is the same as mode 1, except

the controller continues to heat at the Setpoint

after the Dwell has completed. (This mode does

not cool down.)

3. Mode 3 (Opt. 3) is the same as mode 1, except

the Dwell time includes the Ramp (if needed).

4. Mode 4 (Opt. 4) is the same as mode 2, except

the Dwell time includes the Ramp (if needed).

5. Mode 5 (Opt. 5) is a Dwell (delay time) before the

controller Ramps (if needed) to the Setpoint tem-

perature.

Program Overview

•Aprogram mode can be set by changing the

“tm.OP” variable to “Opt. 1, Opt. 2, Opt. 3, Opt. 4,

or Opt. 5.

•ARamp rate may be set by changing the “SPrr”

variable to a value. The Ramp rate units are in

degrees per minute.

•The Dwell time can be set by changing the

“dwEll” variable to the desired value. Dwell time

units are in minutes.

•The program Status can be set by changing the

“StAt” variable to “run” or “oFF.” This variable will

start or stop the program.

Mode 1 (Opt. 1)

Mode 2 (Opt. 2)

Mode 3 (Opt. 3)

Mode 4 (Opt. 4)

Mode 5 (Opt. 5)

SINGLE RAMP & DWELL CONTROLLER

Note

The program must be stopped and

the controller must be displaying the

actual temperature before beginning

the Setup.

Program 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. Press the SCROLL button once, “tm.OP” (Ramp &

Dwell mode) will be displayed, select the desired

mode with the UP or DOWN buttons. (Opt. 1, Opt. 2,

Opt. 3, Opt. 4, Opt. 5)

4. Press the SCROLL button once, “dwEll” will be dis-

played, set the desired Dwell time with the UP or

DOWN buttons. (Dwell in minutes.)

5. Press the PAGE button until the Actual temperature is

displayed.

Running the Program

1. Press the SCROLL button until “StAt” is displayed, set

to “run” with the UP or DOWN buttons.

2. Press the PAGE button to display Actual temperature.

Stopping the Program

Press the SCROLL button until “StAt” is displayed, set to “oFF”

with the UP or DOWN buttons.

Clearing the Flashing End

Press the PAGE and SCROLL buttons at the same time.

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 dis-

play Actual temperature.

SINGLE RAMP & DWELL CONTROLLER

8 Segment & 4x16 Segment

Programmable Models w/OTP

Output 1

PAGE

Button

AUTO/MAN

Button

Display

Window

Upper

Display

Lower

Display

RUN/HOLD

Button

UP ARROW

Button

DOWN ARROW

Button

SCROLL

Button

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.

4x16 & 8 Segment Programmable Models with OTP

The 8 segment programmable controller consists of

a microprocessor based three-mode PID

(Proportional, Integral, Derivative), programmable

temperature controller with over-temperature protec-

tion and appropriate output switching devices to con-

trol the furnace. The digital readout continuously dis-

plays chamber (upper display) and setpoint (lower

display) temperatures unless the SCROLL or PAGE

button is depressed. The programmable controller can

be used as a single setpoint controller or as a pro-

grammable controller. The 8 segment digital model

enables eight segments of programming.

The 4x16 segment programmable controller con-

sists of a microprocessor based three-mode PID

(Proportional, Integral, Derivative), programmable

temperature controller with over-temperature protec-

tion and appropriate output switching devices to con-

trol the furnace. The digital readout continuously dis-

plays chamber (upper display) and setpoint (lower

display) temperatures unless the SCROLL or PAGE

button is depressed. The programmable controller can

be used as a single setpoint controller or as a pro-

grammable controller. The 4 program controller has

four 16 segment programs.

Basic Operation

When the controller is turned ON, it will perform a

short self-test and then change to the HOME DIS-

PLAY. The HOME DISPLAY shows the measured

temperature (process value) in the upper display and

the desired value (setpoint) in the lower display.

To Change the Setpoint

If you want to change the setpoint, press the UP or

DOWN button until the desired setpoint value is dis-

played in the lower display and then release the but-

ton.

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.

Buttons and Indicators

OP1 (Output 1): illuminates when the heating output of

the temperature controller is on.

AUTO/MAN: (Auto/Manual Mode): when the controller is

in the automatic mode the output automatically adjusts to

keep the temperature or process value at the setpoint.

The “AUTO” light will illuminate. The manual mode has

been disabled through factory configuration. Call

Customer Service for further information.

RUN/HOLD (Run/Hold button):

•Starts a program when pressed once—RUN

light illuminates.

•Holds a program when pressed again—HOLD

light illuminates.

•Cancels hold and continues running when

pressed again—HOLD light is off and RUN light

illuminates.

•Exits a program when the button is held down

for two seconds—RUN and HOLD lights are off.

•At the end of a program the RUN light will flash.

•During holdback the HOLD light will flash.

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.

Contact Customer Service if a different temperature unit is

required.

OP: % output power demand; displayed in lower display

(cannot be changed).

C.id: Controller identification number.

PrG: Program number (displayed when a program is run-

ning; 4x16 programmable models only.)

IdHi: Deviation High Alarm

tunE: One-shot autotune enable.

run LiSt (Program Run List)

PrG: Currently running program (only used on 4x16 pro-

grammable models)

StAt: Displays the program status [OFF, run (running

active program), hoLd (program on hold), 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). The controller

will default to “no.”

SEG.d: Flash active segment type in the lower display of

the home display (no/YES). The controller will default to

“no.” 23

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.U: Press the UP or DOWN ARROW to select the

holdback value (in display units).

rmP.U: Press the UP or DOWN ARROW to toggle

between ramp units (SEc, min or Hour). Controller will

default to “SEc.”

dwL.U: Press the UP or DOWN ARROW to toggle

between dwell units (SEc, min or Hour). Controller will

default to “SEc.”

Cyc.n: Press the UP or DOWN ARROW to set the

number of program cycles (1 to 999 or cont). The con-

troller will default to “cont.”

SEG.n: Press the UP or DOWN ARROW to select the

segment number (1-8 in 8 segment models, 1-16 in

4x16 models).

tYPE: Press the UP or DOWN ARROW to select the

segment type [End (end of program), rmP.r = ramp rate

(ramp to a specified setpoint at a set rate), rmp.t =

ramp time (ramp to a specified temperature in a set

time), dwEll (to maintain a constant temperature for a

set time), StEP (climb instantaneously from current to

specified temperature), cALL (to call a program as a

subroutine, available only on 4x16 programmable mod-

els)]. The controller will default to “End.” Other parame-

ters used with tYPE include; tGt target setpoint), Rate

(rate of temperature increase) and dur (time to target

setpoint or time to dwell).

End.t: End segment type: dwELL (dwell continuous),

rSEt (reset) and S OP (End Segment Output power

level.

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. (SEt 1)

Pb2: Proportional band. (SEt 2)

ti2: Integral time in seconds. (SEt 2)

td2: Derivative time in seconds. (SEt 2)

ACCS LiSt (Access List)

Access Code (Code needed to enter or change the

other configuration parameters which are not normally

accessible.) Not accessable.

Note

The following alarm messages are factory

default settings and may vary if you have

changed the configuration of your

controller:

IDHi: = 50°C

2FSH = 1118°C (all models

except -60)

2FSH = 1000°C (-60 models only)

Alarms

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.

LCr: load current low alarm.

HCr: load current high alarm.

S.br: Sensor break: check that sensor is connected

correctly.

L.br: Loop Break: Check that the heating circuits are

working properly.

Ld.F: Heater Circuit Fault: indication of either an open

or short solid sate relay, a blown fuse, missing supply

or open circuit heater.

SSr.F: Solid state relay failure indications in a solid

state relay: indicates either an open or short circuit in

the SSR.

Htr.F: Heater failure: Indication that there is a fault in

the heating circuit: indicates either a blown fuse, miss-

ing supply or open circuit heater.

Sensor Break Protection

This controller provides sensor break protection in the

event the thermocouple opens. If an open thermocou-

ple condition occurs, the digital display will Blink “S.br”

and the power to the heating element will be shut OFF

(Cycle light will extinguish).

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. We recommend a value of 20° above your

working temperature to provide protection for your

workload.

To Operate the Controller as a

Single Setpoint Controller

1. Switch the circuit breaker to the “ON” posi-

tion. The setpoint temperature presently set in

the controller will appear in the lower display.

(The upper display indicates the actual cham-

ber temperature.)

2. To change the setpoint, press the UP or

DOWN button until the desired setpoint value

is displayed; then release the button.

3. The furnace will begin to heat if the new set-

point temperature is higher than the present

chamber temperature.

Programming the Controller

The controller is capable of varying temperature or

process value with time through programming. A pro-

gram is stored as a series of segments and can be run

once, repeated a set number of times or run continu-

ously. To create a customized program using the con-

troller parameters listed under “Controller Parameters”

at the beginning of this section, follow the procedures

outlined in the proceeding sections of this manual.

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 pro-

gram and editing an existing program with the excep-

tion being that a new program starts with all its seg-

ments set to End in the tYPE parameter. 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. Follow the steps

below to create or edit a program.

1. Press the PAGE button until you reach the

program list (ProG LiSt).

2. Press the SCROLL button until display reads,

“PrG.n.”

3. Press the UP or DOWN button to select a

number for a new program or to edit an exist-

ing program.

Hb: Holdback

Holdback consists of a value and a type. If the meas-

ured value lags behind the setpoint by an undesirable

amount during a ramp or dwell, the holdback feature

can be used to freeze the program at its current state

(the HOLD light will flash). The program will resume

when the error comes within the holdback value.

OFF: holdback is disabled.

Lo (Deviation Low Holdback): holds the program

back when process variable deviates below the set-

point by more than the holdback value.

Hi (Deviation High Holdback): holds the program

back when process variable deviates above the set-

point by more than the holdback value.

8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP

bAnd (Deviation Band Holdback): combines the fea-

tures of the high and low deviation holdback in that 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.”

Hb U: Holdback Value

To set the holdback value:

1. Press the PAGE button until you reach the

program list (ProG LiSt).

2. Press the SCROLL button until display reads,

“Hb.U.”

3. Press the UP or DOWN button to enter a

holdback value.

rmP.U: Setting Ramp Units

Ramp units are time units which are used in “rmP.r”

segments (ramp to a setpoint at degrees per second,

minute or hour) and “rmP.t” segments (ramp to setpoint

in a specific amount of time). See “Setting the

Segment Type” for an explanation on how to set a

ramp segment.

1. Press the PAGE button until you reach the

program list (ProG LiSt).

2. Press the SCROLL button until display reads,

“rmP.U.”

3. Press the UP or DOWN button to toggle

between seconds, minutes and hours.

Note

The value set in this parameter is always

for the entire program.

8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP

dwL.U: Setting Dwell Units

Dwell units are time units which are used in “dwELL” seg-

ments (amount of time to remain at a specific temperature

). See “Setting the Segment Type” for an explanation on

how to set a dwell segment.

1. Press the PAGE button until you reach the pro-

gram list (ProG LiSt).

2. Press the SCROLL button until display reads,

“dwL.U.”

3. Press the UP or DOWN button to toggle between

seconds, minutes and hours.

CYC.n: Setting the Number of Cycles

Set the number of times a group of segments or programs

are to be repeated by following the steps listed below.

1. Press the PAGE button until you reach the pro-

gram list (ProG LiSt).

2. Press the SCROLL button until display

reads,”CYC.n.”

3. Press the UP or DOWN button to select the num-

ber of cycles you want to run or, press the DOWN

button to select “cont.” so the program will run

continuously.

Setting the Segment Type

There are five segment types. Proceed with the following

steps according to the type of segment you have selected.

rmP.r (Ramp)

To ramp linearly at a set rate to a specified temperature:

1. Press the PAGE button until you reach the pro-

gram list (ProG LiSt).

2. Press the SCROLL button until display

reads,”tYPE.”

3. Press the UP or DOWN button until display

reads, “rmP.r.”

Note

The program ramp rate is designed to

reduce the heatup rate or cooling rate

that the furnace normally exhibits.

When not using this feature, the fur-

nace will operate at its maximum

heating and cooling capability.

Note

When the program ramp has ended

or has been reset, the furnace will

continue to maintain setpoint temper-

ature. It will not cool to ambient tem-

perature unless the setpoint is set to

ambient temperature by the program

or by the operator.

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. Press the UP or DOWN button to select a

value in ramp units (seconds, minutes or

hours; set in the “rmP.U” parameter).

rmP.t

To ramp to a specified temperature at a set 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, “rmP.t.”

4. Press the SCROLL button until display reads,

“tGt.”

5. Press the UP or DOWN button to set a target

setpoint.

6. Press the SCROLL button until display reads,

“dur.”

7. Press the UP or DOWN button to select a

time in ramp units (seconds, minutes or

hours; set in the “rmP.U” parameter.

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 pro-

gram 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).

StEP

To climb instantaneously from the current temperature to a

specified temperature.

1. Press the PAGE button until you reach the pro-

gram list (ProG LiSt).

2. Press the SCROLL button until display reads,

tYPE.”

3. Press the UP or DOWN button until the display

reads, “StEP.”

4. Press the SCROLL button until display reads,

“tGt.”

5. Press the UP or DOWN button to set a target set-

point.

cALL (Running Multiple Programs; 4x16 Segment

Programmable Models Only)

To call a program as a subroutine:

If you want to run multiple programs, you can program the

controller to “call” or link one program to another. This

makes it possible to run one program at any time during

another program and also return to the original program if

desired.

1. Press the PAGE button until you reach the pro-

gram list (ProG LiSt).

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 pro-

gram number to be linked.

6. Press the SCROLL button until display reads,

“CYC.n.”

7. Press the UP or DOWN button to select the

number of cycles the linked program is to be

run.

End

To end or repeat a program:

1. Press the PAGE button until you reach the pro-

gram list (ProG LiSt).

2. Press the SCROLL button until display reads,

“tYPE.”

3. Press the UP or DOWN button until display

reads, “End.”

4. Press the SCROLL button until display reads,

“End.t.”

5. Press the UP or DOWN button to toggle

between “dwEll” (an indefinite dwell), “S OP”

(End Segment Output Power) and “rSET”

(reset).

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 tar-

get setpoint temperature.

Running a Program (8

Segment Programmable

Models)

To run a program, press the RUN/HOLD button. (The

RUN light will illuminate.)

Running a Program (4x16

Segment Programmable

Models)

To run a program, press the RUN/HOLD button. (The

RUN light will illuminate) or:

1. Press the PAGE button until you reach the run

list (run LiSt).

2. Press the SCROLL button until display reads,

“PrG.”

3. Press the UP or DOWN button to select the

program number you want to run.

4. Press the RUN/HOLD button once to start the

program. (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.

Tuning your Furnace

The purpose of tuning your furnace is to match the char-

acteristics of your controller to the characteristics of the

process being controlled. Good control is evidenced by:

stable, straight-line control of the setpoint temperature

with no fluctuations; No overshoot or undershoot of the

setpoint temperature; rapid restoration of the setpoint

temperature when external disturbances cause deviations

from the setpoint.

This controller has automatic tuning features which install

optimum tuning parameters to give the best temperature

accuracy. No manual loading of tuning parameters is

needed. We recommend that you tune the furnace to your

specific application to obtain the best results. To provide

the best temperature accuracy possible, use these fea-

tures when you install your furnace and whenever you

change your application or procedure.

Tuning Error

The display will flash “tu.ER” if an error occurs during tun-

ing. To clear the error and restart tuning, simultaneously

press the PAGE and SCROLL buttons and follow the

steps outlined in “Autotuning.”

Note

Display will flash “tu.ER” if an error

occurs during tuning. To clear the

error and restart tuning, simultane-

ously press the PAGE and SCROLL

buttons and follow the steps outlined

in “Autotuning.”

Note

To stop the tuning function, simulta-

neously press the PAGE and

SCROLL buttons.

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 schedul-

ing 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.SP must be adjusted to 200°C from the

desired setpoint temperature when tuning.

Setting the Transfer Point

If gain scheduling has been enabled, “G.SP will appear

at the top of the PID list. This sets the value at which

the transfer will occur. When the process value is

below this level, PID1 will be active and when it is

above, Pid2 will be active. Set a value between the

control regions that show the greatest change to

achieve the best point of transfer.

Tuning

The two sets of PID values can be manually set or

automatically tuned. To tune automatically you must

tune above and below the transfer point G.SP. If the

process value is below the transfer point G.SP, the cal-

culated values will automatically be inserted into the

(SEt 1) set and if the process value is above G.SP, the

calculated values will automatically be inserted into the

(SEt 2).

Autotuning

The Autotune feature automatically sets up the PID val-

ues in the control parameters to suit new process con-

ditions.

To tune your furnace using autotuning:

1. Load your furnace with a load similar to your

normal load and close the door.

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 parame-

ters. Adaptive tuning automatically installs new values if

better accuracy is possible. Adaptive tuning should be

used when the characteristics of a process change due to

load or setpoint changes or, in a process that can not

handle the oscillation caused by a one-shot tune.

To tune your furnace using adaptive tuning:

1. Load your furnace with a load characteristic of

those you intend to heat in it.

2. Press the PAGE button until display reads, “Atun

LiSt.”

3. Press the SCROLL button until “drA OFF” is dis-

played.

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

5. Press the SCROLL button until “drA.t” is dis-

played.

6. Press the UP or DOWN button until the desired

trigger value is achieved.

Installation and Operation of

Air Control

Note

Ashing furnaces -60 models contain a

feature to provide air (or inert gas)

flow within the furnace chamber.

Note

Apressurized 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.

Note

Appropriate exhaust must be provided

to remove smoke and gases produced

in an ashing procedure.

Models F30420-33-60-80, F30420C-60-80,

F30428C-60-80, F30430CM-33-60, F30430CM-

60, F30438CM-60

Installation

Compressed air hook-up

1. 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

length of tubing from this input fitting to a corre-

sponding 0.250 inch fitting located on the regulat-

ed side of a pressurized air service line.

3. Prior to making connections at the regulator,

insure that the regulator is turned fully closed (0

psi).

4. Turn flow control valve located at the bottom of

the flow meter (front control panel) fully clockwise

to closed position.

5. Turn regulator to maximum output pressure of 30

psi. Check for any leaks at connection points of

connecting tubing.

6. Open flow control valve slowly until ball in flow

meter reads between 40 to 45 liters per minute

flow rate.

7. Open furnace door and check that air is exhaust-

ing from the manifold located at the bottom rear

of the chamber.

8. Turn flow control valve to off (fully clockwise).

Exhaust tubing hook-up

Using accessory tubing available from Barnstead

International (part number AY408X1A for furnace temper-

atures less than 975°C, part number AY718X1 for furnace

temperatures of 975°C or greater) or equal quality 2.5" I.D.

tubing appropriate for the temperatures at which you will

operate your furnace, connect flexible tubing from vent port

at top of furnace case to an appropriate negative pressure

exhaust system. This exhaust system must be capable of

handling smoke and gases produced in an ashing proce-

dure.

Furnace Loading

Note

Failure to connect the exhaust port to

an appropriate exhaust system will re-

sult 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 cham-

ber. If the load is to be heated uniform-

ly it should not occupy more than two-

thirds of the furnace chamber. Failure

to observe this caution could result in

damage to furnace components.

•For best results, use only the center two-thirds

of the furnace chamber.

•Use Hearth plate to elevate load when placing

on bottom heating element. This prevents bot-

tom heating element from overheating and burn-

ing out. (Part Numbers PHX1 & PHX2)

•If you are heating a number of small parts,

spread them throughout the center of the fur-

nace chamber.

•Keep objects away from thermocouple.

•Use insulated tongs and mittens when loading

and unloading furnace.

•Always wear safety glasses.

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 el-

ement 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 occasion-

ally to burn off the contamination that may exist on the in-

sulation and elements. Maintain 1600°F for at least 4

hours to insure complete ashing of foreign materials.

Element life is reduced somewhat by repeated heating

and cooling. If the furnace is to be used again within a

few hours, it is best to keep it at the operating tempera-

ture or at a reduced level such as 500°F (260°C).

General Cleaning Instructions

Wipe exterior surfaces with lightly dampened cloth con-

taining mild soap solution.

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 The furnace is not connected to Check furnace connection

not illuminate. power supply. to power source.

ON and OFF power switch is Replace power switch.

defective.

Door switch defective. Realign door strike or

replace door safety switch.

Incorrect power source. Check power source.

Defective circuit breaker. Replace circuit breaker.

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

breakers.

Defective electrical hookup. Repair electrical hookup.

Thermocouple has oxidized Replace thermocouple.

and opened the circuit.

Controller malfunction. Contact customer service.

Two or more heating elements Replace defective elements.

burned out.

Door switch malfunction. Realign door strike or replace door

safety switch.

Defective safety relay. Replace safety repay.

Defective solid state relay (SSR) Replace SS relay.

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 Replace burned out elements.

elements are burned out.

Wired improperly. Check wiring diagram for

correct wiring of your furnace.

Door switch does not cut Door switch is not functioning. Realign door strike or

power to the furnace chamber. replace door safety switch.

Safety relay malfunction. Replace safety relay.

Repeated element burnout. Overheating furnace. Do not exceed the maximum

operating temperature of

furnace or recommended

continuous intermittent use

values.

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.

PROBLEM SOLVING

Problem Probable Causes Corrective Action

Contamination present from Clean and/or replace insulation

previous burnout. material.

Wired improperly. Check wiring diagram for

correct wiring of your furnace.

Inaccurate. Oxidized or contaminated Replace thermocouple.

thermocouple.

Poor thermocouple connections. Tighten connections.

Improper loading. Use proper loading procedures.

Poor ventilation of base. Clear area around furnace base.

Control out of calibration. Contact customer service.

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 pro-

duce respirable dust or fibers during

disassembly. Dust or fibers can cause

irritation and can aggravate preexisting

respiratory diseases. Refractory

ceramic and refractory ceramic fibers

(after reaching 1000°C) contain crys-

talline silica, which can cause lung

damage (silicosis). The International

Agency for Research on Cancer

(IARC) has classified refractory ceram-

ic fiber and fiberglass as possibly

carcinogenic (Group 2B), and crys-

talline silica as carcinogenic to

humans (Group 1).

Warning

To avoid electrical shock, this furnace

must always be disconnected from the

power supply prior to maintenance

and service.

Perform only maintenance described

in this manual. Contact an authorized

dealer or our factory for parts and as-

sistance.

Warning

Please note the following WARNINGS:

This warning is presented for compliance with California

Proposition 65 and other regulatory agencies and only

applies to the insulation in this product. 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. Refractory ceramic and refractory ceramic

fibers (after reaching 1000°C) contain crystalline silica,

which can cause lung damage (silicosis). The Internation-

al Agency for Research on Cancer (IARC) has classified

refractory ceramic fiber and fiberglass as possibly

carcinogenic (Group 2B), and crystalline silica as

carcinogenic to humans (Group 1).

The insulating materials can be located in the door, 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. However, there may be a risk of

exposure to respirable dust or fibers when repairing or

maintaining the insulating materials, or when otherwise

disturbing them in a manner which causes release of dust

or fibers. By using proper handling procedures and

protective equipment you can work safely with these

insulating materials and minimize any exposure. Refer to

the appropriate Material Safety Data Sheets (MSDS) for

information regarding proper handling and recommended

protective equipment. For additional MSDS copies, or

additional information concerning the handling of refracto-

ry ceramic products, please contact the Customer Service

Department at Barnstead International at 1-800-553-0039.

To Replace a Heating Element

a. Disconnect furnace from power supply.

b. Remove the back terminal cover of the furnace

(Note placement and connections of wires).

c. Loosen the screws and nuts on the terminals of

MAINTENANCE AND SERVICING

c. Loosen the screws and nuts on the terminals 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 con-

nections and tighten screws and nuts securely.

g. Replace the back terminal cover.

h. Reconnect furnace to power supply.

i. Test operation of furnace.

To Replace a Platinel II

Thermocouple

a. Disconnect furnace from power supply.

b. Remove the back terminal cover of the furnace.

(Note placement and connection of T/C lead

wires).

c. Remove the screws on the thermocouple termi-

nals and pull the thermocouple straight out.

d. Insert the new thermocouple into the furnace

with colored beaded lead connected to the posi-

tive (+) marked terminal and other lead to nega-

tive (-) terminal.

e. Secure connections with screws removed earlier.

f. Replace the back terminal cover.

g. Reconnect the furnace to power supply.

h. Test operation of furnace.

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, discon-

nect 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. Control section can now be removed from fur-

nace housing.

g. Disconnect the wires from the relay and remove

relay. (Note placement and connection of wires).

h. Install new relay.

i. Reverse steps a - e to reassemble furnace.

j. Test operation of furnace.

To Replace Door Switch

(Microswitch)

a. Disconnect furnace from power supply.

b. Remove the screws on the front dial and 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, discon-

nect the lead wire from terminal block (note

placement and location of wires).

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 fur-

nace 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 fur-

nace.

l. Reconnect to power supply.

m. Test operation of door switch. (To realign door

strike, see To Realign Door Strike).

To Realign Door Strike

a. Disconnect furnace from power supply.

b. Loosen the screws which retain the door strike

on the bottom left side of the door.

c. Move the bracket closer to the furnace to make

strike engage sooner. Move bracket further

away to make strike engage later. (Lightly tight-

en screws between each adjustment to hold

bracket while you test the strike.)

d. The door switch should click when the door is

approximately 1” from being completely closed.

e. Tighten screws when bracket is positioned cor-

rectly.

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. 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 Description Quantity Notes

CAX99 Line filter 1 “-33” model only

CA1249X1 Capacitor 1 “-33” model only

CN71X88 Controller 1 All models

EL412X1 Element 1 208V model

EL412X2 Element 1 208V model

EL412X3 Element 2 208V model

EL412X4 Element 1 240 V model

EL412X5 Element 1 240 V model

EL412X6 Element 2 240 V model

FA1262X1 Fan 1 All models

PLX82 Pilot light 1 All models

RYX37 S.S. relay 1 All models

RYX62 Mechanical relay 1 All models

SWX103 Circuit breaker 1 All models

SWX144 Power switch 1 All models

SWX163 Door switch 1 All models

TC412X119 Thermocouple 1 All models

TRX96 Terminal block 1 All models

TRX178 Terminal block 1 All models

F30420C-33-80, F30420-33-60-80, F30420C-60-80, F30420C-80, F30428C-60-80,

F30428C-80

Part Number Description Quantity Notes

CAX98 Line Filter 1 “-33” model only

CA1249X1 Capacitor 1 “-33” model only

CN71X89 Controller 1 F30420C-38-80, F30420C-80, F30428C-80

CN71X91 Controller 1 F30420-33-60-80, F30420C-60-80,

F30428C-60-80

EL412X1 Element 1 208V model

EL412X2 Element 1 208V model

EL412X3 Element 2 208V model

EL412X4 Element 1 240 V model

EL412X5 Element 1 240 V model

EL412X6 Element 2 240 V model

FA1262X1 Fan 1 All models

SWX103 Circuit breaker 1 All models

PLX82 Pilot light 1 All models

RYX37 S.S. relay 1 All models

8 Segment Programmable Models with OTP

REPLACEMENT PARTS

4X16 Segment Programmable Models with OTP

F30430CM, F30430CM-33, F30430CM-33-60, F30430CM-60, F30438CM, F30438CM-60

Part NumberDescription Quantity Notes

CAX99 Line Filter 1 “-33” model only

CA1249X1 Capacitor 1 “-33” model only

CN71X90 Controller 1 F30430CM, F30430CM-33, F30438CM

CN71X92 Controller 1 F30430CM-33-60, F30430CM-60,

F30438CM-60

EL412X1 Element 1 208V model

EL412X2 Element 1 208V model

EL412X3 Element 2 208V model

EL412X4 Element 1 240 V model

EL412X5 Element 1 240 V model

EL412X6 Element 2 240 V model

FA1262X1 Fan 1 All models

SWX103 Circuit breaker 1 All models

PLX82 Pilot light 1 All models

RYX37 S.S. relay 1 All models

RYX62 Mechanical relay 1 All models

SWX144 Power switch 1 All models

SWX163 Door switch 1 All models

TRX96 Terminal block 1 All models

TRX178 Terminal Block 1 All models

TC412X1A Thermocouple 1 All models

RYX62 Mechanical relay 1 All models

SWX144 Power switch 1 All models

SWX163 Door switch 1 All models

TRX96 Terminal block 1 All models

TRX178 Terminal Block 1 All models

TC412X1A Thermocouple 1 All models

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 concern-

ing 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. If the dealer cannot handle your request, then con-

tact our Customer Service Department at 563-556-2241 or

800-553-0039.

Prior to returning any materials to Barnstead International,

please contact our Customer Service Department for a “Return

Goods Authorization” number (RGA). Material returned without

a RGA number will be refused.

Ordering Procedures

Wiring Diagrams

SINGLE SETPOINT CONTROL

WIRING DIAGRAM

WIRING DIAGRAMS

SEGMENT PROGRAMMABLE CONTROL

WIRING DIAGRAM

WIRING DIAGRAMS

4X16 SEGMENT PROGRAMMABLE CONTROL

WIRING DIAGRAM

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”). Except as expressly stated above, BARNSTEAD MAKES NO OTHER WARRANTY,

EXPRESSED OR IMPLIED, WITH RESPECT TO THE PRODUCTS AND EXPRESSLY DISCLAIMS ANY AND

ALL WARRANTIES, INCLUDING BUT NOT LIMITED TO, WARRANTIES OF DESIGN, MERCHANT ABILITY

AND FITNESS FOR A PARTICULAR PURPOSE.

An authorized representative of BARNSTEAD must perform all warranty inspections. In the event of a defect

covered by BARNSTEAD’s warranty, BARNSTEAD shall, as its sole obligation and exclusive remedy, provide

free replacement parts to remedy the defective product. In addition, for products sold by BARNSTEAD within

the continental United States or Canada, BARNSTEAD shall provide provide free labor to repair the products

with 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 there

is 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 the

BARNSTEAD factory and if, upon inspection, it is concluded that failure is due to factors other than excessive

high temperature or contamination, BARNSTEAD will provide warranty replacement. As a condition to the

return of any product, or any constituent part thereof, to BARNSTEAD’s factory, it shall be sent prepaid and a

prior written authorization from BARNSTEAD assigning a Return Goods Number to the product or part shall

be 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 OF

USE OR PROFITS, ANTICIPATED OR OTHERWISE, ARISING OUT OF OR IN CONNECTION WITH THE

SALE, USE OR PERFORMANCE OF ANY PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CON-

TRACT, TORT (INCLUDING NEGLIGENCE), ANY THEORY OF STRICT LIABILITY OR REGULATORY

ACTION.

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 Boulevard

P.O. Box 797

Dubuque, Iowa 52001-0797

Phone: 563-556-2241 or 800-553-0039

Fax: 563-589-0516

E-mail: mkt@barnstead.com

www.barnstead.com

LT1262X1(new) 30400 Mufla Thermolyne F30400 Manual Operacion

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