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Barnstead International 30400 Series, Operation Manual And Parts List

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Barnstead International 30400 Series Operation Manual And Parts List Download Page 46

46

M

AINTENANCE AND

S

ERVICING

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).

Summary of Contents for 30400 Series

Page 1: ...int Models F30402C 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 12 27 01 ...

Page 2: ...ngle 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 Setting Variables 18 Program Setup 19 Running the Program 20 Stopping the Program 20 C...

Page 3: ...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 Contro...

Page 4: ...l 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 aggr...

Page 5: ... 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 recomme...

Page 6: ...ts 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 accor...

Page 7: ...ments 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 ...

Page 8: ...l 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 l...

Page 9: ...nace 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 Y...

Page 10: ...ces 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 ...

Page 11: ...e 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 ...

Page 12: ...commended 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 T...

Page 13: ...emperature 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 Illumin...

Page 14: ...ow 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 Te...

Page 15: ...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 in...

Page 16: ...eyond 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 con...

Page 17: ... 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 tuni...

Page 18: ... 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 Setting Variables The Manual or Automatic modes can be set by changing m A variable to mAn or Auto The Manual mode will keep the controller from heating without setting the Setpoint temperature below the Actual temeperature...

Page 19: ...button once set the desired Setpoint temperature with the UP or DOWN buttons 3 Press the PAGE button until the SP is displayed 4 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 5 Press the SCROLL button once tm OP R...

Page 20: ... the Flashing End Press the PAGE and SCROLL buttons at the same time Switching from Manual Mode to Auto Mode Press the SCROLL button until m A is displayed Press the UP or DOWN buttons to set to Auto Press PAGE button to display Actual temperature 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 runn...

Page 21: ...able 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 co...

Page 22: ...roller 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 Hol...

Page 23: ...ed 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 activ...

Page 24: ...ROW 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 d...

Page 25: ...nt 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 configu...

Page 26: ...e 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 ope...

Page 27: ...oint 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 Contro...

Page 28: ...ram 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 HO...

Page 29: ...alue 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 ...

Page 30: ...o 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...

Page 31: ...eads 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 t...

Page 32: ...o 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 ...

Page 33: ... 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...

Page 34: ...g 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 pr...

Page 35: ...ic 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 Tunin...

Page 36: ...s 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...

Page 37: ... 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 ...

Page 38: ... 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 fur...

Page 39: ...irds 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 th...

Page 40: ...ce 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 o...

Page 41: ...eplace 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 Control...

Page 42: ...ed 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 va...

Page 43: ...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 ...

Page 44: ...ate 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 ca...

Page 45: ...inal 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 be...

Page 46: ...or 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 d...

Page 47: ...nd 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 enga...

Page 48: ...ntrol 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 Instal the new controller to the sleeve ...

Page 49: ...X163 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...

Page 50: ...8V 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 ...

Page 51: ...ased 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 Autho...

Page 52: ...52 Wiring Diagrams SINGLE SETPOINT CONTROL WIRING DIAGRAM ...

Page 53: ...53 WIRING DIAGRAMS SEGMENT PROGRAMMABLE CONTROL WIRING DIAGRAM ...

Page 54: ...54 WIRING DIAGRAMS 4X16 SEGMENT PROGRAMMABLE CONTROL WIRING DIAGRAM ...

Page 55: ...55 ...

Page 56: ...tative 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 mu...

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