Thermo Electron 6540 Operating And Maintenance Manual Download Page 2

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Thermo Electron Corporation

MANUAL NUMBER 3177885

23443

5/06

Consolidated 230V manual (P/N 3179180) with 120V, no CE

ccs

2/06

Knob part number from 3174902 to 3174903, page 14

1/06

Part number from 3176708 to 3176738, page 13

11/05

Part number from 3174892 to 3174903, page 14

7/05

new manual number (36100120 [34001783]), manufacture location

8/03

Add temperature control range specification, page 3-4

11/01

Add “plastics can melt”, page 8

8/99

Updated for new kit #s, pages 12-14

6/99

Initial release

REV

ECR/ECN

DATE

DESCRIPTION

Preface

3177885 Thelco Oven i

Current Model #

Previous Model #

Voltage

6540

120V

6541

230V

6545

70D

120V

6546

70D

230V

6550

70M

120V

6551

70M

230V

6555

70DM

120V

6556

70DM

230V

6542

130

120V

6543

130

230V

6547

130D

120V

6548

130D

230V

6552

130M

120V

6553

130M

230V

6557

130DM

120V

6558

130DM

230V

6544

160

230V

6549

160D

230V

6554

160M

230V

6559

160DM

230V

Table 1.

Models Covered In This Manual

Summary of Contents for 6540

Page 1: ...Analyze Detect Measure Control Model 6540 and 6550 Series Thelco Oven Operating and Maintenance Manual 3177885 Rev I Dated 05MAY06 ...

Page 2: ...dd temperature control range specification page 3 4 C 11 01 Add plastics can melt page 8 B 8 99 Updated for new kit s pages 12 14 A 6 99 Initial release REV ECR ECN DATE DESCRIPTION By Preface 3177885 Thelco Oven i Current Model Previous Model Voltage 6540 70 120V 6541 70 230V 6545 70D 120V 6546 70D 230V 6550 70M 120V 6551 70M 230V 6555 70DM 120V 6556 70DM 230V 6542 130 120V 6543 130 230V 6547 130...

Page 3: ... European market and are supplied with a European style power cord For domestic use a U S style cord P N 3179481 must be ordered separately Models 6544 6549 6554 6559 are only available in 230V and are supplied from the factory with both cord styles V Material in this manual is for information purposes only The contents and the product it describes are subject to change without notice Thermo Elect...

Page 4: ...002 96 EC WEEE and the equipment that has been put on the market after 13 August 2005 This product is required to comply with the European Union s Waste Electrical Electronic Equipment WEEE Directive 2002 96 EC It is marked with the WEEE symbol Thermo Electron has contracted with one or more recycling disposal companies in each EU Member State European Country and this product should be disposed o...

Page 5: ...Thermo Electron Corporation iv 3177885 Thelco Oven Thermo Electron Corporation Preface ...

Page 6: ...ing and Damage 2 1 General Information 3 1 Specifications 4 1 Installation 5 1 Location 5 1 Electrical Connections 5 1 Explanation of Controls 6 1 Operation 7 1 Loading 7 3 Safety 7 4 Cleaning 7 5 Periodic Safety Check 7 6 Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 ...

Page 7: ... Resistance Check 8 3 Parts Replacement 9 1 Heater Replacement 9 1 Heater Wire Replacement 9 1 Probe Replacement 9 2 Motor Replacement Mechanical Models 9 2 Control Replacement Analog Models 9 2 Control Replacement Digital Models 9 3 Door and Latch Repair 9 3 Door Latch Grabber on body of oven 9 4 Electrical Schematics 10 1 Warranty 11 1 Table of Contents Section 8 Section 9 Section 10 Section 11 ...

Page 8: ...requirements are important for safe and satisfactory operation The unit should be used for its intended application alterations or modifications will void the warranty Warning As a routine laboratory precaution always wear safety glasses when working with this apparatus V Warning This product is not intended nor can it be used as a sterile or patient connected device In addition this apparatus is ...

Page 9: ......

Page 10: ...ce of loss or damage may result in the carrier s refusing to honor your damage claim The form required to file such claim will be supplied by the carrier 2 Concealed Loss or Damage Concealed loss or damage means loss or damage which does not become apparent until the merchandise has been unpacked and inspected Should either occur make a written request for inspection by carrier s agent within 15 d...

Page 11: ......

Page 12: ... curing or long term sample storage under closely controlled conditions Gravity convection ovens are ideal for drying powders soil samples paper goods semiconductors and cosmetics Models 6540 6541 6542 6543 and 6544 use an analog solid state temperature control with analog solid state safety thermostat Models 6545 6546 6547 6548 and 6549 use a microprocessor control with digital set point digital ...

Page 13: ... 6551 6552 6553 and 6554 provide mechanical convection of heat controlled by an analog solid state control with analog solid state safety thermostat Models 6555 6556 6557 6558 and 6559 provide mechanical convection of heat controlled by a microprocessor with digital set point digital display and digital safety thermostat Environmental Conditions This instrument is designed to operate safely under ...

Page 14: ...18 1 2x27 15 3 4x18 1 2x33 15 3 4x18 1 2x15 15 3 4x18 1 2x27 15 3 4x18 1 2x33 mm 400x470x381 400x470x686 400x470x838 400x470x381 400x470x686 400x470x838 Overall inches 21 1 4x24x28 21 1 4x24x40 21 1 4x24x46 21 1 4x24x28 21 1 4x24x40 21 1 4x24x46 mm 540x610x711 540x610x1016 540x610x1168 540x610x711 540x610x1016 540x610x1168 Electrical 50 60 Hz 115V 1200W 10 4A 1700W 14 8A N A N A 1200W 10 4A 1700W ...

Page 15: ... 4x18 1 2x27 15 3 4x18 1 2x33 15 3 4x18 1 2x15 15 3 4x18 1 2x27 15 3 4x18 1 2x33 mm 400x470x381 400x470x686 400x470x838 400x470x381 400x470x686 400x470x838 Overall inches 21 1 4x24x28 21 1 4x24x40 21 1 4x24x46 21 1 4x24x28 21 1 4x24x40 21 1 4x24x46 mm 540x610x711 540x610x1016 540x610x1168 540x610x711 540x610x1016 540x610x1168 Electrical 50 60 Hz 115V 1300W 11 3A 1800W 15 6A N A N A 1300W 11 3A 180...

Page 16: ... detailed in this manual are equipped with three pronged grounded plug power cords These mate with standard three prong receptacles to minimize the possibility of electric shock The user should have the wall receptacle and circuit checked by a qualified electrician to make sure the receptacle is properly grounded Where a standard two prong wall receptacle is encountered it is the personal responsi...

Page 17: ...and easily reached to disconnect the unit from the power source V Model 6557 115 volt units Cat No 3166789 are equipped with non standard plugs one horizontal and one vertical blade and will require installation of a special matching receptacle To be in compliance with the National Electrical Code non standard plugs and receptacles are required to accommodate higher current draw The aforementioned...

Page 18: ...above the High Temperature Limit is illuminated only when first set If this lamp is ON it indicates that oven is controlling on the High Temperature Limit thermostat which has taken over control of from the Temperature Control thermostat When the High Temperature Limit lamp comes on it is due to either a Temperature Control thermostat failure or that the High Temperature Limit thermostat is set to...

Page 19: ...th the arrow buttons when you are either in Temp or High Limit mode Mute The Mute button will silence the audible alarm if activated Timer The Timer Button will put the oven into either Continuous or Timed mode as indicated by the Hours digital display When in Continuous mode the display will show dashes the Continuous lamp is illuminated and the oven runs constantly When in Timed mode the display...

Page 20: ... to a more closed position to retain heat Insert shelf supports into the holes punched in the side walls of the inner chamber Insert the shelves into the shelf supports and try to keep an equal distance between shelves whenever possible Try to position the shelves so they can be withdrawn more than halfway without falling Never cover the shelves with foil or reduce their open surface area by more ...

Page 21: ...ress the SET button 4 If you wish to run the oven continuously the Continuous lamp should be on If it is not depress the Timer button to light the Continuous lamp If you wish to run the oven for a set number of hours depress the Timer button again a 0 will be displayed Use the arrow buttons to enter the desired number of running hours in one hour increments Press the Start Stop button once to star...

Page 22: ... and off rotate Temperature Control slightly clockwise Turn Temperature Control slightly counterclockwise if the thermometer indicates chamber temperature is above the desired setpoint 7 When thermometer indicates chamber is at desired temperature and the lamp above Temperature Control is cycling on and off at fairly uniform intervals begin to turn High Temperature Limit Knob slowly counterclockwi...

Page 23: ...er 2 DO NOT place sealed containers in the chamber Sealed containers filled with materials do not provide room for expansion or evaporation and can develop dangerous vapor pressure as the temperature increases 3 Avoid placing plastic materials in the oven Extreme temperatures may cause plastics to melt posing a fire hazard If plastics are placed in the oven do not leave the oven unattended 4 Avoid...

Page 24: ...hyde or quaternary ammonium germicide available from Thermo P N 3166250 Important If it is necessary to use the following chemicals limit the time to a maximum of four hours Clean surfaces immediately after use V Caution Do not use other cleaning or decontamination methods without first contacting the Technical Services department V Never use the following chemicals 3177885 Thelco Oven 7 5 Thermo ...

Page 25: ...reas with adequate ventilation V Prepare a solution of 20 nitric and 1 5 hydrochloric acid if preferred a 2 to 5 solution of warm oxalic acid may be used Swab solution over surface allowing it to remain until all rust is loosened This will usually take 1 to 2 minutes As soon as rust is loosened immediately flush with clean water until all acid is removed Test the operation of the Hi Limit thermost...

Page 26: ...sfactory the chamber was improperly loaded Redistribute the load 3 Be sure to allow ample time for an empty chamber to stabilize at the desired temperature setting It could take over one hour to equilibrate depending upon the difference between ambient and operating temperatures The mass of the load can also affect stabilization time 4 Make certain severe line voltage fluctuations are not occurrin...

Page 27: ... ohm resolution is required for this procedure V 1 Turn oven power off and disconnect from power 2 Open control panel by removing top screws which secure it Lift and pull out 3 Disconnect temperature sensor from CPU board and replace with decade box set at 100 00 ohms 4 Reconnect oven to power source 5 Press SET button while turning oven on 6 Press SET button again and use the up arrow button to m...

Page 28: ...end of the manual and locate the electrical leads for the heater Use the values in the Heater Cold Resistance Table to find the appropriate value Be sure to disconnect at least one heater lead from the terminal strip before taking the reading with the ohm meter Again it is imperative that the unit be completely disconnected from its electrical power source before any readings are taken V If the he...

Page 29: ......

Page 30: ...sible 3 Open control panel by removing two top screws Set panel down exposing controls 4 Unplug the heater connection located on the board 5 Remove 2 screws from stainless steel flange just above control panel 6 The chamber floor is now free Pull forward and lift out 7 Disconnect heater leads 8 Remove heater leads and connector from the opening in control panel 9 Replace heater leads by reversing ...

Page 31: ...nd heater mounting screws remove heater 4 Detach blower wheel from motor shaft 5 Open control panel by removing top screws which secure it and disconnect motor terminals 6 Remove motor mounting bracket from underside of oven Turn oven on its back or side to facilitate this removal 7 Replace with new motor reinstall in reverse order 1 Disconnect power 2 Open control panel by removing top screws whi...

Page 32: ...lace door in reverse order 1a Replace door gasket by removing the screws which secure inner door liner Reassemble in reverse order 2a Replace door latches by removing inner door liner door gasket and door insulation 3a Unscrew door latch clips and replace latches 4a Reassemble in reverse order 1b Replace door handle by removing inner door liner door gasket and door insulation 2b Remove nuts which ...

Page 33: ...ment 1 Disconnect power 2 Remove screws which secure door latch grabber and remove from front Note Used retaining nuts will fall into oven body V 3 Insert replacement latch assembly through open slot and fasten with screws and washer provided Door Latch Grabber on body of oven ...

Page 34: ...Packaging Small 230V X 3164530 Kit Oven Packaging Med X 3164531 Kit Oven Packaging Large X 3167249 Door Gasket Kit X X X 3175318 Switch DPST Non Lighted X X X 3167186 Leveling Foot Kit X X X 3175511 Heater 1100 Watts X 3175512 Heater 1600 Watts X 3175513 Heater 1900 Watts X 3176552 Cord and Plug Set X 3176562 Cord Set 14GA X 3176559 Line Cord 220V 3 Conductor X X X 3177386 Vent Shutter Cap X X X 3...

Page 35: ...176705 PCB Assembly High Limit X X X X X X 3176706 PCB Assembly C P U X X X X X X 3176738 RTD Sensor X X X X X X 3176758 Interface High Limit X X X X X X 3167193 Fuse Kit 1 4A 250V 115V X X X X X X 3175930 Fuse FST 6 3x32 63mA 230V X X X X X X 3175897 Blower Wheel X X X 3166987 Motor Assembly 115V X X 3167015 Motor Assembly 230V X X X 3176726 Wiring Harness X X X X X X 3176736 Interface Cable X X ...

Page 36: ...echanical X X X X X X 3174903 Knob Analog Timer X X X X X X 3176728 Wiring Harness X X X X X X 3174903 Knob Temperature X X X X X X 3162433 Light Assembly 115V X X X X 3162434 Light Assembly 230V X X X X X X 3167189 Temperature Controller PCB Kit X X X 3167188 Hi Limit Controller PCB Kit X X X 2 2 2 3176739 RTD Assembly 1000 0HM X X X X X Accessory List Thelco Oven Model 70 130 160 70M 130M 160M P...

Page 37: ......

Page 38: ...OVENS MECHANICAL AND GRAVITY CHAMBER LIGHT INNER CHAMBER BLOWER MOTOR HR1 3 TIMER SWITCH EMR1 1 HEATER CONNECTION FOR 230 V HEATER CONNECTION FOR 115 V HR1 3 HR1 1 HR1 2 TEMPERATURE CONTROLLER TEMPERATURE SENSOR ___ ___ ___ M1 S1 LIGHT SWITCH 1 1 2 2 5 C1 4 5 POWER SWITCH TEMPERATURE INDICATOR HIGH LIMIT INDICATOR HIGH LIMIT CONTROLLER HR1 1 HR1 2 HIGH LIMIT SENSOR ___ ___ ___ 1 4 AMP SLO BLO F1 ...

Page 39: ...1 1 TB1 3 TB1 2 OR YL GR TB1 3 TB1 2 1 4 AMP SLO BLO TEMPERATURE CONTROL LAMP OR BK GR HIGH LIMIT CONTROLLER ALL MODELS P N 34384802 TEMPERATURE CONTROLLER GRAVITY MODELS P N 34384801 MECHANICAL MODELS P N 34384802 MOTOR CONNECTION 230V MOTOR CONNECTION 115V HEATER CONNECTION 115V HEATER CONNECTION 230V 5 4 1 2 5 4 1 2 TIMER SWITCH N O 2 C1 T7 T6 T5 T4 T3 T2 T1 T7 T6 T5 T4 T3 T2 T1 NONE SEE PARTS ...

Page 40: ...CTION FOR 230 V HEATER CONNECTION FOR 115 V A FULL 1 OF 1 D DWG NO REV SIZE SCALE SHEET DWG TITLE CONTROL WIRING DIAGRAM THELCO DIGITAL OVENS MECHANICAL AND GRAVITY RTD LINE 115 OR 230V 50 60 HZ BLOWER MOTOR POWER SWITCH S1 CHAMBER LIGHT INNER CHAMBER LIGHT SWITCH S2 16 COND HEAT ON LED HIGH LIMIT LED TEMPERATURE SENSOR ___ ___ ___ 5 COND 16 COND HIGH LIMIT SENSOR ___ SSR M1 1 1 2 2 5 4 4 5 HR1 1 ...

Page 41: ...D DIGITAL OVEN LINE CORD LAMPHOLDER 660W 600V BULB 40W 115V A DWG NO REV SIZE SCALE SHEET DWG TITLE THELCO DIGITAL OVENS 115 V MECHANICAL AND GRAVITY 383301 CONTROL WIRING DIAGRAM BLACK WHITE LINE 115 V 60 HZ GREEN FRAME GROUND HEATER HR1 HR1 2 HR1 1 HR1 3 3 2 1 3 2 1 TB1 L1 ORN BLK FRAME GROUND GRN POWER ON OFF SWITCH 4 5 2 1 4 1 5 2 LIGHT INNER CHAMBER ON OFF SWITCH J302 J304 J303 CPU PCB ASSY P...

Page 42: ...SEMBLY PCB ASSEMBLY C P U MOTOR ASSEMBLY HEATER PCB ASSEMBLY HIGH LIMIT TERMINAL BLOCK 3 POSITIONS SENSOR HIGH LIMIT 1 1 1 1 2 KEYBOARD DIGITAL OVEN LINE CORD LAMPHOLDER 660W 600V BULB 50W 230V A DWG NO REV SIZE SCALE SHEET DWG TITLE THELCO DIGITAL OVENS MECHANICAL AND GRAVITY 230 V 390101 CONTROL WIRING DIAGRAM BLACK WHITE LINE 230 V 60 HZ GREEN FRAME GROUND HEATER HR1 HR1 2 HR1 1 HR1 3 3 2 1 3 2...

Page 43: ......

Page 44: ...or to the component part beyond the original warranty period The Technical Services Department must give prior approval for return of any components or equipment At Thermo s option all non conforming parts must be returned to Thermo Electron Corporation postage paid and replacement parts are shipped FOB destination THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN ORAL...

Page 45: ...nt or repair of components parts or equipment under this warranty shall not extend the warranty to either the equipment or to the component part beyond the original warranty period The Technical Services Department must give prior approval for return of any components or equipment At Thermo s option all non conforming parts must be returned to Thermo postage paid and replacement parts are shipped ...

Page 46: ...Thermo Electron Corporation Controlled Environment Equipment 401 Millcreek Road Marietta Ohio 45750 United States www thermo com ...

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