ATS 3110 Instruction Manual
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ATS 3110 Instruction Manual

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INSTRUCTION MANUAL
FURNACE
Model Number: 31XX, 32XX
This manual contains important operating and safety information. Carefully read and
understand the contents of this manual prior to the operation of this equipment.
www.atspa.com

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  • Page 1 INSTRUCTION MANUAL FURNACE Model Number: 31XX, 32XX This manual contains important operating and safety information. Carefully read and understand the contents of this manual prior to the operation of this equipment. www.atspa.com...
  • Page 2 Applied Test Systems (ATS). © Copyright Applied Test Systems 2017 For assistance with set-up or operation, contact the ATS service department. Please have this manual and product serial number available when you call. Telephone: +1-724-283-1212.

  • Page 3: Table Of Contents

    MANUAL CONTENTS A. Safety ........................1 A.1 Owners, Operators, and Maintenance ...............1 A.2 Environmental Conditions ..................B. Introduction ......................5 B.1 Unpacking ......................5 B.2 After Sale Support ....................5 C. Installation ........................ 6 C.1 General Installation ....................6 C.2 Positioning and Connecting ..................6 D.
  • Page 4 G.2 Embedding & Patching Element ................13 G.3 Element Replacement ..................14 3110 Tube Furnace Element Replacement ............... 14 3210 Split Tube Furnace Element Replacement ............16 3150/3160 Box Furnace Element Replacement............18 Removing Side Elements – 3150 and 3160 ............18 Removing Bottom Elements –...

  • Page 5: Safety

    A. Safety A.1 Owners, Operators, and Maintenance This manual uses note, caution, and warning symbols throughout to draw your attention to important operational and safety information. Read and understand all instructions and safety precautions listed in this manual before installing or operating your unit. If you have any questions regarding operation of the unit or instructions in this manual, contact our Service Engineering Department at +1-724- 283-1212.
  • Page 6 local electrical code requirements. Handle the furnace carefully. Avoid dropping and jarring the furnace. Avoid damage to cables. Do not let the power cables touch the heated furnace shell. Do not exceed maximum operating temperature. Operate the furnace and accessories within the appropriate temperature range. Refer to the appropriate manuals.

  • Page 7: Environmental Conditions

    Do not use a temperature control system with a power output rating lower than the current rating of the furnace. Use the same thermocouples as indicated on the setpoint controller. Other types will result in faulty control which may cause damage from overheated components.
  • Page 8 • Installation category II • Pollution degree 2 Series 31XX, 32XX Furnaces | A. Safety...

  • Page 9: Introduction

    If you have any questions concerning the operation of your unit, contact your sales representative. Before calling, please obtain the serial number from the unit’s data label. Also, please be prepared to give a complete description of your problem. Figure B.1 - Sample ATS data tag Series 31XX, 32XX Furnaces | B. Introduction...

  • Page 10: Installation

    C. Installation C.1 General Installation This section describes how to prepare your Applied Test Systems (ATS) furnace for operation. Only perform the steps that apply to your specific furnace type. The installation of the equipment must be performed by a qualified and licensed electrician in accordance with National Electric code and local codes.
  • Page 11 5. Locate the Line Power Access Port on the center of the back side of the control system. Determine the appropriate gauge wire by confirming the amperage on the data label. Insert the wire into the Line Power port. 6. Connect the power cord to the power supply block and replace the top cover. Tighten the line power clamp to the power cord to help prevent bad connections and any movement of the cord.

  • Page 12: Pre-Operation Instructions

    D. Pre-Operation Instructions D.1 Furnace Bake-Out The following bake-out procedure must be performed on new furnaces or those that have new insulation. If the furnace is used with a retort, perform the bake-out with the retort. By baking-out the retort with the furnace, any impurities on the retort’s surface will burn off.

  • Page 13: Temperature Controller

    E. Temperature Controller E.1 Temperature Controller Overview The ATS temperature control system regulates the power applied to the resistive heating elements to reach and maintain the desired temperature (setpoint) as measured by a control thermocouple. The basic temperature control system includes the following: •...

  • Page 14: Temperature Controller Operation

    4. Provide a source of grounded electrical power per the (furnace/oven) data label to the terminal block labeled “customer power” inside the control cabinet. Refer to the power block labeling inside the control cabinet for wiring data. CAUTION: Obey all national and local electrical code requirements. Furnaces and control systems must be grounded and wired according to national and local electrical codes.
  • Page 15 The over-temperature controller is an independent controller with an independent thermocouple. When an over-temperature is reached, an alarm is signaled and the electrical current is interrupted from the power controller to the heating elements. This protects against a runaway temperature controller or malfunctioning power controller. In the event of shutdown, the operator will have to manually reset the controller after the over-temperature condition is cleared.

  • Page 16: Furnace Operation

    F. Furnace Operation After completing furnace installation and pre-operational procedures, refer to the manufacturer’s instructions for temperature controller operation. CAUTION: Before setting the temperature controller to the desired temperature, check restrictions of other system components such as pull rods, extensometers, retorts, and specimens. Comply with recommended heat-up and cool-down rates.

  • Page 17: Furnace And Element Maintenance

    G.2 Embedding & Patching Elements If heating elements have exposed wire, use only ATS supplied embedding compound to secure them. NOTE: Not all elements require embedding cement. Contact ATS with any questions by calling +1-724-283-1212.

  • Page 18: Element Replacement

    3110 Tube Furnace Element Replacement The element replacement procedure described below is for an ATS Series 3110 Tube Furnace only. Refer to Figure G.1 during disassembly. 1. Turn off furnace and allow to cool completely.
  • Page 19 Carefully position the element in place. Align any ports if applicable. Figure G.2 - End View of ATS Series 3110 Tube Furnace Refer to Figure G.2. Series 31XX, 32XX Furnaces | G. Furnace and Element Maintenance...

  • Page 20: 3210 Split Tube Furnace Element Replacement

    Bake-out is not necessary unless the insulation has been replaced. 3210 Split Tube Furnace Element Replacement The element replacement procedure described in this section is for ATS Series 3210 Split Tube Furnace types only. Refer to Figure G.3 for an identification of parts.
  • Page 21 3. Remove the terminal cover. Isolate element wires from the terminal block and check resistance with an ohmmeter. If there is resistance, no further action is needed. If there is not any resistance, replacement is needed. Disconnect and mark the terminal block for reassembly.

  • Page 22: 3150/3160 Box Furnace Element Replacement

    13. If applicable, mount the furnace on the testing machine. Connect the leads and instrumentation, and install the terminal covers. 14. If any insulation has been replaced, follow the bake-out procedures outlined in Section D.1 (p. 8). Bake-out is not necessary unless the insulation has been replaced. NOTE: Do not operate the furnace with open end bores.

  • Page 23: Removing Bottom Elements - 3150

    3. The element then can be lifted up to clear the lower element and pulled directly out through the front door opening. Removing Bottom Elements – 3150 1. Side elements must be removed before removing bottom element. 2. Once the hearth plate and side elements are removed the bottom element can be pulled directly out through the front door opening.
  • Page 24 4. Check resistance of elements to verify elements are properly wired and not shorting against each other. 5. Continue replacing elements as needed. 6. Repeat bake-out procedure for new furnace, especially if insulation has been replaced. Series 31XX, 32XX Furnaces | G. Furnace and Element Maintenance...

  • Page 25: Temperature Controller Maintenance

    H. Temperature Controller Maintenance H.1 Preventative Maintenance Inspect components every month for defects. If defects are discovered during operation, make a note of the defect and correct it as soon as possible. Stop the process immediately if a deficiency is discovered that could ultimately damage the equipment or present a safety hazard.

  • Page 26: Troubleshooting

    I. Troubleshooting I.1 Controller Does Not Operate Power applied, controller does not operate. Check power to controller. No Power. Power is OK. Check Check wiring engagement and fuses. of controller in housing. Does not OPERATIONAL Power, but OPERATIONAL operate: Perform still not Perform FAULTY...

  • Page 27: Over-Temperature

    I.2 Over-Temperature Overtemperature Display reads Display reads below set point. above set point. OUTPUT #1: OUTPUT #1: OUTPUT #1: OUTPUT #1: Lamp is on. Lamp is off. Lamp is off. Lamp is on. Remove Defective Remove Defective temperature controller: temperature controller: controller leads.

  • Page 28: Under-Temperature

    I.3 Under-Temperature Under temperature or not heating. Temperature droop: Extreme under retune temperature controller. Check controller output. Controller calls for Controller output but output is OK. no output - return for repair. Check power controller output. Output OK - No output - bad heating check fuses.

  • Page 29: Appendix A: Safety Data Sheet Information

    APPENDIX A: Safety Data Sheet Information SAFETY DATA SHEET SDS No. M0042 Effective Date: 02/12/2015 1. IDENTIFICATION (a) Product identifier used FIBERFRAX® DURABOARD® LD on the label (b) Other means of Duraboard® LD, Duraboard® LD-RG, Duraboard® LD-HT identification (c) Recommended use of Primary Use: Refractory Ceramic Fiber (RCF) materials are used primarily in ...
  • Page 30 Hazard Pictogram Signal Word Warning Hazard Statements Suspected of causing cancer by inhalation. Precautionary statements Do not handle until all safety instructions have been read and understood. Use respiratory protection as required; see section 8 of the Safety Data Sheet. If concerned about exposure, get medical advice.
  • Page 31 inhalation, skin and eye contact, and ingestion SKIN Handling of this material may generate mild mechanical temporary skin irritation. If this occurs, rinse affected areas with water and wash gently. Do not rub or scratch exposed skin. EYES In case of eye contact flush abundantly with water; have eye bath available. Do not rub eyes. NOSE AND THROAT If these become irritated move to a dust free area, drink water and blow nose.
  • Page 32 7. HANDLING AND STORAGE (a) Precautions for safe handling Handle fiber carefully to minimize airborne dust. Limit use of power tools unless in conjunction with local exhaust ventilation. Use hand tools whenever possible. (b) Conditions for safe storage, including any incompatibilities Store in a manner to minimize airborne dust.
  • Page 33 (c) Individual protection measures, such as personal protective equipment Skin Protection Wear personal protective equipment (e.g gloves), as necessary to prevent skin irritation. Washable or disposable clothing may be used. If possible, do not take unwashed clothing home. If soiled work clothing must be taken home, employees should be informed on best practices to minimize non-work dust exposure (e.g., vacuum clothes before leaving the work area, wash work clothing separately, and rinse washer before washing other household clothes).
  • Page 34 10. STABILITY AND REACTIVITY (a) Reactivity RCF is non-reactive. (b) Chemical stability As supplied RCF is stable and inert. (c) Possibility of hazardous reactions None Please refer to handling and storage advice in Section 7 (d) Conditions to avoid (e) Incompatible materials None (f) Hazardous decomposition products Thermal decomposition of binder from fires or from first heat of product may...
  • Page 35  Respiratory or skin sensitization No evidence from human epidemiological studies of any respiratory or skin sensitization potential .  Germ cell mutagenicity/genotoxicity Method: In vitro micronucleus test Species: Hamster (CHO) Dose: 1-35 mg/ml Routes of administration: In suspension Results: Negative ...
  • Page 36 Results: No effects were seen in an OECD 421 screening study. There are no reports of any reproductive toxic effects of mineral fibers. Exposure to these fibers is via inhalation and effects seen are in the lung. Clearance of fibers is via the gut and the feces, so exposure of the reproductive organs is extremely unlikely. ...
  • Page 37 13. DISPOSAL CONSIDERATIONS (Non-mandatory) WASTE MANAGEMENT To prevent waste materials from becoming airborne during waste storage, transportation and disposal, a covered container or plastic bagging is recommended. DISPOSAL This product, as manufactured, is not classified as a hazardous waste according to Federal regulations (40 CFR 261). Any processing, use, alteration or chemical additions to the product, as purchased, may alter the disposal requirements.
  • Page 38 local regulatory agency. INTERNATIONAL REGULATIONS Canada Canadian Workplace Hazardous Materials Information System (WHMIS) – Classified as Class D2A – Materials Causing Other Toxic Effects Canadian Environmental Protection Act (CEPA) - All substances in this product are listed, as required, on the Domestic Substance List (DSL) Europe Integration of RCF into ANNEX XV of the REACH Regulation RCF is classified under the CLP (classification, labelling and packaging of substances and mixtures)
  • Page 39 IARC’s evaluation of crystalline silica states “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1)” and additionally notes “carcinogenicity in humans was not detected in all industrial circumstances studied.” IARC also studied mixed mineral crystalline silica containing dusts such as coal dusts (containing 5 –...
  • Page 40 TSCA: Toxic Substances Control Act Time Weighted Average TWA: WHMIS: Workplace Hazardous Materials Information System (Canada) Revision Summary: Updated SDS to align with OSHA HCS 2012. Replaces 06/06/2013 SDS. Revison Date: 02/12/2015 SDS Prepared By: UNIFRAX RISK MANAGEMENT DEPARTMENT DISCLAIMER The information presented herein is presented in good faith and believed to be accurate as of the effective date of this Safety Data Sheet.
  • Page 41 Page 1/9 Safety Data Sheet according to 1907/2006/EC (REACH), 1272/2008/EC (CLP), and OSHA Printing date 15.06.2015 Revision: 15.06.2015 SECTION 1: Identification of the substance/mixture and of the company/ undertaking · 1.1 Product identifier · Trade name: EA1043, EA162, EA198, GA287, MA1099, MA1100, MA176, PA748, RA206, RA207 ·...
  • Page 42 Page 2/9 Safety Data Sheet according to 1907/2006/EC (REACH), 1272/2008/EC (CLP), and OSHA Printing date 15.06.2015 Revision: 15.06.2015 Trade name: EA1043, EA162, EA198, GA287, MA1099, MA1100, MA176, PA748, RA206, RA207 (Contd. of page 1) · NFPA ratings (scale 0 - 4) Health = 0 Fire = 0 Reactivity = 0...
  • Page 43 Page 3/9 Safety Data Sheet according to 1907/2006/EC (REACH), 1272/2008/EC (CLP), and OSHA Printing date 15.06.2015 Revision: 15.06.2015 Trade name: EA1043, EA162, EA198, GA287, MA1099, MA1100, MA176, PA748, RA206, RA207 (Contd. of page 2) · 4.2 Most important symptoms and effects, both acute and delayed Breathing difficulty Coughing ·...
  • Page 44 Page 4/9 Safety Data Sheet according to 1907/2006/EC (REACH), 1272/2008/EC (CLP), and OSHA Printing date 15.06.2015 Revision: 15.06.2015 Trade name: EA1043, EA162, EA198, GA287, MA1099, MA1100, MA176, PA748, RA206, RA207 (Contd. of page 3) · 7.2 Conditions for safe storage, including any incompatibilities ·...
  • Page 45 Page 5/9 Safety Data Sheet according to 1907/2006/EC (REACH), 1272/2008/EC (CLP), and OSHA Printing date 15.06.2015 Revision: 15.06.2015 Trade name: EA1043, EA162, EA198, GA287, MA1099, MA1100, MA176, PA748, RA206, RA207 (Contd. of page 4) · Eye protection: Safety glasses · Body protection: Not required under normal conditions of use. ·...
  • Page 46 Page 6/9 Safety Data Sheet according to 1907/2006/EC (REACH), 1272/2008/EC (CLP), and OSHA Printing date 15.06.2015 Revision: 15.06.2015 Trade name: EA1043, EA162, EA198, GA287, MA1099, MA1100, MA176, PA748, RA206, RA207 (Contd. of page 5) · Viscosity: Dynamic: Not applicable. Kinematic: Not applicable.
  • Page 47 Page 7/9 Safety Data Sheet according to 1907/2006/EC (REACH), 1272/2008/EC (CLP), and OSHA Printing date 15.06.2015 Revision: 15.06.2015 Trade name: EA1043, EA162, EA198, GA287, MA1099, MA1100, MA176, PA748, RA206, RA207 (Contd. of page 6) · Aspiration hazard Based on available data, the classification criteria are not met. SECTION 12: Ecological information ·...
  • Page 48 Page 8/9 Safety Data Sheet according to 1907/2006/EC (REACH), 1272/2008/EC (CLP), and OSHA Printing date 15.06.2015 Revision: 15.06.2015 Trade name: EA1043, EA162, EA198, GA287, MA1099, MA1100, MA176, PA748, RA206, RA207 (Contd. of page 7) · UN "Model Regulation": SECTION 15: Regulatory information ·...
  • Page 49 Page 9/9 Safety Data Sheet according to 1907/2006/EC (REACH), 1272/2008/EC (CLP), and OSHA Printing date 15.06.2015 Revision: 15.06.2015 Trade name: EA1043, EA162, EA198, GA287, MA1099, MA1100, MA176, PA748, RA206, RA207 (Contd. of page 8) · Other regulations, limitations and prohibitive regulations This product has been classified in accordance with hazard criteria of the Controlled Products Regulations and the SDS contains all the information required by the Controlled Products Regulations.
  • Page 50 APPENDIX B: Warranty Your Applied Test Systems product has been manufactured and inspected by experienced craftsmen. Applied Test Systems warrants, for the original purchaser, each product to be free from defects in material and workmanship for a period of thirteen (13) months from date of shipment or twelve (12) months from date of installation - whichever comes first.
  • Page 51 Figure C.2 - Interior Controller - Line Power Access Port ..........7 Figure G.1 - Series 3110 Furnace Disassembly ............. 15 Figure G.2 - End View of ATS Series 3110 Tube Furnace ..........15 Figure G.3 - Series 3210 Furnace................16 Figure G.4 - Safe Distance Between Lead Wires ............
  • Page 52 154 East Brook Lane - Butler, PA 16002 USA | +1-724-283-1212 sales@atspa.com | www.atspa.com...

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