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Barnstead 30400 Operation Manual

Series 1262 thermolyne furnace
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Thermolyne Furnace
Single Setpoint Models
8 Segment Programmable
Models with OTP
4 X 16 Segment
Programmable Models
with OTP
LT1262X1 • 10/8/04
Type 30400
OPERATION MANUAL
AND PARTS LIST
Series 1262
F30420C, F30420C-33, F30428C
F30420C-33-80, F30420-33-60-80
F30420C-60-80, F30420C-80
F30428C-60-80, F30428C-80
F30430CM, F30430CM-33,
F30430CM-33-60, F30430CM-60
F30438CM, F30438CM-60

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Summary of Contents for Barnstead 30400

  • Page 1 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 •...

  • Page 2: Table Of Contents

    Table of Contents 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...
  • Page 3 ABLE OF ONTENTS 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...

  • Page 4: Safety Information

    Safety Information Your Barnstead Thermolyne furnace has been designed Alert Signals 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 Warning alert signals throughout the manual.
  • Page 5 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).

  • Page 6: General Specifications

    General Specifications 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)

  • Page 7: Declaration Of Conformity

    ENERAL PECIFICATIONS 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...

  • Page 8: Introduction

    See specific model number in proceeding chart for total num- ber of program segments. 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.

  • Page 9: Principles Of Operation

    NTRODUCTION MODEL NUMBER DIGITAL COMMUM. TOTAL NUMBER OF NUMBER OF PROGRAMMABLE STORED SEGMENTS PROGRAMS F30420C-33-80 F30420-33-60-80 F30420C-60-80 F30420C-80 F30428C-60-80 F30428C-80 F30430CM 16 Segment Programs F30430CM-33 16 Segment Programs F30430CM-33-60 16 Segment Programs F30430CM-60 16 Segment Programs F30438CM 16 Segment Programs F30438CM-60 16 Segment Programs Principles of Operation...

  • Page 10: Unpacking

    Unpacking Visually check for any physical damage to the shipping container. Inspect the equipment surfaces that are adja- cent to any damaged area. Open the furnace door and remove the packing material from inside the furnace chamber. Vacuum the chamber prior to use to remove the insulation dust due to shipment.

  • Page 11: Installation

    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 Caution before connecting the furnace to your electrical supply.

  • Page 12: Operation, All Models

    Operation, All Models Power Switch Warning Both the ON/OFF power switch and the digital display To avoid personal injury do not use in the will illuminate when power is switched ON. The furnace presence of flammable or combustible will begin to heat to its controller's current setpoint. chemicals;...

  • Page 13: Single Setpoint Models With Otp

    Single Setpoint Models w/OTP Temperature single setpoint model w/ OTP furnace controller Output 2 Output 1 Display 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.

  • Page 14: To View Or Change The Setpoint

    /OTP INGLE ETPOINT ODELS W 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.

  • Page 15: Alarms

    /OTP INGLE ETPOINT ODELS W 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.

  • Page 16: Sensor Break Protection

    /OTP INGLE ETPOINT ODELS W 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).

  • Page 17: Tuning

    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- Note mends you use this feature to provide the best temper- Furnace must be at ambient ature accuracy the controller can attain.

  • Page 18: Single Ramp And Dwell

    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.

  • Page 19: Program Setup

    & D INGLE WELL ONTROLLER Program Setup Press the PAGE button until the “SP” is displayed. 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.

  • Page 20: Running The Program

    & D INGLE WELL ONTROLLER 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.

  • Page 21: Segment & 4X16 Segment Programmable Models W/Otp

    8 Segment & 4x16 Segment Programmable Models w/OTP The 8 segment programmable controller consists of a microprocessor based three-mode PID Note (Proportional, Integral, Derivative), programmable The controller will return to the HOME temperature controller with over-temperature protec- DISPLAY if left idle for more than a few tion and appropriate output switching devices to con- seconds.

  • Page 22: To View The 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.

  • Page 23: Controller Parameters

    & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W 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.
  • Page 24 & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W 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...
  • Page 25 & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W 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...

  • Page 26: Alarms

    & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W Alarms The controller will flash an alarm message in the home Note display if an alarm condition is detected. The following alarm messages are factory default settings and may vary if you have IdHi: PV deviation high alarm.

  • Page 27: Over Temperature Protection

    & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W 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.

  • Page 28: Creating A New Program Or Editing An Existing Program

    & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W 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.
  • Page 29 & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W 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.
  • Page 30 & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W 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.
  • Page 31 & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W Steps 4 and 5 are used in the 4 program model only. If you are using an 8 segment program, skip to step 6. Press the SCROLL button until display reads “Hb.”...
  • Page 32 & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W dwEll To maintain a constant temperature for a specified time: Press the PAGE button until you reach the pro- gram list (ProG LiSt). Press the SCROLL button until display reads, “tYPE.”...
  • Page 33 & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W Press the SCROLL button until display reads, “tYPE.” Press the UP or DOWN button until display reads, “cALL.” Press the SCROLL button until display reads, “PrG.n.” Press the UP or DOWN button to select a pro- gram number to be linked.

  • Page 34: Running A Program

    & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W Setting the Target Setpoint (4x16 Segment Programmable Models Only) Press the PAGE button until you reach the program list (ProG LiSt). Press the SCROLL button until display reads, “tGt.” Press the UP or DOWN button to set the tar- get setpoint temperature.

  • Page 35: Holding A Program

    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. Note Tuning your Furnace Display will flash “tu.ER”...

  • Page 36: Gain Scheduling

    & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W 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.

  • Page 37: Adaptive Tuning

    & 4 16 S /OTP EGMENT EGMENT ROGRAMMABLE ODELS W Set the setpoint temperature. Press the PAGE button until the display reads, “Atun LiSt.” Press the SCROLL button until “tunE OFF” is displayed. Press the UP or DOWN button to select “on.” Simultaneously press the PAGE and SCROLL buttons to return to the HOME DISPLAY.

  • Page 38: Installation And Operation Of Air Control

    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.

  • Page 39: Furnace Loading

    Furnace Loading • For best results, use only the center two-thirds of the furnace chamber. Note Failure to connect the exhaust port to • Use Hearth plate to elevate load when placing an appropriate exhaust system will re- on bottom heating element. This prevents bot- sult in smoke and gases filling the tom heating element from overheating and burn- work area.

  • Page 40: Preventative Maintenance

    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.

  • Page 41: Problem Solving

    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...
  • Page 42 ROBLEM OLVING 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.
  • Page 43 ROBLEM OLVING 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.

  • Page 44: Maintenance And Servicing

    Customer Service and service. Department at Barnstead International at 1-800-553-0039. Perform only maintenance described in this manual. Contact an authorized dealer or our factory for parts and as- To Replace a Heating Element sistance.

  • Page 45: To Replace A Platinel Ii Thermocouple

    AINTENANCE AND ERVICING Loosen the screws and nuts on the terminals of the element to be replaced. Open the door and pull the defective element out. Slide the new element into place, threading the leads through the insulating porcelain bushing on the back of the furnace.

  • Page 46: To Replace Solid State Relay

    AINTENANCE AND ERVICING To Replace Solid State Relay: Disconnect furnace from power supply. Remove the screws on the front dial and the screws on the lower back cover. Remove the upper back cover. Disconnect the element lead wires and one ground wire from back of furnace.

  • Page 47: To Realign Door Strike

    AINTENANCE AND ERVICING Slide the control section forward. Disconnect the wires from the door switch. (Note connection and placement of wires to Microswitch). Control section can now be removed from fur- nace housing. Remove the two screws and nuts from the Microswitch.

  • Page 48: To Replace Control Module

    AINTENANCE AND ERVICING Reconnect to power supply. 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”...

  • Page 49: Replacement Parts List

    Replacement Parts Single Setpoint Models F30420C, F30420C-33, F30428C Part Number Description Quantity Notes CAX99 Line filter “-33” model only CA1249X1 Capacitor “-33” model only CN71X88 Controller All models EL412X1 Element 208V model EL412X2 Element 208V model EL412X3 Element 208V model EL412X4 Element 240 V model...
  • Page 50 EPLACEMENT ARTS RYX62 Mechanical relay All models SWX144 Power switch All models SWX163 Door switch All models TRX96 Terminal block All models TRX178 Terminal Block All models TC412X1A Thermocouple All models 4X16 Segment Programmable Models with OTP F30430CM, F30430CM-33, F30430CM-33-60, F30430CM-60, F30438CM, F30438CM-60 Part Number Description Quantity...

  • Page 51: Ordering Procedures

    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 ( ).

  • Page 52: Wiring Diagrams

    Wiring Diagrams SINGLE SETPOINT CONTROL WIRING DIAGRAM...
  • Page 53 IRING IAGRAMS SEGMENT PROGRAMMABLE CONTROL WIRING DIAGRAM...
  • Page 54 IRING IAGRAMS 4X16 SEGMENT PROGRAMMABLE CONTROL WIRING DIAGRAM...

  • Page 56: Two Year Limited Warranty

    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.

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