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Installation, Operation &
Maintenance Instructions
Microwave Assisted Technology
MRF 16/22
Important note:
This product needs to be "burnt off" and its elements conditioned before it can be used. See
section 3.6 for details.
This manual is for the guidance of operators of the MRF 16/22 furnace and should be read
before the furnace is connected to the electricity supply. It contains information required for
safe and trouble-free furnace operation. If, however, any questions remain unanswered please
contact our service division at the address at the end of this manual.
MF 55-GB 1.21
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Table of Contents
Related Manuals for Carbolite MRF 16
Summary of Contents for Carbolite MRF 16
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Page 1: Maintenance Instructions
This product needs to be “burnt off” and its elements conditioned before it can be used. See section 3.6 for details. This manual is for the guidance of operators of the MRF 16/22 furnace and should be read before the furnace is connected to the electricity supply. It contains information required for safe and trouble-free furnace operation. -
Page 2: Table Of Contents
MRF 16/22 Contents Introduction to the furnace PECIFICATION PERATING MODES 3508 C ONTROLLER PROGRAMMER EE SECTION 2132 O VER TEMPERATURE CONTROLLER EE SECTION Safety ENERAL WARNINGS PERATOR SAFETY HEAT OOR LATCHES AND SAFETY INTERLOCKS AFETY PRECAUTIONS WHEN OPENING THE DOOR... -
Page 3: Mf 55-Gb 1.21
MRF 16/22 ONTROLLER PAGES ICROWAVE Temperature control (SP) HANGING THE SETPOINT TEMPERATURE AMP TO SETPOINT Microwave control POWER LEVEL SETTING OUNTDOWN TIMER DURATION SETTING 5.5] EE FIGURE O SWITCH ON OFF THE MICROWAVE POWER 5.5] EE FIGURE ULSED MICROWAVE POWER 5.6]... -
Page 4: Digital Communication
MRF 16/22 11 Digital communication 11.1 RS232 COMMUNICATION ADDRESSING 11.2 RS232 COMMUNICATION CABLES 12 Maintenance 12.1 LEANING 12.2 ECONTAMINATION 12.3 EGULAR MICROWAVE SAFETY CHECKS 12.4 HECK THE OPERATION OF THE DOOR SAFETY INTERLOCKS 12.5 HERMOCOUPLE SHEATH AGING 12.6 THER ELECTRICAL COMPONENTS 12.7... -
Page 5: Mf 55-Gb 1.21
MRF 16/22 List of Figures Figure Title Page Fork lift access panel Electrical connections Rating label, RS 232 connection and cooling fans Control panel Controller keys and indicators Temperature control Program editing Microwave control Microwave pulse control Program example 1 Program example 2 11.1... -
Page 6: Introduction To The Furnace
For the full specification refer to the table in section 17. Operating modes The MRF 16/22 can be used as a conventional radiant heating furnace, operating continuously at a set temperature or following a program profile. The microwave (MW) power can be applied continuously or as part of the program. -
Page 7: Safety
If this furnace is used in a way not specified by Carbolite, the protection provided by the furnace may be impaired. -
Page 8: Use Of Probes
If the furnace is being switched on for the first time, then following the burn off process will dry the furnace. Note; if after following the drying procedure the furnace has note fully dried then repeat the procedure, if in doubt contact Carbolite. MF 55-GB 1.21... -
Page 9: Warning Symbols
MRF 16/22 Warning symbols The following warning symbols are used in this manual and on the product. DANGER OF DEATH – HIGH VOLTAGE – read any warning printed next to this symbol. DANGER of electrical shock – read any warning printed next to this symbol. -
Page 10: Installation
Ensure that there is at least 75mm of free space around the furnace and Carbolite recommends 1.5 meters of free space above the furnace. Do not obstruct any of the fan inlets or outlets. -
Page 11: Internal Unpacking
It must be fused to give a level of discrimination between the MRF 16/22 internal fuses and the external isolation fuses. See Product rating label for voltage and specification. [See section 13.5 for the internal fuses fitted]. - Page 12 MRF 16/22 has been set up, there is a “+2%” position on the transformer primary side which may be used to compensate for this. Safety note: Refer to section 2.1. MF 55-GB 1.21...
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Page 13: Switching On For The First Time
MRF 16/22 Switching on for the first time To minimise the chance of transport damage to the insulation, the binder in the insulation has not been burnt off. (Burn off is the process of burning out organic binders from the insulation boards). -
Page 14: General Operating Notes
MRF 16/22 4 General operating notes This manual explains how to operate and maintain the MRF 16/22. Heating element life is shortened by use at temperatures close to maximum, so avoid leaving the furnace at high temperatures when not required. The furnace can be cycled between room temperature and maximum without a detrimental effect on element life. -
Page 15: Thermocouples - Low Temperatures
MRF 16/22 furnace, with consequent damage to both. Thermocouples – low temperatures At temperatures below 600°C the thermocouples will not give accurate readings. When the furnace is started from cold they may show a negative temperature. If the Setpoint temperature is at 0°C, this negative temperature reading will cause the heating power to come on. -
Page 16: Rating Label, Rs 232 Port And Cooling Fans
MRF 16/22 Rating label, RS 232 port and cooling fans Case cooling fan outlet Chimney Control box cooling fan outlet Magnetron cooling fan outlet Magnetron cooling fan intake Microwave circuit cooling fans outlets RS 232 port Rating label Figure 4.1 Rating label, RS 232 port and cooling fans The case and control box cooling fans will be on when the power is turned on. -
Page 17: Controllers, Lights And Indicators
MRF 16/22 5 Controllers, lights and indicators Control panel [See Fig 5.1] Introduction On the control panel the green light and switch is illuminated whenever the electrical supply to the furnace is connected, also the case cooling fan will be on. The switch cuts off power to the controllers and contactor. -
Page 18: Control Panel
MRF 16/22 running. A program can be edited while it is running. Changes made to the current segment will not take effect until next time it is run; changes made to further segments will take effect in the current program run. -
Page 19: Controller Home Display Layout - Keys And Indicators
MRF 16/22 Controller home display layout – keys and indicators Element power EUROTHERM Measurement units output indicator Alarm indicator °C Measured temperature RUN HLD MW Power Setpoint temperature program output indicators* (SP) /Page titles 1200 Program status Control and indicator... -
Page 20: Controller Pages: Temperature And Programming
MRF 16/22 Controller pages: Temperature and programming ‘Controller home page display’ Measured temperature Setpoint temperature [See section 6] Over temperature limit [See section 10] Figure 5.3 Temperature control Program Edit page. Press page twice [See section 8] Figure 5.4 Program editing... -
Page 21: C Ontroller Pages : M Icrowave
MRF 16/22 Controller pages: Microwave Press page three times Measured temperature MW power percentage [See section 7.1] MW countdown timer duration [See section 7.2] MW countdown timer on/off. Starts/stops the MW Figure 5.5 Microwave control [See section 7.3] MW on/off pulse setting [See section 7.4]... -
Page 22: Temperature Control
MRF 16/22 Temperature control Changing the setpoint temperature (SP) On the home page, press up down to select the required Setpoint temperature (SP). If the SP is higher than the measured temperature*, the OP1 indicator will illuminate at the top of the display, indicating that the controller is calling for power (giving an output). -
Page 23: Microwave Control
MRF 16/22 7 Microwave control The MW power is not controlled by the thermocouple. There is no feedback from the thermocouple to the MW power. To set the MW power, from the home page: Press page 3 times to get to the microwave control page. [See figure 5.5]... -
Page 24: Programming
MRF 16/22 8 Programming Programming notes To return to the home page, press page and scroll at the same time. To avoid unwanted radiant heating at the end of a program, set the controller setpoint temperature to -20°C before running a program. -
Page 25: R Unning The Current Program
MRF 16/22 Segment Type Press scroll until the display shows “Segment Type”. Press up or down to select Rate, Time, Dwell, Step, Wait, GoBack, Call or End. Target Setpoint (visible only for Rate, Time and Step segments) Press scroll until the display shows “Target SP”. Press up or down to set a value. -
Page 26: T O Stop And Reset A Program
MRF 16/22 To pause (hold) a program Press RUN/HOLD once. To stop and reset a program Press RUN/HOLD once, then press again and hold for 2 seconds. To run a different program To select a program: From the home page, press page once to get to the Program Status page. -
Page 27: H Oldback
MRF 16/22 Holdback Holdback can be used to prevent the program from running ahead of the actual heating or cooling. The Holdback value is the amount, in degrees, by which the Program Setpoint can run ahead of the measured temperature before Holdback operates. The value applies to a whole program. -
Page 28: P Rogram Example 1
MRF 16/22 8.11 Program example 1 Time display examples 30min 80min 120min 30min 12:34.5 Min / Sec / 10 1400°C 12:34:59 Hour / Min / Sec 1000°C 123:45 Hour / Min 8°C/m Segment 1 Segment 2 Segment 3 Segment 4 Segment 5 Rate 8.3°C/min... - Page 29 MRF 16/22 Press scroll Ramp Rate is displayed. Press up or down to set to ‘8.3’ degrees per minute (500°C/hr). Press scroll Holdback Type is displayed. Default ‘Off’ Press scroll Micro% is displayed. Press up or down to set to ‘50%’...
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Page 30: Program Example
MRF 16/22 8.12 Program example 2 Multi prog units only 60min Continuous dwell at 800°C 145min Natural cool down to 803°C Program 3 example 1200°C 800°C Segment 1 Segment 2 Segment 3 Segment 4 Segment 5 Holdback Time Dwell Call... - Page 31 MRF 16/22 Press scroll Value is displayed. Press up or down to set to ‘3’ degrees Holdback Press scroll Ramp Units is displayed. Press up or down to set to ‘Min’ Press scroll Cycles is displayed. Default ‘1’ Press scroll...
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Page 32: Main Controller Navigation Diagrams
MRF 16/22 9 Main controller navigation diagrams Navigation diagram - no program running Home Program Program Microwave Display Page Status Page Edit Page Control Page Temp°C Temp°C Temp°C Temp°C Micro % Prog Status Prog Edit SetPoint°C hrs:mins:sec Micro % Prog Nr... -
Page 33: N Avigation Diagram - Program Running
MRF 16/22 Navigation diagram - program running Home Program Program Microwave Display Page Status Page Edit Page Control Page Temp°C Temp°C Temp°C Temp°C Micro % Prog Status Prog Edit SetPoint°C hrs:mins:sec Micro % Prog Nr Prog Nr Timer on/off Segment nr... - Page 34 MRF 16/22 Navigation diagram – main controller calibration offset To enter Level 2 (Level 1) (Level 2) Access Home Access Home Press to Press & Go-to Press to display Pass display select Level 1 hold for 3 select code level 2...
- Page 35 Positive or negative offsets may be used, determined by calibration of the thermocouple and controller. Thermocouple calibration The thermocouple must be removed from the MRF 16/22 and calibrated by comparison using a calibrated heat source. Controller calibration The controller and thermocouple connection cables must be calibrated by injecting milli- volts down the thermocouple cables into the controller from a calibrated source.
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Page 36: Over Temperature Controller Keys And Indicators
10.1 Description The 2132 over temperature controller is made by Eurotherm, and is configured by Carbolite. When an over temperature condition occurs, the controller cuts the power to the heating elements. Power is not restored until the controller is “reset”. -
Page 37: U Ser Calibration Of Over Temperature
Positive or negative offsets may be used, determined by calibration of the thermocouple and controller. Thermocouple calibration The thermocouple must be removed from the MRF 16/22 and calibrated by comparison using a calibrated heat source. Controller calibration The controller and thermocouple connection cables must be calibrated by injecting milli- volts down the thermocouple cables into the controller from a calibrated source. -
Page 38: Digital Communication
The cable is 9-pin at both the furnace and computer. The computer must have appropriate communication software installed such as Eurotherm’s ‘i-Tools’, which is available from Carbolite. 11.1 RS232 communication addressing:... -
Page 39: Maintenance
12.3 Regular microwave safety checks Regular checks should be made for levels of microwave leakage, Carbolite recommends a weekly check. Areas to check are; around the door edge, door handle recesses, across the top, fan inlets and exhausts, around the edge of the back panel. The maximum allowable level of leakage is 5mW/cm2 when measured in accordance with BS EN 60519-6:2002 part 6.1. -
Page 40: O Ther Electrical Components
The thermocouples can not be calibrated in the MRF 16/22. The thermocouples must be removed and calibrated by comparison. MF 55-GB 1.21... -
Page 41: M Icrowave Power Determination
A telephone call or fax often enables a fault to be diagnosed and the necessary spare part despatched. Each furnace has its own record card at Carbolite. In all correspondence please quote the serial number, model type and voltage given on the rating label of the furnace. The serial number and model type are also given on the front of this booklet when supplied with a furnace. -
Page 42: Access Panels
MRF 16/22 13 Repairs & replacements 13.1 Safety warning – disconnection from supply Always ensure that the furnace is disconnected from the supply before repair work is carried out. Note: the Instrument switch on the front panel does not isolate the furnace from the supply. -
Page 43: T Emperature Controller Replacement
Fig 14.1 Access panels 13.4 Temperature controller replacement Ease apart the two tabs on the sides; grip the instrument and withdraw it from its sleeve; push in the replacement. Contact Carbolite for a replacement controller correctly configured for this product. MF 55-GB 1.21... -
Page 44: Internal Fuses
MRF 16/22 13.5 Fuse sizes and fuse replacement Access to fuses for the heating elements and supply to the microwave circuit is by removal of the left side cover [See figure 13.31]. Internal Fuses Power Phase Thyristor Microwave Aux Fuse... -
Page 45: Thermocouple And Sheath Assembly
4 screws from the flange of the thermocouple and sheath assembly, (ref fig 13-3) and remove from MRF 16/22. Undo and remove the sheath fixing nut. Note the distance from the sheath end to the split compression rings then remove the split compression rings from the sheath using a flat MF 55-GB 1.21... -
Page 46: E Lement Replacement
Refit the split rings onto the new sheath over the foil then insert back in to the assembly and tighten the sheath fixing nut. Fit back into the MRF 16/22 and connect up the thermocouples observing the colour coding, ensure that the thermocouples are not twisted as they are being inserted. -
Page 47: Element Assembly Parts
If fitted incorrectly, or if not all 12 bolts are replaced then microwave leakage may occur. Contact Carbolite if in doubt. Replace the ferrite cores. Connect the braids according to your notes (and photographs) taken earlier, using the clip tool provided. It helps to pinch the braid on with a pair of long nosed pliers. -
Page 48: E Lement M Ica W Asher R Eplacement
Withdraw the element and brass assemblies from the aluminium plate. The bottom mica washers can now be removed. Contact Carbolite for spare mica washers. Replacement of the washers is the reverse of this procedure. Refer to section 13.8 –... -
Page 49: Fault Analysis
Check 1: A visual inspection of the is ON failed elements inside the chamber for signs of failure Check 2: Isolate the MRF 16/22 from the electrical supply; disconnect the element circuit from the transformer secondary windings, check the continuity of the element circuit. -
Page 50: Environment
Microwave faults For any microwave faults, contact Carbolite at the address given at the back of this manual. 15 Environment The furnace contains electrical parts and should be stored and used indoors in conditions as follows: Temperature: 5°C - 40°C... -
Page 51: Glossary Of Terms
MRF 16/22 17 Glossary of terms Interrupts a program to run another program, then returns to Call continue Dwell Time period during which the PSP is fixed. Element The heating device used in the furnace or oven. A segment type to end a program by either: Going into Reset and controlling to the SP. - Page 52 MRF 16/22 The products covered in this manual are only a small part of the wide range of ovens, chamber furnaces and tube furnaces manufactured by Carbolite for laboratory and industrial use. For further details of our standard or custom built products please contact us at the address below, or ask your nearest stockist.