ATS 31 Series User manual

FURNACE
Model Number: 31XX, 32XX
INSTRUCTION MANUAL
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

Applied Test Systems
REVISED MAY 2017
Information in this document is subject to change without notice and does not represent a
commitment on the part of 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: [phone].

www.atspa.com i
MANUAL CONTENTS
A. Safety........................................................................................................................ 1
A.1 Owners, Operators, and Maintenance.......................................................................1
A.2 Environmental Conditions........................................................................................
3
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. Pre-Operation Instructions ..................................................................................... 8
D.1 Furnace Bake-Out .................................................................................................8
E. Temperature Controller ........................................................................................... 9
E.1 Temperature Controller Overview.............................................................................9
E.2 Temperature Controller Installation ..........................................................................9
E.3 Temperature Controller Operation ......................................................................... 10
E.4 Over-Temperature Option ..................................................................................... 10
F. Furnace Operation ................................................................................................. 12
G. Furnace and Element Maintenance ..................................................................... 13
G.1 Preventative Maintenance .................................................................................... 13

ii Applied Test Systems
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 – 3150 ................................................................... 19
Removing Side Elements – 3160 ....................................................................... 19
Removing Rear Elements – 3160 ....................................................................... 19
Replacement and Reassembly ........................................................................... 19
H. Temperature Controller Maintenance .................................................................. 21
H.1 Preventative Maintenance .................................................................................... 21
I. Troubleshooting ...................................................................................................... 22
I.1 Controller Does Not Operate.................................................................................. 22
I.2 Over-Temperature................................................................................................ 23
I.3 Under-Temperature .............................................................................................. 24
APPENDIX A: Safety Data Sheet Information .......................................................... 25
APPENDIX B: Warranty.............................................................................................. 46

Series 31XX, 32XX Furnaces | A. Safety 1
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.
In addition to the safety warnings listed here, warnings are posted throughout the
manual. Read and follow these important instructions. Failure to observe these
instructions can result in permanent damage to the unit, signicant property damage,
personal injury, or death.
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.
Thoroughly understand the safety features and operation of the
equipment. This manual will provide operators with safety concerns and
general procedures. Be familiar with correct operating principles and
use good judgment. Also refer to the appropriate manuals for system
component safety instruction manuals.
Use caution when working with elements at elevated temperatures.
Prevent burns by wearing protective clothing, and follow safety, operation,
and maintenance procedures described in the appropriate instruction
manuals.
Avoid radiating heat. Items with a large mass retain heat for a long time.
First-degree burns may occur from heat radiation as well as from direct
contact with a hot surface.
Obey all national and local electric code requirements. Furnaces and
control systems must be grounded and wired according to national and

2Series 31XX, 32XX Furnaces | A. Safety
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.
Dangerous high voltages present. Do not attempt to open the enclosure
or gain access to areas where you are not instructed to do so. Refer
servicing to qualied service personnel only.
Caution - Injury to the operator could occur if operational procedures are
not followed. Follow all steps or procedures as instructed and refer to
accompanying documents.
Ventilation – Slots and openings in the cabinet are provided for ventilation
and to ensure reliable operation of the product. To protect the unit from
overheating, those openings must not be blocked or covered. This product
should not be placed in a built-in installation, such as a wall cut-out unless
proper ventilation is provided. Hot temperatures will result.
Refer to manual. Before tuning the temperature controller, be sure to read
and understand the tuning instructions in the controller manual. Follow all
operating and other instructions carefully.
If it should become necessary to clean this equipment, disconnect the unit
from its power source rst. Do not use liquid cleaners, aerosols, abrasive
pads, scouring powders or solvents, such as benzene or alcohol. Use a
soft cloth lightly moistened with a mild detergent solution. Ensure the
surface cleaned is fully dry before reconnecting power.
Do not attempt to operate the temperature control system in ambient
temperatures higher then 120° F (49° C) without providing a cooling fan
or air conditioning.

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.
When changing fuses in current limiting power controllers, use only the
fuse type and size specied by the power controller manufacturer.
Use interconnecting cables of the proper gauge to match the ratings on
the data labels for the furnace and controller.
Do not connect any measuring or controlling devices to the thermocouple
other than the main temperature controller.
Use thermocouple extension wires and connectors that match the
thermocouple type being used. Use of copper wires will cause errors in
readings and result in faulty control.
Do not allow the bare thermocouple wires or any part of the thermocouple
to come in contact with other metals. This could induce incorrect voltages
and result in erroneous readings and faulty control.
A.2 Environmental Conditions
The furnace is meant for use in laboratory/factory settings in a dry, clean work
environment. There should be a clean and sturdy work surface both at a reasonable
working height and away from any water, gas, or electrical hazards. The work surface
should be able to support more than the weight of the unit itself. The indoor area should
be well ventilated and containing no open ames or materials that may constitute a re
hazard.
• Temperature of 15° C to 35° C
• Relative humidity not more than 75%
• Air pressure of 75 kPa to 106 kPa
• No hard-frost, dew, percolating water rain, solar irradiation, etc.
Series 31XX, 32XX Furnaces | A. Safety 3

4Series 31XX, 32XX Furnaces | A. Safety
• Installation category II
• Pollution degree 2

Series 31XX, 32XX Furnaces | B. Introduction 5
B. Introduction
B.1 Unpacking
Retain all cartons and packaging materials until the unit is operated and found to be in
good condition. If damage has occurred during shipping, notify Applied Test Systems
and the carrier immediately. If it is necessary to le a damage claim, retain the packing
materials for inspection by the carrier.
B.2 After Sale Support
When you receive your equipment, copy your data label information onto the data
label template below (Figure B.1). Doing this will ensure you will have the appropriate
information for your records.
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

6Series 31XX, 32XX Furnaces | C. 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 specic furnace type. The installation
of the equipment must be performed by a qualied and licensed electrician in accordance
with National Electric code and local codes.
C.2 Positioning and Connecting
The following procedure describes how to position and connect an ATS Furnace that
is equipped with leg levelers. For furnaces that are mounted to a test machine or are
mounted using a test bracket, refer to appropriate mounting drawings.
1. Carefully remove the shipping crate and packing materials. Do not discard the packing
materials until all items on the invoice have been accounted for.
2. Position the furnace in the desired location.
3. If the unit did not come with a control system, skip to step 8 (p. 7).
4. The control system may or may not have a power cord supplied. If it does not, remove
the top cover of the control system to locate the power supply connection. To do this,
remove the two screws at the top of the back of the unit and slide the cover o toward
the back side. See Figure C.1 for screw location.
NOTE: Figure C.1 shows a typical control system. Not all control systems
will appear exactly the same.
Figure C.1 - Typical Control System (Back)

Series 31XX, 32XX Furnaces | C. Installation 7
5. Locate the Line Power Access Port on the center of the back side of the control system.
Determine the appropriate gauge wire by conrming 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.
7. Use the supplied interconnecting cord to connect the control system to the furnace,
along with the thermocouples. Skip to step 9.
NOTE: When attaching the green twist lock plug, make sure to push the
lock in then turn. Repeat this motion until the plug is tight.
8. Remove the terminal block cover to access the terminal block. Refer to the electrical
connection drawings to make the proper power connections.
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.
9. Connect the thermocouples to the control system. Use the thermocouple type specic
to your furnace.
CAUTION: Thermocouple extension cables and connectors must be
compatible with the thermocouple type being used.
10. Verify that the heating elements do not have any exposed wires. If sections of the
embedding are missing or there are large cracks in the embedding, refer to Section
G (p. 13) of this manual for repair instructions. Not all elements require embedding
cement.
Figure C.2 - Interior Controller - Line Power Access Port

8Series 31XX, 32XX Furnaces | D. 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
o.
NOTE: The following procedure is NOT required after replacing heating
elements only. Be sure to vent the retort during the bake-out.
CAUTION: If your furnace is equipped with sealed terminal covers, these
covers must be opened during bake-out to allow moisture to escape.
WARNING: Bake-out will produce odors and smoke. It should be
performed in a well-ventilated area.
1. If supplied with sealed terminal covers, slightly open to provide ventilation. After bake
out is complete, reseal terminal box. Heat the furnace to 400° F (205° C). Maintain
this temperature for approximately two (2) hours or until all traces of water vapor and
gases are gone, whichever takes more time.
2. When all traces of water vapor and gases are gone, increase the furnace temperature
to 1000° F (537° C), or the rated temperature of the furnace, whichever is lower. Bake
until smoke and odor are eliminated.
3. Increase the temperature to the expected operating temperature, if higher than 1000°
F (537° C). At this time, the temperature control system may be auto-tuned for
operation.
4. After the operating temperature is reached, shut o the power. With the door or end
caps closed, allow the furnace to cool 8-10 hours before opening.

Series 31XX, 32XX Furnaces | E. Temperature Controller 9
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:
• Setpoint temperature controller
• Solid state power controller
• One (1) matching control thermocouple
• Additional optional features include:
• High-limit alarms and over-temperature controllers
• SCR power controllers
• Multiple-zone independent controls
• Programmable Capabilities
The most extensive information needed to operate the system is found in the
manufacturers’ literature. It is recommended the operator read the entire manual and
become familiar with the equipment before attempting to perform any tests.
ATS temperature control systems are available in a variety of options and several
congurations. Those explained here are typical examples. Your model will dier in
appearance due to the options requested; however, the basic operating principles are the
same.
E.2 Temperature Controller Installation
1. Position the control cabinet in the desired location.
2. Connect the cables between the furnace and the control cabinet.
CAUTION: Use interconnecting cables of the proper gauge to match the
ratings on the data labels for the furnace and controller.
3. Connect the thermocouple to the control system.

10 Series 31XX, 32XX Furnaces | E. Temperature Controller
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.
5. Verify all connections are correct and in accordance with any applicable wiring codes.
E.3 Temperature Controller Operation
Although the appearance of the controllers dier, the basic operation is similar. Functional
dierences are noted in the operation sequences.
1. Turn the power “on” to the main system.
2. Turn the power “on” to the setpoint controller.
3. Bake-out the furnace according to the Pre-Operation Instructions (Section D, p.8).
4. You are now ready to tune and perform operating sequences with the controller. Refer
to the manufacturers’ literature for specic instructions.
CAUTION: Before tuning and operating the temperature controller, be sure
to read and understand the instructions in the manufacturers’ literature.
E.4 Over-Temperature Option
The over-temperature systems provide protection from over-temperature of the furnace
that may be caused by:
• Controller failure
• Shorted power controller
• Defective thermocouple
• Outside interference

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.
NOTE: All new systems require the high limit to be set before the rst
initial run. It will be necessary to press the manual reset button to
activate the system when power is turned on.
Series 31XX, 32XX Furnaces | E. Temperature Controller 11

12 Series 31XX, 32XX Furnaces | F. 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.
CAUTION: Use caution when working with elements at elevated
temperatures. Refer to the Safety Section of this manual for further safety
concerns.

Series 31XX, 32XX Furnaces | G. Furnace and Element Maintenance 13
G. Furnace and Element Maintenance
G.1 Preventative Maintenance
Once a month, ensure the thermal insulation is not damaged, cracked, or ill-tting. If the
thermal insulation is cracked, eliminate heat loss at these points by sealing cracks with a
blanket insulation of a similar temperature rating.
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 [phone].
The following tools are necessary for this procedure:
• Embedding compound powder
• Distilled water
• Tool to mix compound
1. After the furnace is in place and the leads are secure, mix the embedding compound
powder with distilled water so a paste is formed. The paste should be thin enough to go
down into the coils, but thick enough to maintain body.
2. Work the paste down into the groove, making sure it goes between the coils. Smooth
the surface and remove any excess paste.
3. After the coils are embedded, turn the power on to heat the element to approximately
200°C. This will allow the cement to dry quickly and prevents possible coil damage.
NOTE: Do not overheat the coils at this point. If necessary, turn the
power on and o in order to prevent the coils from becoming so hot they
are red. Notice that the compound texture is powdery at this time. The
compound will harden when it is brought up to operating temperature
later.

14 Series 31XX, 32XX Furnaces | G. Furnace and Element Maintenance
4. Allow the furnace to cool. Clean o any excess compound with a ne emery cloth or
sandpaper.
G.3 Element Replacement
Please use the instructions following that are specic to your furnace type. The following
tools are necessary for all element replacement procedures:
• Ohmmeter
• Wire Clippers
• Screw Driver
• Bar Clamp (optional)
• Hammer (optional)
• Punch (optional)
Before performing the element replacement procedure, carefully inspect the furnace. Plan
to replace any excessively worn or deteriorated parts that also aect furnace performance,
such as excessively-deteriorated insulation.
NOTE: Use all ceramic insulators as originally supplied to prevent
electrical short circuits. Use a voltmeter to check for short circuits before
applying power to the furnace.
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 o furnace and allow to cool completely.
2. Disconnect the power and instrumentation wiring from the furnace. If applicable,
remove the furnace from the testing machine and position the furnace on a workbench
in a suitable cradle.
WARNING: Failure to completely disconnect the furnace from the power
supply before attempting disassembly may cause personal injury or
death.

3. Remove the terminal cover. Isolate element wires from 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 element from
the terminal block. It is important to straighten or cut o the loops at the end of the
element leads in order to prevent damage to the insulation cylinder when the leads are
pulled through it.
4. Mark the shell and end anges for easy assembly alignment. Remove the end ange
closest to the burned-out element and carefully remove the end ange and end disk.
5. Carefully feed the element lead wires through the shell while removing the defective
element from its seat. Be careful not to damage the insulation.
6. If necessary, straighten the new wire
leads. Align the wires with the wire
paths in the insulation and feed the
wires through the shell by inserting
a guide tube into the wire path and
pushing the wire through the guide
tube, or by putting a string through
the hole, tying it to the wire, and
pulling it through the wire path.
7. Place the wires to maintain the
maximum distance between them.
Carefully position the element in
place. Align any ports if applicable.
Refer to Figure G.2.
Series 31XX, 32XX Furnaces | G. Furnace and Element Maintenance 15
Figure G.1 - Series 3110 Furnace Disassembly
Figure G.2 - End View of ATS Series 3110 Tube Furnace

16 Series 31XX, 32XX Furnaces | G. Furnace and Element Maintenance
8. After installing the new element, insert the thermocouple to ensure alignment.
9. Install the insulation end disk. Align the end ange with the shell and install it. If
necessary, a bar clamp can be used to gently compress the assembly enough to align
the screw holes.
10. Ensure that the leads do not short circuit against the outside case.
11. Use an ohmmeter to check for short circuits. Install the terminal block and attach
the wires. Cut o any excess wires. Check again for short circuits, and correct any
problems before completing the installation.
12. Inspect the embedding material for cracks or damage. If the embedding must be
repaired, refer to the Embedding & Patching Elements section of this manual (Section
G.2, p. 13).
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 the
furnace manual. 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
identication of parts.
1. Turn o furnace and allow to cool completely.
2. Disconnect the power and instrumentation
wiring from the furnace. If applicable, remove
the furnace from the testing machine and
position the furnace on the workbench in a
suitable cradle.
WARNING: Failure to completely
disconnect the furnace from the
power supply before attempting
disassembly may cause
personal injury or death. Figure G.3 - Series 3210 Furnace