ATS Pyro-Clean User manual
MAN - Pyrolytic Oven - REV: Original
Pyrolytic Oven
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
MAN - Pyrolytic Oven - REV: Original
REVISED AUGUST 2018
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 2018
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.
iMAN - Pyrolytic Oven - REV: Original
Manual Contents
A. Introduction................................................................................................................................ 1
A.1 Unpacking........................................................................................................................................................... 1
A.2 Warranty Information .......................................................................................................................................... 1
A.3 After Sale Support .............................................................................................................................................. 1
A.4 Declaration of Conformity ................................................................................................................................... 2
B. Safety .......................................................................................................................................... 3
B.1 For Owners, Operators, and Maintenance ......................................................................................................... 3
B.2 Safety Instructions .............................................................................................................................................. 3
B.3 Warnings............................................................................................................................................................. 3
C. System Overview ....................................................................................................................... 6
C.1 Equipment Parts................................................................................................................................................. 6
Front of Unit ................................................................................................................................................. 6
Back of Unit.................................................................................................................................................. 7
C.2 General Overview............................................................................................................................................... 8
Use............................................................................................................................................................... 8
How it Works................................................................................................................................................ 8
Parts That Can Be Cleaned ......................................................................................................................... 8
Organic Residues That Can Be Cleaned..................................................................................................... 9
Organics Which Should Not be Processed.................................................................................................. 9
Automatic Cleaning Cycle ........................................................................................................................... 9
Limitations.................................................................................................................................................. 10
Cost of Operation....................................................................................................................................... 10
Training of Operators ................................................................................................................................ 10
C.3 Product Specications.......................................................................................................................................11
D. Installation................................................................................................................................ 12
D.1 Installation Overview ........................................................................................................................................ 12
D.2 Receiving ......................................................................................................................................................... 12
D.3 Electrical Service.............................................................................................................................................. 13
D.4 Installing Unit with Tilt....................................................................................................................................... 13
D.5 Location and Venting........................................................................................................................................ 13
Venting to the Outdoors Through Wall or Roof .......................................................................................... 14
Venting to a Lab Hood or Other Negative Pressure Exhaust System ....................................................... 14
ii MAN - Pyrolytic Oven - REV: Original
D.6 How to Measure Oven Negative Pressure (Draft)............................................................................................ 15
D.7 How to Adjust to Oven Draft ............................................................................................................................. 15
D.8 Pressure Switch for Draft Inducer Blower Motor .............................................................................................. 16
E. Software Overivew................................................................................................................... 17
E.1 Software Screen Map ....................................................................................................................................... 17
E.2 Main Screen ..................................................................................................................................................... 18
Start Button ................................................................................................................................................ 18
End/Stop Button......................................................................................................................................... 18
Alarm Button .............................................................................................................................................. 18
View Button................................................................................................................................................ 18
State Status Indicator Bar .......................................................................................................................... 19
O State ..................................................................................................................................................... 19
Oxidizer Preheat ........................................................................................................................................ 19
Oven Soak ................................................................................................................................................. 20
Run Soak .................................................................................................................................................. 20
Cool Down ................................................................................................................................................. 20
Cycle Finished ........................................................................................................................................... 20
Delay Start ................................................................................................................................................. 20
E.3 View Screen...................................................................................................................................................... 21
ID................................................................................................................................................................ 21
Password ................................................................................................................................................... 21
Manual Button............................................................................................................................................ 21
Passwords Button ...................................................................................................................................... 22
Standardize Button .................................................................................................................................... 22
Settings, Language, Data, and Alarm Butons ........................................................................................... 22
Done Button ............................................................................................................................................... 22
E.4 Language Screen ............................................................................................................................................. 22
E.5 Settings Screen ................................................................................................................................................ 23
Cycle Time ................................................................................................................................................. 23
IP Address.................................................................................................................................................. 23
Current Time .............................................................................................................................................. 23
Preheat Delay ............................................................................................................................................ 23
Done Button ............................................................................................................................................... 24
E.6 Manual Screen .................................................................................................................................... 24
Six Buttons Across Top of Screen.............................................................................................................. 24
Four Indicators on the Left Side................................................................................................................. 24
Values on the Right Side............................................................................................................................ 24
Set Point for Both Oven and Oxidizer Chamber ........................................................................................ 24
Current Draft .............................................................................................................................................. 25
iiiMAN - Pyrolytic Oven - REV: Original
Done Button ............................................................................................................................................... 25
F. Operation................................................................................................................................... 26
F.1 Important Operation Notications...................................................................................................................... 26
Warnings (Yellow) ...................................................................................................................................... 26
Alarms (Orange) ........................................................................................................................................ 26
Faults (Red) ............................................................................................................................................... 26
F.2 Initial Start-Up: Empty Load .............................................................................................................................. 26
F.3 Starting a Normal Load of Dirty Glasswear or Metal Parts ............................................................................... 27
Tips on Loading.......................................................................................................................................... 27
F.4 Cycle Times for Cleaning .................................................................................................................................. 28
F.5 Cool-Down Before Removing the Glasswear or Metal Parts ............................................................................ 28
F.6 Additional Operation Precautions...................................................................................................................... 29
F.7 Operation Instructions ....................................................................................................................................... 29
G. Troubleshooting....................................................................................................................... 31
G.1 Troubleshooting Electrical Problems................................................................................................................ 31
G.2 Manual Operation to Check Electrical Operaton.............................................................................................. 31
H. Maintenance ............................................................................................................................. 32
H.1 Door Seals and Gaskets .................................................................................................................................. 32
H.2 Cleaning the Oven Trays.................................................................................................................................. 32
H.3 Removal of Ashes and Pigments ..................................................................................................................... 32
H.4 Periodic Empty Tests & “Self-Cleaning” Cycles................................................................................................ 32
H.5 Cleaning of Draft Inducer Fan .......................................................................................................................... 32
H.6 Replacement of Parts....................................................................................................................................... 33
Every Six Months ....................................................................................................................................... 33
Every Twelve Months ................................................................................................................................. 34
H.7 Spare Parts List................................................................................................................................................ 34
H.8 New HMI Software ........................................................................................................................................... 35
Appendix A: Warranty .................................................................................................................. 37
Appendix B: Wiring Diagrams..................................................................................................... 38
Appendix C: Image Glossary....................................................................................................... 44
MAN - Pyrolytic Oven - REV: Original | A. Introduction 1
A. Introduction
A.1 Unpacking
Retain all cartons and packing materials until the unit is operated and found to be in good condition. If damage has
occurred during shipping, notify Applied Test Systems (ATS) and the carrier immediately. If it is necessary to le a
damage claim, retain the packing materials for inspection by the carrier.
A.2 Warranty Information
All new ATS systems are shipped with a warranty. Units have a warranty against defective parts and workmanship
for one full year from the date of shipment. Please see APPENDIX A of this manual for complete details on the
warranty.
A.3 After Sale Support
If there are any questions concerning the operation of the unit or software, contact the ATS Service Department at
+1-724-283-1212.
Before calling, please obtain the software revision number and the serial number from the unit’s data tag. A sample
data tag is illustrated below, and can be completed with the unit’s information for easy reference. Please be
prepared to give a complete description of the problem to the ATS Service Department.
Figure A.1: ATS Sample Data Tag
MAN - Pyrolytic Oven - REV: Original | A. Introduction2
A.4 Declaration of Conformity
We hereby declare under our sole responsibility that this product conforms to the technical requirements of the
following standards:
EMC: EN 61000-3-2, EN 61000-3-3, EN 61326-1
Limits for harmonic current emissions (OV134510-33 only) Limits for voltage uctuations and icker (OV134510-33
only)
Electrical equipment for measurement, control, and laboratory use; Part I: Generic Requirements
Safety: EN 61010-1, EN 61010-2-010
Safety requirements for electrical equipment for measurement, control, and laboratory use; Part I: General
Requirements.
Part II: Particular requirements for laboratory equipment for the heating of materials per the provisions of the
Electromagnetic Compatibility Directive 89/336/EEC as amended by 92/31/EEC and 93/68/EEC, and per the
provisions of the Low Voltage Directive 73/23/EEC, as amended by 93/68/EEC.
Copies of the Declaration of Conformity are available upon request.
MAN - Pyrolytic Oven - REV: Original | B. Safety 3
B. Safety
B.1 For Owners, Operators, and Maintenance
All ATS equipment is designed to be operated with the highest level of safety. 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 the ATS
Service Department at +1-724-283-1212.
Read and follow these important instructions. Failure to observe these instructions can result in permanent damage
to the unit, signicant property damage, personal injury or death.
B.2 Safety Instructions
Your Pyrolytic Oven has been designed with function, reliability, and safety in mind. It is the user’s responsibility
to install it in conformance with local electrical codes. For safe operation, please pay attention to the alert boxes
throughout the manual.
WARNING: Warnings alert you to a possibility of personal injury.
CAUTION: Cautions alert you to a possibility of damage to the equipment.
NOTE: Notes alert you to pertinent facts and conditions.
HOT SURFACE: This symbol alerts you to a possibility of personal injury if you come in contact
with a surface during use or for a period of time after use.
ELECTRICAL SHOCK: This symbol alerts you to a possibility of personal injury due to live
electrical components which may be exposed inside of the cover or unit.
B.3 Warnings
The following statements are WARNING statements. Unlike CAUTION statements, WARNING statements alert the
operator to conditions that may injure personnel. Operators must be aware of these conditions in order to prevent
injuries that may occur while operating this equipment.
MAN - Pyrolytic Oven - REV: Original | B. Safety4
WARNING: To avoid electrical shock, this furnace must use a properly grounded electrical supply
of correct voltage and current handling capacity, and be disconnected from the power supply
prior to maintenance and servicing.
WARNING: To avoid personal injury do not use in Class I, II, or Ill locations as dened by the
National Electrical Code.
WARNING: Do not use in the presence of ammable or combustible materials; re or explosion
may result. This device contains components which may ignite such materials.
WARNING: Do not put sealed containers in oven.
WARNING: Refer servicing to qualied personnel.
WARNING: THIS PRODUCT CONTAINS REFRACTORY CERAMIC, REFRACTORY
CERAMIC FIBER OR FIBERGLASS (GLASS WOOL) INSULATION WHICH CAN PRODUCE
RESPIRABLE FIBERS AND DUST WHEN HANDLED. THESE FIBERS OR DUSTS CAN
CAUSE IRRITATION AND CAN AGGRAVATE PRE-EXISTING RES PIRATORY DISEASE.
REFRACTORY CERAM IC INSULATIONS MAY CONTAIN OR MAY FORM CRYSTALLINE
SILICA (CRYSTO BALITE) WHICH MAY CAUSE LUNG DAMAGE (SILICOSIS).
THE INTERNATIONAL AGENCY FOR RESEARCH ON CANCER (!ARC) HAS CLASSIFIED
REFRACTORY CERAMIC FIBER AND FIBERGLASS AS {28) POSSIBLY CARCINOGENIC.
!ARC HAS CLASSIFIED CRYSTALLINE SILICA AS (2A) PROBABLY CARCINOGENIC.
The insulating materials are located in the door, the hearth collar, in the chamber of the product
or the top plate assembly. Tests performed by the manufacturer indicate that there is no
signicant risk of exposure to dust or respirable bers resulting from operation of this equipment
under normal conditions. However, there may be a risk of exposure to respirable dusts or
bers when repairing or maintaining the insulating materials, or when otherwise disturbing the
materials in a manner which causes release of dust or bers therefrom. Through the use of
proper handling procedures you can work safely with these insulating materials and minimize
any exposure.
Accordingly, before you repair or replace any insulating materials, or perform any other servicing
on this product which could disturb or cause exposure to dust from insulating materials, you
should consult the appropriate Material Safety Data Sheets (MSDS’s) for such products with
respect to proper handling and appropriate protective equipment. For additional MSDS’s, or
additional information concerning the handling of refractory ceramic products, please contact the
ATS Service Department at +1-724-283-1212.
WARNING: This warning is presented for compliance with California Proposition 65 and other
regulatory agencies and only applies to the insulation in this product. This product contains
refractory ceramic, refractory ceramic ber or ber glass insulation, which can produce respirable
dust or bers during disassembly. Dust or bers can cause irritation and can aggravate pre-
existing respiratory diseases. Refractory ceramic and refractory ceramic bers (after reaching
1000°C) contain crystalline silica, which can cause lung damage (silicosis). The International
MAN - Pyrolytic Oven - REV: Original | B. Safety 5
Agency for Research on Cancer (IARC) has classied refractory ceramic ber and berglass as
possibly carcinogenic (Group 28), and crystalline silica as carcinogenic to humans (Group 1).
The insulating materials can be located in the door, the hearth collar, in the chamber of the
product or under the hot plate top.
Tests performed by the manufacturer indicate that there is no risk of exposure to dust or
respirable bers resulting from operation of this product under normal conditions. However, there
may be a risk of exposure to respirable dust or bers when repairing or maintaining the insulating
materials, or when otherwise disturbing them in a manner which causes release of dust or
bers. By using proper handling procedures and protective equipment you can work safely with
these insulating materials and minimize any exposure. Refer to the appropriate Material Safety
Data Sheets (MSDS) for information regarding proper handling and recommended protective
equipment. For additional MSDS copies, or additional information concerning the handling of
refractory ceramic products, please contact ATS Service Department at +1-724-283-1212.
6MAN - Pyrolytic Oven - REV: Original | C. System Overview
C. System Overview
C.1 Equipment Parts
Front of Unit
Figure C.1: Pyrolytic Oven Front
1. Draft Inducer
2. Oxidizer Chamber
3. Blow-O Door
4. Oven Chamber
5. Electrical Box
6. Power Light
7. HMI Touch Screen
8. USB Port
9. Power Switch
5
3
1
2
7
6
4
8
9
MAN - Pyrolytic Oven - REV: Original | C. System Overview 7
Back of Unit
1. Draft Inducer
2. Oxidizer Chamber
3. Oven Chamber
4. Electrical Control Box
5. Air Intake Filter
6. Ethernet Port
7. Draft Inducer Power Outlet
8. Power Cord
Figure C.2: Pyrolytic Oven (Rear View)
1
2
3
4
5
6
7
8
8MAN - Pyrolytic Oven - REV: Original | C. System Overview
C.2 General Overview
Use
The Pyrolytic Oven is designed to clean glass or metal parts contaminated with residues of various organic
substances such as polymers, waxes, resins, asphalts, tars, or other similar contaminants. Cleaning is done entirely
with heat, eliminating the use of solvent or chemical cleaning. Organic residues are thermally decomposed and
vaporized from glass or metal parts at 900 degrees F. Virtually all types of heat-resistant glass and metal parts can
be cleaned in the oven. As long as the heat will not hurt the parts being cleaned, and the residues to be removed
are organic and can be removed thermally, the Pyrolytic Oven is a suitable alternative to solvent and chemical
cleaning methods.
How it Works
1. Heat Decomposes and Vaporizes Organic Residues from the Glass or Metal Parts
The Pyrolytic Oven is a high-temperature oven capable of operating at 800-1000 degrees F. This temperature is
sucient to thermally decompose (vaporize) most polymeric residues and other organic material to volatile gases
and carbonized residues without harming the glass or metal parts. The pyrolysis smoke and gases produced by
degradation of the organic residues reacts with a catalyst suspended in stainless steel wire mesh which comprise of
two racks (trays) inside the oven chamber. If sucient smoke or pyrolysis gases are produced inside the oven, the
oxidation of this smoke will consume oxygen inside the oven and actually inert the oven to a very low oxygen level of
one to two percent.
2. Pyrolysis Smoke and Gases are consumed by Electric/Catalytic Oxidizer (Afterburner)
Any un-reacted pyrolysis products formed inside the oven exit through a pipe at the top of the oven and passes
through a small Oxidizer chamber which sits on top of the oven. The Oxidizer is a combination electric/catalytic
system which preheats the oven exhaust gases to 1300-1500 degrees F with excess air before they pass through a
honeycomb ceramic catalyst which completes any oxidation not occurring in the preheat zone of the chamber. This
pollution control method is very eective at destroying any smoke and odor produced during the cleaning process.
The exhaust gases from the oxidizer chamber are mixed with fresh air, resulting in a pollution-free exhaust at
temperatures of 130-160 degrees F.
3. Final Cleaning is accomplished by the Oxidation Stage.
The heat-cleaning process actually consists of two distinct stages. The rst stage is the pyrolysis stage described
above. The second stage consists of oxidation of any carbonized residues produced during the rst, pyrolysis stage.
Virtually all organic materials produce some soot-like, carbon residues on thermal decomposition. Injecting air into
the 950 degree F oven chamber during the nal cleaning stage oxidizes carbon residues, leaving the glassware or
metal parts completely free of any organic matter. Ash or other inorganic material is left behind) on the parts and
can be washed o with water.
Parts That Can Be Cleaned
Any part which the normal cleaning temperature of 800-950°F will not hurt can be cleaned in the oven. Laboratory
glassware, particularly the heat resistant types are easily cleaned without damage or distortion. Ceramic parts
which can tolerate the heat can also be cleaned.
MAN - Pyrolytic Oven - REV: Original | C. System Overview 9
Organic Residues That Can Be Cleaned
Virtually any contaminant which is organic in nature can be removed at the normal operating temperature of the
cleaning oven, 950 degrees F. In recent years, new high temperature polymers have been developed which are very
resistant to heat and are not easily removed thermally. However, the numbers of these polymers are limited.
Organics Which Should Not be Processed
Plastics or polymers which contain large amounts of halogens such as chlorine, bromine, or Florine would not be
processed in the oven as they will react with the catalyst contained inside the oven trays and deactivate it. The
most common example of this plastic is PVC (polyvinyl chloride). The oven Oxidizer is designed to handle organic
residues which contain predominantly only carbon, hydrogen, and oxygen. Do not process any parts which may
emit vapors of toxic metals such as lead or mercury. Do not process any material which decomposes violently upon
heating. Nitrocellulose or other explosive materials are in this category.
Never clean any hollow, sealed glass or metal parts which might build up dangerous, internal pressures during the
heating cycle. Make sure all parts have vent holes or openings to allow pyrolysis gases or steam to escape as they
are formed. Any pumps, pipes, or vessels must have openings to allow pyrolysis gases to escape, otherwise they
could rupture in an explosion.
WARNING: NEVER PLACE GLASSWARE OR OTHER PARTS IN THE OVEN WHICH
CONTAINS RESIDUES OF VOLATILE, FLAMMABLE SOLVENTS SUCH AS ACTONE,
TOLUENE, MINERAL SPIRITS, MEK, ETC., AS THEY WILL FORM AN EXPLOSIVE MIXTURE
INSIDE THE OVEN CHAMBER.
SPECIAL NOTE REGARDING SILICONES: Silicone oil is commonly used in many
laboratories as a heating medium for carrying out reactions in glass vessels. Glassware which
contains silicone oil residues from the heating medium should be wiped o with a cloth or paper
towels or rinsed with acetone. Experience has shown that when silicone polymers are removed
in the oven, they leave a “cloudy” residue which etches the glassware and aects it appearance.
A round bottomed ask coated on the outside with silicone heating oil will be cloudy if cleaned in
the oven without removing the silicone. Glass stopcocks lubricated with silicone grease should
likewise be wiped free of silicone before cleaning the glassware in the oven.
Silicones are poisons for the catalysts used both in the oven chamber and the catalyst used in
the afterburner and should not be removed in the oven.
Automatic Cleaning Cycle
The Pyrolytic Oven is equipped with an Automatic Cycle Time Feature which adjusts itself to the load placed in the
oven. The cleaning time is limited by the processing speed of the oxidizer. The more organic residues or polymers
on the parts, the more smoke that will be evolved o the parts during the thermal cleaning process. The oxidizer
is equipped with a temperature sensor and controller which monitors the amount of smoke evolved o the parts
and controls the heatup rate of the oven to prevent the oxidizer from being overwhelmed by too much smoke. The
oxidizer control system will cut o the oven heaters if too much smoke is being produced. The oven temperature
seeks whatever temperature is necessary to produce the maximum amount of smoke the oxidizer can process.
Thus the oxidizer actually controls the heatup rate. When all the organic residue is pyrolyzed/vaporized o the parts
, smoke evolution will fall o, allowing the oven temperature to climb to the normal processing temperature of 950
degrees to nish the pyrolysis stage of the cleaning process.
10 MAN - Pyrolytic Oven - REV: Original | C. System Overview
For the oxidation stage, a cycle time is located on the settings screen, with an adjustable range of 1 to 1000 hours.
The Factory setting of 2 hours is recommended for most applications.
NOTE: For removing asphalts, a factory setting of 3 to 4 hours is recommended as asphalts are
among the more dicult organics to remove. Asphalts produce a carbon residue during pyrolysis
that is resistant to oxidation, therefore requires more processing time during the oxidation stage
of the cleaning cycle. Glassware should be loaded to promote drainage. This will speed up the
cleaning process.
The Cycle Time does not start until the oven temperature reaches within -10 degrees F of the set-point of the Oven
Temperature Controller.
With a normal set-point of 950 degrees F, the Cycle Time does not start timing until the oven temperature reaches
940 degrees °F. When the timer is started, the status bar will show “Run Cycle”. If the glass or metal parts does
not come clean with a 2 hour setting on the Cycle Time, then increase the time until any soot-like, carbonaceous
residues are completely removed. If cleaning times require more than 5 hours on the Cycle Time, then consult
Factory as this would be quite uncommon. (Asphalt residues are the exception).
For safety reasons, never set the Cycle Time to less than one hour. This amount of time at 950 °F should ensure
that the oven cycle does not shut down before all organic residues are evolved o as smoke or pyrolysis gases.
Limitations
Pyrolytic Ovens clean only with heat, so they cannot remove any non-volatile, inorganic residues from the parts
being cleaned. This includes paint pigments such as titanium dioxide, llers such as clay, talc, ber glass, ordinary
dirt, or any other inorganic ashes. However, such inorganic residues normally are easily removed from the glass or
metal parts by wiping o with a cloth or rinsing with water. The ashes are easy to remove because all organic resins
which act as a binder or “glue” are decomposed, freeing the inorganic material.
Cost of Operation
Cost of operation depends on the local rates for electrical power. The Pyrolytic Oven consumes a maximum of 28
amperes at 240 volt, single phase. This is 6.6 kilowatts. At a cost of 0.06 cents per KWH (our current Factory rate in
Butler, PA), operating costs would be 6.6 KWH x $0.06 = $0.40 per hour. With a typical complete cycle times of 5 to
7 hours, then cost per cleaning cycle would average about $2.00 to $ 3.00.
Training of Operators
Because the success and safety of the cleaning process is dependent upon proper loading and operation of the
Pyrolytic Oven, do not allow anyone to use the oven unless they fully understand how it works and its limitations.
Users of the oven must be cautioned against overloading the oven with glass or metal parts containing very large
amounts of organic residues. The oven is designed for removing small amounts of asphalts, organic residues, or
plastics only, from 1/4 pound up to about 2 pounds. More than 2 pounds of organic residues should not be loaded
into the oven.
MAN - Pyrolytic Oven - REV: Original | C. System Overview 11
C.3 Product Specications
Environmental
Conditions
Operating: 17°C to 27°C; 20% to 80% relative humidity, non-condensing.
Installation Category II (overvoltage) in accordance with IEC 664. Pollution
Degree 2 in accordance with IEC 664.
Altitude Limit 2,000 Meters
Storage -25°C to 65°C; 10% to 85% relative humidity
Cleaning Temperature 800 – 950°F
Burno Temperature Approximately 1300°F
Electrical Power 240 V, 60 Hz., Single Phase
Safety Controls High temp switch on both oven and oxidizer
Weight 380 lbs.
Exterior Dimensions 37.85” wide x 59.3” high x 32.8” deep
Oven Capacity 14.88” wide x 16” high x 18.5” deep (2.5 cubic foot)
Construction Stainless Steel, welded interior, dual gasket system, pressure release door
MAN - Pyrolytic Oven - REV: Original | D. Installation12
D. Installation
D.1 Installation Overview
WARNING: Do not use in Class I, II or Ill locations as dened by the National Electrical Code.
CAUTION: Be sure ambient temperature does not exceed 104°F (40°C). Ambient above this
level may result in damage to controller.
NOTE: Allow at least 4 inches of space between the oven and any vertical surfaces.
NOTE: Pyro-Clean ovens are supplied with a power cord but not a plug. The plug will need to
handle 240Vac @ 30A.
WARNING: Use a properly grounded electrical outlet of correct voltage and current handling
capacity.
NOTE: Disconnect from the power supply prior to maintenance and servicing. Refer servicing to
qualied personnel.
WARNING: Do not use in the presence of ammable or combustible materials; re or explosion
may result. This device contains components which may ignite such material
NOTE: Do not put sealed containers in oven.
NOTE: A 30 amp breaker is recommended because the total load of the oven is 28 amps.
D.2 Receiving
The Pyrolytic Oven is shipped completely assembled and crated. Inspect the oven crate and any other additional
boxes or crates carefully upon receipt. If there is any sign of damage to the crate or oven, do not sign the delivery
receipt until the freight company has been notied and such damage has been noted on the receipt. Claims for
shipping damage must be made by the customer to the Freight Company and not to the distributor or manufacturer.
Remove the crate lumber carefully to avoid damaging or scratching the surface of the oven. The Pyrolytic Oven
weighs about 400 pounds crated and can be moved with a fork truck or heavy dolly while crated. Uncrated, the
oven weights slightly over 350 pounds and can be moved by hand with sucient help. Avoid excessive leverage on
MAN - Pyrolytic Oven - REV: Original | D. Installation 13
the door to prevent from bending or spraining its hinges. Use heavy gloves or other protection to prevent cutting or
slicing your hands when lifting on the oven. The door is removable if necessary by removing its hinges.
A draft inducer is wrapped in protective bubble wrap and is packed on top of the oven. After the oven is uncrated
and in position, the draft inducer should be attached to the top of the exhaust port on top of the oven Oxidizer as
shown in the attached photograph. A small section of 1/4 inch aluminum tubing is used to sense the pressure of the
Draft Inducer blower motor.
NOTE: THIS CONNECTION MUST BE MADE AS THE OVEN HEATERS ARE INTERLOCKED
TO THIS PRESSURE SWITCH. THE OVEN HEATERS CANNOT COME ON UNTIL THE
PRESSURE SWITCH CLOSES AS THE BLOWER MOTOR RUNS.
Exhaust gases from the draft inducer must be vented outdoors. Proper venting is very critical. Refer to this section in
later paragraphs.
D.3 Electrical Service
The oven has been completely tested and checked at ATS before shipment. A power cord 10 feet long is supplied
with the oven. You will need to supply a plug and receptacle for 30 amp, 240 volt, single phase. The total power use
of the Pyrolytic Oven unit is about 6600 watts. The oven heaters draw about 16.7 amperes at 240 volts, and the
afterburner heater draws about 9.7 amps at 240 volts. The oven control circuit is 24Vdc and supplied by a 180W
power supply. The oven should be connected to its own separate, 30 amp circuit breaker, and should be clearly
labeled to prevent accidental shut-down of the oven if it is located in a breaker box where personnel routinely shut
o lights or other equipment by using the breakers. Power should be available to the oven at all times except when
it requires electrical service. The power plug should be pulled or the circuit breaker turned o and locked out when
work is necessary inside the control box.
D.4 Installing Unit with Tilt
Rather than install the oven on a level basis, we recommend installing the oven so the front of the unit is about
1/2 to 3/4 inch higher than the back of the unit. The oven has 4 adjustable legs so this small front-to-back tilt is
easily achieved. This front elevation of the unit helps to prevent any liquid residues that might miss the drain pan
on the bottom of the unit from owing out onto the bottom of the door gaskets. Instead any material that degrades
and ows should drain toward the back of the oven interior, which is welded solid. The owable material will be
destroyed during the cleaning cycle, rather than draining out of the gaskets and bottom of the unit.
D.5 Location and Venting
CAUTION: Pyrolytic Ovens are not “ordinary” industrial ovens and have special venting
requirements which must be met Read and follow the guidelines given in the following sections
carefully. Consult ATS if you have any questions.
MAN - Pyrolytic Oven - REV: Original | D. Installation14
For the oven to work properly and safely, it must be correctly vented. Standard double walled vent pipe (6 inch I.D.)
should be used. Long runs and runs with excessive elbows should be avoided to minimize friction losses to achieve
the correct draft. In most cases, long runs of exible vent hose or pipe should not be used as it will often result in
very high friction losses, preventing you from getting an acceptable draft.
However, a small section of exible six inch duct (6 to 8 inches long) is strongly recommended to allow the Draft
Inducer to be removed and replaced for nal adjustment of the draft as seen in Section D.7.
The preferred place for this piece of exible pipe is between the rigid 6 inch duct pipe and the 6 inch side of the 4 to
6 inch adapter which connects to the top of the Draft inducer. The draft inducer located on top of the oven generates
a negative pressure of about 0.02 to 0.06 inches water column before any vent pipe is added to the exhaust of the
draft inducer. It is extremely important that the nal draft achieved on the oven when in operation range from 0.02 to
0.06 inches water column. The nal duct pipe and venting arrangement must achieve this result, regardless of the
specics of how the oven is ducted. Some general guidelines for various possible installations are discussed below.
If There Are Any Questions Regarding Venting Of The Oven, Consult ATS For Recommendations For Your Specic
Location And Circumstances.
For convenience, the system will allow you to turn on the draft inducer and see the current draft. See the “Manual
Screen” section of this manual, but please consult ATS if uncertain how to measure the small negative pressures
required by Pyrolytic Ovens.
Venting to the Outdoors Through Wall or Roof
Standard 6 inch I.D., double walled vent pipe should be used for venting to outdoors for best results. The exhaust
temperature of the gases ranges from 120 to 150 degrees F, so is not much hotter than the exhaust from a clothes
dryer or other low-heat appliance. Elbows can be used, but should be kept to a minimum to prevent excessive
friction losses. Because the Draft Inducer diameter is 4 inch, an adapter to go from 4 to 6 inch duct is necessary.
This adapter is commonly available from most heat/air conditioning supply houses. A non-restricting vent hood or
cap should be used to prevent rain from entering the exhaust pipe.
Regardless of the nal physical arrangement of the vent pipe and cap, it should not decrease the draft below 0.02
inch w.c. and should not increase it over 0.06 inch w.c.
If your venting arrangement to the outdoors gives insucient draft, then means to achieve the proper draft must be
supplied, by an additional powered draft inducer or otherwise. Again, it must be emphasized that if the oven exhaust
pipe is connected to a device capable of pulling a high draft (negative pressure), then the pressure must be adjusted
so it is not too high!
Venting to a Lab Hood or Other Negative Pressure Exhaust System
The Pyro-Clean oven requires a small negative pressure of about 0.04 inches water column to work correctly.
Connection of the vent pipe system of the oven to a lab hood or vent system is recommended and acceptable as
long as the nal measured draft of the oven itself is in the proper range of 0.02 to 0.06 inches w.c.
Do not pipe the oven exhaust directly into the duct work itself of a powered exhaust system, as the suction (negative
pressure) may be too strong to permit adjustment to the slight negative pressures required.
MAN - Pyrolytic Oven - REV: Original | D. Installation 15
CAUTION: IF THE OVEN IS EXHAUSTED INTO A POWERED VENT SYSTEM SUCH AS A LAB
HOOD, THE HOOD EXHAUST SYSTEM SHOULD BE ON ALL THE TIME THAT THE OVEN IS
ON. DO NOT LEAVE THE BUILDING AND SHUT OFF THE HOOD, THEREBY SHUTTING OFF
THE EXHAUST SYSTEM FOR THE OVEN.
WARNING: Draft Inducer must be installed as shown with the ¼” metal tubing connected so that
the Pressure Switch located inside the control box can sense the pressure of the Draft Inducer
Blower Motor. The Blower Motor is interlocked via the Pressure Switch so that the Oven Heaters
cannot come on unless the Draft Inducer Blower Motor runs.
If the Blower Motor fails, the Pressure Switch will sense the loss of fan pressure and shut o the oven heater
elements and give an alarm fault to the operator.
D.6 How to Measure Oven Negative Pressure (Draft)
1. Go to the “Manual Screen” (see “manual screen” section). Observe whether the oven exhibits any draft due
strictly to the installed exhaust piping. For example, connection to a hood exhaust might pull a slight negative
pressure dependent on the power of the hood system itself.
2. Press the “Draft Inducer” button momentarily to start the oven exhaust blower, and observe the negative pressure
achieved inside the oven. The optimum draft is 0.04 inches w.c., and the necessary range is from 0.02 to 0.06
inches w.c. If the exhaust system/duct to which the oven is piped pulls a draft higher than 0.06 inches, then the oven
exhaust must be adjusted until the correct draft is achieved. The oven draft has been factory adjusted with the draft
inducer running without any exhaust stack. Adding stack to the top of the Draft Inducer will change the draft slightly,
but it still should remain in the proper range.
3. Once the oven exhaust has been properly installed and checked, press the “Draft Inducer” button momentarily to
stop the oven exhaust.
CAUTION: DO NOT END A CLEANING CYCLE BY TURNING OFF THE MAIN POWER
TOGGLE SWITCH. THIS PREVENTS THE MAIN OVEN EXHAUST FAN FROM RUNNING TO
REMOVE THE NORMAL HEAT PRESENT DURING COOL-DOWN. IT WILL ALSO UNLOCK
THE DOOR BEFORE COOL DOWN WHICH MAY INTRODUCE AN EXPLOSIVE SITUATION IF
THE DOOR IS OPENED.
D.7 How to Adjust to Oven Draft
Once the Pyrolytic Oven unit is installed and vented, the oven draft should be measured as described in previous
sections. If the draft is not within proper limits, then it must be adjusted. Oven draft is achieved by the venturi eect
of air sucked around the Oxidizer exhaust pipe. See Figure 1. The Draft Inducer suction pulls air past and around
the stainless steel exhaust pipe.
TO INCREASE OVEN DRAFT, THE HEIGHT OF THE EXHAUST PIPE IS INCREASED. TO LOWER OVEN
DRAFT, THE HEIGHT OF THE EXHAUST PIPE IS DECREASED.
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