Barnstead International 30400 Series User manual

Type 30400
Thermolyne Furnace
OPERATION MANUAL
AND PARTS LIST
Series 1262
Single Setpoint Models F30402C, 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 • 12/27/01

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
Intended Use ................................................................................................................................................8
General Usage..............................................................................................................................................8
Principles of Operation ................................................................................................................................9
Unpacking ........................................................................................................................................................10
Installation ........................................................................................................................................................11
Site Selection ..............................................................................................................................................11
Electrical Connections ................................................................................................................................11
Operation, All Models ........................................................................................................................................12
Power Switch ..............................................................................................................................................12
Cycle Light ..................................................................................................................................................12
Door Safety Switch ....................................................................................................................................12
Single Setpoint Models with OTP ....................................................................................................................13
Basic Operation ..........................................................................................................................................13
Buttons and Indicators................................................................................................................................13
To View or Change the Setpoint ................................................................................................................14
To View the Display Units ..........................................................................................................................14
To View the % Output Power......................................................................................................................14
Controller Parameters ................................................................................................................................14
Alarms ........................................................................................................................................................15
Sensor Break Protection ............................................................................................................................16
Over Temperature Protection (OTP) ..........................................................................................................16
Tuning ........................................................................................................................................................17
Single Ramp and Dwell ....................................................................................................................................18
Functions ....................................................................................................................................................18
Setting Variables ........................................................................................................................................18
Program Setup............................................................................................................................................19
Running the Program..................................................................................................................................20
Stopping the Program ................................................................................................................................20
Clearing the Flashing End ..........................................................................................................................20
Switching from Manual Mode to Automatic Mode ......................................................................................20
Verifying a Running Program......................................................................................................................20
8 Segment & 4x16 Segment Programmable Models w/OTP............................................................................21
Basic Operation ..........................................................................................................................................21
To Change the Setpoint ..............................................................................................................................21
To View the Display Units ..........................................................................................................................22
To View the % Output Power......................................................................................................................22
Buttons and Indicators................................................................................................................................22
Controller Parameters ................................................................................................................................23
Alarms ........................................................................................................................................................26
2
Table of Contents

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
Gain Scheduling ........................................................................................................................................36
Installation and Operation of Air Control ..........................................................................................................38
Installation ..................................................................................................................................................38
Furnace Loading ..............................................................................................................................................39
Preventative Maintenance ................................................................................................................................40
General Cleaning Instructions ....................................................................................................................40
Problem Solving ................................................................................................................................................41
Maintenance and Servicing ..............................................................................................................................44
Warning ......................................................................................................................................................44
To Replace a Heating Element ..................................................................................................................44
To Replace a Platinel II Thermocouple ......................................................................................................45
To Replace Solid State Relay ....................................................................................................................46
To Replace Door Switch (Microswitch) ......................................................................................................46
To Realign Door Strike ......................................................................................................................................47
To Replace Control Module ..............................................................................................................................48
Replacement Parts List ....................................................................................................................................49
Ordering Procedures ........................................................................................................................................51
Wiring DIagrams................................................................................................................................................52
Two Year Limited Warranty ..............................................................................................................................56
3
TABLE OF CONTENTS

Your Barnstead Thermolyne furnace has been designed
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
alert signals throughout the manual.
To avoid electrical shock, this furnace must:
1. Use a properly grounded electrical outlet of cor-
rect voltage and current handling capacity.
2. Disconnect from the power supply prior to main-
tenance and servicing.
3. Have the door switch operating properly.
To avoid burns, this furnace must:
1. Not be touched on the exterior or interior sur-
faces during use or for a period of time after
use.
To avoid personal injury:
1. Do not use in the presence of flammable or
combustible materials; fire or explosion may
result. This device contains components which
may ignite such material.
2. Refer servicing to qualified personnel.
Warning
Please note the following WARNINGS:
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 fiber or
fiberglass insulation, which can produce respirable dust or
fibers during disassembly. Dust or fibers can cause
irritation and can aggravate preexisting respiratory
diseases. Refractory ceramic and refractory ceramic
fibers (after reaching 1000°C) contain crystalline silica,
which can cause lung damage (silicosis). The Internation-
al Agency for Research on Cancer (IARC) has classified
refractory ceramic fiber and fiberglass as possibly
4
Safety Information
Hot Surface
Hot surfaces alert 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.
Caution
Cautions alert you to a possibility of
damage to the equipment.
Warning
Warnings alert you to a possibility of
personal injury.
Note
Notes alert you to pertinent facts and
conditions.
Alert Signals

carcinogenic (Group 2B), and crystalline silica as carcino-
genic 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 indi-
cate that there is no risk of exposure to dust or respirable
fibers resulting from operation of this product under nor-
mal conditions. However, there may be a risk of exposure
to respirable dust or fibers when repairing or maintaining
the insulating materials, or when otherwise disturbing
them in a manner which causes release of dust or fibers.
By using proper handling procedures and protective
equipment you can work safely with these insulating
materials and minimize any exposure. Refer to the appro-
priate 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).
5
SAFETY INFORMATION

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)
Chamber Dimensions Width 14 (35) 14 (35)
IN. (CM Height 14 (35) 14 (35)
Depth 14 5/8 (37) 14 5/8 (37)
Weight Lbs. (KG) 188 (86) 188 (86)
Electrical Ratings Volts 240 208
Amps 22.9 26.4
Watts 5500 5500
Freq. 50/60 50/60
Phase 1 1
Temperature Ratings Cont. 400°F-1800°F* 400°F-1800°F*
°F (°C) (204°C)-(982°C) (204°C)-(982°C)
Intermittent 1800°F-2000°F 1800°F-2000°F
(982°C)-(1093°C) (982°C)-(1093°C)
* The maximum continuous temperature for ashing furnaces (-60 models) is 1787°F (975°C).
Environmental Conditions
Operating: 17°C - 27°C; 20% to 80% relative humidity, non-condensing. Installation Category II
(over-voltage) 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.
6
General Specifications

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
EN 61000-3-3 Limits for voltage flutuations and flicker
EN 61326-1 Electrical equipment for measurement, control, and laboratory use; Part I:
Generic Requirements
Safety: EN 61010-1 Safety requirements for electrical equipment for measurement, control, and
laboratory use; Part I: General Requirements
EN 61010-2-010 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.
The authorized representative located within the European Community is:
Electrothermal Engineering, Ltd.
419 Sutton Road
Southend On Sea
Essex SS2 5PH
United Kingdom
Copies of the Declaration of Conformity are available upon request.
7
GENERAL SPECIFICATIONS

Intended Use
1. The Type 30400 Automatic and Programmable
furnaces are general laboratory and heat treat-
ing furnaces. For optimum element life,
Barnstead Thermolyne recommends these fur-
naces for applications requiring temperatures
from 400°F (204°C) to 1800°F (982°C) for con-
tinuous use, or temperatures from 1800°F
(982°C) to 2000°F (1093°C) for intermittent use.
Continuous use is operating the furnace for
more than 3 hours and intermittent use is oper-
ating the furnace for less than 3 hours.
2. The unit consists of 1) a heating chamber; 2) an
automatic proportioning digital set, digital read
control with overtemperature protection and 3) a
door interlock relay for user safety.
3. The Type 30400 Programmable furnace is
designed to control a programmed temperature
profile. The profile is in the format of ramps and
dwell segments. The first ramp, RAMP 1, starts
at the initial measured furnace temperature. This
ramp is positive going at a programmed rate
until the programmed level is reached. The set-
point will stay at this level for a period deter-
mined by the setting of DWELL 1. Additional
positive or negative going ramps are now initiat-
ed starting at the level at the end of DWELL 1.
When the second ramp reaches the second pro-
grammed level, the setpoint stays at that level
for the duration of the segment. Depending
upon the model ordered, additional ramp and
dwell segments may be added. See specific
model number in proceeding chart for total num-
ber of program segments.
4. 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.
8
Introduction
Note
When in the program RUN mode, the
programmable controller serves to pro-
vide a programmed temperature pro-
file as described earlier. When in the
single setpoint automatic mode, the
unit serves as an automatic tempera-
ture controller.

9
INTRODUCTION
Principles of Operation
1. Furnace: The furnace chamber is heated by four
electric resistance heaters which are embedded in a
refractory material. The chamber is insulated with a
ceramic fiber insulation. The temperature is con-
trolled by an automatic proportioning controller using
a platinel thermocouple to feed back information. The
control is located under the furnace chamber and is
well insulated from the heat generated in the furnace
chamber. The temperature is controlled by one of
three types of controllers.
MODEL NUMBER DIGITAL COMMUM. TOTAL NUMBER OF NUMBER OF
PROGRAMMABLE STORED
SEGMENTS PROGRAMS
F30420C-33-80 NO 8
F30420-33-60-80 NO 8
F30420C-60-80 NO 8
F30420C-80 NO 8
F30428C-60-80 NO 8
F30428C-80 NO 8
F30430CM YES 64 16 Segment Programs
F30430CM-33 YES 64 16 Segment Programs
F30430CM-33-60 YES 64 16 Segment Programs
F30430CM-60 YES 64 16 Segment Programs
F30438CM YES 64 16 Segment Programs
F30438CM-60 YES 64 16 Segment Programs

10
1. Visually check for any physical damage to the
shipping container.
2. Inspect the equipment surfaces that are adja-
cent to any damaged area.
3. Open the furnace door and remove the packing
material from inside the furnace chamber.
4. Vacuum the chamber prior to use to remove the
insulation dust due to shipment.
5. Retain the original packaging material if reship-
ment is foreseen or required.
Unpacking

11
Installation
Caution
Be sure ambient temperature does not
exceed 40°C (104°F). The recommended
ambient temperature is 17°C - 27°C.
Ambients above this level may result in
damage to the controller.
Warning
To avoid electrical shock, this furnace
must always use a properly grounded
outlet of correct voltage and current han-
dling capacity.
Caution
Allow at least six inches of space
between the furnace and any combustible
surface. This permits the heat from the
furnace case to escape so as not to cre-
ate a possible fire hazard.
Site Selection
Install furnace on a sturdy surface and allow adequate
space for ventilation.
Electrical Connections
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
before connecting the furnace to your electrical supply.

12
Operation, All Models
Warning
To avoid personal injury do not use in the
presence of flammable or combustible
chemicals; fire or explosion may result.
This device contains components which
may ignite such materials.
Hot Surface
Caution: Avoid Contact. To avoid burns,
this furnace must not be touched on the
exterior or interior surfaces during use or
for a period of time after use.
Warning
To avoid electrical shock, the door safety
switch must be operating properly.
Warning
Always wear safety glasses or a safety
shield and high temperature gloves when
loading or unloading the furnace. Long
sleeved, fire retardant clothing and a fire
retardant apron is also recommended.
Power Switch
Both the ON/OFF power switch and the digital display
will illuminate when power is switched ON. The furnace
will begin to heat to its controller's current setpoint.
(See the instructions for your type of controller for infor-
mation on checking and setting the setpoint.)
Cycle Light
The amber cycle light will illuminate whenever the
power is being applied to the heating elements. The
cycle light will turn on and off as the furnace reaches
the setpoint.
Door Safety Switch
The door safety switch removes power from the heat-
ing elements when the door is opened. Open and
close the door a few times; note that the amber
CYCLE light will switch off when the door is opened. If
this condition is not true, consult the Troubleshooting
section before proceeding. This check must be done
when the furnace is heating and the cycle light is illumi-
nated.

13
Single Setpoint Models
Output 1
Manual
UP ARROW
Button
Temperature
Display
Display
Window
DOWN ARROW
Button
PAGE
Button SCROLL
Button
Output 2
MAN
Single Setpoint Models w/OTP
Note
If at any time you want to return to the
HOME DISPLAY, simultaneously press
the PAGE and SCROLL buttons.
The single setpoint model w/ OTP furnace controller
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.
Basic Operation
When the controller is turned ON it will perform a short
self-test and then display the measured value (process
value) in the HOME DISPLAY.
Buttons and Indicators
OP1 (Output 1): Illuminates when the logic output is
ON.
OP2 (Output 2): Illuminates when the relay output is
ON (will go out during an alarm situation).
PAGE button: Allows you to select a new list of
parameters.
SCROLL button: Allows you to select a parameter
within a list of parameters.
DOWN button: Allows you to decrease a value.
UP button: Allows you to increase a value.

14
SINGLE SETPOINT MODELS W/OTP
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. A few seconds after the button is
released, the controller will accept the new value and revert
to the HOME DISPLAY.
To View the Display Units
From the HOME DISPLAY press the SCROLL button. The
display will show the temperature units in °C/F/K and then
return to the HOME DISPLAY. (Call Customer Service if you
require a different temperature unit.)
To View the % Output Power
From the HOME DISPLAY press the SCROLL button twice.
Press and release the UP or DOWN button to view the %
output power. This value is a read-only value and cannot be
changed.
Controller Parameters
Home display
°C: Temperature units in Celsius. Temperature units can not
be changed without entering the configuration. Contact
Customer Service if a different temperature unit is required.
OP: % output power demand.
IdHi: Deviation high alarm.
Al List
IdHi: Deviation high alarm.
Atun List
tunE: One-shot autotune enable.

15
SINGLE SETPOINT MODELS W/OTP
Note
The following alarm messages are
factory default settings and may vary
if you have changed the configuration
of your controller:
IDHi: = 50°C
2FSH = 1118°C
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.
Alarms
The controller will flash an alarm message in the home
display if an alarm condition is detected.
2FSH: Measured value full scale high alarm.
IdHi: Measured value deviation high alarm.
S.br: Sensor break: check that sensor is connected cor-
rectly.
L.br: Loop break: check that the heating circuits are work-
ing properly.
Ld.F: Heater Circuit fault: indication of either an open or
short solid sate relay, a blown fuse, missing supply or
open circuit heater.

16
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).
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. To change it, press
the SCROLL button until “IdHi” appears on the display.
Press the UP or DOWN button to select the OTP value
you desire. We recommend a value of 20° above your
working temperature to provide protection for your
workload.
In addition to over-temperature protection, units con-
taining a single setpoint controller w/OTP feature a
mechanical OTP relay device which disconnects power
from the elements in an alarm condition (only in fur-
naces with OTP relay). See models listed on front
page.
SINGLE SETPOINT MODELS W/OTP

17
Note
Furnace must be at ambient
temperature before starting a tune.
Note
Tune has completed when “tunE”
stops flashing on display.
SINGLE SETPOINT MODELS W/OTP
Tuning
This controller incorporates a self-tuning feature which
determines the optimum control parameters for the
best temperature accuracy with your load and setpoint.
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-
mends you use this feature to provide the best temper-
ature accuracy the controller can attain. To use the tun-
ing feature:
1. Adjust the setpoint to your desired value.
2. Press the PAGE button until display reads,
“Atun.”
3. Press the SCROLL button. Display will read,
“tunE.”
4. Press the UP or DOWN button to select, “on.”
5. Simultaneously press the PAGE and
SCROLL buttons to return to the HOME DIS-
PLAY. The display will alternately flash
between “tunE” and the HOME DISPLAY
while tuning is in progress.
6. The controller will then turn the heating on
and off to induce an oscillation. When the
measured value reaches the required setpoint
the first cycle will end.
7. Tuning will be complete after two oscillation
cycles and then the tuner will turn itself off.
8. Normal control function will resume after the
controller calculates tuning parameters.

18
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.
1. Mode 1 (Opt. 1) is a Ramp (if needed) to the
Setpoint temperature, a Dwell, and then a cool
down.
2. Mode 2 (Opt. 2) is the same as mode 1, except
the controller continues to heat at the Setpoint
after the Dwell has completed. (This mode does
not cool down.)
3. Mode 3 (Opt. 3) is the same as mode 1, except
the Dwell time includes the Ramp (if needed).
4. Mode 4 (Opt. 4) is the same as mode 2, except
the Dwell time includes the Ramp (if needed).
5. Mode 5 (Opt. 5) is a Dwell (delay time) before the
controller Ramps (if needed) to the Setpoint tem-
perature.
Setting Variables
• The Manual or Automatic modes can be set by
changing “m-A” variable to “mAn” or “Auto.” (The
Manual mode will keep the controller from heating
without setting the Setpoint temperature below
the Actual temeperature. The Automatic mode
will allow the controller to heat to the Setpoint
temperature. (The controller should be left in the
Automatic mode except when programming.)
•Aprogram mode can be set by changing the
“tm.OP” variable to “Opt. 1, Opt. 2, Opt. 3, Opt. 4,
or Opt. 5.
•ARamp rate may be set by changing the “SPrr”
variable to a value. The Ramp rate units are in
degrees per minute.
Mode 1 (Opt. 1)
Mode 2 (Opt. 2)
Mode 3 (Opt. 3)
Mode 4 (Opt. 4)
Mode 5 (Opt. 5)

19
SINGLE RAMP & DWELL CONTROLLER
Note
The program must be stopped and
the controller must be displaying the
actual temperature before beginning
the Setup.
•The Dwell time can be set by changing the “dwEll”
variable to the desired value. Dwell time units are in
minutes.
•The program Status can be set by changing the “StAt”
variable to “run” or “oFF.” This variable will start or
stop the program.
Program Setup
1. Press the SCROLL button until “m-A” is displayed,
then set to “mAn” with the UP or DOWN buttons.
2. Press the PAGE button once, set the desired Setpoint
temperature with the UP or DOWN buttons.
3. Press the PAGE button until the “SP” is displayed.
4. 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. If the Ramp rate is not needed, then set to
“OFF” with the UP or DOWN buttons.
5. Press the SCROLL button once, “tm.OP” (Ramp &
Dwell mode) will be displayed, select the desired
mode with the UP or DOWN buttons. (Opt. 1, Opt. 2,
Opt. 3, Opt. 4, Opt. 5)
6. Press the SCROLL button once, “dwEll” will be dis-
played, set the desired Dwell time with the UP or
DOWN buttons. (Dwell in minutes.)
7. Press the PAGE button until the Actual temperature is
displayed.

20
Running the Program
1. Press the SCROLL button until “StAt” is dis-
played, set to “run” with the UP or DOWN
buttons.
2. Press the PAGE button to display Actual tem-
perature.
Stopping the Program
Press the SCROLL button until “StAt” is displayed, set
to “oFF” with the UP or DOWN buttons.
Clearing the Flashing End
Press the PAGE and SCROLL buttons at the same
time.
Switching from Manual Mode
to Auto Mode
Press the SCROLL button until “m-A” is displayed.
Press the UP or DOWN buttons to set to “Auto.” Press
PAGE button to display Actual temperature.
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.
SINGLE RAMP & DWELL CONTROLLER