Barnstead 47900 User manual

Type 47900 & 48000
Furnaces
OPERATION MANUAL
Series 1165, 1166 & 1205
Single Setpoint Models F47910, F47910-26, F47910-33, F47914, F47915, F48010, F48010-26,
F48010-33, F48014, F48015, F48015-60, F48018
Single Setpoint Models F47920, F47920-26, F47920-33, F47924, F47925, F48020, F48020-26,
with OTP F48020-33, F48024, F48025, F48025-60, F48028
8 Segment Programmable F47920-80, F47920-26-80, F47920-33-80, F47924-80, F47925-80,
Models with OTP F48020-80, F48020-26-80, F48020-33-80, F48024-80, F48025-80,
F48025-60-80, F48028-80
4 X 16 Segment F47950, F47950-26, F47950-33, F47954, F47955, F48050, F48050-26,
Programmable Models F48050-33, F48055, F48055-60, F48058
with OTP
LT1165X1 • 3/1/02

Safety Information ..............................................................................................................................................3
Alert Signals..................................................................................................................................................3
Warnings ......................................................................................................................................................3
Introduction..........................................................................................................................................................5
Intended Use ................................................................................................................................................5
General Usage..............................................................................................................................................5
Principles of Operation ................................................................................................................................5
General Specifications ........................................................................................................................................6
Type F47900 Models ....................................................................................................................................6
Type F48000 Models ....................................................................................................................................6
Environmental Conditions ............................................................................................................................7
Declaration of Conformity ............................................................................................................................7
Unpacking ..........................................................................................................................................................8
Installation ..........................................................................................................................................................9
Site Selection................................................................................................................................................9
Electrical Connections ..................................................................................................................................9
Operation, All Models ........................................................................................................................................10
Power Switch ..............................................................................................................................................10
Cycle Light ..................................................................................................................................................10
Door Safety Switch ....................................................................................................................................10
Single Setpoint Models & Single Setpoint Models with OTP ..........................................................................11
Single Ramp & Dwell ........................................................................................................................................16
8 Segment & 4 x 16 Segment Programmable Models with OTP ....................................................................19
Furnace Loading ..............................................................................................................................................39
Preventative Maintenance ................................................................................................................................40
General Cleaning Instructions ....................................................................................................................40
Troubleshooting ................................................................................................................................................41
Maintenance and Servicing ..............................................................................................................................44
To Replace a Heating Element ..................................................................................................................44
To Replace a Chromel/Alumel Thermocouple ............................................................................................45
To Replace Door Switches (Micro-Switch) ................................................................................................46
To Realign Door Switches (Micro-Switch) ..................................................................................................47
To Replace the Controller ..........................................................................................................................48
Replacement Parts............................................................................................................................................49
Single Setpoint Models ..............................................................................................................................49
Single Setpoint Models with OTP ..............................................................................................................49
8 Segment Programmable Models with OTP ............................................................................................50
4 x 16 Segment Programmable Models with OTP ....................................................................................50
Wiring Diagrams................................................................................................................................................51
Ordering Procedures ........................................................................................................................................59
One Year Limited Warranty ..............................................................................................................................60
2
Table of Contents

Your Barnstead Thermolyne Type 47900 or
48000 Furnace has been designed with function,
reliability and safety in mind. It is your responsi-
bility to install it in conformance with local electri-
cal codes. For safe operation, please pay atten-
tion to the alert signals throughout the manual.
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 furnace.
Warnings
To avoid electrical shock, this furnace must:
1. Use a properly grounded electrical outlet
of correct voltage and current handling
capacity.
2. Be disconnected from the power supply
prior to maintenance and servicing.
3. Have the door switch operating properly.
To avoid personal injury:
1. Do not use in the presence of flammable
or combustible materials; fire or explo-
sion may result. This device contains
components which may ignite such mate-
rial.
2. Caution: Hot Surface - Avoid Contact. To
avoid burns, do not touch the exterior or
interior surfaces of this furnace during
use or for a period of time after use.
3. 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.
4. Refer servicing to qualified personnel.
3
Safety Information
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.
Alert Signals
Hot Surface
Hot surfaces alert you to the possibility
of personal injury if you come in contact
with a surface during use or for a period
of time after use.

Warning
This warning is presented for compliance with
California Proposition 65 and other regulatory agen-
cies and only applies to the insulation in this prod-
uct. This product contains refractory ceramic, refrac-
tory ceramic fiber or fiberglass insulation, which can
produce respirable dust or fibers during disassembly.
Dust or fibers can cause irritation and can aggravate
pre-existing respiratory diseases. Refractory ceramic
and refractory ceramic fibers (after reaching 1000°C)
contain crystalline silica, which can cause lung dam-
age (silicosis). The International Agency for
Research on Cancer (IARC) has classified refractory
ceramic fiber and fiberglass as possibly carcinogenic
(Group 2B), 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 man-
ufacturer indicate that there is no risk of exposure to
dust or respirable fibers resulting from operation of
this product under normal conditions. However, there
may be a risk of exposure to respirable dust or fibers
when repairing or maintaining the insulating materi-
als, or when otherwise disturbing them in a manner
which causes release of dust or fibers. By using
proper handling procedures and protective equip-
ment 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 recom-
mended protective equipment. For additional MSDS
copies, or additional information concerning the han-
dling of refractory ceramic products, please contact
the Customer Service Department at Barnstead
International at 1-800-553-0039.
4
SAFETY INFORMATION
Warning
Refer Servicing to qualified per-
sonnel.

Intended Use
The Type F47900 and F48000 furnaces are
general purpose laboratory and heat treating
furnaces. For optimum element life,
Barnstead International recommends observ-
ing these temperature ranges: from 100°C
(212°F) to 1093°C (2000°F) continuous use
or from 1093°C (2000°F) to 1200C (2192°F)
for intermittent use. Continuous use is operat-
ing the furnace for more than 3 hours and
intermittent use is operating the furnace for
less than 3 hours.
All furnaces consist of: 1) a vented heating
chamber; 2) a temperature controller; and 3)
a door safety switch for operator safety.
General Usage
Do not use this product for anything other
than its intended usage.
Principles of Operation
The furnace chamber is heated by open coil
electric resistance elements and is insulated
with ceramic fiber insulation. The controller is
located under the furnace chamber and is
well insulated from the heat generated in the
furnace chamber. A door safety switch
removes power to the heating elements
whenever the furnace door is opened. The
temperature is controlled by one of three
types of controllers.
5
Introduction
Caution
Do not exceed operating temperatures
shown in “General Specifications.”
Exceeding these limits will result in
severely reduced element life.

6
General Specifications
Type F47900 Models
Dimensions in Inches (cm):
Chamber: 5 (12.7) W x 4 (10.2) H x 6 (15.2) D
Overall: 11.25 (28.6) W x 18 (45.7) H x 15.5 (39.4) D
Weight: 37 lb. (16.8 kg)
Electrical Ratings:
Volts: 220-240 100 120
Amps: 4.2 7.5 8.3
Watts: 1000 750 1000
Frequency: 50/60 50/60 50/60
Phase: 1 1 1
Temperature:
Operating Range: 2000°F (1093°C) continuous
2192°F (1200°C) intermittent
Type F48000 Models
Dimensions in Inches (cm):
Chamber: 7 (17.8) W x 5 (12.7) H x 10 (25.4) D
Overall: 13.25 (33.7) W x 19 (48.3) H x 19.5 (49.5) D
Weight: 56 lb. (25.4 kg) (all models except -33)
58 lb. (26.3 kg) (-33 models only)
Electrical Ratings:
Volts: 220-240 120 208 100 220-240*
Amps: 7.5 14.5 15 14.5 6.5*
Watts: 1800 1500 1560 1450 1560*
Frequency: 50/60 50/60 50/60 50/60 50/60*
Phase: 1111 1*
* -33 models only
Temperature:
Operating Range: 2000°F (1093°C) continuous
2192°F (1200°C) intermittent

7
GENERAL SPECIFICATIONS
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; 20% to 80% relative humidity
Declaration of Conformity
Barnstead International hereby declares under its sole responsibility that this product con-
forms with the technical requirements of the following standards (220-240 Volt Models
Only):
EMC: EN 50081-1 Generic Emissions Standard
EN 50082-2 Generic Immunity Standard
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 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.

8
1. Visually check for any physical dam-
age to the shipping container.
2. Inspect the equipment surfaces that
are adjacent 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. (The Type 48000 furnace is
supplied with one ceramic shelf.)
5. Retain the original packaging material
if reshipment is foreseen or required.
Unpacking

9
Site Selection
Install furnace on a sturdy surface and allow
adequate space for ventilation.
Electrical Connections
The electrical ratings are located on the spec-
ification plate on the back of the furnace.
Consult Barnstead International if your electri-
cal service is different than those listed on the
specification plate. Be sure the front power
switch is in the OFF position before connect-
ing the furnace to your electrical supply.
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.

10
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 con-
troller's current setpoint. (See the instructions
for your type of controller for information on
checking and setting the setpoint.)
Cycle Light
The amber cycle light will illuminate whenever
the power is being applied to the heating ele-
ments. 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 heating 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 illuminated.
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.

11
The single setpoint model furnace controller
is a single setpoint controller which provides a
single digital display to indicate the current
chamber temperature or setpoint temperature.
This temperature controller features sensor
break protection and self-tuning capability.
The single setpoint model w/ OTP furnace
controller is a single setpoint controller which
provides a single digital display to indicate the
current chamber temperature or setpoint tem-
perature. This temperature controller 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 per-
form 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 situ-
ation).
PAGE button: Allows you to select a new list
of parameters.
SCROLL button: Allows you to select a
parameter within a list of parameters.
Single Setpoint Models &
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.
Single Setpoint Models
Output 1
Manual
UP ARROW
Button
Temperature
Display
Display
Window
DOWN ARROW
Button
PAGE
Button SCROLL
Button
Output 2
MAN

12
DOWN button: Allows you to decrease a value.
UP button: Allows you to increase a value.
To View or Change the Setpoint
To view the setpoint, press and release the UP or
DOWN buttons. If you want to change the set-
point, continue pressing until the desired setpoint
value is displayed and then release the button. A
few seconds after the button is released, the con-
troller 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 DIS-
PLAY. (Call Customer Service if you require a dif-
ferent 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 dif-
ferent temperature unit is required.
SINGLE SETPOINT MODELS & SINGLE SETPOINT MODELS W/OTP

13
OP: % output power demand.
IdHi: Deviation high alarm.
Al List
IdHi: Deviation high alarm.
Atun List
tunE: One-shot autotune enable.
Pid List
Pb: Proportional band (in display units).
ti: Integral time in seconds.
td: Derivative time in seconds.
ACCS List Code: Access code (Code need-
ed to enter or change the other configuration
parameters which are not normally accessi-
ble.) 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 con-
nected correctly.
L.br: Loop break: check that the heating cir-
cuits are working properly.
SINGLE SETPOINT MODELS & SINGLE SETPOINT MODELS W/OTP
Note
The following alarm messages are fac-
tory default settings and may vary if you
have changed the configuration of your
controller:
IDHi: = 50°C
2FSH = 1225°C

14
Ld.F: Heater Circuit fault: indication of either
an open or short solid sate relay, a blown
fuse, missing supply or open circuit heater.
Sensor Break Protection
This controller provides sensor break protec-
tion in the event the thermocouple opens. If
an open thermocouple 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 containing a single setpoint controller
w/OTP feature a mechanical OTP relay
device which disconnects power from the ele-
ments in an alarm condition (only in furnaces
with OTP relay). See models listed on front
page.
SINGLE SETPOINT MODELS & SINGLE SETPOINT MODELS W/OTP

15
Tuning
This controller incorporates a self-tuning fea-
ture 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 recommends you use
this feature to provide the best temperature
accuracy the controller can attain. To use the
tuning 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 DISPLAY. The display will
alternately flash between “tunE” and
the HOME DISPLAY while tuning is in
progress.
6. The controller will then turn the heat-
ing 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.
SINGLE SETPOINT MODELS & SINGLE SETPOINT MODELS W/OTP
Note
Furnace must be at ambient
temperature before starting a tune.
Note
Tune has completed when “tunE”
stops flashing on display.

16
Functions
This type of controller has single ramp and dwell
programming 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 complet-
ed. (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 temperature.
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.
Single Ramp & Dwell
Note
These instructions are used with the Single Setpoint models with OTP only
(See models listed on front page).
Mode 1 (Opt. 1)
Mode 2 (Opt. 2)
Mode 3 (Opt. 3)
Mode 4 (Opt. 4)
Mode 5 (Opt. 5)

•ARamp rate may be set by changing the
“SPrr” variable to a value. The Ramp rate
units are in degrees per minute.
•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 dis-
played, 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 dis-
played.
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 but-
tons.
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 displayed, set the desired Dwell time with
the UP or DOWN buttons. (Dwell in minutes.)
7. Press the PAGE button until the Actual tem-
perature is displayed.
SINGLE RAMP & DWELL CONTROLLER
Note
The program must be stopped and
the controller must be displaying the
actual temperature before beginning
the Setup.
17

18
Running the Program
1. Press the SCROLL button until “StAt”
is displayed, set to “run” with the UP
or DOWN buttons.
2. Press the PAGE button to display
Actual temperature.
Stopping the Program
Press the SCROLL button until “StAt” is dis-
played, 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 dis-
played. 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 dis-
played. The display will show “run” if the pro-
gram is running, or “oFF” if it is not running.
Press the PAGE button to display Actual tem-
perature.
SINGLE RAMP & DWELL CONTROLLER

19
8 Segment & 4x16 Segment
Programmable Models w/OTP
The 8 segment programmable controller
consists of a microprocessor based three-
mode PID (Proportional, Integral, Derivative),
programmable temperature controller with
over-temperature protection and appropriate
output switching devices to control the fur-
nace. The digital readout continuously dis-
plays chamber (upper display) and setpoint
(lower display) temperatures unless the
SCROLL or PAGE button is depressed. The
programmable controller can be used as a
single setpoint controller or as a programma-
ble controller. The 8 segment digital model
enables eight segments of programming.
The 4x16 segment programmable controller
consists of a microprocessor based three-
mode PID (Proportional, Integral, Derivative),
programmable temperature controller with
over-temperature protection and appropriate
output switching devices to control the fur-
nace. The digital readout continuously dis-
plays chamber (upper display) and setpoint
(lower display) temperatures unless the
SCROLL or PAGE button is depressed. The
programmable controller can be used as a
single setpoint controller or as a programma-
ble controller. The 4 program controller has
four 16 segment programs.
Basic Operation
When the controller is turned ON, it will per-
form a short self-test and then change to the
HOME DISPLAY. The HOME DISPLAY shows
the measured temperature (process value) in
the upper display and the desired value (set-
point) in the lower display.
4x16 & 8 Segment Programmable Models with OTP
Output 1
PAGE
Button
AUTO/MAN
Button
Display
Window
Upper
Display
Lower
Display
RUN/HOLD
Button
UP ARROW
Button
DOWN ARROW
Button
SCROLL
Button
Note
The controller will return to the HOME
DISPLAY if left idle for more than a few
seconds.
Note
Once the desired parameter has been
selected, depressing either the UP or
DOWN button will change the parameter
value. In all cases, the value shown on
the display is the current working value of
that parameter.

20
To Change the Setpoint
If you want to change the setpoint, press the
UP or DOWN button until the desired setpoint
value is displayed in the lower display and
then release the button.
To View Display Units
From the HOME DISPLAY press the SCROLL
button. The display will briefly show the tem-
perature units in °C/F/K and then return to the
HOME DISPLAY. (If you require a different
temperature unit call Barnstead|Thermolyne
Customer Service.)
To View the % Output Power
From the HOME DISPLAY press the SCROLL
button twice. This value is a read-only value
and cannot be changed.
Buttons and Indicators
OP1 (Output 1): illuminates when the heating
output of the temperature controller is on.
AUTO/MAN: (Auto/Manual Mode): when the
controller is in the automatic mode the output
automatically adjusts to keep the temperature
or process value at the setpoint. The “AUTO”
light will illuminate. The manual mode has
been disabled through factory configuration.
Call Customer Service for further information.
RUN/HOLD (Run/Hold button):
•Starts a program when pressed
once—RUN light illuminates.
8 SEGMENT & 4X16 SEGMENT PROGRAMMABLE MODELS W/OTP