THERMO SCIENTIFIC FD1540M (01) PDF Document

The THERMO SCIENTIFIC FD1540M is a general laboratory and heat treating furnace. For optimum element life, it is suggested that this furnace be used for applications requiring temperatures from 212°F (100°C) to 2192°F (1200°C). For maximum element life, it is recommended to operate the furnace at temperatures from 212°F (100°C) to 1950°F (1066°C) for continuous use, or temperatures from 1950°F (1066°C) to 2192°F (1200°C) for intermittent use. Continuous use is operating the furnace for more than 3 hours and intermittent use is operating the furnace for less than 3 hours.

The unit consists of: 1) heating chamber, 2) a digital controller and 3) a door interlock relay for user safety.

The general specifications for the THERMO SCIENTIFIC FD1540M are as follows:

Operating conditions are: 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 conditions are: -25°C to 65°C; 20% to 80% relative humidity.

Visually check for any physical damage to the shipping container. Inspect the equipment surfaces that are adjacent to any damaged area. Unpack furnace from box. The owner’s manual and door handle are included in the box. After unpacking the furnace, attach the door handle and remove packing material from inside furnace chamber. The furnace is supplied with one hearth plate. The 120V models are not supplied with a power cord because current requirements are too great to be handled by ordinary power cords and standard wall supply.

Be sure ambient temperature does not exceed 104°F (40°C). The recommended ambient temperature is 17°C – 27°C. Ambient above this level may result in damage to the controller.

Allow at least six inches of space between the furnace and any combustible surface. This permits the heat from the case surface to escape so as not to create a possible fire hazard.

Prior to connecting your Type 1500 furnace to your electrical supply, be sure the two position power switch is in the OFF position.

Both the ON/OFF power switch and the digital display will illuminate when power is switched ON. The furnace will begin to heat to the controller’s current setpoint.

The amber cycle light will illuminate whenever the power is being applied to the heating elements. The cycle light will flicker on/off as furnace reaches setpoint.

The door safety switches remove 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 be out when door is open. This check must be done when furnace is heating or when cycle light is illuminated. If this condition is not true, consult the Troubleshooting section before proceeding.

The digital readout continuously displays chamber temperature.

If you want to change the setpoint, press the SCROLL button until “SP1” is displayed. Press the UP or DOWN button 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 is indicated by a brief flash of the display. Press PAGE button to return to HOME DISPLAY.

Press SCROLL until “UNITS” is displayed. The temperature units are also shown on the HOME DISPLAY to the right of the measured value (process value). Temperature units can be changed by pressing up and down buttons. Choice of Celsius (°C), Fahrenheit (°F), Kelvin (°K), Percentage (%), or None (nonE).

The controller parameters on the Home display are:

• °C, °F, °K, %, or None: Temperature units in Celsius (default), Fahrenheit, Kelvin, Percentage (PErc), or None (nonE).
• A1.DHI: Deviation high alarm.
• A2.HI: High Limit alarm. Read Only.
• A3.LO: Low Limit alarm. Read Only.
• A.TUNE (tune): One-shot autotune enable.
• WRK.OP: Working Output power. Read Only.
• PV.OFS: Process Value Offset. Read Only.
• SP.RAT: Ramp Rate Setpoint (default units is minutes).
• DWELL: Time for dwell or delay (default units is minutes).
• T.STAT: Timer Status. Active only when timer is active.
• TM.CFG: Timer configuration.

The Pid List parameters are:

• PB: Proportional band (in display units).
• TI: Integral time in seconds.
• TD: Derivative time in seconds.

The controller will flash an alarm message in the home display if an alarm condition is detected:

• A2.HI: Measured value full scale high alarm.
• A1.DHI: Measured value deviation high alarm.
• S.br: Sensor break: check that sensor is connected correctly.
• LBR: Loop break: check that the heating circuits are working properly.
• Ld.F: Heater Circuit fault: indication of either an open or short solid state relay, a blown fuse, missing supply or open circuit heater.

This controller provides sensor break protection 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).

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 “A1.DHi” 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 elements in an alarm condition.

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. To use the tuning feature:

1. Start tuning with the process at ambient temperature. This allows the tuner to calculate the low cutback and high cutback values more accurately.
2. Adjust the setpoint to your desired value.
3. Press the SCROLL button until display reads, “A.TUNE.”
4. Press the UP or DOWN button to select, “on.”
5. Press the PAGE button 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 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.

Note: Furnace must be at ambient temperature before starting a tune. “Stat” and “Sp.rr” must be set to OFF or “tunE” will not initiate.

Note: Tune has completed when “tunE” stops flashing on display.

The Ramp and Dwell can be configured to five different modes:

1. Mode 1 (DWELL) The dwell time begins once the setpoint reaches the set threshold. The END TYPE action is executed when the dwell timer reaches the end.
2. Mode 2 (DELY) The timer starts immediately upon instrument power-up, or when run is selected. The instrument remains in standby until the time has elapsed. After the time has elapsed, the instrument controls up to setpoint.
3. Mode 3 (SF.ST) Starts automatically on power up. This is a soft-start function. If the PV is below the Soft Start Threshold, then the power is limited to the Soft Start Limit until the threshold is met.

To set the SetPoint Rate Limit Setup:

1. Press the SCROLL button until the “SP.RAT” (Ramp Rate) is displayed.
2. 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 feature is needed. If the Ramp rate is not needed, then set to “OFF” with the UP or DOWN buttons.
3. Press the SCROLL button until “TM.CFG” (Ramp & Dwell mode) will be displayed, select the desired mode with the UP or DOWN buttons. (DWEL, DELY, or SF.ST).
4. Press the SCROLL button until “DWELL” will be displayed set the desired Dwell time with the UP or DOWN buttons.
5. Press the PAGE button and SCROLL button together until the Actual temperature is displayed.

To run a program:

1. Press the SCROLL button until “T.STAT” is displayed, set to “run” with the UP or DOWN buttons; or from the HOME DISPLAY, press UP and DOWN arrows together.
2. Press the PAGE button to display Actual temperature.

Note: The program must be stopped and the controller must be displaying the actual temperature before beginning the Setup.

To put a running program on hold:

1. Press the SCROLL button until “T.STAT” is displayed. Set to “hold” with the UP or DOWN buttons; or from the HOME DISPLAY, press UP and DOWN arrows together.
2. Press the PAGE button to display Actual temperature.

Press the SCROLL button until “T.STAT” is displayed, Set to “res” with the UP or DOWN buttons.

Press the PAGE and SCROLL buttons at the same time.

Press the SCROLL button until “T.STAT” is displayed. The display will show “run” if the program is running, “hold” if it is paused or “res if it is not running. Press the PAGE button to display actual temperature.

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.

From the HOME DISPLAY press the SCROLL button. The display will briefly show the temperature units in °C/F/K and then return to the HOME DISPLAY. (If you require a different temperature unit call Customer Service)

From the HOME DISPLAY press the SCROLL button twice. Press the UP or DOWN button to display the value. This value is a read-only value and cannot be changed.

The functions for the buttons and indicators are:

• 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.
  • Holds a program when pressed again—HOLD light illuminates.
  • Cancels hold and continues running when pressed again-HOLD light is off and RUN light illuminates.
  • Exits a program when the button is held down for two seconds-RUN and HOLD lights are off.
  • At the end of a program the RUN light will flash.
  • During holdback the HOLD light will flash.
• PAGE button: allows you to choose a parameter from a list of parameters.
• SCROLL button: allows you to choose a parameter within a list of parameters.
• UP button: allows you to increase the value in the lower display.
• DOWN button: allows you to decrease the value in the lower display.

Stat: Displays the program status [OFF, run (running active program), hoLd (program on hold), HbAc (waiting for process to catch up), End (program completed)] in the lower display. The controller will default to “OFF.”

FAST: Fast run through program (no/YES). The controller will default to “no.”

SEG.d: Flash active segment type in the lower display of the home display (no/YES). The controller will default to “no.”

To set the holdback type:

1. Press the PAGE button until you reach the program list (ProG LiSt).
2. Press the SCROLL button until display reads, “Hb.”
3. Press the UP or DOWN button to toggle between “bAnd, Hi, Lo and OFF.”

To set the holdback value:

1. Press the PAGE button until you reach the program list (ProG LiSt).
2. Press the SCROLL button until display reads, “Hb.U.”
3. Press the UP or DOWN button to enter a holdback value.

To set Ramp Units:

1. Press the PAGE button until you reach the program list (ProG LiSt).
2. Press the SCROLL button until display reads, “rmP.U.”
3. Press the UP or DOWN button to toggle between seconds, minutes and hours.

To set Dwell Units:

1. Press the PAGE button until you reach the program list (ProG LiSt).
2. Press the SCROLL button until display reads, “dwL.U.”
3. Press the UP or DOWN button to toggle between seconds, minutes and hours.

To set the Number of Cycles:

1. Press the PAGE button until you reach the program list (ProG LiSt).
2. Press the SCROLL button until display reads, “CYC.n.”
3. Press the UP or DOWN button to select the number of cycles you want to run or, press the DOWN button to select “cont.” so the program will run continuously.

To ramp linearly at a set rate to a specified temperature (rmP.r segment type):

1. Press the PAGE button until you reach the program list (ProG LiSt).
2. Press the SCROLL button until display reads, “tYPE.”
3. Press the UP or DOWN button until display reads, “rmP.r.”
4. Press the SCROLL button until display reads, “tGt.”
5. Press the UP or DOWN button to set a target setpoint.
6. Press the SCROLL button until display reads, “rAtE.”
7. Press the UP or DOWN button to select a value in ramp units (seconds, minutes or hours; set in the “rmP.U” parameter).

To ramp to a specified temperature at a set time (rmP.t segment type):

1. Press the PAGE button until you reach the program list (ProG LiSt).
2. Press the SCROLL button until display reads, “tYPE.”
3. Press the UP or DOWN button until display reads, “rmP.t.”
4. Press the SCROLL button until display reads, “tGt.”
5. Press the UP or DOWN button to set a target setpoint.
6. Press the SCROLL button until display reads, “dur.”
7. Press the UP or DOWN button to select a time in ramp units (seconds, minutes or hours; set in the “rmP.U” parameter).

To maintain a constant temperature for a specified time (dwEll segment type):

1. Press the PAGE button until you reach the program list (ProG LiSt).
2. Press the SCROLL button until display reads, “tYPE.”
3. Press the UP or DOWN button until display reads, “dwell.”
4. Press the SCROLL button until display reads, “dur.”
5. Press the UP or DOWN button to select a time in dwell units (seconds, minutes or hours; set in the “dwL.U” parameter).

To climb instantaneously from the current temperature to a specified temperature (StEP segment type):

1. Press the PAGE button until you reach the program list (ProG LiSt).
2. Press the SCROLL button until display reads, “tYPE.”
3. Press the UP or DOWN button until the display reads, “StEP.”
4. Press the SCROLL button until display reads, “tGt.”
5. Press the UP or DOWN button to set a target setpoint.

To end or repeat a program (End segment type):

1. Press the PAGE button until you reach the program list (ProG LiSt).
2. Press the SCROLL button until display reads, “tYPE.”
3. Press the UP or DOWN button until display reads, “End.”
4. Press the SCROLL button until display reads, “End.t.”
5. Press the UP or DOWN button to toggle between “dwEll” (an indefinite dwell at last target level), “S OP” (End Segment Output Power) and “rSET” (reset will revert back to setpoint in Single Setpoint mode).

To run a program, press the RUN/HOLD button. (The RUN light will illuminate).

To put a running program on hold, press the RUN/HOLD button. (The HOLD light will illuminate).

To cancel a program, hold the RUN/HOLD button down until the RUN and HOLD lights go off.

The display will flash “tu.ER” if an error occurs during tuning. To clear the error and restart tuning, simultaneously press the PAGE and SCROLL buttons and follow the steps outlined in “Autotuning.”

Note: To stop the tuning function, simultaneously press the PAGE and SCROLL buttons.

The Autotune feature automatically sets up the PID values in the control parameters to suit new process conditions. To tune your furnace using autotuning:

1. Load your furnace with a load similar to your normal load and close the door.
2. Set the setpoint temperature.
3. Press the PAGE button until the display reads, “Atun LiSt.”
4. Press the SCROLL button until “tunE OFF” is displayed.
5. Press the UP or DOWN button to select “on.”
6. Simultaneously press the PAGE and SCROLL buttons to return to the HOME DISPLAY. The display will flash “tunE” while tuning is in progress.

Note: Start tuning with the process at ambient temperature. This allows the tuner to calculate the low cutback and high cutback values more accurately.

Adaptive tuning continuously evaluates tuning parameters. Adaptive tuning automatically installs new values if better accuracy is possible. Adaptive tuning should be used when the characteristics of a process change due to load or setpoint changes or, in a process that cannot handle the oscillation caused by a one-shot tune. To tune your furnace using adaptive tuning:

1. Load your furnace with a load characteristic of those you intend to heat in it.
2. Press the PAGE button until display reads, “Atun LiSt.”
3. Press the SCROLL button until “drA OFF” is displayed.
4. Press the UP or DOWN button to select “on.”
5. Press the SCROLL button until “drA.t” is displayed.
6. Press the UP or DOWN button until the desired trigger value is achieved.

Do not overload your furnace chamber. If the load is to be heated uniformly it should not occupy more than the center two-thirds of the furnace chamber. Failure to observe this caution could result in damage to furnace components.

Furnace Loading procedures:

1. For best results, use only the center 2/3 of the furnace chamber.
2. If you are heating a number of small parts, spread them throughout the center two-thirds of the furnace chamber.
3. Keep objects away from thermocouple.
4. Use insulated tongs and mittens when loading and unloading furnace.
5. Always wear safety glasses.
6. Use the hearth plates supplied to protect bottom of chamber. Part # PHX2.

Before using any cleaning or decontamination method except those recommended by Thermo Scientific, users should check with Thermo Scientific that the proposed method will not damage the equipment.

The possible cause is “The furnace is not connected to power supply.” The corrective action is to “Reconnect furnace to power supply.”

The problems, possible causes, and corrective actions for “Furnace does not heat” are:

The possible cause is “Door switch not functioning.” The corrective action is to “Realign or replace door safety switch.”

The problems, possible causes, and corrective actions for “Controller over-temp. does not cut power to furnace chamber” are:

The problems, possible causes, and corrective actions for “Slow heatup” are:

The problems, possible causes, and corrective actions for “Repeated element burnout” are:

The problems, possible causes, and corrective actions for “Inaccurate temperature readout” are:

To Replace a Heating Element:

1. Disconnect furnace from power supply.
2. Remove back terminal cover.
3. Loosen the nuts on the terminals of the element to be replaced.
4. Straighten the leads of the old element.
5. Open the door and pull the defective element out. (It may be easiest to turn the furnace so that the element to be removed is on top.)
6. Slide the new element into place, threading the leads through the insulating porcelain bushing in the back of the furnace.
7. Reverse the disassembly procedure, making sure you thread all element lead wires through the insulating porcelain bushings on the back of the furnace and cut off any excess element lead wire after securing the leads to the terminal points.
8. Replace the back terminal cover.
9. Reconnect furnace to power supply.
10. Test the operation of the furnace.

To Replace The Platinel II Thermocouple:

1. Disconnect the furnace from power supply.
2. Remove the back terminal cover. (Note placement and connection of wires.)
3. Remove the screw and washer from clip holding the thermocouple in place and remove the nuts and washers on the thermocouple terminals.
4. Remove the thermocouple.
5. Insert the new thermocouple straight through hole in the chamber until the tip extends approximately 1″ into the chamber. Make sure the thermocouple lead wire with the colored bead is connected to the terminal marked positive.
6. Secure the thermocouple extension wires to the terminals (yellow to +).
7. Secure the thermocouple with clip, screw and washer.
8. Replace the back cover.
9. Reconnect furnace to power supply.
10. Test the operation of the furnace.

Note: Pull the thermocouple straight out of the hole in the chamber to avoid damage to the insulation. Note: Do not pull excessively on the internal wires.

To Replace Door Switch (Micro-Switch):

1. Disconnect the furnace from power supply.
2. Remove the screws from the front dial and the three bottom screws and lock washers on the back cover of the control section.
3. Remove the back terminal cover.
4. Disconnect the two wires on terminals T1 and T2 going to the control section.
5. Slide the control section forward.
6. Remove two screws and nuts from the door switch and slide the switch from the wire rod.
7. Disconnect the wires from the door switch. Identify or mark the wires disconnected to insure proper placement and connection when reinstalling.
8. Reconnect the wires identified or marked in step 7 to the new door switch.
9. Install the new door switch while sliding it over the wire rod and secure with the screws and nuts removed in step 6.
10. Slide the control section back and replace the screws and lock washers described in step 2.
11. Connect wire marked T1 to terminal T1 and wire marked T2 to terminal T2 with nuts removed in step 4.
12. Replace the back terminal cover with screws and lock washers removed in step 3.
13. Test operation of door switch. (See next section “To Realign Door Switches” step 5.)
14. Reconnect to power supply.

To Realign Door Switches:

1. Disconnect the furnace from power supply.
2. Loosen the setscrew on the cam. Open the door approximately 1″ and rotate the cam counterclockwise until you hear a click then rotate the cam clock- wise until you hear a click, tighten the set screw on adjusting cam.
3. Open and close the door; the switch should click when the door is opened approximately 2″ and 1″ to 2″ before the door is closed.
4. Reconnect to power supply.
5. To test the operation of the door switch: turn the power switch on, set the control to a setting high enough to keep the control from cycling, open and close the door; the cycle light should turn OFF when the door is opened approximately 2” and turn back ON 1″ to 2″ before the door is closed.

To Replace the Controller: The controller plugs into a panel mounting sleeve, which should be left permanently installed in the furnace housing. To remove the controller, release the side clips and slide the controller out. Do not attempt to dismantle this unit further; replace it with a Thermolyne loaner or a new unit.

The part numbers in the Replacement Parts list that correspond to the THERMO SCIENTIFIC FD1540M are:

The component list for the FD1540M in the Wiring Diagrams section is:

The component list for the FD1540MCN in the Wiring Diagrams section is:

The component list for the FD1540M-33 in the Wiring Diagrams section is: