THERMO SCIENTIFIC FD1540M-33 (01) PDF Document

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

A program mode can be set by changing the “TM.CFG” variable (in the ‘Timer’ menu) to “DWEL, DELY, or SF.ST. Note: value of “None” deactivates the timer.

A Ramp rate may be set by changing the “SP.RAT” variable (in the ‘SP’ menu) to a value. The Ramp rate units are set with the “RAMPU❞ variable (in the ‘SP’ menu). The selections are Hour / Min / Sec.

The Dwell time can be set by changing the “DWELL” variable (in the ‘Timer’ menu) to the desired value. Dwell time units are set with the “TM.RES” variable (in the ‘Timer’ menu). The selections are Hour / Min.

The program Status can be set by changing the “T.STAT” variable to “run”, “hold”, or “res.” This variable will start, hold, or stop the program.

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 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.

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.

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.

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.

°C: measured temperature in Celsius. Temperature units cannot be changed without entering the configuration.

OP: % output power demand; displayed in lower display (cannot be changed).

C.id: Controller identification number.

IdHi: Deviation High Alarm.

tunE: One-shot autotune enable.

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.”

Hb: Press the UP or DOWN ARROW to select the holdback type [OFF (disables holdback), Lo (deviation low holdback), Hi (deviation high holdback) or bAnd (deviation band holdback)] for the entire program. The controller will default to “OFF”

Hb.U: Press the UP or DOWN ARROW to select the holdback value (in display units).

rmP.U: Press the UP or DOWN ARROW to toggle between ramp units (SEc, min or Hour). Controller will default to “SEC.”

dwL.U: Press the UP or DOWN ARROW to toggle between dwell units (SEc, min or Hour). Controller will default to “SEC.”

Cyc.n: Press the UP or DOWN ARROW to set the number of program cycles (1 to 999 or cont). The controller will default to “cont.”

SEG.n: Press the UP or DOWN ARROW to select the segment number (1-8 in 8 segment models).

tYPE: Press the UP or DOWN ARROW to select the segment type [End (end of program), rmP.r = ramp rate (ramp to a specified setpoint at a set rate), rmp.t = ramp time (ramp to a specified temperature in a set time), dwEll (to maintain a constant temperature for a set time), StEP (climb instantaneously from current to specified temperature). The controller will default to “End.” Other parameters used with tYPE include; tGt target setpoint), Rate (rate of temperature increase) and dur (time to target setpoint or time to dwell)].

End.t: End segment type: dwELL (dwell continuous), rSEt (reset) and S OP (End Segment Output power level.

IdHi: Deviation High Alarm.

tunE: One-shot autotune enable.

drA: Adaptive tune enable.

drA.t: Adaptive tune trigger level in display units. Range = 1-9999.

G.SP (Gain Setpoint): Is the temperature at which the controller switches from the (SEt 1) PID values to the (SEt 2) PID values.

Pb: Proportional band in display units. (SEt 1)

ti: Integral time in seconds. (SEt 1)

td: Derivative time in seconds. (SEt 1)

Pb2: Proportional band. (SEt 2)

ti2: Integral time in seconds. (SEt 2)

td2: Derivative time in seconds. (SEt 2)

IdHi: PV deviation high alarm.

2FSH: PV full scale high alarm.

3FSL: PV full scale low alarm.

LCr: Load current low alarm.

HCr: Load current high alarm.

S.br: Sensor break: check that sensor is connected correctly.

L.br: 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.

SSr.F: Solid state relay failure indications in a solid state relay: indicates either an open or short circuit in the SSR.

Htr.F: Heater failure: Indication that there is a fault in the heating circuit: indicates a blown fuse, missing sup- ply 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).

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 = 1025°C.

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.

1. Switch the circuit breaker to the “ON” position. The setpoint temperature presently set in the controller will appear in the lower display. (The upper display indicates the actual chamber temperature.)

2. To change the setpoint, press the UP or DOWN button until the desired setpoint value is displayed; then release the button.

3. The furnace will begin to heat if the new setpoint temperature is higher than the present chamber temperature.

Note: 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 purpose of tuning your furnace is to match the characteristics of your controller to the characteristics of the process being controlled. Good control is evidenced by: stable, straight-line control of the setpoint temperature with no fluctuations; No overshoot or undershoot of the setpoint temperature; rapid restoration of the setpoint temperature when external disturbances cause deviations from the setpoint.

This controller has automatic tuning features which install optimum tuning parameters to give the best temperature accuracy. No manual loading of tuning parameters is needed. We recommend that you tune the furnace to your specific application to obtain the best results. To provide the best temperature accuracy possible, use these features when you install your furnace and whenever you change your application or procedure.

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.”

Gain scheduling is the automatic transfer of control between two sets of PID values. The controller does this at a presettable process value. Gain scheduling is used for difficult control processes which show large changes in their response time or sensitivity at high or low temperatures, or when heating or cooling.

The G.SP gain schedule setpoint is factory set at 700° С. The G.SP must be adjusted to 200°C from the desired setpoint temperature when tuning.

If gain scheduling has been enabled, “G.SP will appear at the top of the PID list. This sets the value at which the transfer will occur. When the process value is below this level, PID1 will be active and when it is above, Pid2 will be active. Set a value between the control regions that show the greatest change to achieve the best point of transfer.

1. Load your furnace with a load similar to your normal load and close the door.

2. Set the setpoint temperature.

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

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.

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.

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.

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 # PΗΧ2.

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.

Disconnect the furnace from power supply before cleaning.

Opening the door for an extended period of time will cause the painted surfaces above the door to be discolored or burnt.

Contamination is a major cause of element failure, therefore, when possible, remove the fume forming material before heating (e.g., cleaning cutting oil from tool steel).

The resistance wire is high-grade nickel-chromium. Some chemicals, notably sulphur, halogens, and cyanides, attack this wire at high temperatures, so avoid spilling these chemicals in the furnace or heating them any hotter than necessary. The refractory cement helps to protect the wire, but will not completely immunize it from damage.

All heating elements must be considered expendable, and replacement is expected; however, reasonable care in their use will greatly extend the service they will give. As the manufacturer has no control over the use or care of the elements, no specific service guarantee can be made.

Housekeeping is vital to your electric furnace—KEEP IT CLEAN! Run your furnace up to 871°C (1600°F) empty occasionally to burn off the contamination that may exist on the insulation and elements. Run for approximately two hours with the door slightly open. See warning.

Element life is reduced somewhat by repeated heating and cooling. If the furnace is to be used again within a few hours, it is best to keep it at the operating temperature or at a reduced level such as 260°C (500°F).

During normal use, the thermocouple in your furnace can become oxidized and cause inaccurate readings; therefore, we suggest that if you regularly use your furnace you should change your thermocouple once every six months to assure the accuracy of your controller readings.

Clean by wiping the outside case of the unit with a damp cloth and mild soap solution.

If the cycle light does not illuminate, the possible causes are: The furnace is not connected to power supply, Incorrect power source, ON and OFF power switch defective, Defective cycle light, or Door switch malfunction.

The corrective actions are: Reconnect furnace to power supply, Connect to correct power source, Replace power switch, Replace cycle light, or Realign or replace furnace door safety switch.

If the furnace does not heat, the possible causes are: No power, Defective electrical hookup, Thermocouple has oxidized and opened the circuit, Controller malfunction, Heating elements burned out, Solid state relay defective, Door switch malfunction, Defective OTP relay, or Defective solid state relay.

The corrective actions are: Check power source and fuses or breakers, Repair electrical hookup, Replace thermocouple, Replace controller, Replace defective elements, Replace solid state relay, Re-align or replace door switch, or Replace relay.

If the door switch does not cut power to heating elements, the possible cause is: Door switch not functioning.

The corrective action is: Realign or replace door safety switch.

If the controller over-temp. does not cut power to the furnace chamber, the possible causes are: Alarm output device malfunction, OTP relay malfunction, or Element shorted to ground.

The corrective actions are: Replace controller, Replace relay, or Replace faulty element.

If there is slow heatup, the possible causes are: Low line voltage, Wrong heating element, Heating element burned out, or Heavy load in chamber.

The corrective actions are: Install line of sufficient size and proper voltage. (Isolate furnace from other electrical loads.), Install proper element, Replace element, or Lighten load in chamber to allow heat to circulate.

If there is repeated element burnout, the possible causes are: Overheating furnace, Heating harmful materials, or Contamination present from previous burnout.

The corrective actions are: Keep furnace under maximum temperature. Closer supervision of control setting., Enclose material in container. Clean up spills in and on chamber. Ventilate chamber by leaving top vent slightly open when heating known harmful reagents., or Replace insulation material.

If there is inaccurate temperature readout, the possible causes are: Oxidized or contaminated thermocouple, Poor thermocouple connection, Improper loading procedures, Poor ventilation of control, or Thermocouple connections reversed.

The corrective actions are: Replace thermocouple, Tighten connections, Use proper loading procedures, Clear area around furnace control, or Reconnect thermocouple correctly.

Warning: To avoid electrical shock, this furnace must always be disconnected from the power supply prior to maintenance and service.

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.

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.

Note: Pull the thermocouple straight out of the hole in the chamber to avoid damage to the insulation.

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.

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.

Note: Center the rod from front to back of hole in control case before tightening screws.

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.

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.

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 following table lists replacement parts applicable to the THERMO SCIENTIFIC FD1540M-33:

The following table lists components for the wiring diagram for the THERMO SCIENTIFIC FD1540M-33:

The following table lists components for the wiring diagram for the THERMO SCIENTIFIC FD1540M-33: