THERMO SCIENTIFIC FD1540MCN (01) PDF Document

The THERMO SCIENTIFIC FD1540MCN has the following specifications:

The operating environmental 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. The altitude limit is 2,000 meters. Storage conditions are: -25°C to 65°C; 20% to 80% relative humidity.

When unpacking the THERMO SCIENTIFIC FD1540MCN, visually check for any physical damage to the shipping container and inspect the equipment surfaces adjacent to any damaged area. Unpack the furnace from the box. The owner’s manual and door handle are included in the box. After unpacking, attach the door handle and remove packing material from inside the furnace chamber. The furnace is supplied with one hearth plate.

For site selection, install the furnace on a sturdy surface and allow adequate space for ventilation. Caution must be taken that the ambient temperature does not exceed 104°F (40°C); the recommended ambient temperature is 17°C-27°C, as ambient temperatures above this level may damage the controller. Also, allow at least six inches of space between the furnace and any combustible surface to permit heat escape and avoid a fire hazard. For electrical connections, the specifications are on the specification plate on the back of the furnace. Prior to connecting to the electrical supply, ensure the two-position power switch is in the OFF position. Warning: To avoid electrical shock, this furnace must be installed by a competent electrician who ensures compatibility among furnace specification, power source and ground code requirements.

The alert signals for the THERMO SCIENTIFIC FD1540MCN are as follows:

Warning: Alerts you to a possibility of personal injury.

Caution: Alerts you to a possibility of damage to the equipment.

Note: Alerts you to pertinent facts and conditions.

Hot Surface: Alerts you to a possibility of personal injury if you come in contact with a surface during use or for a period of time after use.

For safe operation, pay attention to the alert signals throughout the manual.

To avoid electrical shock, this furnace must:

1. Use a properly grounded electrical outlet of correct voltage and current handling capacity.

2. Disconnect from the power supply prior to maintenance and servicing.

3. Have the door switch operating properly.

To avoid burns, this furnace must:

Not to be touched on the exterior or interior surfaces 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 materials.

2. Refer servicing to qualified personnel.

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 the controller’s current setpoint.

Cycle Light: 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.

Door Safety Switches: The door safety switches remove power from the heating elements when the door is opened. Open and close the door a few times, noting that the amber CYCLE light will be out when the door is open. This check must be done when the furnace is heating or when the cycle light is illuminated. If this condition is not true, consult the Troubleshooting section before proceeding.

Digital Readout: The digital readout continuously displays chamber temperature.

Warning: To avoid electric shock, the door safety switch must be operating properly.

To operate the controller on the THERMO SCIENTIFIC FD1540MCN as a single setpoint controller:

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.

If you want to change the setpoint on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN, 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 on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN, 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 on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN, press the SCROLL button twice. Then press the UP or DOWN button to display the value. This value is read-only and cannot be changed.

The controller parameters listed under the Home Display for the 8 Segment Programmable Model w/OTP of the THERMO SCIENTIFIC FD1540MCN are:

°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.

The parameters listed under the Program Run List (run LiSt) for the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN are:

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.”

The parameters listed under the Program Edit List (ProG LiSt) for the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN are:

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.

The parameters listed under the Alarm List (AL LiSt) for the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN are:

IdHi: Deviation High Alarm.

The parameters listed under the Autotune List (Atun LiSt) for the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN are:

tunE: One-shot autotune enable.

drA: Adaptive tune enable.

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

The parameters listed under the Pid LiSt for the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN are:

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)

The alarms that the controller will flash in the home display if detected on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN are:

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 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) on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN.

The OTP on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN 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. A recommended value is 20° above your working temperature to provide protection for your workload.

The following alarm messages are factory default settings and may vary if you have changed the configuration of your controller on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN:

IDHI = 50°C

2FSH = 1025°C

To set the holdback type (Hb) on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN:

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 (Hb.U) on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN:

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 the Ramp Units (rmP.U) on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN:

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 the Dwell Units (dwL.U) on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN:

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 (CYC.n) on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN:

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 set the segment type rmP.r (Ramp) on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN to ramp linearly at a set rate to a specified temperature:

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 “Hb.”

5. Press the UP or DOWN button to toggle between “bAnd, Hi, Lo and OFF.”

6. Press the SCROLL button until display reads, “tGt.”

7. Press the UP or DOWN button to set a target setpoint.

8. Press the SCROLL button until display reads, “rAtE.”

9. Press the UP or DOWN button to select a value in ramp units (seconds, minutes or hours; set in the “rmP.U” parameter).

To set the segment type rmP.t on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN to ramp to a specified temperature at a set time:

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 set the segment type dwell on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN to maintain a constant temperature for a specified time:

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 set the segment type StEP on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN to climb instantaneously from the current temperature to a specified temperature:

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 on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN:

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 level) and “rSET” (reset will revert back to setpoint in Single Setpoint mode).

To run a program on the 8 Segment Programmable Models of the THERMO SCIENTIFIC FD1540MCN, press the RUN/HOLD button (The RUN light will illuminate).

To put a running program on hold on the 8 Segment Programmable Models of the THERMO SCIENTIFIC FD1540MCN, press the RUN/HOLD button (The HOLD light will illuminate).

To cancel a program on the 8 Segment Programmable Models of the THERMO SCIENTIFIC FD1540MCN, hold the RUN/HOLD button down until the RUN and HOLD lights go off.

The purpose of tuning the controller for the THERMO SCIENTIFIC FD1540MCN is to match the characteristics of your furnace 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, and rapid restoration of the setpoint temperature when external disturbances cause deviations from the setpoint. The controller has automatic tuning features that install optimum tuning parameters for the best temperature accuracy. It is recommended to tune the furnace to your specific application to obtain the best results.

The display will flash “tu.ER” if an error occurs during tuning on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN. To clear the error and restart tuning, simultaneously press the PAGE and SCROLL buttons and follow the steps outlined in “Autotuning.”

Gain scheduling on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN is the automatic transfer of control between two sets of PID values at a presettable process value. The G.SP gain schedule setpoint is factory set at 700° C. The G.SP must be adjusted to 200°C from the desired setpoint temperature when tuning.

To set the transfer point 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.

To tune the furnace using autotuning on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN:

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.

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

To tune the furnace using adaptive tuning on the 8 Segment Programmable Model w/OTP controller of the THERMO SCIENTIFIC FD1540MCN:

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.

Furnace Loading recommendations for the THERMO SCIENTIFIC FD1540MCN are:

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.

Caution: 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.

Preventive Maintenance warnings for the THERMO SCIENTIFIC FD1540MCN:

Warning: 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.

Warning: Disconnect the furnace from power supply before cleaning.

Warning: 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; remove fume forming material before heating (e.g., cleaning cutting oil from tool steel).

The resistance wire is high-grade nickel-chromium. Avoid spilling chemicals like sulphur, halogens, and cyanides in the furnace or heating them hotter than necessary.

All heating elements are considered expendable and replacement is expected. Keep the furnace clean by running it empty up to 871°C (1600°F) occasionally with the door slightly open for approximately two hours to burn off contamination.

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

The thermocouple can become oxidized, causing inaccurate readings. If you regularly use your furnace, change the thermocouple once every six months to assure controller reading accuracy.

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

To Replace a Heating Element on the THERMO SCIENTIFIC FD1540MCN:

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 on the THERMO SCIENTIFIC FD1540MCN:

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.

To Replace Door Switch (Micro-Switch) on the THERMO SCIENTIFIC FD1540MCN:

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.

To Realign Door Switches on the THERMO SCIENTIFIC FD1540MCN:

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 on the THERMO SCIENTIFIC FD1540MCN, 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.

If the cycle light does not illuminate on the THERMO SCIENTIFIC FD1540MCN, possible causes and corrective actions are:

If the furnace does not heat on the THERMO SCIENTIFIC FD1540MCN, possible causes and corrective actions are:

If the Door switch does not cut power to heating elements on the THERMO SCIENTIFIC FD1540MCN, the possible cause is the Door switch not functioning, and the corrective action is to Realign or replace door safety switch.

If the Controller over-temp. does not cut power to the furnace chamber on the THERMO SCIENTIFIC FD1540MCN, possible causes and corrective actions are:

Troubleshooting steps for Slow heatup on the THERMO SCIENTIFIC FD1540MCN:

Troubleshooting steps for Repeated element burnout on the THERMO SCIENTIFIC FD1540MCN:

Troubleshooting steps for Inaccurate temperature readout on the THERMO SCIENTIFIC FD1540MCN: