THERMO SCIENTIFIC FD1545M (01) PDF Document

For continuous use (operating the furnace for more than 3 hours), the recommended temperature range for the THERMO SCIENTIFIC FD1545M is 100°C-1066°C. For intermittent use (operating the furnace for less than 3 hours), the recommended temperature range is 1066°C-1200°C.

The electrical specifications for the THERMO SCIENTIFIC FD1545M are:

• VOLTS: 120
• AMPS: 18.6
• WATTS: 2230
• FREQ: 50/60
• PHASE: 1

The environmental conditions are:

Operating: 17°C – 27°C; 20% to 80% relative humidity, non-condensing. Installation Category II (over-voltage) in accordance with IEC 664. Pollution Degree 2 in accordance with IEC 664. Altitude limit: 2,000 meters.

Storage: -25°C to 65°C; 20% to 80% relative humidity.

When unpacking the THERMO SCIENTIFIC FD1545M:

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.

Your 120V Type 1500 furnace may be wired either directly through a conduit system or by using a power cord and plug which conforms to the National Electrical Codes and electrical code requirements of your area. The terminal block to be used in wiring is located on the lower rear of the furnace. For 120V supply connections, use 14 AWG or larger wires suitable for at least 105°C (221°F).

Open and close the door a few times; note 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.

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 parameter is A.TUNE (tune): One-shot autotune enable.

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

• 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.

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 “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.

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.

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

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.

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.

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.

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

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 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, 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. Then 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 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 twice. Press the UP or DOWN button to display the value. This value is a read-only value and cannot be changed.

The RUN/HOLD button performs the following functions:

• 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.

The factory default alarm messages are:

• IDHI = 50°C
• 2FSH = 1025°C

The “Deviation High” alarm (idHi) 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.

To operate the controller 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.

Holdback consists of a value and a type. If the measured value lags behind the setpoint by an undesirable amount during a ramp or dwell, the holdback feature can be used to freeze the program at its current state (the HOLD light will flash). The program will resume when the error comes within the holdback value. OFF: holdback is disabled. Lo (Deviation Low Holdback): holds the program back when process variable deviates below the setpoint by more than the holdback value. Hi (Deviation High Holdback): holds the program back when process variable deviates above the setpoint by more than the holdback value. bAnd (Deviation Band Holdback): combines the features of the high and low deviation holdback in that it holds the program back when the process variable deviates above or below the setpoint by more than the hold- back value.

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 hold- back value.

Ramp units are time units which are used in “rmP.r” segments (ramp to a setpoint at degrees per second, minute or hour) and “rmP.t” segments (ramp to setpoint in a specific amount of time). To set the 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.

Dwell units are time units which are used in “dwELL” segments (amount of time to remain at a specific temperature). To set the 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.

Set the number of times a group of segments or programs are to be repeated by following the steps listed below:

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:

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:

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:

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:

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:

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 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 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.

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.”

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 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.

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.

Furnace Loading best practices include:

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

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 refractory cement helps to protect the wire, but will not completely immunize it from damage.

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

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.

If the Cycle light does not illuminate:

• Possible Cause: The furnace is not connected to power supply. Corrective Action: Reconnect furnace to power supply.
• Possible Cause: Incorrect power source. Corrective Action: Connect to correct power source.
• Possible Cause: ON and OFF power switch defective. Corrective Action: Replace power switch.
• Possible Cause: Defective cycle light. Corrective Action: Replace cycle light.
• Possible Cause: Door switch malfunction. Corrective Action: Realign or replace furnace door safety switch.

If the Furnace does not heat:

• Possible Cause: No power. Corrective Action: Check power source and fuses or breakers.
• Possible Cause: Defective electrical hookup. Corrective Action: Repair electrical hookup.
• Possible Cause: Thermocouple has oxidized and opened the circuit. Corrective Action: Replace thermocouple.
• Possible Cause: Controller malfunction. Corrective Action: Replace controller.
• Possible Cause: Heating elements burned out. Corrective Action: Replace defective elements.
• Possible Cause: Solid state relay defective. Corrective Action: Replace solid state relay.
• Possible Cause: Door switch malfunction. Corrective Action: Re-align or replace door switch.
• Possible Cause: Defective OTP relay. Corrective Action: Replace relay.
• Possible Cause: Defective solid state relay. Corrective Action: Replace relay.

If the Door switch does not cut power to heating elements:

• Possible Cause: Door switch not functioning. Corrective Action: Realign or replace door safety switch.

If the Controller over-temp. does not cut power to the furnace chamber:

• Possible Cause: Alarm output device malfunction. Corrective Action: Replace controller.
• Possible Cause: OTP relay malfunction. Corrective Action: Replace relay.
• Possible Cause: Element shorted to ground. Corrective Action: Replace faulty element.

If Slow heatup occurs:

• Possible Cause: Low line voltage. Corrective Action: Install line of sufficient size and proper voltage. (Isolate furnace from other electrical loads.)
• Possible Cause: Wrong heating element. Corrective Action: Install proper element.
• Possible Cause: Heating element burned out. Corrective Action: Replace element.
• Possible Cause: Heavy load in chamber. Corrective Action: Lighten load in chamber to allow heat to circulate.

If Repeated element burnout occurs:

• Possible Cause: Overheating furnace. Corrective Action: Keep furnace under maximum temperature. Closer supervision of control setting.
• Possible Cause: Heating harmful materials. Corrective Action: Enclose material in container. Clean up spills in and on chamber. Ventilate chamber by leaving top vent slightly open when heating known harmful reagents.
• Possible Cause: Contamination present from previous burnout. Corrective Action: Replace insulation material.

If an Inaccurate temperature readout occurs:

• Possible Cause: Oxidized or contaminated thermocouple. Corrective Action: Replace thermocouple.
• Possible Cause: Poor thermocouple connection. Corrective Action: Tighten connections.
• Possible Cause: Improper loading procedures. Corrective Action: Use proper loading procedures.
• Possible Cause: Poor ventilation of control. Corrective Action: Clear area around furnace control.
• Possible Cause: Thermocouple connections reversed. Corrective Action: Reconnect thermocouple correctly.

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.