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  5. Operation Manual

Barnstead 47900 Operation Manual

Manual is about: Series 1165, 1166 & 1205

Summary of 47900

  • Page 1

    Type 47900 & 48000 furnaces operation manual series 1165, 1166 & 1205 single setpoint models f47910, f47910-26, f47910-33, f47914, f47915, f48010, f48010-26, f48010-33, f48014, f48015, f48015-60, f48018 single setpoint models f47920, f47920-26, f47920-33, f47924, f47925, f48020, f48020-26, with otp ...

  • Page 2

    Safety information ..............................................................................................................................................3 alert signals...............................................................................................................................

  • Page 3

    Your barnstead thermolyne type 47900 or 48000 furnace has been designed with function, reliability and safety in mind. It is your responsi- bility to install it in conformance with local electri- cal codes. For safe operation, please pay atten- tion to the alert signals throughout the manual. This m...

  • Page 4

    Warning this warning is presented for compliance with california proposition 65 and other regulatory agen- cies and only applies to the insulation in this prod- uct. This product contains refractory ceramic, refrac- tory ceramic fiber or fiberglass insulation, which can produce respirable dust or fi...

  • Page 5

    Intended use the type f47900 and f48000 furnaces are general purpose laboratory and heat treating furnaces. For optimum element life, barnstead international recommends observ- ing these temperature ranges: from 100°c (212°f) to 1093°c (2000°f) continuous use or from 1093°c (2000°f) to 1200c (2192°f...

  • Page 6

    6 general specifications type f47900 models dimensions in inches (cm): chamber: 5 (12.7) w x 4 (10.2) h x 6 (15.2) d overall: 11.25 (28.6) w x 18 (45.7) h x 15.5 (39.4) d weight: 37 lb. (16.8 kg) electrical ratings: volts: 220-240 100 120 amps: 4.2 7.5 8.3 watts: 1000 750 1000 frequency: 50/60 50/60...

  • Page 7

    7 g eneral s pecifications environmental conditions operating: 17°c to 27°c; 20% to 80% relative humidity, non-condensing. Installation category ii (overvoltage) in accordance with iec 664. Pollution degree 2 in accordance with iec 664. Altitude limit: 2,000 meters. Storage: -25°c to 65°c; 20% to 80...

  • Page 8

    8 1. Visually check for any physical dam- age to the shipping container. 2. Inspect the equipment surfaces that are adjacent to any damaged area. 3. Open the furnace door and remove the packing material from inside the furnace chamber. 4. Vacuum the chamber prior to use to remove the insulation dust...

  • Page 9

    9 site selection install furnace on a sturdy surface and allow adequate space for ventilation. Electrical connections the electrical ratings are located on the spec- ification plate on the back of the furnace. Consult barnstead international if your electri- cal service is different than those liste...

  • Page 10

    10 power switch both the on/off power switch and the digital display will illuminate when power is switched on. The furnace will begin to heat to its con- troller's current setpoint. (see the instructions for your type of controller for information on checking and setting the setpoint.) cycle light ...

  • Page 11

    11 the single setpoint model furnace controller is a single setpoint controller which provides a single digital display to indicate the current chamber temperature or setpoint temperature. This temperature controller features sensor break protection and self-tuning capability. The single setpoint mo...

  • Page 12

    12 down button: allows you to decrease a value. Up button: allows you to increase a value. To view or change the setpoint to view the setpoint, press and release the up or down buttons. If you want to change the set- point, continue pressing until the desired setpoint value is displayed and then rel...

  • Page 13

    13 op: % output power demand. Idhi: deviation high alarm. Al list idhi: deviation high alarm. Atun list tune: one-shot autotune enable. Pid list pb: proportional band (in display units). Ti: integral time in seconds. Td: derivative time in seconds. Accs list code: access code (code need- ed to enter...

  • Page 14

    14 ld.F: heater circuit fault: indication of either an open or short solid sate relay, a blown fuse, missing supply or open circuit heater. Sensor break protection this controller provides sensor break protec- tion in the event the thermocouple opens. If an open thermocouple condition occurs, the di...

  • Page 15

    15 tuning this controller incorporates a self-tuning fea- ture which determines the optimum control parameters for the best temperature accuracy with your load and setpoint. Use this feature the first time you use your furnace and each time you change either your setpoint or the type of load you are...

  • Page 16

    16 functions this type of controller has single ramp and dwell programming capabilities. The ramp and dwell can be configured to five different modes. 1. Mode 1 (opt. 1) is a ramp (if needed) to the setpoint temperature, a dwell, and then a cool down. 2. Mode 2 (opt. 2) is the same as mode 1, except...

  • Page 17

    • a ramp rate may be set by changing the “sprr” variable to a value. The ramp rate units are in degrees per minute. • the dwell time can be set by changing the “dwell” variable to the desired value. Dwell time units are in minutes. • the program status can be set by changing the “stat” variable to “...

  • Page 18

    18 running the program 1. Press the scroll button until “stat” is displayed, set to “run” with the up or down buttons. 2. Press the page button to display actual temperature. Stopping the program press the scroll button until “stat” is dis- played, set to “off” with the up or down buttons. Clearing ...

  • Page 19

    19 8 segment & 4x16 segment programmable models w/otp the 8 segment programmable controller consists of a microprocessor based three- mode pid (proportional, integral, derivative), programmable temperature controller with over-temperature protection and appropriate output switching devices to contro...

  • Page 20

    20 to change the setpoint if you want to change the setpoint, press the up or down button until the desired setpoint value is displayed in the lower display and then release the button. To view display units from the home display press the scroll button. The display will briefly show the tem- peratu...

  • Page 21

    21 • 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 wi...

  • Page 22

    22 prg: program number (displayed when a pro- gram is running; 4x16 programmable models only.) idhi: deviation high alarm tune: one-shot autotune enable. Run list (program run list) prg: currently running program (only used on 4x16 programmable models) stat: displays the program status [off, run (ru...

  • Page 23

    23 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...

  • Page 24

    24 dra: adaptive tune enable. Dra.T: adaptive tune trigger level in display units. Range = 1 9999. Pid list g.Sp (gain setpoint): is the temperature at which the controller switches from the (set1) pid values to the (set 2) pid values. Pb: proportional band in display units. (set 1) ti: integral tim...

  • Page 25

    25 lcr: load current low alarm. Hcr: load current high alarm. S.Br: sensor break: check that sensor is con- nected correctly. L.Br: loop break: check that the heating cir- cuits are working properly. Ld.F: heater circuit fault: indication of either an open or short solid sate relay, a blown fuse, mi...

  • Page 26

    26 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. ...

  • Page 27

    27 parameters” at the beginning of this section, follow the procedures outlined in the proceed- ing sections of this manual. Creating a new program or editing an existing program (4x16 segment programmable models only) the same steps are used when creating a new program and editing an existing progr...

  • Page 28

    28 lo (deviation low holdback): holds the pro- gram back when process variable deviates below the setpoint by more than the holdback value. Hi (deviation high holdback): holds the pro- gram back when process variable deviates above the setpoint by more than the holdback value. Band (deviation band h...

  • Page 29

    29 “rmp.R” segments (ramp to a setpoint at degrees per second, minute or hour) and “rmp.T” segments (ramp to setpoint in a spe- cific amount of time). See “setting the segment type” for an explanation on how to set a ramp segment. 1. Press the page button until you reach the program list (prog list)...

  • Page 30

    30 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. Setting the segment type there are five segment types. Proceed with the following...

  • Page 31

    31 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). Rmp.T 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 d...

  • Page 32

    32 4. Press the scroll button until dis- play 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). Step to climb instantaneously from the current temperature to a specified temperature. 1. Press the page button until ...

  • Page 33

    33 3. Press the up or down button until dis- play reads, “call.” 4. Press the scroll button until display reads, “prg.N.” 5. Press the up or down button to select a program number to be linked. 6. Press the scroll button until display reads, “cyc.N.” 7. Press the up or down button to select the numb...

  • Page 34

    2. Press the scroll button until display reads, “tgt.” 3. Press the up or down button to set the target setpoint temperature. Running a program (8 segment programmable models) to run a program, press the run/hold but- ton. (the run light will illuminate.) running a program (4x16 segment programmable...

  • Page 35

    35 holding a program to put a running program on hold, press the run/hold button. (the hold light will illumi- nate.) cancelling a program to cancel a program, hold the run/hold but- ton down until the run and hold lights go off. Tuning your furnace the purpose of tuning your furnace is to match the...

  • Page 36

    36 gain scheduling g.Sp: gain scheduling gain scheduling is the automatic transfer of control between two sets of pid values. The 2416 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 sensi...

  • Page 37

    37 autotuning 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...

  • Page 38

    38 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. 8 s egment & 4 x 16 s egment p rogrammable...

  • Page 39

    39 • for best results, use only the center two-thirds of the furnace chamber. • if you are heating a number of small parts, spread them throughout the center two-thirds of the furnace cham- ber. • keep objects away from the thermo- couple. • use insulated tongs and mittens when loading and unloading...

  • Page 40

    40 this unit is equipped with a venting system on the top of the furnace. This is for the removal of fumes from the chamber of the unit. Contamination is a major cause of element failure, therefore, remove all fume forming material before heating. (e.G. Clean cutting oil from tool steel). Housekeepi...

  • Page 41

    41 the troubleshooting section is intended to aid in defining and correcting possible service problems. When using the chart, select the problem category that resembles the malfunc- tion. Then proceed to the possible causes category and take necessary corrective action. Problem possible causes corre...

  • Page 42

    42 door switch does door switch not functioning. Realign or replace door safety not cut power to switch. Heating elements. Controller over-temp. Alarm output device malfunction. Replace controller. Does not cut power to furnace chamber. Otp relay malfunction. Replace relay. Element shorted to ground...

  • Page 43

    43 inaccurate temp. Oxidized or contaminated replace thermocouple. Readout. Thermocouple. Poor thermocouple connection. Tighten connections. Improper loading procedures. Use proper loading procedures. Poor ventilation of control. Clear area around furnace control. Thermocouple connections reconnect ...

  • Page 44

    44 to replace a heating element 1. Disconnect the furnace from the power supply. 2. Remove the back terminal cover of the furnace. (note placement and connection of wires.) 3. Loosen the nuts on the terminal points of the four heating element lead wires and remove the element wires from the terminal...

  • Page 45

    45 to replace a chromel/alumel thermocouple (all furnaces) 1. Disconnect the furnace from the power supply. 2. Remove both back covers. (note placement and connection of wires.) 3. Remove the clip holding the thermo- couple in place (1 screw), and remove the two screws on the ther- mocouple terminal...

  • Page 46

    46 8. Replace both back covers. 9. Reconnect to the power supply. 10. Test the operation of the furnace. To replace door switches (micro-switch) 1. Disconnect the furnace from the power supply. 2. Remove the screws on the front dial and the screws and lock washers on the back cover. 3. Slide the con...

  • Page 47

    47 described in step 2. 10. Reconnect to the power supply. 11. Test the operation of the door switch- es. (see next section, step 8.) to realign door switches (micro-switch): 1. Disconnect the furnace from the power supply. 2. Remove the lower rear cover. 3. With the door closed, loosen the screws o...

  • Page 48

    48 and close the door; the cycle light should turn off when the door is opened approximately 3" 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 remov...

  • Page 49

    49 single setpoint models f47910, f47910-26, f47910-33, f47914, f47915, f48010, f48010-26, f48010-33, f48014, f48015, f48015-60, f48018 part number description qty. Notes cn71x96 controller 1 f48010-33 only . Cn71x73 controller 1 all models except f48010-33 cax94 line filter 1 “-33” models only. El4...

  • Page 50

    50 8 segment programmable models with otp f47920-80, f47920-26-80, f47920-33-80, f47924-80, f47925-80, f48020-80, f48020-26-80, f48020-33-80, f48024-80, f48025-80, f48025-60-80, f48028-80 part number description qty. Notes cn71x97 controller 1 -33 models only . Cn71x74 controller 1 all models except...

  • Page 51

    51 wiring diagrams s ingle s etpoint c ontrol v- 1b tc1 red yello w tb1 ab v+ aa n l + - cn1 1a description ref . No . Cn1 contr ol dia gram component list model no . And our p a r t no .(s) cn71x73 f47910 f47910-26 f47914 f47915 ds1 pilo t light plx104 plx104 plx103 plx103 hea ting element h1 el479...

  • Page 52

    52 w iring d iagrams s ingle s etpoint c ontrol w /otp tc- tc+ tc1 t4 t3 t1 t2 h1 ry 1 ry 2 1 4 2 3 + h2 line l1 l2 gnd line load f47920-33 onl y ds1 g line l2 l1 g gnd s3 s2 l1 l2 s1 fl1 f1 f2 tb1 red yel - cn1 v- 1b - ab v+ aa + 1a n l wiring dia gram no tes: d ashed lines " " deno te 100/120 v . ...

  • Page 53

    53 w iring d iagrams 8 s egment p rogrammable c ontrol f47920-33-80 onl y ry 1 f2 f1 ds1 gnd fl1 load line gnd g l2 line g l2 l1 line l1 h1 t2 t1 h2 t3 t4 1a 1b 3b 3a 2b 2a hf he hd hc hb ha n l v- v+ vi yl w tc+ tc1 tb1 gnd s3 red tc- ry 2 1 4 2 3 s2 -+ tc1 165x1 fzx30 fzx30 swx163 cax94 plx82 r yx...

  • Page 54

    54 w iring d iagrams 4 x 16 s egment p rogrammable c ontrol yl w tc+ tc1 tb1 gnd 1a 1b 3b 3a 2b 2a s3 red tc- ry 2 1 4 2 3 s2 ry 1 s1 hf he hd hc hb ha n l v- v+ vi ds1 f47950-33 onl y f1 f2 gnd line load fl1 gnd l1 line l1 l2 g line l2 g sg td rd 7 3 2 o b w hd he hf + - connect or communica tion c...

  • Page 55

    55 w iring d iagrams s ingle s etpoint c ontrol v- 1b tc1 red yello w tb1 ab v+ aa n l + - cn1 1a description ref . No . Cn1 contr ol dia gram component list model no . And our p a r t no .(s) cn71x73 f48010 f48010-26 f48014 f48015, f48015-60 ds1 pilo t light plx82 plx82 plx76 plx76 hea ting element...

  • Page 56

    56 w iring d iagrams s ingle s etpoint c ontrol w /otp tc- tc+ tc1 t4 t3 t1 t2 h1 ry 1 ry 2 1 4 2 3 + h2 line l1 l2 gnd line load f48020-33 onl y ds1 g line l2 l1 g gnd s3 s2 l1 l2 s1 fl1 f1 f2 tb1 red yel - cn1 v- 1b - ab v+ aa + 1a n l cycle wiring dia gram no tes: d ashed lines " " deno te 100/12...

  • Page 57

    57 w iring d iagrams 8 s egment p rogrammable c ontrol f47950-33 onl y ry 1 f2 f1 ds1 gnd fl1 load line gnd g l2 line g l2 l1 line l1 h1 t2 t1 h2 t3 t4 1a 1b 3b 3a 2b 2a hf he hd hc hb ha n l v- v+ vi yl w tc+ tc1 tb1 gnd s3 red tc- ry 2 1 4 2 3 s2 + - s1 d ashed lines " " wiring dia gram wire conne...

  • Page 58

    58 w iring d iagrams 4 x 16 s egment programmable control yl w tc+ tc1 tb1 gnd 1a 1b 3b 3a 2b 2a s3 red tc- ry 2 1 4 2 3 s2 ry 1 s1 hf he hd hc hb ha n l v- v+ vi ds1 f48050-33 onl y f1 f2 gnd line load fl1 gnd l1 line l1 l2 g line l2 g sg td rd 7 3 2 o b w hd he hf + - connect or communica tion cab...

  • Page 59

    59 ordering procedures please refer to the specification plate for the complete model number, serial number, and series number when requesting service, replacement parts or in any correspondence concerning this unit. All parts listed herein may be ordered from the barnstead international dealer from...

  • Page 60

    60 one year limited warranty barnstead international (“barnstead”) warrants that if a product manufactured by barnstead shall be free of defects in materials and workmanship for one (1) year from the first to occur of (i) the date the prod- uct is sold by barnstead or (ii) the date the product is pu...