BARNSTEAD|THERMOLYNE CORPORATION Type F6000 Furnace OPERATION MANUAL AND PARTS LIST Series 1060 MODEL NUMBER F6010 F6010-33 F6018 F6020C F6020C-33 F6020C-33-60 F6020C-33-60-80 F6020C-33-80 F6020C-60 F6020C-60-80 F6020C-80 F6028C F6028C-60 F6028C-60-80 F6028C-80 F6030CM F6030CM-33 F6030CM-33-60 F6030CM-60 F6038CM F6038CM-60 VOLTAGE 220-240 220-240 208 220-240 220-240 220-240 220-240 220-240 220-240 220-240 220-240 208 208 208 208 220-240 220-240 220-240 220-240 208 208 CONTROL Basic Automatic Basic Autom
Table of Contents Important Information This manual contains important operating and safety information. The user must carefully read and understand the contents of this manual prior to the use of this equipment. Safety Information ..............................................................................................................................................3 Alert Signals...........................................................................................................................
Safety Information Alert Signals Warning Warnings alert you to a possibility of personal injury. Your Thermolyne F6000 type furnace has been designed with function, reliability, and safety in mind. It is your responsibility to install it in conformance with local electrical codes. For safe operation, please pay attention to the alert signals throughout the manual. Warning Please note the following WARNINGS: Caution Cautions alert you to a possibility of damage to the equipment.
Introduction Intended Use The Type 6000 Basic Automatic, Automatic and Programmable furnaces are general laboratory and heat treating furnaces. For optimum element life, observe the following temperature ranges. These furnace models are intended for applications requiring temperatures from 100°C (212°F) to 1093°C (2000°F) for continuous use, or temperatures from 100°C (212°F) to 1200°C (2192°F) for intermittent use.
INTRODUCTION MODEL NUMBER DIGITAL F6020C-80 F6020C-33-60-80 F6020C-33-80 F6020C-60-80 F6028C-60-80 F6028C-80 F6030CM F6030CM-33 F6030CM-33-60 F6030CM-60 F6038CM F6038CM-60 DIGITAL COMMUM.
Principles of Operation Note When in the program RUN mode, the programmer/controller serves to provide a programmed temperature profile as described earlier. When in the AUTOMATIC mode, the unit serves as a single set point automatic temperature controller. Furnace The furnace chamber is heated by four electric resistance heaters which are embedded in a refractory material. The chamber is insulated with a ceramic fiber insulation.
General Specifications For F6000 Furnace Model # Dimensions in. (cm) Overall Chamber Weight Electrical Ratings Width Height Depth Width Height Depth LBS. (kg) Volts Amps Watts Freq. Phase Oper. Temp. Range °F(°C) F6020C F6020C-33 F6020C-33-60 F6020C-33-60-80 F6020C-33-80 F6020C-60 F6020C-60-80 F6020C-80 F630CM F6030CM-33-60 F6030CM-33-60 F6030CM-60 F6028C F6028C-60 F6028C-60-80 F6028C-80 F6038CM F6038CM-60 F6010 F6010-33 F6018 19.25 (48.9) 21 (53.3) 20 (50.8) 12.75 (32.4) 6.75 (17.1) 10 (25.
GENERAL SPECIFICATIONS Declaration of Conformity (-33 Models only) Barnstead|Thermolyne hereby declares under its sole responsibility that this product conforms with the technical requirements of the following standards: EMC: EN 50081-1 Generic Emission Standard; EN 50082-1 Generic Immunity Standard; Safety: IEC 1010-1-92 Safety requirements for electrical equipment for measurement, control, and laboratory use; Part I: General Requirements IEC 1010-2-010 Part II: Particular requirements for laboratory equi
Push To Set Temperature Button Digital Display Cycle Light ON/OFF Power Switch Temperature Set point Adjustment Knob Figure 1: Basic Automatic Controller Furnace Chamber Temperature Secret Key Temperature Set point Cycle Light Alarm Indicator Down Button Up Button Scroll Button Figure 2: Single Set point Controller 9
Output Indicator Furnace Chamber Temperature Non-functional Alarm Indicator Non-functional Set point Temperature "SEL" Button Down Button Up Button Enter Button Figure 3: Programmable (4 Ramp & 4 Dwell) Alarm Active Temperature Set point Adaptive or Self Tune Selected (AT) Furnace Chamber Temperature (At Startup, Displays Software Version Number) Digital Communications Parameter Selected on Secondary Display: SP = Set point OP = Output Power Time = Time Remaining in Program Down Button Condition o
Unpacking Note (-60) Models are supplied with two stainless steel trays, handle and porcelain pegs. Note The Type 6000 furnaces do not come with a power cord because current requirements are too great to be handled by ordinary power cords and standard wall supply. (F6010, F601033 and F6018 are supplied with cord and plug). Visually check for any physical damage to the shipping container. Inspect the equipment surfaces that are adjacent to any damaged area.
Installation Caution Be sure ambient temperature does not exceed 104°F (40°C). Ambients above this level may result in damage to the controller. Allow at least six inches of space between the furnace and any vertical surface. This permits the heat from furnace case to escape so as not to create a possible fire hazard.
Basic Automatic Temperature Control Operation Models F6010, F6010-33, F6018 Power Switch The On/OFF power switch will illuminate when power is turned ON. Also, the digital display will illuminate. Cycle Light The amber cycle light will illuminate whenever the power is being applied to the heating elements. The cycle light will turn on and off as furnace reaches set point. Warning To avoid electrical shock, this furnace must have the door switch operating properly.
BASIC AUTOMATIC TEMPERATURE CONTROL OPERATION Temperature Controller This controller provides accurate control at one single temperature setting. To set temperature, simply: 1. Turn Power switch ON. Note If at any time the Temperature Adjustment knob is turned in either direction, the set point will change, even if the Push To Set Temperature button is not depressed. To view the current set point temperature, depress the Push To Set Temperature button. 2.
Automatic Models Note The temperature control in these models is a single set point device. By using the UP or DOWN buttons, a specific temperature can be chosen. The control will cause the furnace chamber to heat to the chosen temperature and hold it at this temperature until you turn off the power switch or select another temperature. Models F6020C, F6020C-33, F6020C-33-60, F6020C-60, F6028C, F6028C-60 Controls and Displays Power Switch Switch power switch to the “ON” position.
AUTOMATIC MODELS Caution Do not exceed limitations for continuous or intermittent operating temperature shown in the General Specifications section. Exceeding these limits will result in severely reduced heating element life. Adjusting Furnace Set point Temperature • To illuminate the “DOWN” button, “SCROLL” button, and “UP” button, touch anywhere on the front panel. • Push the “UP” button or the “DOWN” button to modify the temperature set point (lower digital display).
AUTOMATIC MODELS Changing Temperature Indication Push “SCROLL” button once, “°C” will appear. This indicates temperature measurement. (Contact Thermolyne if control needs to be changed to °F.) Note HIAL-HIGH ALARM (over temperature protection - OTP). The controller is fitted with a mechanical relay which is de-energized in the alarm mode. This relay, when de-energized, removes power from the heating elements.
Programmable Control Models (4 Ramp & 4 Dwell) F6020C-33-60-80, F6020C-33-80, F6020C-60-80, F6020C-80, F6028C-60-80, F6028C-80 Warning To avoid electrical shock, this furnace must have the door switch operating properly. Note For optimum control of a single set point operation, set the “CTrL” parameters to “FUZY” to take advantage of the controller’s fuzzy logic capabilities. Note The furnace will begin to heat to the current set point temperature when you turn the power switch ON.
PROGRAMMABLE CONTROL MODELS the enter button again to set the new value as the current value. (See “Programming Controller” for information on programming.) The control parameters in order are: LoCt - Parameter lock level. Determines the number of parameters displayed when you press “SEL”. It should be set to “0002.” If it does not, set to “0002.” Nod - Mode. By pushing “UP” or “DOWN” buttons, this can be set to “Auto” or “NAn” (Manual). Set to “Auto”.
PROGRAMMABLE CONTROL MODELS tN2S - Dwell time 2. Sü-3 - Set point 3. tN3R - Ramp time 3. tN3S - Dwell time 3. Sü-4 - Set point 4. tN4r - Ramp time 4. tN4S - Dwell time 4. P-on - Power-on start. Push the “Up” or “Down” Buttons to set to “Yes” or “No.” When set to “Yes,” your furnace will immediately begin running the set program when you power on your furnace. For most applications, set to “No.” The next three parameters - Proportional band, Integral and Derivative - are the three control parameters of a P.
PROGRAMMABLE CONTROL MODELS how far the furnace chamber temperature can rise above your set point. We recommend a setting of 20; since a P.I.D. control process involves some degree of temperature overshoot, a setting of less than 20 may interfere with the function of your controller. LooP - Thermocouple break alarm detection time. For proper operation of your furnace, this parameter should be set to “0.00”. If it is not, set it to “0.00”. CTrL - Control type.
PROGRAMMABLE CONTROL MODELS ton to enter the set value as the current value. Push “SEL” button until “TH1S” is displayed. Push the Enter button (>) to select the current value. Push “UP” or “DOWN” button and set Dwell time 1 in hours and minutes in the format “X.XX” (hour.minutes). Push the Enter button to enter the set value as the current value. Set “Sü-2” “TN2r” “TN2S” “Sü-3” “TN3r” “TN3S” “Sü-4” “TN4r” and “TN4S” in the same manner as “Sü-1” “TN1r” “TN1S”.
PROGRAMMABLE CONTROL MODELS first time you use your furnace and each time you change your set point or program or the type of load you are heating. To use the Tuning feature: Note For processes which cannot tolerate the overshoot naturally generated during the tuning process, select “Lo” rather than on for the “AT” setting. The “Lo” setting will tune your furnace at a temperature below your set point, then apply the result to your set point.
Multi-Programmable Models (8 ramp & 8 dwell) F6030CM, F6030CM-33, F6030CM-33-60, F6030CM-60, F6038CM, F6038CM-60 Note When performing operations with the controller, if you depress and release either the SCROLL, Up or DOWN push button and more than eight seconds elapse before the buttons are used again, the display screen will automatically switch back to displaying set point temperature.
MULTI-PROGRAMMABLE MODELS Note The two center push buttons are inactive and not used. a few times, note that the amber furnace cycle light will go out while the door is open. If the furnace cycle light does not go out while the door is open, consult the Troubleshooting section before proceeding. Parameters Pnr - Program Number. The program number of the program you are going to work with. By pushing the up or down button you can select a program numbered from 1 to 4. PR1 - Program Ramp Rate.
MULTI-PROGRAMMABLE MODELS SP2 - Set point two. Not configured into control and nonfunctional. Set to “20.” AT - Adaptive Tune. Analyzes and inputs optimum PID values when temperature has reached set point. This function does not have a value; it is either “ON” or “OFF.” (See Furnace Operation for function of Adaptive Tune). ATR - Adaptive Tune Range setting. Determines the operational band width of the adaptive tuning function. Self Tuning automatically determines this setting.
MULTI-PROGRAMMABLE MODELS HC - Cycle Time is the rate at which power is supplied to power control switch. Push up or down button to set. Sbr - the percent of power that is supplied to the control output terminals if an open thermocouple condition exists. Push up or down button to check. 0.0 will be displayed. This parameter cannot be changed; if 0.0 is not displayed, contact Barnstead/Thermolyne. The upper display will flash “OR” if an open thermocouple condition exists.
MULTI-PROGRAMMABLE MODELS point either above or below the process value indicated on the upper display. (If you will be using the controller as a single Set point Controller, set the furnace’s set point to the temperature you intend to use for your application. If you will be running a multi-step program, set the furnace’s set point to the value of PL1 (Program Level #1).) At the end of the minute, the “SP” indicator will stop flashing, indicating that the set point can no longer be changed.
MULTI-PROGRAMMABLE MODELS Programming Controller The multi-programmable controller in these units provides up to 4 separate programs of 8 ramps and 8 dwells each. This controller also allows you to link programs together, which allows you to achieve 64 total segments (4 programs X 16 segments). These functions are controlled by the controller’s first two programming parameters, “Pnr” and “Cnt.
MULTI-PROGRAMMABLE MODELS Set Ramp Rates 1. With the programmer not operating, indicated by the bottom right hand side of the display extinguished, depress scroll button until PR1 is displayed. Push the up or down button to scroll to the desired value, which is degrees per minute.
MULTI-PROGRAMMABLE MODELS All other dwells in the program can be set in a similar fashion by selecting “PD” followed by the relevant dwell number. Set the Number of Times to Repeat the Program 4. Scrolling through the main scroll until the parameter “PLC” is displayed and then depressing the up or down button will reveal the present setting of the loop count. This is the number of times that the entered program will be repeated before a continuous set point at the last level of the program is achieved.
MULTI-PROGRAMMABLE MODELS button once; time remaining for the current segment, either ramp or dwell will be indicated. If the loop counter has been set to any value other than one, then the above procedure will be repeated for each loop. At the end of the complete program, an “E” will appear on the display. Parameter Change While Running The previous parameters can be inspected but not changed while a program is running.
Installation and Operation of Air Control Note Coal ashing furnaces -60 models contain a feature to provide air (or inert gas) flow within the furnace chamber. Note A pressurized air line with a minimum working pressure range of 0 to 20 psi is required. Note A flow rate of 40 to 45 liters per minute will provide three air exchanges of the chamber per minute. Note If the furnace is to be used regularly, the airline regulator may be left open to 20 psi.
INSTALLATION AND OPERATION OF AIR CONTROL Furnace Programming Refer to “Programmable Models” in this manual to program in the following values for performing ASTM specification D3174.
INSTALLATION AND OPERATION OF AIR CONTROL 3. Ensure the exhaust system is operating. 4. Set flow control valve so flow indicator reads between 40 and 45 liters per minute. (Check regulator to ensure 20 psi pressure). 5. Switch power switch to “ON”. 6. Depress run button. Controller will automatically step the program through the various steps outlined earlier. 7.
Furnace Loading For best results, use only the center two-thirds of the furnace chamber. Caution Do not overload your furnace chamber. If the load is to be heated uniformly, it should not occupy more than twothirds of the furnace chamber. Failure to observe this caution could result in damage to furnace components. 36 1. If you are heating a number of small parts, spread them throughout the center of the furnace chamber. 2. Keep objects away from thermocouple. 3.
Maintenance and Servicing Warning This warning is presented for compliance with California Proposition 65 and other regulatory agencies and only applies to the insulation in this product. This product contains refractory ceramic, refractory ceramic fiber or fiberglass insulation, which can produce respirable dust or fibers during disassembly. Dust or fibers can cause irritation and can aggravate preexisting respiratory diseases.
MAINTENANCE AND SERVICING Preventative Maintenance 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). 1. Housekeeping is vital to your electric furnace KEEP IT CLEAN.
MAINTENANCE AND SERVICING 6. Tighten the nuts securely. Cut off any excess lead wire. 7. Replace the back terminal cover. 8. Reconnect furnace to power supply. 9. Test operation of furnace. To Replace a Platinel II Thermocouple in Programmable and Automatic Furnaces 1. Disconnect furnace from power supply. 2. Remove the back terminal cover of the furnace. (Note placement and connection of wires). 3. Remove the screws on the thermocouple terminals and pull the thermocouple straight out. 4.
MAINTENANCE AND SERVICING connection of wires). 3. Remove clip holding thermocouple in place (1 screw) and remove the two screws on the thermocouple terminals. 4. Remove the thermocouple. Pull thermocouple straight out of hole in the chamber first to avoid damage to the insulation. 5. Guide the looped ends of the new thermocouple through the plastic bushings with the red (-) lead to the right as you face the back of the furnace. 6.
MAINTENANCE AND SERVICING 4. Remove nuts, washers, and screws from relay, then remove relay. 5. Install new relay. 6. Reconnect the wires identified or marked in step 3. 7. Replace back control cover. 8. Reconnect furnace to power supply. 9. Test operation of furnace. To Replace Door Switch (Micro Switch) 1. Disconnect furnace from power supply. 2. Remove the four top screws on the front dial and the four bottom screws on the back cover. 3. Slide the control section forward.
MAINTENANCE AND SERVICING 11. Test operation of door switch. (See below, step 10.). To Realign Door Switch (Micro Switch) 1. Disconnect furnace from power supply. 2. Remove the four top screws on the front dial and the four bottom screws on the back cover. 3. Slide the control section forward. (Do not pull excessively on the internal wires). 4.
MAINTENANCE AND SERVICING To Replace Control Module Programmable Models 1. Turn the screw on the control counterclockwise. 2. As the control module starts to disengage, pull it straight out of the control sleeve. Automatic Models 1. Grasp top and bottom of control, squeeze and pull straight out. Basic Automatic Control - PC Board 1. Disconnect from power supply. 2. Remove lower back cover and remove screws from front cover. 3. Pull control section out to gain access to PC board.
Troubleshooting PROBLEM PROBABLE CAUSE CORRECTIVE ACTION The power light does not illuminate. The furnace is not connected Check furnace connection to power supply. to power source. ON and OFF power switch is Replace power switch. defective. Fuses blown. Replace fuses. Heating elements burned out or Replace heating elements or The furnace does not heat, cycle light illuminated. improper connections. The furnace does not heat, repair connections. No power.
TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTIVE ACTION No temperature control. Shorted thermocouple circuit. Check thermocouple connection and/or replace thermocouple. Shorted solid state relay - over Replace solid state relay. temperature protection may be activated. Defective control - error message on display may appear. Slow heat-up. Return control for repair or replace. Thermocouple leads are reversed. Connect leads correctly (see manual). One or two heating elements are burned out.
TROUBLESHOOTING PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Repeated element burnout (cont.) Wrong element. Install proper element. Oxidized thermocouple. Replace thermocouple. Contamination present from previous burnout. Replace insulation material. Wired improperly. Check wiring diagram for correct wiring of your furnace. Oxidized or contaminated Replace thermocouple. Inaccurate temperature display. thermocouple. Improper loading. Use proper loading procedures. Refer to start-up procedure.
Replacement Parts List SERIES 1060 Listed below is the common replacement parts for all models of the 6000 furnace. The far left column contains the letter designation found on the circuit diagrams. Be sure to identify the correct part number with respect to the exact model number found on your furnace.
H3 T1 Wiring Diagram (F6010, F6010-33, F6018) H2 H1 SWITCH, DOOR SWITCH, DOOR SWITCH, SET POINT TERMINAL BLOCK THERMOCOUPLE S2 S3 S4 TB1 TC1 T2 H4 RESISTOR, POT RESISTOR RELAY, SOLID STATE SWITCH, POWER R1 R2 RY1 S1 GND L2 L1 FUSE FILTER HEATING ELEMENT HEATING ELEMENT HEATING ELEMENT HEATING ELEMENT F2 FL1 H1 H2 H3 H4 FL1 ONLY F6010-33 L2 L1 PILOT LIGHT FUSE CONTROL DESCRIPTION CN1 DS1 F1 NO. REF.
S2 TC- CN1 5 3 + 1 2 4 3 L1 1 T1 H1 RY1 RY2 2 H3 H4 L2 4 6 H2 T2 S1 S2 TC1 RY2 S1 DS1 CYCLE DOOR SWITCH THERMOCOUPLE RELAY, DPST, N.O. SWITCH FILTER, EMI HEATING ELEMENT HEATING ELEMENT HEATING ELEMENT HEATING ELEMENT SOLID STATE RELAY FL1 H1 H2 H3 H4 RY1 CONTROL CURCUIT BREAKER PILOT LIGHT, NEON CN1 CB1 DS1 CB1 FL1 LOAD TC1 TC+ 10 9 4 11 8 3 12 7 2 5 6 1 DESCRIPTION REF. NO.
S2 9 10 4 5 TC- CN1 5 3 2 3 + 1 4 L1 1 T1 H1 RY1 RY2 2 H3 H4 L2 4 6 H2 T2 S1 HEATING ELEMENT HEATING ELEMENT SOLID STATE RELAY RELAY, DPST, N.O. SWITCH DOOR SWITCH H2 H3 H4 RY1 RY2 S1 S2 DS1 CYCLE CB1 THERMOCOUPLE HEATING ELEMENT FL1 H1 TC1 FILTER, EMI HEATING ELEMENT CB1 DS1 FL1 LOAD TC1 TC+ 8 6 3 12 7 11 2 1 CONTROL CURCUIT BREAKER PILOT LIGHT, NEON CN1 DESCRIPTION REF. NO.
S2 6 5 3 1 18 GND 25 TC- CN1 5 3 2 3 + 1 4 L1 1 T1 H1 RY1 RY2 2 H3 H4 L2 4 6 H2 T2 S1 DS1 CYCLE HEATING ELEMENT HEATING ELEMENT SOLID STATE RELAY RELAY, DPST, N.O. SWITCH DOOR SWITCH THERMOCOUPLE H3 H4 RY1 RY2 CB1 FILTER, EMI HEATING ELEMENT HEATING ELEMENT FL1 H1 H2 S1 S2 TC1 CONTROL CURCUIT BREAKER PILOT LIGHT, NEON CN1 CB1 DS1 FL1 LOAD TC1 TC+ 26 33 31 DESCRIPTION REF. NO.
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|Thermolyne dealer from whom you purchased this unit or can be obtained promptly from the factory. When service or replacement parts are needed we ask that you check first with your dealer.
Two Year Limited Warranty Barnstead|Thermolyne Corporation warrants that if a product manufactured by Barnstead|Thermolyne and sold by it within the continental United States or Canada proves to be defective in material or construction, it will provide you, without charge, for a period of ninety (90) days, the labor, and a period of two (2) years, the parts, necessary to remedy any such defect.
