Despatch LCC-14 Installation Manual

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C-198 PN 161871 REVISION M

3/2010

LCC/LCD2-14-3 NON PASS-THROUGH SERIES WITH PROTOCOL INSTRUCTION MANUAL

PLUS

™

NOTICE

Users of this equipment must comply with operating procedures and training of operation personnel as required by the Occupational Safety and Health Act (OSHA) of 1970, Section 6 and relevant safety standards, as well as other safety rules and regulations of state and local governments. Refer to the relevant safety standards in OSHA and National Fire Protection Association (NFPA), section 86 of 1990.

CAUTION

Setup and maintenance of the equipment should be performed by qualified personnel who are experienced in handling all facets of this type of system. Improper setup and operation of this equipment could cause an explosion that may result in equipment damage, personal injury or possible death.

Dear Customer, Thank you for choosing Despatch Industries. We appreciate the

opportunity to work with you and to meet your heat processing needs. We believe that you have selected the finest equipment available in the heat processing industry.

At Despatch, our service does not end after the purchase and delivery of our equipment. For this reason we have created the Service Products Division within Despatch. The Service Products Division features our Response Center for customer service. The Response Center will direct and track your service call to ensure satisfaction.

Whenever you need service or replacement parts, contact the Response Center at 1-800-473-7373: FAX 612-781-5353.

Sincerely, Despatch Industries

PREFACE

WARNING: Failure to heed

warnings in this instruction manual and on the oven could result in personal injury, property damage or death.

NOTE: Read the entire INTRODUCTION and THEORY OF OPERATION before installing the oven.

This manual is your guide to the Despatch LCC/LCD2-14-3 SERIES ovens. It is organized to give you the information you need quickly and easily.

The INTRODUCTION section provides an overview of the oven.

The OVEN OPERATION section details the function and operation of assemblies and subassemblies on the oven.

The INSTRUCTIONS section provides directions on unpacking, installing, operating and maintaining the oven.

An efficient way to learn about the oven would be to read the manual while working with the corresponding oven control system. This will give you practical hands-on experience with information in the manual and the oven.

Before operating the equipment, be sure you understand all of the technical information contained in this manual. Information skipped, not understood or misunderstood could create the possibility of operating the equipment in an unsafe manner. This can cause damage to the oven or personnel or reduce the efficiency of the equipment.

Revision A (7-02): Initial Creation. Revision B (11-02): Drawing Changes, add line connection detail. Revision C (08-03): Update drawings. Revision D (11-03): Updated to Protocol Plus Version 4.0. Revision E (03-04): Update drawings, change Class A warning. Revision F (06-04): Change water drain/outlet temp rating. Revision G (08-06): Update to current design. Revision H (05-07): Update drawings Revision I (07-07: General updates Revision J (11-07): Updated warranty Revision K (09-08): Added LL*1-* model reference Revision L (03-09): Updated Controller Instructions Revision M (03-10): Updated Declaration of Conformity

TABLE OF CONTENTS

INTRODUCTION ............................................................................................................. 1

Features ...................................................................................................................... 2

Options ........................................................................................................................ 2

SPECIFICATIONS .......................................................................................................... 3

Electrical Specifications ............................................................................................... 3

Physical Specifications ................................................................................................ 4

Functional Specifications ............................................................................................. 4

OVEN INSTRUCTIONS .................................................................................................. 5

Unpacking and Inspection ........................................................................................... 5

Set-up .......................................................................................................................... 6

Wiring .......................................................................................................................... 9

HEPA Filter Installation .............................................................................................. 10

HEPA Filter Burn-off ............................................................................................... 11

Filter High Limit ...................................................................................................... 13

OVEN OPERATION ...................................................................................................... 14

Oven .......................................................................................................................... 14

System Control .......................................................................................................... 15

HEPA Filters .............................................................................................................. 17

HEPA Filter Validation Testing ............................................................................... 18

Filter Unit Replacement .......................................................................................... 19

HEPA Filter / Magnehelic Pressure Gauge ............................................................ 20

HEPA Filter Preventative Maintenance Table ............................................................ 20

OPERATING ................................................................................................................. 21

Loading the Oven ...................................................................................................... 21

Pre-Startup Checklist ................................................................................................. 22

Operating Procedure ................................................................................................. 23

Starting the Oven ................................................................................................... 23

Sequence of Operation (with Optional Beacon Light) ............................................ 23

Sequence of Operation for Inert Atmosphere Oven ............................................... 24

High Limit Alarm with Alarm Silence ...................................................................... 25

Class A Configuration ............................................................................................ 26

Maintenance .............................................................................................................. 28

Checklist ................................................................................................................ 28

Lubrication ............................................................................................................. 28

PROTOCOL PLUS CONTROL ..................................................................................... 29

Theory of Control Operation ...................................................................................... 29

Operating Modes .................................................................................................... 31

Setup Mode ............................................................................................................ 31

Fast Start Mode ...................................................................................................... 31

High Limit ............................................................................................................... 32

Indicators ............................................................................................................... 32

Displays ................................................................................................................. 33

Key Functions ........................................................................................................ 33

Outputs .................................................................................................................. 34

Relay (Continued) .................................................................................................. 35

Communication ...................................................................................................... 35

Optional Software ................................................................................................... 35

INSTRUCTIONS ........................................................................................................... 36

Start-Up ..................................................................................................................... 36

Operation ................................................................................................................... 37

Manual Mode ......................................................................................................... 37

Timer Mode ................................................................ ................................ ............ 38

Profile Mode ................................................................ ........................................... 39

Auto Start Mode ..................................................................................................... 39

Setup Mode ............................................................................................................ 40

Instructions for Setup Mode Pages ............................................................................ 41

Program Page ........................................................................................................ 41

Sample Profile ........................................................................................................ 44

Auto Start Page ...................................................................................................... 45

PID Page ................................................................................................................ 47

Control Page ................................................................................................ .......... 49

Communication Page (optional) ............................................................................. 50

Real Time Clock Page ........................................................................................... 50

Relay Outputs Page (optional) ............................................................................... 51

Test Page ............................................................................................................... 52

Zone Calibration Page ........................................................................................... 53

Sensor Calibration Page ........................................................................................ 55

Enable Page .......................................................................................................... 57

Digital Inputs (optional) .......................................................................................... 58

Error Messages and Alarms ...................................................................................... 59

Quick Reference and Default Values ......................................................................... 60

Technical Specifications ............................................................................................ 67

APPENDIX: DRAWINGS .............................................................................................. 68

Atmosphere

Max Temp C

Seals

Model

Air

260

Silicone

LCC2-14-3

Air

260

Silicone Free

LCC2-14V-3

Air

350

Silicone

LCD2-14-3

Air

350

Silicone Free

LCD2-14V-3

Inert

260

Silicone

LCC2-14N-3

Inert

260

Silicone Free

LCC2-14NV-3

Inert

350

Silicone

LCD2-14N-3

Inert

350

Silicone Free

LCD2-14NV-3

Class A

260

Silicone

LCC2-14A-3

Class A

260

Silicone Free

LCC2-14AV-3

Class A

350

Silicone

LCD2-14A-3

Class A

350

Silicone Free

LCD2-14AV-3

INTRODUCTION

The LCC/LCD2-14-3 SERIES offers HEPA filtration for processes where minimization of contamination is essential. The removable HEPA (High Efficiency Particulate Air) filter is designed to provide a constant flow of clean air to the product being heated. The HEPA filter with silicone seal provides 99.99% filtration. A magnehelic differential pressure gauge monitors pressure drop across the HEPA filter.

The LCC2-14-3 Series ovens are rated up to 260 C, and are available with air, inert (nitrogen), or “Class A” atmospheres. The LCD2-14-3 Series have all the above listed

atmosphere options, but with a maximum temperature of 350 C. Additionally, silicone free construction is available on all models.

The voltages available are 208V / 3 phase, 240V / 3 phase, 415V / 3 phase, and 480V / 3 Phase; all ovens use a 16kW heater. A 380V / 3 phase option is available, the heater is rated for 12kW.

Model numbers that begin with the designation LL*1-* are without HEPA filter.

The oven’s operator interface components are located on the hinged control panel at

the front of the oven. The power components; fuse blocks and motor starters are located on the equipment panel, behind the hinged control panel for easy access. The transformer and the heater SSR’s are located in the lower compartment with the recirculation and exhaust/cooling motors. Electrical components are either touch-proof or are shielded with Lexan to prevent accidental exposure during maintenance and troubleshooting.

The optional Despatch Protocol Manager software is used to enable customer PC control of an oven. Despatch Protocol Plus controllers may be networked together with a Modbus communication option when multiple ovens are operated.

Features

Despatch Protocol Plus microprocessor-based digital programmable control, with

simultaneous digital readout of both setpoint and actual temperatures.

CE and SEMI S2 compliance, including yellow and red disconnect switch/EMO

mounted in the front control panel door. Manual reset high-limit control. Proportioning temperature control using solid state relays. Four (4) inches of insulation minimizes heat loss, external thermal spots and air

leakage. Stainless steel exterior and interior, with all interior seams continuously welded

on the insulation side to protect the work chamber from contamination and to

permit chamber cleaning without damaging insulation. Horizontal airflow, which achieves air temperature uniformity of +/- 1% of

operating temperature. Recirculation motor is mounted in the machinery compartment underneath the

oven, providing convenient access. Electrical door lock prevents operator from opening chamber door when cycle is

in process. The door lock is de-energized at the end of a cycle or when power is

off.

Options

Beacon light option on control panel provides visual cycle process indication to

operator (red/amber/green) High-limit alarm/alarm silence switch option Oven door switch option for fans Recorder option Modbus RS422/485 communications option to Protocol Plus controller

VOLTS

AMPS

PHASE

HERTZ

HEATER

208

50.5

50/60

16 kW

240

44.5

50/60

16 kW

380

21.6

12 kW

415

25.2

16 kW

480

22.2

16 kW

NOTE that this oven is not intended to process solvents or other volatile or

flammable materials unless the “Class A” option is ordered. The oven’s forced

exhaust is intended for cooling purposes ONLY on standard and inert (nitrogen) models.

WARNING: Failure to heed warnings in this instruction manual and on the oven

could result in personal injury, property damage or death.

WARNING: Do not use any flammable solvent or other flammable material in this oven. Do not process closed containers of any substance or liquid in this oven because they may explode under heat.

WARNING: Do not use the oven in wet, corrosive or explosive atmospheres unless this oven is specifically designed for a special atmosphere.

SPECIFICATIONS

Electrical Specifications

If your line voltage is much lower than the oven voltage rating, heat up time is significantly longer and motors may overload or run hot. If your line voltage is higher than the nameplate rating, the motors may run hot and draw excessive amps. If the line voltage varies more than 10% from the oven voltage rating, some electrical components such as relays, temperature controls, etc. may operate erratically. Power connection is performed by the user.

CHAMBER SIZE INCHES (CM)

CAPACITY IN CU. FT. (LITERS)

OVERALL SIZE INCHES (CM)

SHELVES PROVIDED ON SHELF CENTERS

APPROX. WEIGHT

MAX. # OF SHELVES

MODEL

WIDTH**

DEPTH

HEIGHT

WIDTH

DEPTH

HEIGHT

LBS. (KG) NET

LBS. (KG) SHIPPING LCC/LCD2-14

25.5 (64)

26 (66)

37 (94)

14 (396)

47.5 (121)

41.5 (105)

71 (180)

2 ON 3”

955 (434)

1050 (477)

11 LCC/LCD2-14V

LCC/LCD2-14N

25.5 (64)

26 (66)

37 (94)

14 (396)

47.5 (121)

41.5 (105)

71 (180)

2 ON 3”

955 (434)

1050 (477)

11 LCC/LCD2-14NV

LCC/LCD2-14A

25.5 (64)

26 (66)

37 (94)

14 (396)

47.5 (121)

41.5 (105)

71 (180)

2 ON 3”

955 (434)

1050 (477)

11 LCC/LCD2-14AV

ATMO-

SPHERE

TIME TO TEMP

(minutes, w/ no load)

COOLING TIME TO TEMP

(minutes, w/ no load)

TEMPERATURE

UNIFORMITY AT

CONTROL STABILITY

OPERATING

RANGE

W / 20°C

AMBIENT

MAX LOAD CAPACITY

LBS. (KG)

MAX

SHELF

CAPACITY

LBS. (KG)

RECIRCULATING

FAN

MODEL

50-

100°C

50-

175°C

50-

260°C

50-

350°C

100-

65°C

175-

65°C

260-

65°C

350-

65°C

100°C

175°C

260°C

350°C

CFM

H.P.

LCC/LCD 2-14

AIR 3 9

35*

116*

±1°C

±2°C

±3°C

±3.5°C

±0.5°C

60-260°C*

400

950

1.5

LCC/LCD 2-14V

LCC/LCD 2-14N

INERT 3 9

35*

±1°C

±2°C

±3°C

±3.5°C

±0.5°C

30-260°C*

400

950

1.5

LCC/LCD 2-14NV

LCC/LCD 2-14A

AIR 3 9

35*

116*

±1°C

±2°C

±3°C

±3.5°C

±0.5°C

60-260°C*

400

950

1.5

LCC/LCD 2-14AV

Physical Specifications

V = Silicone free N = Nitrogen A = Class A ** Actual Clear width is 24.0” (61 cm)

Functional Specifications

V = Silicone free N = Nitrogen A = Class A

Notes: Figures based on actual tests in an empty oven: uniformity can vary slightly depending on unit and operating conditions. Specifications are subject to change without notice. Addition of water cooling to air units provides cooling time to temperature equivalent to the inert units. Assumes 55°F (13ºC) maximum water temperature at 3 GPM (11 LPM). Exhaust fan specification is 85 CFM. 380V, and other special voltages not included.

*LCD operating range is 60º-350ºC. All measurements to and from 350ºC are based on LCD models

OVEN INSTRUCTIONS

The OVEN INSTRUCTIONS section provides directions on unpacking, installation, operation and maintenance of the Despatch LCC/LCD2-14 Series Ovens.

Unpacking and Inspection

Remove all packing materials and thoroughly inspect the oven for damage of any kind that could have occurred during shipment.

See whether the carton and plastic cover sheet inside carton are still in good

condition. Look at all outside surfaces and corners of the oven for scratches and dents. Check the oven controls and indicators for normal movement, bent shafts,

cracks, chips or missing parts such as knobs and lenses. Check the door and latch for smooth operation. Check the filter carton for damage.

If there is damage that could have happened during shipment follow these instructions:

1. Contact the shipper immediately and file a written damage claim.

2. Contact Despatch Industries to report your findings and to order replacement parts for those that were damaged or missing. Please send a copy of your filed damage claims to Despatch.

3. Check the packing list to make sure you have received all the specified components of the oven system. If any items are missing, contact Despatch Industries to have them forwarded to you.

4. Complete the warranty card and mail it to Despatch within 15 days after receipt of the equipment.

WARNING: Do not use the oven in wet, corrosive or explosive atmospheres unless this oven is specifically designed for a special atmosphere.

Set-up

1. Select the location for installing your oven.

2. Make sure the oven is level and plumb; this will assure proper heat distribution and operation of all mechanical components. The rear of the oven may be placed against a wall. If possible, provide room at the sides and rear of the oven for maintenance.

NOTE: If your oven has the “Class A” package, the rear of the oven must have a

minimum of six (6) inches of clearance between the oven and any wall for explosion relief.

3. The oven has a four (4) inch diameter exhaust opening and is located on the rear of the oven. The oven may be placed next to another cabinet on its right, or next to another oven, with three-quarters of an inch clearance (measure with door open). Exhaust air may reach 260°C on the LCC version and 350°C on the LCD version. Make sure exhaust piping materials can withstand these temperatures.

4. (Nitrogen models only) Connect the nitrogen supply line to the inlet marked

“nitrogen” on the side of the oven. The nitrogen supply should run at 70 PSI but

not more than 80 PSI (4.83 – 5.52 Bar). Check for leaks.

5. (Nitrogen and Water Cooled Models) Install water connection for cooling coils to the inlet marked "Water Inlet." Verify the valve on the flow meter is turned off (fully clockwise). The water supply to the oven must not exceed 100 PSI (6.89 Bar). It is recommended to install a regulator to prevent any surge. Check for leaks. Slowly open the valve on the flowmeter and allow any air to bleed out. Failure to do this will result in damage to the flowmeter. Repeat this procedure if water supply is shut off. Adjust the flowmeter to 3 GPM (11 LPM) (recommended amount of flow).

6. (Nitrogen and Water Cooled Models) Make the drain connection at the rear of the oven. Note there are two drain connections: water outlet and water drain. Note the water outlet may be connected in a closed loop system, but the water drain must be left in an open-to-atmosphere condition.

7. (Water Cooled Models) Connect the compressed air supply line to the inlet

marked “Dry Air”. The compressed air supply should run at 70 PSI but not more

than 80 PSI (4.83 – 5.52 Bar). Check for leaks.

WARNING: Never allow drain to be plugged as a hot oven will generate a small amount of steam when the water is first turned on. STEAM BURNS!

CAUTION: Design the drain system to prevent operator injury from high temperature or pressure buildup. Piping must be able to withstand short periods of up to 650 °F (343 °C) temperatures. Drain lines should be insulated and/or warning labels installed that a hazard exists.

Conduit fitting for customer power line. Conduit runs up to front control panel. Wires terminate at disconnect switch.

Cabinet cooling fan, air blowing out. DO NOT COVER! Required for lower compartment ventilation.

4.00” (10.16CM) diameter

exhaust opening. Exhaust temperatures may reach 260ºC on LCC versions, and 350ºC on LCD versions. Make sure exhaust piping materials can withstand these temperatures.

LCC/LCD2-14-3 POWER & EXHAUST CONNECTIONS

Nitrogen or Clean Dry Air Inlet. 70 to 80 PSI (4.83 to

5.52 Bar). Used for Nitrogen/Clean Dry Air Purge and Maintain Inlet and to purge water out of the coil prior to heating the oven.

3/8” NPT female brass

connections are provided.

During cooling cycle, water flows through the water coil and out this connection.

3/8” NPT female brass

connections are provided. Piping must be rated for up to 257 F (125 C)

At the end of a cooling cycle, Nitrogen or Clean Dry Air is purged through the water coil. Water and pressurized nitrogen/air exit this connection for 30 seconds. Must be connected to gravity style drain (no backpressure).

3/8” NPT female brass

connections are provided. Piping must be rated for up to 257 F (125 C)

Water Inlet for cooling.

3/8” NPT female brass

connections are provided. Requires 3 GPM (11 LPM) flow at 55 F (13

C) to meet published

cooling rates. MAXIMUM PRESSURE

100 PSI (6.89 Bar)

LCC/LCD2-14 UTILITY CONNECTIONS FOR NITROGEN AND WATER COOLING

WARNING: All grounding and safety equipment must be in compliance with applicable codes, ordinances and accepted safe practices.

Power wires are connected to this disconnect switch and ground bus.

Approximately 70”

(1.77 meters) of wire length is required from the entrance on the rear of oven to these connections.

Power wires are routed through this unused conduit to main equipment panel.

Conduit for power wires are routed through this compartment.

Hole for conduit fitting provided on rear of oven marked LINE CONNECTIONS for customer power. See

LCC/LCD-14N-3 POWER & EXHAUST CONNECTIONS.

Wiring

NOTE: The oven must be directly hardwired to the disconnect switch on the equipment panel. A one (1)

inch conduit run is provided from the rear of the lower oven compartment, which is marked LINE CONNECTIONS to the front equipment panel, through which the line voltage power wiring can be connected to the disconnect switch labeled LINE CONNECTIONS in the front of panel. Consult the electrical drawings included with the oven for wiring details. All wiring to be completed by properly trained and licensed personnel.

LCC/LCD2-14-3 LINE CONNECTION DESCRIPTION (ALL SERIES)

WARNING: Repairing the damaged filter unit, particularly the medium, should not be attempted by the user. Any unit so repaired must be retested to assure that hidden damage does not exist which will reduce filtering efficiency. Repair and retest is uneconomical for most users.

WARNING: Make certain that power is disconnected from the oven before removing or replacing the HEPA filter.

HEPA Filter Installation

Technicians responsible for installing the filter should use caution. The filter is delicate and must not be damaged during installation. Any filter unit dropped, whether or not in the carton, should be examined for damage. Equally important, the filter unit must be installed so that unfiltered air will not leak past the unit.

1. Remove the filter from the carton. a. Place the carton on the floor. The floor must be clear of nuts, bolts, and

similar protrusions, which would damage the face of the unit. Do not drop or jar the carton.

b. Tilt the carton on one corner. Be sure to handle the carton at opposing

corners. c. Remove the sealing tape and fold the flaps of the carton back. d. Gently upend the filter to place the exposed end of the filter on the floor.

Do not jar the filter. e. Pull the carton from the filter unit. Do not pull the filter from the carton.

2. Inspect the filter. Use a strong lamp to examine the exposed areas of both faces to assure that no breaks, cracks, or pinholes are evident. A flashlight, can be used in a darkened room.

Look for visible defects with the light projected along the full length of

each channel created by the separators. Translucent spots may not necessarily indicate holes or cracks but may simply be variations in thickness of the filter medium.

Check that the adhesive seal around the filter unit faces are complete

and unbroken.

Check the corner joints of the frame for adhesive sealing and

tightness.

WARNING: Make certain that power is disconnected from the oven before removing or replacing the HEPA filter.

NOTE: If it is necessary to move the equipment after the burn-off process, considerable care should be used. The binder which gives strength to new filters is now burned-off and the media is very fragile. Rough handling of either the filter alone or the equipment with the filter installed is not recommended as it may tear the media and lead to reduced filter efficiency. Removal of the filter after heating can also result in damage to the frame seal, and is only recommended when replacing the filter.

Check that the gaskets are cemented firmly to the filter frame and that

the gasket pieces are butted or mated at the joints.

3. Pull the shelf out from the oven and set it aside.

4. Loosen the screws at the sides and top of the supply duct/shelf supports on the right side of the chamber. Pull out the duct/shelf support and set it aside.

5. Remove the brass nuts and washers from the rods that are holding the filter frame in place. These nuts will be reused to hold the filter in place.

6. Remove and discard the conduit spacers from the rods behind the filter frame. Place the filter in the oven with the seal side towards the right side oven wall. (LCD ovens using Termikfil filter: place the filter in the oven with the glass braid seal, not the rolled paper seal, toward the right side oven wall.)

Reinstall the filter frame using the nuts removed earlier. Make sure the filter face is tight against the inside perimeter of the frame on all sides.

7. Reinstall the brass nuts and washers to tighten the filter frame down. Tighten the four nuts alternately for even tightness. Be careful not to over tighten. Correct installation torque is 28 +/- 3 in-lbs (3.16 +/- .33 N-m). Be sure to compress the gasket evenly and equally at all points with the filter frame completely covering the opening.

8. Reinstall the shelf support/duct assembly using the screws removed earlier.

9. Reinstall the oven shelf.

HEPA Filter Burn-off

The burn-off process will take place in any piece of equipment where a new HEPA filter is used at temperatures above 180°C / 356°F. There will be smoke, possibly a pungent odor, and a light residue on interior surfaces. This is the result of oxidation of the binder. Most of the binder will leave the filter after running at a temperature of 260°C/500°F for 48 (forty-eight) hours. Check the oven for particles or the exhaust for smoke and odor to determine that the process is finished.

Select a location for this process where the smoke and odor generated will be ventilated with the least amount of interruption and inconvenience. Ideally this will be in the final location for the oven. However, it may be a receiving dock, some well ventilated space or even outside if the weather is acceptable. If this location is a very clean area, then special attention must be given to an exhaust hook-up that will capture the smoke and odor. The post-cleaning (i.e. oven wipe down) may also generate dust, and care should be taken if this is done in a clean room.

The following procedure is recommended:

1. Locate the equipment exhaust opening where chamber air is being expelled. If the oven filter is burned off in a clean area, be sure to handle the equipment

exhaust appropriately. If the equipment is large and the exhaust stack is a permanent service connection, it should be connected before the burn-off process is run. If the equipment is small with no permanent exhaust duct required, arrange a temporary connection out of the clean area that will handle the maximum temperature of the equipment. Direct the smoke and odor outside, or to a highly ventilated area.

2. Set the temperature control at the maximum process temperature.

Silicone: Ramp at 1.25°C/min to 260°C and soak for 48 hours. Media Pack: Ramp at 1.25°C/min to 260°C and soak for 48 hours. Termikfil: Ramp at 5°C/min to 350°C and soak for 48 hours.

3. Start the fan after making the electrical power connections.

4. Energize the equipment heater. Use enough fresh air to remove the smoke, while still being able to achieve and

maintain the necessary temperature. The completion of the burn-off period should be based on the particle level in the oven or smoke-free exhaust and minimal odor level.

The filter hold-down nuts should be checked after burn-off and tightened again if necessary. For best oven particle control, this step should be repeated on a regular basis.

LCC2-14 HEPA / Redundant

High Limit.

Filter High Limit

The LCC/D2-14*-3 series ovens have been equipped with a redundant high limit device to protect the HEPA filter. The sensor for the high limit is located before the air inlet of the HEPA filter. The high limit device is located in the lower compartment of the oven. If the oven temperature exceeds the factory set Filter High Limit temperature, the high limit will trip, shutting down the heater and protecting the HEPA filter.

If the oven has no HEPA filter (LLC models), this redundant high limit is also used to protect the oven from excessive operating temperatures.

Before resetting the high limit, determine the cause of the excessive temperature. Under normal operating conditions the Filter High Limit should never trip. If the high limit trips, it must be reset by removing the access panel to the lower compartment. The high limit is located next to the transformer; press the reset button on the high limit. See the MIC1162 reference manual for the operation of this high limit.

OVEN OPERATION

Oven

The LCC/LCD2-14 Series oven is a class 100 clean room oven with HEPA (High Efficiency Particulate Air) filtration. This oven is ideal for processes where minimization of contamination is essential.

Forced convected airflow provides rapid uniform distribution of heat. A HEPA (High Efficiency Particulate Air) filter is mounted in a stainless steel frame in the supply plenum. These filters are 99.97% effective in filtering 0.3 micron particles.

For the LCC/LCD2-14 model, the cooling/exhaust fan is controlled on/off by an event relay in the Protocol Plus Control. The cooling fan is used for rapid cool-down at the end of the process cycle, or to maintain low temperature setpoints during process cycle. It may also be turned on at the start of a process cycle to assure that starting temperature is less than 70°C. For Class A, the exhaust fan event relay is hardwired in

the on position, as the exhaust fan is used for removing volatiles in a “Class A” oven. For “Class A” the exhaust fan must remain on at all times. Water cooling option is also

available for faster cool down times. The nitrogen models have type 316 stainless steel water coil which permits rapid cool

down and lower temperature operation. The nitrogen oven comes with an adjustable flowmeter for adjusting purge rate, and needle valve for setting maintain rate, separate solenoid valves for purge and maintain operation and a pressure relief exhaust port. An exhaust fan which powers on whenever the oven is running maintains consistent chamber pressure control with varied exhaust stack conditions.

The oven has a type 304-2B stainless steel interior. All interior seams are continuously welded on the insulation side. This protects the work chamber from contaminated air and permits chamber washing without damaging the insulation. Interior ductwork may be easily removed for cleaning. Heater frame, fan wheel and motor shaft are constructed of stainless steel.

All controls are mounted on the front of the oven for easy operation and readability. Two electropolished stainless steel wire shelves are provided. The shelves are removable and adjustable on three inch centers.

System Control

A Despatch Protocol Plus controller/high-limit device is used to control the unit. This is located on the control panel of the oven. See the section on the Protocol Plus controller for detailed operation.

The Protocol Plus controller provides temperature control for the process. The Protocol Plus controller provides outputs for the cooling/exhaust fan, End of

Cycle/door lock, and purge and maintain operation for inert atmosphere. The control relays are set up on standard models as follows

o RLY1 = EV1 (Exhaust/Cooling event) o RLY2 = CYCL (End of Cycle/Door Lock) o RLY3 = EV3 (Nitrogen Purge) If option purchased o RLY4 = EV4 (Nitrogen Maintain) If option purchased

As many as eight (8) profiles for oven heating cycles are stored in the Protocol

Plus controller. These are accessed by the operator using the Protocol Plus keypad.

The Protocol Plus controls the solenoid valves in an inert atmosphere oven for

purge and maintain operation.

Optional MODBUS RS422/485 serial communications hardware may be installed

on the Protocol Plus controller, with a 9-pin communications port located on front of the oven. This provides the ability to network the oven(s) with a host PC.

The optional three-color beacon light provides visual indication of the cycle

status, as follows:

Green – Cycle in process Yellow – Standby. Operator has unloaded product. Oven waiting for next

cycle.

Red – Error or fault condition.

The optional High-Limit Alarm indicates when the high-limit setpoint has been

exceeded. An illuminated Alarm Silence push-button lets the operator turn off the alarm while providing a red warning light until the high-limit condition is corrected.

Protocol Plus Controller on upper portion of control panel

Lower Portion of Control Panel

Main Disconnect Switch: This disconnect switch is connected to the load break switch behind the panel that disconnects or connects power from the main line.

Power Stop/Stop Push-button: Pushing start energizes the motor and control circuit, providing the main disconnect switch is on and door is closed. Pushing stop will shut down the oven.

HEPA Filters

HEPA (High Efficiency Particulate Air) filters are used to limit particulate size in the work chamber to 0.3 microns or less.

NOTE: Chamber temperature transitions must not exceed 1.25°C/minute in order to maintain class 100 chamber conditions. An optional (Termikfil brand) filter is available for transition rates up to 5°C/minute. Consult factory.

Definitions

HEPA - High Efficiency Particulate Air Burn-Off - A process for getting rid of the binder contained in the filter. D.O.P. - Dioctyl Phthalate - Aerosol particles of submicron size used in the testing

phase to spot defects or measure filter efficiency. Despatch Industries DOES NOT RECOMMEND use of this or other organic challenge agents.

Binder - An organic substance that is used in the construction of the filter that gives

some structural strength to the media.

Filter Packaging and Shipping

Packaging practice varies among the filter unit manufacturers. Normally units are packaged in cardboard cartons with various approaches for internal strengthening and impact-resistance of the container. The shipping carton normally is marked with a vertical arrow and "This Side Up". A filter unit is placed in the carton so that the pleated folds are vertical (running from top to bottom - not side to side).

Filters should be shipped, handled and stored with the pleats in the vertical position. If shipped with the pleats in the horizontal position, the filter medium may break at the adhesive line. If handled or stored with the pleats in the horizontal position the pleats may sag.

Moreover, the filter unit should be installed with the pleats in the vertical position. When installed in the horizontal position the pleats form shelves for the collection of entrapped material. The accumulated weight of this material causes sagging and leads to an early failure of the unit.

Handling

The filter is shipped in the original carton or package that the filter manufacturer uses. This will give good storage and maximum protection from dirt and moisture.

HEPA filters should be stored and moved in the shipping carton with in the upright position. Handling should be kept to a minimum. During installation the filter should be removed from the shipping carton and installed directly into the oven.

If for any reason an unpackaged filter unit must be placed with its face on the floor or other surface, the surface must be cleared of every object or irregularity, which might damage the filter pack.

HEPA Filter Validation Testing

This section describes the Despatch position and recommendations for HEPA filter testing and oven validation procedures. Despatch guarantees that the filters will meet specified efficiency ratings when the filter is:

properly installed run at or below 180°C, at a constant temperature burned off at 260°C for 48 hours before running

D.O.P. Testing

In D.O.P. testing, aerosol particles of submicron size are used to spot defects or measure filter efficiency. Degenerative by-products of this test are distributed throughout the oven chamber upon heat-up. These and other organic challenge agents also present a fire hazard for this non-Class A (NFPA 86) oven. Therefore Despatch does not recommend D.O.P. filter testing.

Class 100 Testing

Despatch guarantees the environment within the oven to be Class 100. This classification is based upon measurement of the particulate level within the oven work chamber.

Class 100 testing may be performed before or after a proper filter burn-off procedure has been performed. Despatch will guarantee Class 100 conditions measurements based on the direct method of test employing an extraction-type particulate analyzer. An indirect method of testing involves particle settling over a specified period of time onto a clean disk. Please consult the factory for expected levels.

Validation Testing

Based on the issues discussed in this section, Despatch recommends the following test sequence for pharmaceutical Class 100 ovens.

1. Proper installation of the HEPA filters.

2. Ambient air challenge to determine integrity of oven chamber and filter gaskets.

3. Proper filter burn-off procedure.

4. Class 100 testing inside the work chamber.

The Necessity of the Burn-off Process

HEPA filters contain a binder material, which protects the filter media during production and shipping. This smoke is typically not desirable during normal operation of the oven. Burning off the binder will ensure a clean process at elevated temperatures.

When the binder is burned off of the filter media, the filter becomes very fragile, too fragile to withstand normal shipping and handling. For this reason, Despatch does not perform the burn-off procedure. The burn-off process is not necessary at process temperatures consistently under 180°C.

Filter Unit Replacement

Replacement of the filter unit is necessary for these reasons:

Resistance, or pressure drop, across the filter unit. Maximum level of resistance

in inches (water gauge) will vary depending upon the operation of the filter and the available fan capacity. Adequate fan capacity must be available.

Loss of efficiency (leakage), determined from air-sampling measurements made

downstream of the filter unit.

Visible damage or rupture of the filter media in a unit. Change in process application. Excessive build-up of lint or combustible particulate matter on the filter unit. Water droplets in airstream through filter, free water (RH = 100%), will saturate

filter very quickly and may cause burnout or holes in burned off filter media.

B C D

Date

Comments

Pressure with 350 SCFH nitrogen purge

Pressure with 220 SCFH nitrogen maintain

Pressure (inches of water)

Oven Temperature

Typical Values

1.5-2.5” above value in column E

0.3-0.8” above value in column E

2-3 inches

60°C Filter first installed.

HEPA Filter / Magnehelic Pressure Gauge

The LCC Series oven is equipped with a Magnehelic pressure gauge which measures the pressure in front of the HEPA filter. As the filter becomes dirty, the pressure will

increase. Despatch recommends changing the filter when the pressure is 1” w.c.

greater than when the filter was first installed. Since the pressure can be affected by many factors involved in the installation, it is

important to record the pressure of a new filter, so that the pressure readings can be periodically checked against this baseline. The table below is provided for recording this information.

HEPA Filter Preventative Maintenance Table

WARNING: If not Class A, do not use any flammable solvent or other flammable material in this oven. Do not process closed containers of any substance or liquid in this oven because they may explode under heat.

OPERATING

Users and operators of this oven must comply with operating procedures and training of operating personnel as required by the Occupational Safety and Health Act (OSHA) of 1970, Section 5 and relevant safety standards, and other safety rules and regulations of state and local governments. Refer to the relevant OSHA and National Fire Protection Association (NFPA) safety standards.

Loading the Oven

Despatch Industries cannot be responsible for either the process or process temperature used, or for the quality of the product being processed. It is the responsibility of the purchaser and operator to see that the product undergoing processing in a Despatch oven is adequately protected from damage.

Carefully following the instructions in this manual will help the purchaser and operator in fulfilling that responsibility.

When loading the oven avoid spills of anything onto the heater elements or onto the floor of the oven. Do not place the load on the oven floor plate. This may cause the load to heat unevenly and the weight may cause shorting out of the heater elements. Use the shelves provided.

The two shelves are designed to be pulled out about halfway without tipping. Do not overload the shelves.

Distribute the workload evenly so that airflow is not restricted. Do not overfill your oven. The workload should not take up more than two-thirds of any dimension of the inside cavity.

WARNING: Do not use any flammable solvent or other flammable material in this oven. Do not process closed containers of any substance or liquid in this oven because they may explode under heat.

CLASS A OVENS ONLY!

WARNING: “Class A” ovens are designed for a specific amount of

solvent. Exceeding this amount could result in an explosion. Do not process closed containers of any substance or liquid in this oven because they may explode under heat. In case of fire, leave door(s) as

they are. Shut off electricity. Shut off fuel. Call the fire department. Stay away.

Pre-Startup Checklist

Know the system. Read this manual carefully.

Make use of its instructions and explanations. The know how of safe, continuous, satisfactory, trouble-free operation depends primarily on the degree of your understanding of the system and of your willingness to keep all parts in proper operating condition.

Check line voltage. This must correspond to nameplate requirements of motors

and controls. A wrong voltage can result in serious damage. Refer to the section on power connections in the INTRODUCTION of this manual.

Check fresh air & exhaust dampers. Do not be careless about restrictions in and

around the fresh air and exhaust openings and stacks. Under no condition, permit them to become so filled with dirt that they reduce airflow.

If your oven is equipped with the “Class A” option (Models LCC/LCD2-14 A*-3);

the purge timer is preset with the time listed on the nameplate at the factory.

Operating Procedure

Starting the Oven

1. Turn the yellow/red DISCONNECT SWITCH to ON.

2. Press the POWER pushbutton ON switch.

The door remains unlocked. NOTE: during the process cycle the door is

locked. To unlock the door press the STOP push-button or remove power from the oven by using the disconnect switch

(optional “Class A” equipped units) Once the power switch is turned on,

the recirculation fan and exhaust fan are turned on, the airflow switch will actuate and the purge timer will begin timing. NOTE: The heater will not turn on and the oven will not begin heating until the purge period is complete.

(optional beacon light-equipped units) The amber (center) beacon light will

illuminate, indicating that the oven is ready to receive work to be processed.

3. The heater is wired in series with the door switch. The door must be completely closed to activate the heater.

Sequence of Operation (with Optional Beacon Light)

This section describes operation of the oven with the optional beacon light feature.

1. After the system is powered up (see above procedure), the Protocol Plus controller is initialized.

2. At this point the oven is idle, empty, door closed, and waiting for the next lot to be processed. The Protocol Plus is not running a profile. The amber beacon light is on steady for steps 2 through 5, until profile is started. Refer to the Protocol Plus instructions in this manual.

3. Open the oven door.

4. Place the product on the shelf in the oven. Close the oven door.

5. Run the desired profile from the Protocol Plus controller.

Press the Select key until Profile is displayed (you can press the Run key at

any time to activate Profile Mode). Press the key to display the desired profile to run. To start Profile Mode, press the Run key.

NOTE: The display will change from Stop to Run and the segment time remaining, along with the current segment number, will be displayed.

6. The oven profile cycle is in process and the door is LOCKED. The green beacon light is on steady, the amber beacon light is off.

7. When the process is complete, the amber beacon is on, and the door is unlocked.

8. The operator removes the product, and closes oven door to complete the process cycle. The oven is ready for the next lot.

Sequence of Operation for Inert Atmosphere Oven

1. After the system is powered up (see previous procedure), the Protocol Plus controller is initialized to run an event. Refer to the Protocol Plus instructions in this manual for more information on programming event outputs.

2. At this point the oven is idle, empty, door closed, and waiting for the next lot to be processed. The Protocol Plus is not running a profile.

3. Open the oven door.

4. Place the product on the shelf in the oven. Close the oven door.

5. Run the desired profile from the Protocol plus controller.

Press the Select key until Profile is displayed (note that you can press

the Run key at any time to activate Profile Mode). Press the key to display the desired profile to run. To start Profile Mode, press the Run key.

WARNINGS:

Suffocation can occur in a nitrogenatmosphere oven chamber if it is not thoroughly purged with room air before a person goes inside it. Before entering an oven chamber, run the oven for at least five minutes with the nitrogen (or any other inert) gas turned off, doors open and recirculation fan running. Only then should a person work inside the oven chamber with the doors closed.

6. The first segment of the program is the PURGE MODE. Set the nitrogen flow meter to 300 - 350 SCFH. This program energizes the purge solenoid valve.

7. The second segment is the MAINTAIN MODE, the purge solenoid valve is de-energized and the maintain solenoid is energized to maintain the nitrogen level to less than the purge level. Adjustment is made with a needle valve located in the front bottom of the oven. The maintain valve is left energized for as long as the nitrogen level is desired to be maintained.

8. The last segment of the program is the cooldown, where the water valves are energized to bring the chamber temperature down to a safe unloading temperature. Set the water cooling flow meter to 3 GPM (11 LPM), and adjust, if necessary. The water cooling flow meter is located on the lower left side of the oven.

High Limit Alarm with Alarm Silence

This option provides an audible and visual alarm when the temperature exceeds the high limit setpoint on the control. The alarm horn is located on the right side of the control panel door. On the front of the control panel door, there is an illuminated (red) momentary push button switch to silence the alarm horn.

When the chamber temperature exceeds the high limit setting on the control, the heater will shut down the Alarm Horn will sound and the red push button will illuminate. To silence the alarm:

1. Depress the Alarm Silence push button.

The Alarm Horn will be silenced, but the red pilot light on the push

button will remain illuminated.

(optional beacon light-equipped units) The red (top) beacon light will

2. When the high limit condition clears, press reset on the control. See the section on the Protocol Plus controller for detailed operation.

3. The heater should be back on and the control should be functioning correctly. The red pilot light will be off.

illuminate, indicating a fault has occurred.

CLASS A OVENS ONLY!

WARNING: “Class A” ovens are

designed for a specific amount of solvent. Exceeding this amount could result in an explosion. Do not process closed containers of any substance or liquid in this oven because they may explode under heat. In case of fire,

leave door(s) as they are. Shut off electricity. Shut off fuel. Call the fire department. Stay away.

4. If the high limit trips repeatedly, identify the cause and correct the problem.

Class A Configuration

The “Class A” configuration is used for

handling flammable solvents. NOTE: With this option the exhaust fan is wired to be ON at all times. The “Class A” option has

an explosion relief panel and purge interlock devices:

In case the LEL (lower explosive

limit) is exceeded, and an explosive mixture is ignited in the oven, the explosion relief will rupture, preventing any more

physical damage to the oven. An airflow switch on the exhaust, to verify exhaust fan is operating. A purge timer, which is preset to keep heater off until the purge period is

complete. The preset purge period guarantees a complete four (4) air

exchanges of to remove volatiles in the chamber before the heater can be

turned on. Any failure of these devices will shut down the heater, preventing any further

processing until the condition is remedied.

Set Up

The rear of the oven must have a minimum of six (6) inches of clearance between the oven and any wall for explosion relief.

When this option is installed, the LCC/D2-14A*-3 is designed for SPECIFIC amount of solvent. Exceeding this amount could result in an explosion. Refer to the nameplate decal for the exact amount of solvent, exhaust, and fresh air required.

CLASS A OVENS ONLY!

WARNING: “Class A” ovens are

leave door(s) as they are. Shut off electricity. Shut off fuel. Call the fire department. Stay away.

Class A Operation

Verify the purge time with the

time listed on the nameplate. Close the main disconnect

switch. Press the START push button. Start the profile; at this time the

exhaust fan will start, the airflow

switch will actuate, and the purge

timer will begin timing. When the purge period is complete, the oven will begin heating.

WARNING:

Disconnect the main power switch or power cord before attempting any repair or adjustment.

Maintenance

Do not attempt any service on this oven before opening the main power disconnect switch.

Checklist

Do not allow flammable solvents, combustibles, or other organic material to

accumulate in Class A ovens, as this could lead to fire or explosion, particularly if the maximum solvent rating of the oven is exceeded.

Keep equipment clean. Gradual dirt accumulation retards airflow. A dirty oven

can result in unsatisfactory operation such as unbalanced temperature in the work chamber, reduced heating capacity, reduced production, overheated components, etc. Keep the walls, floor and ceiling of the oven work chamber free of dirt and dust. Floating dust or accumulated dirt may produce unsatisfactory work results. Keep all equipment accessible. Do not permit other materials to be stored or piled against it.

Protect controls against excessive heat. This is particularly true of controls,

motors or other equipment containing electronic components. Temperatures greater than 50.5°C (122°F) should be avoided.

Establish maintenance & checkup schedules. Do this promptly and follow the

schedules faithfully. Careful operation and maintenance will be more than paid for in continuous, safe and economical operation.

Maintain equipment in good repair. Make repairs immediately. Delays may be

costly in added expense for labor and materials and in prolonged shut down.

Practice safety. Make it a prime policy to know what you are doing before you do

it. Make CAUTION, PATIENCE, and GOOD JUDGMENT the safety watchwords for the operation of your oven.

Lubrication

Fan motor bearings are permanently lubricated. All door latches, hinges, door operating mechanisms, bearing or wear surfaces should be lubricated to ensure easy operation.

PROTOCOL PLUS CONTROL

The special features of the Protocol PlusTM control include:

PID tuning Ramp/Soak programming of up to 64 segments Segment looping and profile linking Built-in manual reset high limit control Built-in process timer Dedicated LED display for process temperature Multi-purpose two-line LCD display with backlight Auto-tuning Security access Process temperature retransmission signal Digital inputs for remote profile control Real time clock Optional relay outputs for events, alarms, or end-of-cycle signal Optional RS232/RS422/RS485 MODBUS communications

Theory of Control Operation

The Protocol Plus is a modular microprocessor based digital temperature controller. The Protocol Plus operates as a dual functioning controller/high limit instrument. The control portion utilizes a time-proportioning voltage signal to control heating devices with minimal temperature fluctuations.

The high limit portion protects the product and/or the oven from overheating. If the product being processed has a critical high temperature limit, the high limit setpoint should be set to a temperature somewhat below the temperature at which the product could be damaged. If the product does not have a critical high temperature limit, the high limit setpoint should be set 5 to 15 degrees higher than the maximum programmed setpoint at which the oven will operate.

Protocol Plus Faceplate and Wiring Diagram

Operating Modes

The Protocol Plus control has five modes of operation available: Stopped Mode: All control and relay outputs are off. Stopped Mode is integrated

into each of the following four modes of operation.

Manual Mode: Control operates as a single setpoint control until Stopped mode is

accessed

Timer Mode: Control operates as a single setpoint control until preset time period

has expired.

Profile Mode: Control operates as a ramp/soak profiling control until the end of

the profile. 8 profiles are available with up to 8 ramp/soak segments in each profile.

Auto Start Mode: Control may automatically start Manual, Timer, or Profile mode

based on a preset time and day.

The optional event outputs can be utilized during Manual, Timer, or Profile modes.

Setup Mode

The control has a Setup Mode which provides access to control configuration and programming of profiles. The Setup Mode contains ten separate electronic Pages where the configuration and programming parameters (Menu items) are found. The Setup Mode Pages are described in detail elsewhere in this manual.

Fast Start Mode

The Protocol Plus control has the ability to automatically start an operating mode when power is applied. This feature may be useful if the same mode of operation is used everyday. The user can turn on the power and the oven will start the desired process automatically. The Fast Start Mode is controlled by the Power-Up Start parameters on the Control page (see Setup Mode).

High Limit

The control has an integrated high limit function which will disable the heater output when tripped. If the high limit does trip, the relay will need to be manually reset. When the high limit relay is tripped, the Hi-Limit indicator will be lit. Allow the oven to cool several degrees (or increase the high limit setpoint) and then press the Reset key. The indicator will turn off.

High-Limit temperature readout is provided on LCD Line #2 in all Modes (Stop, Run, Hold, and Standby) except Setup Mode. High-Limit temperature is displayed for 10 seconds, alternating with current Mode and Status display for 10 seconds.

The control will not allow the high limit setpoint to be set below the current setpoint value.

Indicators

The Protocol Plus control has 12 indicating LEDs that provide operational information to the user.

Power LED: Indicates that power is supplied to the instrument. Heater LED: Indicates that the heater output is active. Profile LED: Indicates that the Profile Mode is in operation. Timer LED: Indicates that the Timer Mode is in operation. Manual LED: Indicates that the Manual Mode is in operation. Cycle Complete LED: Indicates that the control is in Stopped mode. Hi-Limit Alarm LED: Indicates that the high limit relay has tripped

(de-energized).

Soak Alarm LED: Indicates that the guaranteed soak deviation is in alarm

condition.

Outputs 1 through 4: Indicate that the optional relay outputs are in the ON

state. These outputs may be configured as timed event outputs, process temperature trip point outputs, alarm outputs, or as an end of cycle relay output. The ON state can be configured as energized or de-energized.

Displays

The Protocol Plus control has two displays. A dedicated LED upper display shows the oven temperature. A two-line LCD lower display provides information on control status, high limit temperature, and allows changes to be made to the control settings.

Key Functions

The Protocol Plus control has seven keys that provide operation.

Select key: Press to select mode of operation. In Setup Mode, to select profile

number or relay. In Profile/Run Mode, press simultaneously with the UP key to advance a segment.

Run/Hold key: Press to activate a mode of operation. If a Profile (or Timer)

Mode is running, pressing the Run/Hold key will place the Profile (or Timer) in

Hold status. A subsequent press will resume the Profile (Timer). Stop key: Press to stop any mode of operation. Page/Reset key: While in Setup Mode, press to access different Pages of

configuration, Press this key to silence an alarm if the instrument alarm sounds

during operation. In an operating mode, if an alarm or error condition occurs,

press this key to return the instrument to normal operation once the condition is

cleared. Menu/View key: While running any operating mode, pressing this key will

display the high limit setpoint. While in Setup Mode, pressing this key will provide

access to each Menu parameter. keys: Press these keys to adjust parameter settings. In Profile/Stopped

Mode, press to select profile to run. In Profile/Run Mode, press key

simultaneously with the Select key to force the program to advance one

segment.

Outputs

The Protocol Plus control has seven different outputs available.

Heating output: The control output is a DC voltage open-collector output which

is time-proportioned and designed to control a heat control device such as a solid

state relay. High limit: The high limit output is a form C relay which is energized under

normal operating conditions. If the control senses a temperature higher than the

high limit setpoint, or if there is a sensor error, the high limit relay will de-energize

until the condition is cleared and the Reset key is pressed. When the high limit

relay is de-energized, the heater is disabled. Retransmission: The retransmission output is a DC 1 to 5 volt or 4 to 20 ma

(DC) signal that is proportional to the process temperature. The signal can be an

input to other devices such as a chart recorder. Relay (four optional outputs): The four form A dry contact relay outputs can be

configured to function as alarms, events, or end of cycle. These outputs can be

utilized in Manual, Timer, or Profile Mode.

Layout for Optional Components

Relay (Continued) Use the Relay Card Optional Ay p/n 144562 to add relays to the standard controller. Each relay card contains two relays (maximum of two cards Ay’s allowed).

Communication

The Protocol Plus control has optional MODBUS communication available which can communicate via RS232, RS422, or RS485 to a computer. See communications option assembly p/n 161957 for board and cable assembly. Please refer to the MODBUS communications manual which comes with this option.

Optional Software

The Protocol Manager program allows the operator to start/stop multiple ovens (32 maximum) from a personal computer. A data log can also be used to record process information (p.n. 140008).

INSTRUCTIONS

Start-Up

These instructions are provided as a quick reference for operating the Protocol Plus control. If the Profile Mode is to be used, or the configuration of the control needs to be changed, please refer to the Setup Mode instructions before operating the control. For more detailed operating instructions refer to the Operation instructions for the mode you wish to use.

Upon initial power-up the control is in Manual/Stopped Mode (unless the Autostart or Fast Start Modes are active). To activate any operating mode from Stopped Mode, press the Select key until the desired mode is displayed, then press the Run key. If the proper Profile number is not displayed when the Profile Mode is accessed, press the or keys until the desired Profile number is displayed, then press the Run key. If no profile numbers can be displayed (display only reads NONE) then no profiles are currently programmed (see Setup Mode).

The Hi-limit thermocouple actual temperature reading is displayed, when the lower LCD display reads HL Temp. Note: This is not a error message.

The temperature setpoint can be adjusted while Manual or Timer Mode is running by pressing the UP or DOWN key.

To momentarily hold the Timer or Profile Mode, press the Hold key. To continue the Timer or Profile Mode, press the Run key.

To return to Stopped Mode at any time, press the Stop key and the cycle complete LED will illuminate.

Note that the control can be configured to automatically activate Manual, Timer or Profile Mode when power is applied (power switch turned on). See Control Page in the Setup Mode to utilize the Fast Start mode.

Operation

Manual Mode

Press the Select key until Manual is displayed (note you can press the Run key at any time to activate Manual Mode).

1. Press the Menu key to display the Process Temperature Setpoint (setpt). You can change the Setpoint with the keys.

Note: If the SPChange parameter on the Enable page in Setup Mode has been set to DISABLED, it must be changed to ENABLED before any changes to the process temperature and high limit setpoints can be made.

2. Press the Menu key a second time to display current high limit setpoint (Hi-Lim SP). The value can be adjusted by pressing the keys. If Band is displayed, the high limit band feature is activated (see Control page) and the high limit can not be adjusted.

3. (optional feature) Press the Menu key a third time to display Event1. Press the key to turn on the event or to turn off the event. Repeat for all events which are enabled (up to 4).

4. To start Manual Mode, press the Run key.

The display will change from Stop to Run. To return to Stopped Mode, press the Stop key. While in operation, the process setpoint can be adjusted by using the

keys to change the value while the mode is running. Pressing the Menu key

will display the High Limit Setpoint (HLSP) setting.

If changes to the high limit setpoint or event output configuration are needed, they must be done from the stopped mode.

Timer Mode

1. Press the Select key until Timer is displayed (note you can press the Run key at any time to activate Timer Mode).

2. Press the Menu key to display the Process Temperature Setpoint (Setpt). You can change the Setpoint with the keys.

Note that if the SPChange parameter on the Enable page in Setup Mode has been set to DISABLED, it must be changed to ENABLED before any changes to the process temperature and high limit setpoints can be made.

3. Press the Menu key a second time to display current high limit setpoint (Hi-lim SP). The value can be adjusted by pressing the keys. If Band is displayed, the high limit band feature is activated (see Control page) and the high limit can not be adjusted.

4. Press the Menu key a third time to display Time Set. You can change the time setting with the keys.

5. (optional feature) Press the Menu key a fourth time to display Event1. Press the

key to turn on the event or to turn off the event. Repeat for all events which

are enabled (up to 4).

6. Press the Menu key a fifth time to display the current guaranteed soak band (TmrGuarSoak) value. If the process temperature deviates from the setpoint by more than this value, the timer is placed in a hold condition. The timer continues when the process temperature falls within range. Reference the Quick Reference and Default Values section for available settings.

7. To start Timer Mode, press the Run key. The display will change from Stop to Run and the time remaining will be

displayed. To return to Stopped Mode, press the Stop key. While in operation, the process setpoint can be adjusted by using the keys to change the value while the mode is running. Pressing the Menu key will display the High Limit Setpoint.

Pressing the Run/Hold key while the Timer Mode is in operation will put the control in Hold status. The Timer LED will flash to indicate the held status. Press the Run/Hold key again to continue timing. The Timer LED will return to lit status.

Profile Mode

1. Press the Select key until Profile is displayed. “None” may be displayed if a profile has not been selected or no profiles entered.

2. Press the key to display the desired profile to run.

3. To start Profile Mode, press the Run key. The display will change from Stop to Run and the segment time remaining,

Temperature Setpoint, Profile #, along with the current segment number, will be displayed. To return to Stopped Mode, press the Stop key.

Pressing the Run/Hold key while the Profile Mode is in operation will put the control in Hold status. Press the Run/Hold key again to continue the mode. The Profile LED will flash to indicate the hold status.

To advance to the next segment while running a profile, press the Select and UP arrow keys at the same time.

If Link To is set to Standby in the Program Page, at the End of Program/Profile,

1. Cycle Complete LED indication goes ON.

2. Controller beeps if End of Cycle beep is enabled.

3. Heater/control output keeps controlling oven temperature at last Soak setpoint.

4. All events programmed (if relay cards installed and programmed as an event) for the last Soak Segment stays active.

Note that ramping down too fast may cause the high limit relay to trip unexpectedly if the high limit band feature is used. This can be avoided by using a separate cooling profile that does not utilized the high limit band and then jumping to that profile to perform rapid cooling.

Auto Start Mode

The Auto Start Mode allows the control to start Manual, Timer, or Profile mode automatically at a preset time and day. See the Auto Start Page in Setup Mode for the time, day, and operating mode settings.

To activate the Auto Start Mode,

1. On Auto Start page, Enable is set to Yes.

2. LCD reads Active on line 1 in Auto Start Mode.

3. On Auto Start page Enable set to No, will deactivate Auto Start Mode.

Note that once you activate Auto Start, you can continue to use all operating modes as normal. If an operating mode is running at the time of a preset Auto Start function, and Auto Start is activated, the existing operating mode will override the auto Start function and the Auto Start will not turn on.

Note: All process Set to Run in Auto Start Mode must be at least one minute long for all Run Modes (Manual, Timer, and Profile).

Setup Mode

Configuration of the control and programming of the ramp/soak profiles must be done in the Setup Mode. To access Setup Mode, the control must first be in Stopped Mode.

1. Press the Select key until Setup is displayed.

2. Press the Page key and Security will be displayed.

3. Press the Menu key and Password will also be displayed. Use the keys to enter the proper password.

4. Once the proper password is displayed, press the Page key twice to enter the Setup Mode.

To exit Setup Mode, press and hold the Page key for three seconds. The control has two levels of password-protected security. Level one provides access

only to those menu pages that are enabled on the Enable page. Level two provides access to all menu pages, including the Enable page. The default security password values are 1 for level one and 2 for level two.

If an improper password has been entered, the control will remain at the Security display. To enter the proper password, press the Menu key. To exit Setup Mode, press and hold the Page key for three seconds.

Mapping of the Setup Mode is provided in the following sections. To access each parameter Page, which are described in detail in the following sections, press the Page key until the desired page heading is displayed. Press the Menu key to access each Menu parameter. Press the keys to change Menu parameter settings.

Refer to the Quick Reference and Default Values section for available settings for each Menu parameter.

Press the Page key to continue with each Page, or press and hold the Page key for three seconds to exit Setup Mode.

Instructions for Setup Mode Pages

Program Page

Programming of the profiles is provided on the Program Page. Eight profiles are available with up to eight ramp and soak segments per profile.

If the optional relay outputs are installed, they must be configured as alarms or events on the Relay Outputs Page before they can be utilized. If configured as event outputs, these relays can be used as time or temperature events.

When entering the Program Page, press the Select key to select the profile you wish to enter/edit, then press the Menu key. The first parameter (Profile #, Segment 1, Ramp Time) will display. Adjust the time value with the keys. Once the proper value is displayed, press the Menu key to continue. Continue with the Menu key to adjust/view each parameter.

If the ramp time value of the current segment is left at 0:00, the next press of the Menu key will advance the control to the High Limit Setpoint parameter for that profile. Continue entering / verifying all parameters until you get to the last parameter (Guaranteed Soak Band). Once all parameters have been properly entered, press the Page key to return to the top of the Profile Page. You can press the Select key to enter/edit another profile, press the Page key to access another page, or press and hold the Page key to exit Setup mode.

While editing any profile, pressing the Select key will advance the control to the time value for the next segment, until the last segment has been reached. This allows faster editing of the profile rather than pressing the Menu key to advance past each parameter.

If Link To is set to Standby in the Program Page, at the End of Program/Profile,

1. Cycle Complete LED indication goes ON.

2. Controller beeps if End of Cycle beep is enabled.

3. Heater/control output keeps controlling oven temperature at last Soak setpoint.

4. All events programmed (if relay cards installed and programmed as an event)

for the last Soak Segment stays active.

To run a profile indefinitely, link the profile to itself.

Menu Item

Display

Description

Ramp Time Seg 1

Pro-1 Seg-1 Ramp Time

Ramp time for segment 1 of profile

Event 1 Set Value*

Pro-1 Seg-1 Ramp Event 1

Event 1 setting for segment 1 ramp of profile

Event 2 Set Value*

Pro-1 Seg-1 Ramp Event 2

Event 2 setting for segment 1 ramp of profile

Event 3 Set Value*

Pro-1 Seg-1 Ramp Event 3

Event 3 setting for segment 1 ramp of profile

Event 4 Set Value*

Pro-1 Seg-1 Ramp Event 4

Event 4 setting for segment 1 ramp of profile

Soak Temp Seg 1

Pro-1 Seg 1 Soak Temp

Soak temperature for segment 1 of profile

Soak Time Seg 1

Pro-1 Seg 1 Soak Time

Soak time for segment 1 of profile

Event 1 Set Value*

Pro-1 Seg-1 Soak Event 1

Event 1 setting for segment 1 soak of profile

Event 2 Set Value*

Pro-1 Seg-1 Soak Event 2

Event 2 setting for segment 1 soak of profile

Event 3 Set Value*

Pro-1 Seg-1 Soak Event 3

Event 3 setting for segment 1 soak of profile

Event 4 Set Value*

Pro-1 Seg-1 Soak Event 4

Event 4 setting for segment 1 soak of profile

(repeat for segments 2-8, until ramp or soak time = 00:00)

High Limit Setpoint

Pro-1 Hi-Lim SP

High limit setpoint for profile**

Loop From

Pro-1 Loop From Seg

To start a loop action in a profile

Loop To

Pro-1 Loop To Seg

To end a loop action in a profile

Loop Count

Pro-1 Loop Number

Number of times to execute loop

Profile Link

Pro-1 Link To Pro

To jump from this profile to another

Guaranteed Soak

Pro-1 Guar Band

Guaranteed soak band for profile

See the definitions on the following pages for parameter ranges.

* only available if optional relay outputs are installed (repeat all for profiles 2-8) ** Set to Band to use the high limit band feature

Profile #

There are eight profiles available.

Segment#

Recipe segments 1 through 8 may be programmed, each with its own set of events, ramp and soak times, and soak temperature.

Ramp Time

The time required to ramp from one setpoint up to another setpoint. Values between 0 and 99:59 are allowable. In the Protocol Plus controller, the profile ramp and soak times are stored without units. Units are set as either hours and minutes (HH:MM) or minutes and seconds (MM:SS). The setpoint will automatically increment from the actual temperature to the soak temperature.

EV1 through 4

From 1 to 4 events may be programmed into the ramp time portion of each segment here. These typically involve actuating/disabling relays to close/open valves or perform other relay-controlled functions. NOTE: These will only actuate when the controller has the relay cards installed and programmed for an event.

Soak Temp.

The temperature setpoint of a particular segment is entered here; it can range from -18 to 540 degrees C (0 to 1000 degrees F).

Soak Time

The duration of soak is entered here; the value can range from 0 to 99:59.

EV1 through 4

From 1 to 4 events may be programmed into the soak portion of each segment here. These typically involve actuating/disabling relays to close/open valves or perform other relay-controlled functions. NOTE: These will only actuate when the controller has the relay cards installed and programmed for an event.

Hi Limit SP

The high limit setpoint may be entered here; if the temperature exceeds this value, the hi-limit will alarm and shut off the heater.

Loop From

Values are No, Seg-1 to Seg-8.

Loop To

Values are No, Seg-1 to Seg-8.

Loop Number

Values are 0 - 99. These values enable the operator to jump from a certain step to another step of the recipe a preset number of times.

Profile Link

Values are STANDBY/STOP/HOLD/1 - 8. When the profile ends, the profile can hold the temperature setpoint while keeping the events active, turn the heater off, hold the temperature setpoint at the end of the profile, or jump to another specified profile.

Guaranteed Soak Band

If the process temperature deviates from the setpoint by more than this value, the soak timer is placed in a hold condition. The timer continues when the process temperature falls within range.

Seg-

ment

Ramp

Soak

Time

Events

Temp-

erature

Time

Events

1 2 3 4 1 2 3

01h00

100

01h00

02h00

00h01

00h00

4 5 6

7 8

High Limit Setpoint

115

Loop From Seg

Loop To Seg

No Loop Number

Link To Pro

Guar Soak Band

Sample Profile

Programming Table Profile Number____1______ Profile Name__________

Auto Start Page

The Auto Start Page can be configured to automatically start Manual, Timer or Profile Mode at a specified time and day. Note that if Auto Start Enable is set to Yes in the Setup Mode, the Auto Start feature is not turned on - it is available to the operator to be activated in Stopped Mode.

To configure the Auto Start feature:

1. Access the Setup Mode.

2. Press the Page key until Auto Start is displayed.

3. Press the Menu key. If there is no change in the display, the controller may not have the realtime clock option.

4. Set Auto Start Enable to Yes.

5. Using the Menu key, scroll through the options available and use the keys to set the mode desired for each day of the week. You may select from Manual, Timer, or Profile 1 through 8.

6. When the mode is set press the Menu key.

7. Enter the time of day you wish the mode to activate.

8. Continue through the rest of the week by pressing the Menu key, or press the Page key when done.

One Auto Start mode can be set for each day of the week. Exit the Setup mode by pressing and holding the Page key for three seconds. Press the Select key until Auto Start is displayed. Make sure the correct time and day is displayed. If not proper, set it to the correct time on the Real Time Clock Page in the Setup mode.

To activate the Auto Start Mode,

1. On Auto Start page, Enable is set to Yes.

2. LCD reads Active on Line 1 in Auto Start Mode.

3. On Auto Start page Enable set to No, will deactivate Auto Start Mode.

Note that once you activate Auto Start, you can continue to use all operating modes as normal. If an operating mode is running at the time of a preset Auto Start function, and Auto Start is activated, the existing operating mode will override the Auto Start function and the Auto Start will not turn on.

Note: All process Set to Run in Auto Start Mode must be at least one minute long for all Run Modes (Manual, Timer, and Profile).

Menu Item

Display

Description

Range

Enable Autostart

Auto Start Enable

Enable (yes) or disable (no) the Autostart function

No, Yes

Sunday mode

Auto Start Sun Mode

Set mode on Sunday to activate

Off, Manual, Timer, Pro-1 to Pro-8

Sunday time

Auto Start Sun Time

Set time on Sunday for mode to activate

00:00 to 23:59

Monday mode

Auto Start Mon Mode

Set mode on Monday to activate

Off, Manual, Timer, Pro-1 to Pro-8

Monday time

Auto Start Mon Time

Set time on Monday for mode to activate

00:00 to 23:59

Tuesday mode

Auto Start Tue Mode

Set mode on Tuesday to activate

Off, Manual, Timer, Pro-1 to Pro-8

Tuesday time

Auto Start Tue Time

Set time on Tuesday for mode to activate

00:00 to 23:59

Wednesday mode

Auto Start Wed Mode

Set mode on Wednesday to activate

Off, Manual, Timer, Pro-1 to Pro-8

Wednesday time

Auto Start Wed Time

Set time on Wednesday for mode to activate

00:00 to 23:59

Thursday mode

Auto Start Thu Mode

Set mode on Thursday to activate

Off, Manual, Timer, Pro-1 to Pro-8

Thursday time

Auto Start Thu Time

Set time on Thursday for mode to activate

00:00 to 23:59

Friday mode

Auto Start Fri Mode

Set mode on Friday to activate

Off, Manual, Timer, Pro-1 to Pro-8

Friday time

Auto Start Fri Time

Set time on Friday for mode to activate

00:00 to 23:59

Saturday mode

Auto Start Sat Mode

Set mode on Saturday to activate

Off, Manual, Timer, Pro-1 to Pro-8

Saturday time

Auto Start Sat Time

Set time on Saturday for mode to activate

00:00 to 23:59

Menu Item

Display

Description

Range

Display units

PID Temp Unit

Set display units to °C or °F

°C or °F

Proportional band

PID Prop Band

Set proportional band for tuning

1 to 56°C (1 to 100°F)

Integral reset

PID Reset/Rep/Min

Set integral reset for tuning

0.0 to 100 seconds/repeat

Derivative Rate

PID Rate In Sec

Set derivative rate for tuning

0.0 to 500 seconds

AutoTune

PID AutoTune

Enable auto tuning function

Disable, Enable

PID Page

The PID Page contains parameters which control the response to the setpoint and process variable input. To access the PID Page, enter the Setup Mode. Press the Page key until PID is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the

keys to change the value.

The AutoTune parameter disables or enables the AutoTune function. To utilize AutoTuning:

1. Access the Setup Mode.

2. Press the Page key until the display reads AutoTune. Press the key to enable the AutoTune.

3. Press the Page key for three seconds to exit Setup Mode.

4. Cycle power to the instrument.

5. Set Manual Mode to run. The display will alternately display AutoTune and Manual.

If the Manual Mode setpoint is less than 50 degrees higher than the actual process temperature, the AutoTune function will create an error condition. This can be cleared by either cooling off the process temperature or increasing the setpoint until there is more than 50 degrees between them. Once the AutoTune function is allowed to complete tuning, the AutoTune parameter will disable by itself.

If you wish to cancel the AutoTune function, press the STOP key, access the PID page in Setup Mode, and set the AutoTune parameter to Disable.

Menu Item

Display

Description

Range

Cycle Time

Control Cycle Time Sec

Set cycle time in seconds for control output

1 to 60 seconds

High limit setpoint

Control Hi-Lim SP***

Maximum value for all high limit setpoints

MinHiLimSP - MaxHiLimSP*

High limit band

Control Hi-Lim Band

If=0, high limit setpoint= Control Hi-Lim SP If>0, high limit setpoint= Control SP* + Band

Off, 3°C to 11°C (5°F to 20°F)

Power fail recovery

Control PwrFRec

Controls response to loss of power

Stop, Restart, Hold, Resume

Recovery time limit

Control PFRTime

Control aborts to Stopped mode if power is lost for time period longer then set value

00m00s to 99m59s

Powerup start enable

ControlPwrUpStrt

Allows mode to automatically start when power is first applied

Disable, Enable

Powerup Start Mode

Control StrtMode

Operating mode for powerup start

Off, Manual, Timer, Pro-1 to Pro-8

Hysteresis

Control Hysteresis

Hysteresis for all alarms and temperature events

1°C to 56°C (1°F to 100°F)

Process out low

Control RetOutLo

Process value for retransmit output = 1VDC

-73°C to 760°C (-100°F to 1400°F)

Process out high

Control RetOutHi

Process value for retransmit output = 5VDC

-73°C to 760°C (-100°F to 1400°F)

Time scale

Control TimeScale

Time scale setting for program and timer mode**

hh:mm or mm:ss

Key press beep

Control KeyBeep

Internal beeper sounds when key is pressed

On or Off

End of cycle beep

Control EOCBeep

Internal beeper sounds at end of cycle

On or Off

Alarm beep

Control AlarmBeep

Internal beeper sounds for alarms

On or Off

Control Page

The Control Page contains various parameters which control miscellaneous functions. To access the Control Page, enter the Setup Mode. Press the Page key until Control is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.

* includes ramping setpoints during profiles and controlled ramps ** power fail recovery time limit is always MM:SS regardless of time scale setting *** high limit setpoint is a read-only item which is calculated on Enable page

Menu Item

Display

Description

Range

Address

Communication CommAddr

Sets address node for control

1 to 247

Mode

Communication Mode

Turns on/off communications

OFF, Modbus

Baud Rate

Communication BaudRate

Sets interface speed

2400, 4800, 9600, 19.2K,

38.4K

Parity

Communication Parity

Sets parity for interface

None, Odd, Even

Menu Item

Display

Description

Range

Day of the week

Clock Day

Setting for current day of the week

Sun, Mon, Tue, Wed, Thu, Fri, Sat

Time of day

Clock HH:MM

Setting for current time of the day

00:00 to 23:59

Reset clock

Clock UP to Reset CLK*

Press the key to set the clock to entered values

Ready, Done

Communication Page (optional)

The Communication Page contains parameters for the communications feature. To access the Communications Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Communication is displayed. Press the Menu key. (NOTE: If there is no change in the display, the controller does not have the communications board installed.) Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.

Real Time Clock Page

The Real Time Clock Page allows the control to be configured to have an operating mode begin automatically at a specific time on a specific day of the week. The real time clock feature is also used for using the Power Failure Recovery mode Time Limit feature (see Control Page). The real time clock is a seven day, 24 hour clock with battery backup.

To access the Real Time Clock Page, enter the Setup Mode. Press the Page key until Clock is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.

* If the key is not pressed, the clock values will retain their original values. The display will change to Done if the clock is reset

Menu Item

Display

Description

Range

Type of relay

Relay 1 RelayType

Set function of relay

Off, Alarm, Cycl, Ev1 to Ev4

Action of relay

Relay 1 RelayAction

Set coil and contact state of relay

NDE, NE, NDEL, NEL*****

Type of alarm*

Relay 1 AlarmType

Set alarm type for relay

High, Low, Plus, Minus, Band

Alarm setpoint*

Relay 1 AlmHi/Lo SP

Setpoint for alarm

-73°C to 760°C (-100°F to 1400°F)

Alarm deviation*

Relay 1 AlmDevBand

Deviation band for alarm

1 to 56°C (1 to 100°F)

Inhibit alarm*

Relay 1 ALMInhibit

Inhibits alarm until "safe" condition is reached

En or Dis

Type of event**

Relay 1 EventType

Set event type for relay

Time or Temp

Event setpoint***

Relay 1 Event SP

Setpoint for temperature event

SPLoLim to SPUpLim****

Relay Outputs Page (optional)

The Relay Outputs Page configures the four alarm/event outputs. Each output has a dedicated indicator light and can be configured as a temperature alarm, profile event, or end of cycle output. Temperature alarms can be of type process high, process low, deviation high, deviation low, or deviation band.

To access the Relay Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Relay is displayed. Press the Select key until the desired relay output is selected. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value. To configure a specific relay, press the Select key until the desired relay appears.

NOTE: If Relay 0 appears, then no relays are installed (see relay kit assembly p.n.

144562).

(repeat for relay outputs 2-4, if available) * appears only for alarm types

** appears only for time or temperature event types *** appears only for temperature event types

Turning on the Alarm Inhibit function disables the alarm output on power up until the process temperature has reached a non-alarming condition ("safe").

If the relay output has been configured as latching, the RESET key must be pressed to return the output to the non-alarm state once the alarm condition has cleared.

Menu Item

Display

Description

Range

Heater output

Test HeatOut

Activate SSR output 100%

High limit relay

Test HiLimOut

Activate high limit alarm (de-energize relay)

Relay 1 output

Test Rly1 Out

Energize relay output 1

Relay 2 output

Test Rly2 Out

Energize relay output 2

Relay 3 output

Test Rly3 Out

Energize relay output 3

Relay 4 output

Test Rly4 Out

Energize relay output 4

HiLim Sensor

Test HL Temp (push and hold up)

Displays sensor reading*

Test Page

The Test Page contains parameters which allow manual control of the heat control and optional relay outputs and should be used only for testing the functionality of the control instrument. Do not operate the oven for processes using the Test Page.

To access the Test Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Test is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.

*Push key to refresh display When the Test Page is entered, all outputs are automatically set to off. When exiting

the Test Page, all outputs will return to their previous condition regardless of the Test Page settings.

Menu Item

Display

Description

Range

Zone 1 actual

Zone Cal Zone1Act

Point at which Zone 1 is set (center of chamber)

-73°C to 760°C (-100°F to 1400°F)

Zone1 displayed

Zone Cal Zone1Dis

Desired displayed value for Zone 1 setting

-73°C to 760°C (-100°F to 1400°F)

Zone 2 actual

Zone Cal Zone2Act

Point at which Zone 2 is set (center of chamber)

-73°C to 760°C (-100°F to 1400°F)

Zone2 displayed

Zone Cal Zone2Dis

Desired displayed value for Zone 2 setting

-73°C to 760°C (-100°F to 1400°F)

Factory calibration*

Zone Cal FactCal

Restores the factory calibration values

Ready or Done (push- key)

Zone Calibration Page

The Zone Calibration Page allows adjustment of the displayed temperature versus the actual temperature measured by the control thermocouple. This may be desirable in certain conditions where the center of the oven chamber is not the same temperature as the control thermocouple. This may occur when the oven is not allowed to soak at a constant temperature for long periods of time, or the oven is being used at high temperature.

There is also a Factory Calibration Recovery which will restore the factory calibration values when the control was first shipped by the manufacturer. This may be helpful if the calibration has been lost and a calibration instrument is not readily available. To use the Factory Calibration Recovery feature only, bypass the Zone 1 and Zone 2 calibration parameters by pressing the Menu key.

To access the Zone Calibration Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Zone Cal is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.

*Only use when no calibration instrument is available, push key to restore factory values.

Press the Page key to exit the Zone Calibration Page. Two points of display calibration (temperature offset) are available. The Zone 1 Actual

and Zone 2 Actual parameters are the two temperature points where the offset is to take effect. These values are adjustable. The Zone 1 and Zone 2 Displayed parameters are the values the user wishes to have displayed at the Actual temperatures, and are also adjustable.

As an example, the control is displaying 400°F with the setpoint being 400°F, but the center of the oven chamber is actually 395°F. This can occur due to oven wall losses and product loading variations. The operator may change the zone calibration so that the center of the oven is 400°F when the display reads 400°F. In this case operate the oven in manual mode with a setpoint of 400°F. Record the center of the chamber (as measured with an independent sensor). Access the Zone Calibration Page and enter this measured value as the Zone 2 Actual value, with 400° as the Zone 2 Displayed value.

Zone 1 can be adjusted using the same method at a lower temperature. The instrument will then create a linear offset based on the Zone1 and Zone 2 Actual temperature values. Note that the oven does not have to be heated to adjust the zone parameters if the zone values are known based on prior experience.

Sensor Calibration Page

The Sensor Calibration Page has parameters which can change the internal calibration of the temperature sensor input signal. There is a low and high calibration point for both the control sensor and the high limit sensor. To calibrate the instrument, allow the control to warm up for at least 30 minutes.

To access the Sensor Calibration Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Control Sensor is displayed. Press the Menu key.

The control may have the optional process value retransmission output feature. The output is a 1 to 5VDC signal. To calibrate the retransmit signal, the RetOutLo and RetOutHi values from the Control Page must be known. You may bypass calibrating the control and high limit sensor input to access only the retransmit calibration by pressing the Menu key until RetCalLo is displayed (skip steps 4-17).

To re-calibrate the instrument:Disconnect the control and high limit sensor thermocouples.

1. Connect a calibration instrument with a type J thermocouple output to the

control sensor input. Allow the control to warm up at least 30 minutes.

2. Access Setup Mode.

3. Press Page key until -100F is displayed.

4. Press Menu key until Ctrl Sens -100F is displayed.

5. With Ctrl Sens -100F displayed, adjust the calibration instrument to Type J

thermocouple, -100 degrees Fahrenheit output.

6. Wait 30 seconds. Press the key.

7. With Ctrl Sens 1400F displayed, adjust the calibration instrument to 1400

degrees Fahrenheit output (Type J thermocouple).

8. Wait 30 seconds. Press the key.

9. When the control displays Ctrl Sens Done, disconnect the calibration

instrument from the control sensor input and connect it to the high limit sensor input. Reconnect the control sensor thermocouple.

10. Press the Menu key until HL Sens -100F is displayed.

11. With the control displaying HL Sens -100F, adjust the calibration instrument

to -100 degrees Fahrenheit output (Type J thermocouple).

12. Wait 30 seconds. Press the key.

13. With the control displaying HL Sens 1400F, adjust the calibration instrument

to 1400 degrees Fahrenheit output (Type J thermocouple).

14. Wait 30 seconds. Press the key.

15. When the control displays HL Sens Done, disconnect the calibration

instrument from the high limit sensor input. Re-connect the high limit sensor thermocouple.

16. To skip calibration of the retransmit signal, press the Page key twice to exit the

Sensor Calibration Page.

17. To calibrate the retransmit signal, press the Menu key until RetCalLo is

displayed.

Menu Item

Display

Description

Range

Control Sensor Cal

Ctrl Sens -100F Ctrl Sens 1400F Ctrl Sens Done

Calibrate Sensor Low End Calibrate Sensor High End Control Sensor Cal Complete

-100 to 1400°F

-100 to 1400°F (read only)

HiLim Sensor Cal

HL Sens -100F HL Sens 1400F HL Sens Done

Calibrate HiLim Sensor Low End Calibrate HiLim Sensor High End HiLim Sensor Cal Complete

-100 to 1400°F

-100 to 1400°F (read only)

Retransmit Cal

RetCalLo XXXX * RetCalHi XXXX *

Calibrate Retransmit Output Low Calibrate Retransmit Output High

0 to 4096** 0 to 4096***

18. Connect a calibration instrument with a type J thermocouple output to the

control sensor input.

19. Connect a voltage measurement device to the retransmit output terminals.

20. Set the calibration instrument output to the temperature value of the RetOutLo

parameter from the Control Page.

21. Adjust the RetCalLo * value using the keys until the voltage measurement

device reads 1VDC.

22. Press the Menu key.

23. Set the calibration instrument output to the temperature value of the RetOutHi

parameter from the Control Page.

24. Adjust the RetCalHi * value using the keys until the voltage measurement

device reads 5VDC.

25. Press the Menu key.

26. Press the Page key to exit the Sensor Calibration Page.

27. Calibration is now complete. Disconnect the calibration instrument and voltage

measurement device (if used).

28. Verify that the control and high limit sensor thermocouples are connected.

*Note that the actual RetCalLo and RetCalHi values displayed are of no importance.

Menu Item

Display

Description

Range

Profiles

Enable Profile 1-8

Controls access to Program Page

Yes or No

Autostart

Enable Auto Start

Controls access to AutoStart Page

Yes or No **

PID

Enable PID

Controls access to PID Page

Yes or No

Control

Enable Control

Controls access to Control Page

Yes or No

Communication

Enable Communication

Controls access to Communication Page

Yes or No **

Real Time Clock

Enable Clock

Controls access to Real Time Clock Page

Yes or No **

Relay outputs

Enable Relay 1-4

Controls access to Relay Page

Yes or No **

Test

Enable Test

Controls access to Test Page

Yes or No

Zone Calibration

Enable Zone Cal

Controls access to Zone Calibration Page

Yes or No

Sensor Calibration

Enable Sensor Cal

Controls access to Sensor Calibration Page

Yes or No

Setpoint lower limit

Enable SPLowerLim

Sets minimum setpoint allowed

-73°C to 759°C (-100°F to 1399°F)

Setpoint upper limit

Enable SPUpperLim

Sets maximum setpoint allowed

-73°C to 760°C (-100°F to 1400°F)

High limit overhead

Enable HiLimOH

Sets maximum high limit setpoint allowed*

3 to 11°C (5 to 20°F)*

Password level 1

Enable Password 1

Sets password for access level 1

0 to 999

Password level 2

Enable Password 2

Sets password for access level 2

0 to 999

Setpoint Change

Enable SPChange

Set to DISABLE to lock out setpoint and high limit setpoint changes in Manual and Timer Modes

Yes or No Analog Output

Type

Enable Analog Type

Sets Analog Output type

Ctrl or Proc

Enable Page

The Enable Page controls access to the other Setup Pages. The setpoint minimum and maximum values, and the security passwords are also set on the Enable Page. To access the Enable Page, enter the Setup Mode using a level 2 access code (see description earlier in this manual). Press the Page key until Enable is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.

NOTE: Changing the enable to “yes” for each page will allow access to the page in

Level 1 security.

* Maximum high limit setpoint = SPUpperLim + HiLimOH ** If the controller does not have this feature, “No” is the only option.

Input 1

Input 2

Input 3

Profile Selected

OFF

none

Digital Inputs (optional)

The Protocol Plus control can be run by external inputs wired to the control from an external source such as a PLC or control panel switches. The external run operation can Run, Hold or Stop profiles 1 through 7 (profile 8 can not be operated externally). Refer to the table below for the inputs required for the desired operation. NOTE: A profile must be created in the program page before trying to run a profile number.

To start the selected profile, set Input 1, 2, 3 or 4 to ON. To hold a profile, set Input 4 to OFF. To stop a profile, set all inputs to OFF.

Digital Inputs

Error Messages and Alarms

The Alarm Status Hi-limit LED is flashing. This indicates a problem with the thermocouple, or the Hi-limit setpoint has been exceeded. Once the problem has corrected, press the Reset pushbutton.

The Alarm Status Soak LED is flashing. This indicates that the oven temperature has not entered or dropped out of the soak band and the soak timer has stopped.

The top LED Display reads OPEN and the lower LCD display reads CONTROL SENS ERR. This indicates that the Control thermocouple is disconnected or broken. Repair or replace the thermocouple.

The lower LCD display reads HI-LIM SENS ERR. This indicates that the Hi-limit thermocouple is disconnected or broken. Repair or replace the thermocouple.

The lower LCD display reads HIGH LIMIT ALARM. This indicates that the Hi-limit temperature setpoint has been exceeded. Determine if the setting is set too close to the setpoint, the SSR is defective, or the calibration is incorrect.

Note: The lower LCD display intermittently reads HL Temp. This is not an error message, but the Hi-limit thermocouple temperature reading.

Menu Item

Display

Default

Range

Setting

Ramp Time Seg 1

Pro-1 Seg-1 Ramp Time

00:00

00m00s to 99h59s

Event 1 Set Value

Pro-1 Seg-1 Ramp Event 1

Off

Off, On

Event 2 Set Value

Pro-1 Seg-1 Ramp Event 2

Off

Off, On

Event 3 Set Value

Pro-1 Seg-1 Ramp Event 3

Off

Off, On

Event 4 Set Value

Pro-1 Seg-1 Ramp Event 4

Off

Off, On

Soak Temp Seg 1

Pro-1 Seg 1 Soak Temp

68°F

SPLowerLim to SPUpperLim *

Soak Time Seg 1

Pro-1 Seg 1 Soak Time

00:00

00m00s to 99h59s

Event 1 Set Value

Pro-1 Seg-1 Soak Event 1

Off

Off, On

Event 2 Set Value

Pro-1 Seg-1 Soak Event 2

Off

Off, On

Event 3 Set Value

Pro-1 Seg-1 Soak Event 3

Off

Off, On

Event 4 Set Value

Pro-1 Seg-1 Soak Event 4

Off

Off, On

(repeat for segments 2-8)

High Limit Setpoint

Pro-1 Hi-Lim SP

Max HiLimSP

MinHiLimSP to MaxHiLimSP *, Band **

Loop From

Pro-1 Loop From XX

No, Seg-1 to Seg-8

Loop To

Pro-1 Loop To XX

No, Seg-1 to Seg-8

Loop Count

Pro-1 Loop Number

0 to 99

Profile Link

Pro-1 Link To XX

Stop

Standby***, Stop, Hold, Pro-1 to Pro-8

Guaranteed Soak

Pro-1 Guar Band

Off

Off, 1 to 778°C (1400°F)

(repeat for profiles 2-8)

Quick Reference and Default Values

Program Page

* See Enable Page ** Band value is set on Control Page

*** If Standby

1. Cycle Complete LED indication goes ON.

2. Controller beeps if End Of Cycle beep is enabled.

3. Heater/control output keeps controlling oven temperature at last Soak setpoint.

4. All events programmed (if relay cards installed and programmed as an event) for the last Soak Segment stays active.

Seg-

ment

Ramp

Soak

Time

Events

Temp-

erature

Time

Events

1 2 3 4 1 2 3

1 2 3

4 5 6

7 8 High Limit Setpoint

Loop From Seg

Loop To Seg

Loop Number

Link To Pro

Guar Soak Band

Programming Table Profile Number__________ Profile Name__________

Menu Item

Display

Default

Range

Setting

Enable Autostart

Auto Start Enable

No, Yes

Sunday mode

Auto Start Sun Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Sunday time

Auto Start Sun Time

00:00

00:00 to 23:59

Monday mode

Auto Start Mon Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Monday time

Auto Start Mon Time

00:00

00:00 to 23:59

Tuesday mode

Auto Start Tue Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Tuesday time

Auto Start Tue Time

00:00

00:00 to 23:59

Wednesday mode

Auto Start Wed Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Wednesday time

Auto Start Wed Time

00:00

00:00 to 23:59

Thursday mode

Auto Start Thu Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Thursday time

Auto Start Thu Time

00:00

00:00 to 23:59

Friday mode

Auto Start Fri Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Friday time

Auto Start Fri Time

00:00

00:00 to 23:59

Saturday mode

Auto Start Sat Mode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Saturday time

Auto Start Sat Time

00:00

00:00 to 23:59

Menu Item

Display

Default

Range

Setting

Display units

PID Temp Unit

°C

°C or °F

Proportional band

PID Prop Band

6°C

1 to 56°C (1 to 100°F)

Integral reset

PID Reset

0 to 100 seconds/repeat

Derivative Rate

PID Rate

0 to 500 seconds

AutoTune

PID AutoTune

Disable

Disable, Enable

Autostart

PID

Menu Item

Display

Default

Range

Setting

Cycle Time

Control Cycle Time

1 to 60 seconds

High limit setpoint

Control Hi-Lim SP

Max HiLimSP

MinHiLimSP - MaxHiLimSP*

High limit band

Control Hi-Lim Band

Off

Off, 3°C to 11°C (5°F to 20°F)

Power fail recovery

Control PwrFRec

Stop

Stop, Restart, Hold, Resume

Recovery time limit

Control PwrFTime

00m00s

00m00s to 99m59s

Powerup start enable

Control EPwrStrt

Dis

Dis, En

Powerup Start Mode

Control StrtMode

Off

Off, Manual, Timer, Pro-1 to Pro-8

Hysteresis

Control Hyst

3°C

1°C to 56°C (1°F to 100°F)

Process out low

Control RetOutLo

80°C

-73°C to 760°C (-100°F to 1400°F)

Process out high

Control RetOutHi

400°C

-73°C to 760°C (-100°F to 1400°F)

Time scale

Control TimeScale

hh:mm

hh:mm or mm:ss

Key press beep

Control KeyBeep

On or Off

End of cycle beep

Control EOCBeep

Off

On or Off

Alarm beep

Control AlarmBeep

Off

On or Off

Menu Item

Display

Default

Range

Setting

Address

Communication CommAddr

1 to 247

Mode

Communication CommMode

OFF

OFF, Modbus

Baud rate

Communication Baud Rate

19.2K

2400, 4800, 9600,

19.2K, 38.4K

Parity

Communication Parity

None

None, Odd, Even

Control

*see Enable Page Communication (optional)

Menu Item

Display

Default

Range

Setting

Day of the week

Clock Day

Mon

Sun, Mon, Tue, Wed, Thu, Fri, Sat

Time of day

Clock HH:MM

00:00

00:00 to 23:59

Reset clock

Clock UP to Reset CLK*

Ready

Ready, Done

Menu Item

Display

Default

Range

Type of relay

Relay 1 RelayType

Off

Off, Alarm, Cycl, Ev1 to Ev4

Action of relay

Relay 1 RelayAction

NDE

NDE, NE, NDEL, NEL*****

Type of alarm*

Relay 1 AlarmType

High

High, Low, Plus, Minus, Band

Alarm setpoint*

Relay 1 AlmHi/Lo SP

538°C

-73°C to 760°C (-100°F to 1400°F)

Alarm deviation*

Relay 1 AlmDevBand

3°C

1 to 56°C (1 to 100°F)

Inhibit alarm*

Relay 1 ALMInhibit

En or Dis

Type of event**

Relay 1 EventType

Time

Time or Temp

Event setpoint ***

Relay 1 Event SP

SPUpLim

SPLoLim to SPUpLim****

Relay

Type

Action

Alarm/ Event Type

Setpoint

Alarm Deviation

Alarm Inhibit

Real Time Clock

* if the key is not pressed, the clock values will retain their original values, the display will change to Done if the clock is reset

Relay Outputs (optional) Push Select key to select relay. If Relay 0 appears, no relays are installed

(repeat for relay outputs 2-4, if available)

* appears only for alarm types ** appears only for time or temperature event types *** appears only for temperature event types **** see enable page ***** Normally de-energized and non-latching, normally energized and non-latching,

normally de-energized and latching, normally energized and latching

Table of Settings

Menu Item

Display

Default

Range

Setting

Heater output

Test HeatOut

Off

On High limit relay

Test HiLimOut

Off

On Relay 1 output

Test Rly1 Out

Off

On Relay 2 output

Test Rly2 Out

Off

On Relay 3 output

Test Rly3 Out

Off

On Relay 4 output

Test Rly4 Out

Off

On High Limit Sensor

Test HL Temp

(sensor reading)

Menu Item

Display

Default

Range

Setting

Zone 1 actual

Zone Cal Zone1Act

38°C

-73°C to 760°C (-100°F to 1400°F)

Zone1 displayed

Zone Cal Zone1Dis

38°C

-73°C to 760°C (-100°F to 1400°F)

Zone 2 actual

Zone Cal Zone2Act

260°C

-73°C to 760°C (-100°F to 1400°F)

Zone2 displayed

Zone Cal Zone2Dis

260°C

-73°C to 760°C (-100°F to 1400°F)

Factory calibration*

Zone Cal FactCal

Ready

Ready or Done (push- key)

Menu Item

Display

Default

Range

Setting

Control Sensor Cal

Ctrl Sens 0F Ctrl Sens 1000F Ctrl Sens Done

-100°F 1400°F Done

-100 to 1400°F

-100 to 1400°F (read only)

HiLim Sensor Cal

HL Sens 0F HL Sens 1000F HL Sens Done

-100°F 1400°F Done

-100 to 1400°F

-100 to 1400°F (read only)

Retransmit Cal

RetCalLo XXXX * RetCalHi XXXX *

0 4096

0 to 4096** 0 to 4096***

Test

Zone Cal

*only use when no calibration instrument is available

Sensor Cal

* note that the actual RetCalLo and RetCalHi values displayed are of no

importance. ** press keys until retransmission output = 1VDC *** press keys until retransmission output = 5VDC

Menu Item

Display

Default

Range

Setting

Profiles

Enable Profile 1-8

Yes

Yes or No

Autostart

Enable Auto Start

Yes or No **

PID

Enable PID

Yes

Yes or No

Control

Enable Control

Yes or No

Communication

Enable Communication

Yes or No **

Real Time Clock

Enable Clock

Yes or No **

Relay outputs

Enable Relay 1-4

Yes or No **

Test

Enable Test

Yes or No

Zone Calibration

Enable Zone Cal

Yes or No

Sensor Calibration

Enable Sensor Cal

Yes or No

Setpoint lower limit

Enable SPLowerLim

20°C

-73°C to 759°C (-100°F to 1399°F)

Setpoint upper limit

Enable SPUpperLim

260°C

-73°C to 760°C (-100°F to 1400°F)

High limit overhead

Enable HiLimOH

5°C

3 to 11°C (5 to 20°F)*

Password level 1

Enable Password 1

0 to 999

Password level 2

Enable Password 2

0 to 999

Manual/Timer mode setpoint change

Enable SPChange

Yes

Yes or No

Analog Output Type

Enable Analog Type

Proc

Ctrl or Proc

Enable Page

* Maximum high limit setpoint (MaxHiLimSP) = SPUpperLim + HiLimOH Minimum high limit setpoint (MinHiLimSP) = SPLowerLim + HiLimOH

** If the controller does not have this feature, “No” is the only option.

UL, cUL listed:

UL file E136675

CE compliance to:

EMC Directive 89-366/EEC European Standard EN55011/1991 European Standard EN50082-2/1995

Power supply:

100 to 240 VAC +10% -15%, 50-60Hz, 30VA Maximum 12 to 24 VAC/VDC +/-10%, DC to 60Hz, 30VA Maximum

Temperature:

Storage -20 to 60°C Operating 0 to 50°C

Humidity:

90% or less, non-condensing

Sensor inputs:

Type J thermocouple -73°C to 760°C (-100°F to 1400°F) Input impedance 1M ohm or greater Common mode noise rejection of 140db@60Hz Common mode input voltage of +/-12.0VDC Sample rate of at least 1 sample per second Stability of +/- 0.5°C per 5°C change in ambient temperature Repeatability of +/- 0.5°C, or +/-0.1% of sensed temperature (whichever is

greater) Accuracy (@ 77°F +/-0.2 percent of span (+/-3°F) Supply Voltage Influence of +/-0.5°C per 10% change in nominal line voltage

Temperature display:

1 degree resolution (C or F) Accuracy after calibration of +/- 1°C, or +/-0.2% of sensed temperature

(whichever is greater) @25°C Four-digit seven-segment LCD, 0.43 inches high (11mm) Readout Stability (+/-1°F/10°F Change in ambient temperature)

Message display:

Two-line, 16 alpha-numeric 5x7 dot matrix characters per line

0.2 inches high (5mm)

Time base:

+/- 4 seconds accuracy in 24 hours

Heat control output:

SSR Drive 24VDC nominal @ 70mA

Relay output: (plug-in module)

Form A dry contact, rated 3 amps @ 24-264VAC

Retransmit output:

1 to 5 VDC into > 100K ohm load

Communications: (plug-in module)

RS232 Single drop, isolated RS422 Multi-drop, isolated RS485 Multi-drop, isolated

Remote inputs: (plug-in module)

Dry-contact closure type with less than 250 ohm ON resistance

Front panel:

NEMA 4X (with gasket)

Dimensions:

3.57H x 7.24W x 2.84D inches (91H x 184W x 72D mm)

Panel opening:

3.63H x 7.30W inches (92H x 185W mm)

Technical Specifications

APPENDIX: DRAWINGS

The following pages contain electrical drawings for the LCC/LCD2-14*-3.

Despatch LCC-14 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual