P/N 125166
Model
Volts
Phase Hz
Heater Watts
Total
LCC 1-11
240 1 50/60
3,000
14.2
LCC 1-11N
240 1 50/60
3,000
14.2
LCC 1-54
240 1 50/60
6,000
26.7
LCC 1-54N
240 1 50/60
6,000
26.7
LCC 1-54NV
240 1 50/60
6,000
26.7
LCC 1-87
240 1 50/60
9,000
42.2
LCC 1-87N
240 1 50/60
9,000
42.2
LCC 1-87NV
240 1 50/60
9,000
42.2
REV. 11/07
C-159
LCC SERIES OVENS
INSTRUCTION MANUAL
Prepared by:
Despatch Industries
P.O. Box 1320
Minneapolis, MN 55420-1320
Customer Service 800-473-7373
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.
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.
Thank you for choosing Despatch.
Sincerely,
Despatch Industries
i
PREFACE
NOTE:
Read the entire
INTRODUCTION and THEORY
OF OPERATION before
installing the oven.
WARNING:
Failure to heed warnings in this
instruction manual and on the
oven could result in personal
injury, property damage or
death.
This manual is your guide to the Despatch oven. It is organized to give you the
information you need quickly and easily.
The INTRODUCTION section provides an overview
of the Despatch oven.
The THEORY OF OPERATION section details the
function and operation of assemblies and subassemblies on the Despatch oven.
The INSTRUCTIONS section provides directions on unpacking, installing, operating
and maintaining the Despatch oven.
The APPENDIX section contains Special Instructions
for operating the control instrument, a Troubleshooting Table, and a list of Accessories.
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.
ii
iii
TABLE OF CONTENTS
INTRODUCTION ............................................................................................................. 1
Special Features .................................................................................................. 1
SPECIFICATIONS .......................................................................................................... 2
Dimensions ........................................................................................................... 2
Capacities ............................................................................................................. 3
Power ................................................................................................................... 3
Temperature ......................................................................................................... 4
THEORY OF OPERATION ............................................................................................. 5
Construction ......................................................................................................... 6
Cooling ................................................................................................................. 6
Inert Atmosphere .................................................................................................. 6
HEPA Filters ......................................................................................................... 7
Definitions .................................................................................................. 7
Packaging and Shipping ............................................................................ 7
Handling ..................................................................................................... 8
HEPA Filter Validation Testing .................................................................. 8
D.O.P. Testing ................................................................................ 8
Class 100 Testing ........................................................................... 8
Validation Testing ........................................................................... 9
The Necessity of the Burn-off Process ...................................................... 9
Filter Unit Replacement ............................................................................ 9
CONTROL Instrument ........................................................................................ 10
HIGH LIMIT Instrument ...................................................................................... 10
Product High Limit Instrument ................................................................. 10
Oven High Limit Instrument ..................................................................... 11
INSTRUCTIONS ........................................................................................................... 12
Unpacking and Inspection .................................................................................. 12
Set-up ................................................................................................................. 13
HEPA Filter Installation ............................................................................ 15
HEPA Filter Burn-off ................................................................................ 16
OPERATING ................................................................................................................. 18
Loading the Oven ............................................................................................... 18
Pre-Startup Checklist .......................................................................................... 19
Startup ................................................................................................................ 19
Shut Down ............................................................................................... 22
Maintenance ....................................................................................................... 23
Checklist .................................................................................................. 23
Tests ................................................................................................................... 24
Nitrogen Supply Check ........................................................................... 24
iv
Control Output Check .............................................................................. 24
Thermocouple Test .................................................................................. 25
Safety Controls ........................................................................................ 25
Replacement ...................................................................................................... 26
Parts ........................................................................................................ 26
CONTROL Instrument ............................................................................. 26
Fan Motor ................................................................................................ 27
Replacing HIGH LIMIT ............................................................................ 28
Thermocouple Break Protection .............................................................. 29
Replacing the Thermocouple ........................................................ 29
Heater Unit ............................................................................................... 30
APPENDIX .................................................................................................................... 31
Troubleshooting .................................................................................................. 31
Factory Installed Options .................................................................................... 33
Drawings ............................................................................................................. 34
v
1
INTRODUCTION
This section provides an overview of the Despatch LCC Series oven. The LCC offers
HEPA filtration for processes where minimization of contamination is essential. Fresh
air and nitrogen (noted with an N suffix) models are available.
Special Features
The removable HEPA (High Efficiency Particulate Air) filter is designed to provide a
constant flow of 99.97% clean air to the product. Other special features include:
Digital TEMP CONTROL and manual reset HIGH LIMIT to protect the chamber
workload as well as the oven itself.
Stainless steel interior with all interior seams continuously welded on the
insulation side to protect the work chamber from contamination and to permit
chamber washing without damaging insulation.
Silicon door seals, shaft seals and gasketing (Viton Fluorocarbon on NV
models).
Door seals and interior chamber walls are removable for cleaning.
Heater with a five year warranty.
Cooling coil to provide rapid cooldown and low temperature operation (nitrogen
models only).
Scratch-resistant SilverClay® baked enamel exteriors and a stainless steel
interior for easy cleaning.
Silicon-free construction on NV models.
Nitrogen operation (N and NV models only)
2
SPECIFICATIONS
Model
Chamber Size, inches (cm)
Capacity,
ft3 (liters)
Overall Size, inches (cm)
Maximum
Number of
Shelves
W D H W D
H
LCC 1-11
10
(25)
14
(35)
14
(35)
1.1
(31)
25
(64)
21
(53)
32
(81)
5
LCC 1-11N
10
(25)
14
(35)
14
(35)
1.1
(31)
26
(66)
21
(53)
32
(81)
5
LCC 1-54
18
(46)
20
(51)
26
(66)
5.4
(153)
34
(153)
29
(74)
43
(109)
11 LCC 1-54N,
LCC 1-54NV
18
(46)
20
(51)
26
(66)
5.4
(153)
34
(153)
29
(74)
43
(109)
11 LCC 1-87
22
(56)
20
(51)
34
(86)
8.7
(248)
39
(99)
29
(74)
52
(132)
14 LCC 1-87N,
LCC 1-87NV
22
(56)
20
(51)
34
(86)
8.7
(248)
39
(99)
29
(74)
52
(132)
14
Dimensions
3
Capacities
Model
LCC 1-11
LCC 1-11N
LCC 1-54
LCC 1-54N,
LCC 1-54NV
LCC 1-87
LCC 1-87N,
LCC 1-87NV
Maximum
Load
Lbs
25 25 150 150 200 200 Maximum
Shelf Load
Lbs
10 10 25 25 25 25 Recirculating
Fan
CFM
H.P.
265
1/4
265
1/4
400
1/4
400
1/4
990
3/4
990
3/4
Approximate
Net Weight
Lbs.
KG
285
129
285
129
380
172
380
172
500
227
500
227
Shipping
Weight
(approximate)
Lbs.
KG
400
181
400
181
615
279
615
279
750
341
750
341
Model
Volts *
Amps
Hertz
Heater Phase
KW Cord and Plug
LCC 1-11
240 14.2
50/60
1 3
None, Hardwired
LCC 1-11N
240 14.2
50/60
1 3
None, Hardwired
LCC 1-54
240 26.7
50/60
1 6
None, Hardwired
LCC 1-54N
240 26.7
50/60
1 6
None, Hardwired
LCC 1-54NV
240 26.7
50/60
1 6
None, Hardwired
LCC 1-87
240 42.2
50/60
1 9
None, Hardwired
LCC 1-87N
240 42.2
50/60
1 9
None, Hardwired
LCC 1-87NV
240 42.2
50/60
1 9
None, Hardwired
Power
Line voltages may vary in some geographical locations. If your line voltage is much
lower than the oven voltage rating, warm up time will be longer and motors may
overload or run hot. If your line voltage is higher than name plate rating, the motor 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.
* Oven designed for 240 volts (see nameplate on oven) will operate satisfactorily on a minimum of 208 volts, but with a 25%
reduction in heater power. If your power characteristics are lower, contact Despatch Industries.
4
Temperature
Model
LCC 1-11
LCC 1-11N
LCC 1-54
LCC 1-54N,
LCC 1-54V
LCC 1-87
LCC 1-87N,
LCC 1-87NV
Time to
Temperature
(approximate
minutes)
25 C 100 C
4 4 5 5 4 4
25 C 200 C
13 13 14 14 12 12
25 C 260 C
20 20 23 23 18 18
Recovery Time
Door Open 1
Minute
(approximate
minutes)
125 C
0.5 0.5 1 1 1 1
200 C
1 1 2 2 2
2
260 C
2.5 2.5 3 3 3 3
Temperature
Uniformity at
(maximum)
125 C
± 1 C
± 1 C
± 2 C
± 2 C
± 1 C
± 1 C
200 C
± 2 C
± 2 C
± 2 C
± 2 C
± 2 C
± 2 C
260 C
± 3 C
± 3 C
± 3 C
± 3 C
± 3 C
± 3 C
Maximum Operating
Temperature
260 C
260 C
260 C
260 C
260 C
260 C
Minimum
Operating
Temperature
Above Ambient
(approximate)
Without
Water
Cooling
48 C
53 C
34 C
85 C
54 C
116 C
With
Water
Cooling
9 C 9 C 18 C
18 C
35 C
40 C
Cooling Time
Empty Oven
(approximate
minutes)
200 C 50 C
63 64 48 58 54 78
Control Stability
± 0.3 C
± 0.3 C
± 0.3 C
± 0.3 C
± 0.3 C
± 0.3 C
Repeatability
± 0.5 C
± 0.5 C
± 0.5 C
± 0.5 C
± 0.5 C
± 0.5 C
5
THEORY OF OPERATION
The THEORY OF OPERATION section details the function and operation of the
Despatch LCC Series Ovens.
The LCC 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. An absolute
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.
6
Construction
The LCC series 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 chamber walls and silicon door gaskets (Viton Fluorocarbon on NV models) can
be easily removed for cleaning. Heater frame, fan wheel and motor shaft are
constructed of stainless steel.
Exteriors are steel finished in SilverClay enamel, baked to a 2H hardness for chip and
scratch resistance. 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 two inch centers.
Cooling
Air models have an adjustable fresh air damper which allows cooling of the oven.
Nitrogen models have a stainless steel water coil. When used in conjunction with the
optional flowmeter the cooling coil permits rapid cooldown and low temperature
operation.
Inert Atmosphere
An inert atmosphere option offers the advantages of both a clean room oven and inert
atmosphere oven. The nitrogen portion for the LCC series oven includes a manual
three way valve and two flowmeters, connected by piping to the inlet connection on the
lower back panel marked nitrogen supply.
7
HEPA Filters
NOTE:
Chamber temperature transitions must not
exceed 1.5 C/minute in order to maintain
class 100 chamber conditions. Optional
filter is available for transition rates up to 5
C/minute. Consult the factory.
Absolute HEPA (High Efficiency Particulate Air) filters are used to limit particulate size
in the work chamber to 0.3 microns or less. The gentle entrance and exit air velocity to
and from the HEPA filter results in high efficiency and long life for the HEPA filters.
Definitions
HEPA - High Efficiency Particulate Air
Burn-Off - A process for getting rid of the
binder and D.O.P. contained in the filter
from the manufacturing and testing function.
D.O.P. - Dioctyl Phthalate - Aerosol particles of submicron size used in the testing
phase to spot defects or measure filter efficiency.
Binder - An organic substance that is used in the construction of the filter that gives
some structural strength to the media.
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.
8
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 200 C, at a constant temperature
run before burn-in
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. 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-in procedure
has been performed. Despatch will guarantee Class 100 conditions measurements
based on two methods of test. The direct method of test employs an extraction type
particulate analyzer. The indirect method involves particle settling over a specified
9
period of time onto a clean disk.
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. Cold D.O.P. 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 out 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.
Filter Unit Replacement
Replacement of the filter unit will be necessary for various 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.
10
Water droplets in airstream through filter, free water (RH = 100%), will saturate
NOTE:
Despatch Industries cannot be responsible
for either the process, the 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 assist the purchaser and
operator in fulfilling that responsibility.
filter very quickly and may cause burnout or holes in burned off filter media.
High level of radiation in the vicinity of the filter unit.
CONTROL Instrument
The CONTROL instrument operates the heating element in response to the entered
temperature setpoint. It provides digital indication of the setpoint and actual oven
temperature. Please refer to the operator’s manual for the CONTROL instrument
provided with the oven, for detailed operating instructions.
HIGH LIMIT Instrument
The purpose of the HIGH LIMIT instrument is to protect the product and/or the oven
from excessively high temperatures. If the setting on the HIGH LIMIT is exceeded, the
heating process will discontinue.
The HIGH LIMIT instrument must be set to a temperature slightly higher than the
CONTROL instrument setpoint or to a temperature that should not be exceeded in the
process. The instrument must be manually reset by pushing the red button.
Product High Limit
Instrument
If the product being processed has a
critical high temperature limit, the HIGH
LIMIT instrument should be used as a
product high limit instrument. The HIGH
LIMIT instrument should be set to a
temperature somewhat below the
temperature at which the product could be
damaged. Use the CONTROL instrument
or a pyrometer to determine the product
setting. If the destructive temperature of
the product is already known, this could be
used as a point below which the product
HIGH LIMIT is set.
11
Oven High Limit Instrument
If the product does not have a critical high temperature limit, the HIGH LIMIT can be
used as an oven HIGH LIMIT instrument. An oven HIGH LIMIT instrument protects
oven equipment.
Since the HIGH LIMIT instrument does not show the temperature, it can be properly set
only after oven is in operation. Until then, the HIGH LIMIT should be set at maximum
position so all preliminary testing and adjusting can be done.
Never operate the oven at a temperature in excess of the maximum operating
temperature of 260 C (500 F).
12
INSTRUCTIONS
The INSTRUCTIONS section provides directions on unpacking, installation, operation
and maintenance of the Despatch LCC 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.
3. Please send a copy of your filed damage claims to Despatch.
4. Check to make sure you have received all the required materials. Your shipment
should include:
One (1) Despatch oven,
One (1) Filter,
One (1) oven instruction manual,
One (1) control instrument instruction manual,
One (1) high limit instrument manual,
One (1) Warranty card,
Two (2) Shelves
One (1) Package containing four rubber pads
If any of these items are missing from the packaged contents, contact Despatch
13
Industries to have the appropriate materials forwarded to you. Any optional
WARNING:
DO NOT use oven in wet,
corrosive, or explosive
atmosphere.
WARNING:
DO NOT use with other than inert gases
(nitrogen model only).
CAUTION:
The design and piping of the drain system
should preclude the possibility of operator
injury from high temperature or pressure
buildup. Piping must be able to withstand
short periods of up to 450 temperatures.
Drain lines should be insulated or warning
labels installed for the distance that a
hazard exists.
accessories ordered will be shipped separately.
5. Complete the warranty card and mail it to Despatch within 15 days after receipt
of the equipment.
Set-up
1. Remove adhesive backing sheet from the rubber pads.
2. Attach rubber pads to the bottom corners of the oven.
3. Place oven on a bench top or an optional
cabinet base. The oven must have a minimum
of two (2) inches clearance in the rear to
provide proper ventilation. The oven may be
placed next to another cabinet, or next to
another oven, with three-quarters (¾) of an inch clearance (the doors are still
open).
4. Make sure oven is level and plumb; this will assure proper heat distribution and
operation of all mechanical components.
5. (Nitrogen models only) Connect the
nitrogen supply line (from your
plant nitrogen system) to the inlet
marked nitrogen supply on the oven
rear panel. The nitrogen supply to the oven must not exceed 40 PSI.
6. (Nitrogen models only) Install water
connection for cooling coils.
a. Pipe the coil with a
three-way water supply/drain
valve on the inlet (bottom
fitting) and a vacuum breaker
valve at the high point of the
drain line. This will keep
water moving through the
cooling coil, minimizing
steam generation. The water
supply to the oven must not exceed 100 PSI.
b. Mount the optional cooling water flowmeter (included in cooling kit part
number 090020.)
14
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.
WARNING:
All grounding and safety
equipment must be in
compliance with
applicable codes,
ordinances and accepted
safe practices.
The brass needle valve on the face of the
water flowmeter can be used for adjusting the
water flow or shutting off the water flow.
i. Run tubing from flowmeter to water valve.
ii. Connect a clean water supply to the flowmeter marked inlet.
iii. Adjust the water flow. Cooldown times and steam generation are
dependent on cooling water flow rate. Recommended flow rate is
50 gallons per hour.
c. The pipe on the rear of the oven marked WATER DRAIN should be piped
to a vacuum breaker and then to an open drain.
15
7. Identify correct power source indicated on the specification plate. Power
NOTE: 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.
requirements are also listed on the cover of this manual.
8. Hardwire oven directly to a disconnect switch and wire the disconnect switch
directly to the electric supply. Refer to the electrical schematic in the back of this
manual and the power requirements table in the Specifications section.
HEPA Filter Installation
Craftsmen 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.
16
Check the corner joints of the frame for adhesive sealing and tightness.
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 lose its efficiency rating.
Check that the gaskets are cemented firmly to the filter frame and that the
gasket pieces are butted or mated at the joints.
3. Remove the old HEPA filter.
a. Unscrew the four (4) brass nuts on the left side of the work chamber.
b. Remove the perforated duct exposing the filter.
c. Remove and discard the old HEPA filter.
4. Install the filter with the gasket centered around the hole in the side wall of the
oven. Be sure to install the filter with pleats and separators running from top to
bottom.
5. Install and tighten the perforated duct. Be sure to compress the gasket evenly
and equally at all points with the filter frame completely covering the opening.
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 150 C /
300 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 and the evaporation/
decomposition of any D.O.P.. Most of the
binder will leave the filter after running at a
temperature of 260 C/500 F for eight (8) to 48 (forty-eight) hours. After eight hours
6.7% of the total media weight is lost, 11.2% after 24 hours and 16.0% after 48 hours.
Check the oven for particles or the exhaust for smoke and odor to determine that the
process is finished.
Significant advantage in paper strength and shedding characteristics is obtained for
some filters if some of the binder is left on the media (burn-off done below 220 C/428 F
and lower.) Lower burn-off temperature are more advantageous. However, the
burn-off should be done at or above the maximum process temperature. If the binder
is burned off in the range from 150 C/300 F to 220 C/428 F, it is wise to remember that
additional binder will be given off if the oven is ever heated above this temperature.
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
17
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 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. Filters for 260 C/500 F and below: Set the temperature control at the maximum
process temperature.
Filters for above 260 C/500 F: To maximize the life of the filter, set the control to
ramp the oven temperature at 1 C (1.8 F) per minute or slower. Program a 3
hour soak at 75 C/167 F, and a 3.5 hour soak at 105 C/220 F during the first
heating ramp. The limited ramp rate and soaks will cure the ceramic adhesive in
these filters for maximum strength.
3. Start the fan after making the electrical power connections.
4. Energize the equipment heater.
Use enough fresh air or purge nitrogen 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.
18
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 safety standards in OSHA and
National Fire Protection Association (NFPA), Section 86 of 1990.
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 half way without tipping. The
support capacity of the shelves is listed in the Capacities Table in the Specifications
section in this manual. 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.
19
Pre-Startup Checklist
WARNINGS:
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 touch cooling coil drain
piping during chamber operation
- steam can be generated in the
cooling coil and STEAM BURNS.
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 (Non-atmosphere models only). 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.
Startup
For fastest oven heat-up time, close the
vent (fresh air models). After desired
temperature is reached, vent may be
adjusted as needed.
1. Start fan.
a. Open oven door.
b. Press POWER toggle switch to the ON
position. You will hear the recirculating
fan start.
c. Shut oven door.
d. Check that the amber LED on the CONTROL panel is on.
2. Enter setpoint on the CONTROL instrument.
3. Set HIGH LIMIT instrument to a temperature 10 C - 15 C higher than the
setpoint or to a temperature that should not be exceeded in the process. It will
be necessary to reset the HIGH LIMIT instrument whenever it has tripped. To
reset, allow the oven to cool slightly or increase the HIGH LIMIT setpoint above
the actual temperature. Press the RESET button.
20
4. For the inert atmosphere ovens,
NOTE: When operating the oven without
the optional water cooling, the minimum
operating temperature is approximately
78 C (nitrogen models) and
approximately 20 C (non-nitrogen
models) over the ambient room
temperature. This is the result of the
heat generated by the recirculating fan.
NOTE: This graph is an approximate measure.
Actual conditions will vary. The grade of the inlet
gas used will also affect performance.
adjust flow rate.
a. Determine the desired
oxygen level.
b. Use the following chart to
determine the time to
achieve the desired oxygen
level.
21
c. Turn the nitrogen valve
WARNING: Never operate the oven at a
temperature in excess of the maximum
operating temperature which is 260 C
(500 F).
WARNING: Never operate the oven at a
temperature in excess of the maximum
operating temperature which is 260 C
(500 F).
switch to the PURGE
position for the time to
achieve oxygen level as
determined in step 2b.
d. When the purge is complete, turn the nitrogen valve switch to the
MAINTAIN position.
e. Determine the MAINTAIN flowmeter value to maintain the oxygen
stabilization level.
f. Adjust the MAINTAIN flowmeter to the value determined in step 2e.
5. Press the heater toggle switch to the ON position. The white light will come on,
indicating a heat on condition. Heater indicator light should come on. When the
desired temperature is reached, the control instrument will proportion power to
the heater as needed and the heater indicator light will flash on and off.
6. To cool down the oven, set the control to a lower temperature. If necessary, turn
on water supply to the cooling coil or the valve on the face of the optional cooling
water flowmeter. On fresh air models, you may open the fresh air damper by
adjusting the damper control knob.
The water cooling coil should be used when cooling a load in a relatively short
period of time. The water is controlled by the optional cooling water flowmeter
and can be adjusted or shut off by the brass needle valve on its face.
22
7. After heating cycle is complete, turn the heater toggle switch to the OFF position.
Do not turn the power off until the oven chamber temperature is below 100 C
(212 F).
Shut Down
1. Push the heater switch to OFF after the heating cycle is complete.
2. Do not turn the power off until the oven temperature is below 150 C (302 F). If
the oven is turned off before it is properly cooled, the fan shaft and motor
bearings may become overheated, shortening the life of the motor.
3. Turn the nitrogen control valve to OFF (nitrogen models).
4. Turn off the water supply to the cooling coil or the valve on the face of the
optional cooling water flowmeter (nitrogen models).
5. Push the POWER switch to OFF.
23
Maintenance
Do not attempt any service on this oven before opening the main power disconnect
switch.
Checklist
Keep equipment clean. Gradual dirt accumulation retards air flow. 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 51.5 C (125 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 JUDGEMENT 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.
24
Tests
WARNING:
High voltage is present on terminals,
voltage checks should be made only by
qualified electrical maintenance personnel:
e.g. electrician or technician. Failure to
heed this warning can result in serious
bodily injury, property damage, or death.
Tests should be performed carefully and regularly. The safety of personnel as well as
the condition of equipment may depend upon the proper operation of any one of these
controls at any time.
Nitrogen Supply Check
This test is necessary in nitrogen models only.
1. Turn the inert atmosphere valve on
the control panel to the OFF
position.
2. Screw the adjusting knob on the
flowmeters clockwise all the way to
the OFF position. The adjusting
knobs must be off on both the
PURGE and MAINTAIN flowmeters.
3. Open the tank valve on the nitrogen supply and set the pressure regulator to
about 40 psi.
4. Check the nitrogen plumbing for leaks using a soapy water solution. As nitrogen
gas is odorless, all leaks should be stopped to prevent the possibility of
suffocation in a small work area in which a nitrogen leak might displace much of
the oxygen in the atmosphere.
Control Output Check
1. On a cool oven (< 100 C or 212 F), adjust CONTROL setpoint to 20 F (11 C)
higher than current actual chamber temperature.
2. Set HEATER switch to ON.
3. When the CONTROL output indicator light is on, the HEATER indicator should
also be on.
4. When the CONTROL output indicator light turns off, the HEATER indicator light
should also turn off. If the HEATER light remains on, the SSR may be shorted.
You can also verify the CONTROL output by measuring across the output (+ and
-) terminals with a voltage meter. The output should measure >4 VDC when on,
25
and < 1 VDC when off.
5. Reconnect line power to the control.
6. Replace the SSR if shorted or replace the CONTROL instrument if the output
does not measure properly.
Thermocouple Test
1. Place a jumper or short the thermocouple terminals on the control. The display
should read ambient temperature and be very stable.
2. Replace the CONTROL if the unit is not stable.
Safety Controls
Make these tests carefully and do them regularly. The safety of personnel as well as
the equipment may depend upon the proper operation of any one of these controls at
any time.
Temperature Control (every 40 hours) - The heater indicator light should flash every 1
to 2 seconds when the control is operating at a steady set point temperature.
HIGH LIMIT (every 40 hours) - With the oven operating at a given temperature,
gradually lower the high limit setpoint to the setpoint operating temperature. Verify that
the HIGH LIMIT trips (heater indicator will turn off and remain off). Return the HIGH
LIMIT to its original setting and press the high limit reset button.
26
Replacement
WARNING:
Shut down nitrogen supply and
disconnect main power switch
or power cord before
attempting any repairs or
adjustments.
Parts
To return parts contact Despatch Industries to obtain an MRA (material return
authorization) number. This number must be attached to the returned part for our
identification. If required, a new part will be sent and invoiced to you. When the return
part is received, credit will be given, if in warranty.
When ordering parts or service, be sure to specify the model, serial number and part
number. This will expedite the process of obtaining your replacement part.
CONTROL Instrument
(Tools needed: one quarter (¼) inch socket set)
1. Disconnect power.
2. Remove screws from the face of the control panel and slide it forward.
3. Remove wires from the old control, noting which numbered wires connect to
which terminals.
4. Replace old control with new control.
5. Reattach wires to the new CONTROL instrument. Make sure that the wires are
connected correctly. Refer to the wiring diagram in the appendix of this manual.
6. Replace control panel.
27
Fan Motor
(Tools needed: Screwdriver, Allen wrench, crescent wrench)
1. Disconnect power.
2. Remove filter cover and filter from left side.
3. Remove floor plate.
a. Remove screws from the floor plate.
b. Lift floor plate out of the oven.
4. Remove the screws from the heater frame then tip up and to the right.
5. Loosen set screws on fan wheel inside fan housing.
6. Remove the screws from the face of the control panel and slide it forward to
uncover motor.
7. Tip oven on its back.
8. Remove outside floor.
9. Unbolt the four bolts holding the motor to the motor mount.
10. Remove motor. After fan wheel has run at temperature for a while it will stick to
the shaft. Some force may be required to separate the two. Suggest holding the
fan wheel against the insulated wall while using a mallet and center punch to
loosen the shaft from the fan.
11. Disconnect motor leads from terminal block.
12. Hold new motor in place while you remount fan wheel to motor shaft. Reattach
motor to motor mount.
13. Attach motor lead wires to terminal block (see wiring diagram).
14. Replace oven control panel and bottom, then tip oven upright again.
15. Adjust fan wheel for 3/16 inch clearance between wheel and inlet ring.
28
16. Tighten set screws making sure set screws hit the flats machined into the motor
shaft.
17. Bolt heater back in place.
18. Replace interior floor.
19. Replace filter and filter cover.
20. Reconnect power.
Replacing HIGH LIMIT
(Tools needed: Screwdriver, one quarter (¼) inch socket set)
1. Disconnect power.
2. Remove screws from face of control panel and slide it forward.
3. Remove wires from HIGH LIMIT noting which numbered wires connect to which
terminals. Refer to wiring diagram in this manual.
4. Replace old HIGH LIMIT with new HIGH LIMIT.
5. Reattach wires to the new HIGH LIMIT. Make sure the wires are connected
correctly.
6. Replace control panel.
29
Thermocouple Break Protection
If the thermocouple breaks, the control instrument will shut off power to the heater,
preventing excessive temperature in the chamber.
Replacing the Thermocouple
(Tools needed: Small screwdriver and small crescent wrench)
The controller thermocouple is type J (iron/constantan) and is replaceable using the
following procedure:
1. Disconnect power and remove screws from the face of the control panel and
slide it forward.
2. Locate thermocouple along the left side of the control chamber.
3. Loosen the nut on the fitting holding the thermocouple in place.
4. Pull thermocouple out of brass fitting.
5. Feed new thermocouple through the nut and ferrule and place back into the
fitting.
6. Re-tighten the fitting nut.
7. Remove old thermocouple from terminals on the CONTROL and HIGH LIMIT
instruments.
8. Attach new thermocouple leads to the proper terminals of the CONTROL and
HIGH LIMIT instruments.
9. Replace oven control panel.
30
Heater Unit
(Tools needed: Crescent wrench, screwdriver, one quarter (¼) inch socket set)
1. Disconnect power.
2. Remove filter cover and filter from left side.
3. Remove floor plate.
a. Remove screws from the floor plate.
b. Lift floor plate out of the oven.
4. Disconnect heater leads from heater element with wrench. Note which wires go
on which terminals.
5. Unscrew screws holding the frame to the oven body.
6. Remove heater and discard.
7. Screw down new heater frame.
8. Attach heater leads to appropriate terminals.
9. Replace interior floor and screws.
10. Replace filter and filter cover.
11. Reconnect power.
31
APPENDIX
Difficulty
Probable Cause
Suggested Remedy
Failure to heat
No power
Check power source and/or oven and wall fuses.
Burned out heating
element
Replace element (see warranty statement).
CONTROL instrument
malfunction
See troubleshooting information in CONTROL
instrument manual.
Loose wire connections
Disconnect power and check connections behind
control panel.
Slow heat up
Improperly loaded
Reduce load or redistribute load in chamber
Low line voltage
Supply sufficient power and proper connections.
Check to see if circuit is overloaded.
Heating elements
Replace burned out element(s) (see warranty
statement)
240 volt oven is connected
to a 208 volt line.
Consult with factory.
Fan motor failure
Replace fan motor.
Water flow in optional
cooling coil.
Shut water off.
Filter clogged
Replace filter (see section on HEPA filter
Frequent heater
process. element
burn out
Harmful fumes generated
by load
Increase vent opening or discontinue
Overheating oven
Do not operate over 260+ C (500+ F)
Excessive dust build up in
filter
Replace filter (see section on HEPA filter)
Erratic or inaccurate
temperature
CONTROL instrument
malfunction
See troubleshooting information in CONTROL
instrument manual.
Inaccurate
temperatures
CONTROL miscalibration
See troubleshooting information in CONTROL
instrument manual.
Excess surface
Troubleshooting
Equipment operating for long periods may have occasional problems. Below are
possible problems and suggested solutions. If you have a problem not listed and do
not know what to do, contact Despatch Industries at our toll-free Help Line
(800-473-7373).
32
Difficulty
Probable Cause
Suggested Remedy
temperature around
door
Door seal deterioration
Replace door seal.
Improper airflow
Fan motor failure
Replace fan motor.
Unbalanced fan heel
Replace fan heel.
Filter clogged
Replace filter.
Excessive vibration
Dirty fan wheel
Clean fan.
Unbalanced fan wheel
Replace fan.
Oven will not control
at setpoint
HIGH LIMIT instrument
set too low
Set the HIGH LIMIT instrument higher.
HIGH LIMIT is out of
calibration
Recalibrate the HIGH LIMIT
Solid state relay
malfunction
Replace solid state relay.
Control instrument
malfunction
See troubleshooting information in CONTROL
instrument manual.
Air friction of recirculation
fan
The minimum operating temperature is around
65 C above ambient room temperature. Use
optional water cooling coil.
Heater does not shut
off until the
temperature reaches
the high limit setting
Solid state relay shorted
Replace solid state relay.
Excessive O2 levels
Door seal deterioration
Replace door seal.
Pressure relief valve
leaking
Replace valve
Fan shaft seal leaking
Replace shaft seal (remove fan motor first)
33
Factory Installed Options
Access Ports
Circular openings welded into top or rear of chamber.
Standard sizes available include 1, 2, 3 and 4 inches in
diameter and come complete with a threaded cap.
Door Switch
A switch activated by the chamber door which will disable the
heater, or the heater and recirculation fan.
High limit/end of cycle
alarm
Alarm horn and red light which will indicate a HIGH LIMIT
condition or the end of a process cycle.
Auto nitrogen
Solenoid valves actuate the purge and maintain flows of
nitrogen. Valves are controlled by event outputs on the
control instrument, or by a switch on the control panel.
Auto H20
Solenoid valves actuate the cooling water flow. Valves are
controlled by event output on the control instrument, or by a
switch on the control panel. Includes flow meter.
Door lock
Pneumatic cylinder locks closed chamber door. Cylinder is
actuated by solenoid valve which is controlled by event
output on the control instrument. Requires an air supply.
34
Drawings
The drawings on the next pages are the electrical schematics for the following ovens:
LCC 1 - 11 - 2 & LCC 1 - 11N – 2
Digitronic Controller DA351-080928J00
MIC1462 Controller DA351-140028B00
LCC 1 - 54 - 2 & LCC 1 - 54N - 2 & LCC 1 - 54NV – 2
Digitronic Controller CA351-054552T00
MIC1462 Controller DA351-140029B00
LCC 1 - 87 - 2 & LCC 1 - 87N - 2 & LCC 1 - 87NV – 2
Digitronic Controller CA368-081389I00
MIC1462 Controller DA351-140030B00
35
36
37
38
39
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