Despatch LCC2-14PT-3, LCC-14PT-3, LCC-LCD2-14PT-3 Installation Manual

C-199 PN 161872 REVISION H
4/2009
LCC/LCD2-14PT-3 PASS-THROUGH SERIES WITH PROTOCOL
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 952-469-4513.
Sincerely, Despatch Industries
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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.
PREFACE
This manual is your guide to the Despatch LCC/LCD2-14PT-3 SERIES pass-through 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.
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Revision A (6-02): Initial Creation Revision B (11-02): Update drawings, add line connection detail. Revision C (9-03): Update drawings. Revision D (1-04): Update to software revision 4.0 Revision E (8-06): Revised Protocol Plus numbers. Updated Despatch address.
Updated CE documents Revision F (4-07): Updated Set-up to include water cooling installation. Revision G (11-07): Updated warranty Revision H (4-09): Updated Controller Instructions
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TABLE OF CONTENTS
PREFACE ....................................................................................................................... iii
INTRODUCTION ............................................................................................................. 1
Features ...................................................................................................................... 2
Options ........................................................................................................................ 2
SPECIFICATIONS .......................................................................................................... 3
Electrical Specifications ............................................................................................... 3
Physical Specifications ................................................................................................ 4
Functional Specifications ............................................................................................. 4
INSTRUCTIONS ............................................................................................................. 5
Unpacking and Inspection ........................................................................................... 5
Set-up .......................................................................................................................... 6
Wiring .......................................................................................................................... 8
HEPA Filter Installation ................................................................................................ 9
HEPA Filter Burn-off ............................................................................................... 10
Filter High Limit ...................................................................................................... 12
OVEN OPERATION ...................................................................................................... 13
Oven .......................................................................................................................... 13
System Control .......................................................................................................... 14
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 (system using Beacon Light) ............................................ 24
High Limit Alarm with Alarm Silence ...................................................................... 25
Maintenance .............................................................................................................. 26
Checklist ................................................................................................................ 26
Lubrication ............................................................................................................. 26
PROTOCOL PLUS CONTROL ..................................................................................... 27
Theory of Control Operation ...................................................................................... 27
Operating Modes .................................................................................................... 29
Setup Mode ............................................................................................................ 29
Fast Start Mode ...................................................................................................... 29
High Limit ............................................................................................................... 30
Indicators ............................................................................................................... 30
Displays ................................................................................................................. 31
Key Functions ........................................................................................................ 31
Outputs .................................................................................................................. 32
Relay (Continued) .................................................................................................. 33
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Communication ...................................................................................................... 33
Optional Software ................................................................................................... 33
INSTRUCTIONS ........................................................................................................... 34
Start-Up ................................................................................................ ..................... 34
Operation ................................................................................................................... 35
Manual Mode ......................................................................................................... 35
Timer Mode ............................................................................................................ 36
Profile Mode ........................................................................................................... 37
Auto Start Mode ..................................................................................................... 37
Setup Mode ............................................................................................................ 38
Instructions for Setup Mode Pages ............................................................................ 39
Program Page ........................................................................................................ 39
Sample Profile ........................................................................................................ 42
Auto Start Page ...................................................................................................... 43
PID Page ................................................................................................................ 45
Control Page .......................................................................................................... 46
Communication Page (optional) ............................................................................. 47
Real Time Clock Page ........................................................................................... 47
Relay Outputs Page (optional) ............................................................................... 48
Test Page ............................................................................................................... 49
Zone Calibration Page ........................................................................................... 50
Sensor Calibration Page ........................................................................................ 52
Enable Page .......................................................................................................... 55
Digital Inputs (optional) .......................................................................................... 56
Error Messages and Alarms ...................................................................................... 57
Quick Reference and Default Values ......................................................................... 58
Technical Specifications ............................................................................................ 65
APPENDIX: DRAWINGS .............................................................................................. 66
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Atmosphere
Max Temp C
Model
Air
260
LCC2-14PT-3
Air
350
LCD2-14PT-3
INTRODUCTION
The LCC/LCD2-14PT-3 SERIES pass-through oven is equipped with sterile and non­sterile doors, for clean room operation. Safety interlock switches on each door prevents both doors to open at the same time (these may be manually overridden if required). The operator loads the product from the non-sterile side, and selects the program to run. At the end of the process, the product is unloaded from the sterile side.
The LCC/LCD2-14PT-3 SERIES pass-through oven 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 99.97% clean air to the product being heated. The HEPA filter with silicone seal provides 99.99% filtration prior to filter burnoff. A magnehelic differential pressure gauge monitors pressure drop across the HEPA filter.
The LCC2-14PT-3 Series ovens are rated up to 260 C, and the LCD2-14PT-3 Series has a maximum temperature of 350 C.
The voltages available are 208V, 240V, 415V, and 480V, 3 Phase; with a 16kW heater.
The oven’s main operator interface components are on the hinged control panel located on the non-sterile side. 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. An EMO (emergency off) switch, and indicator lights showing what step the process is in, is located on the sterile side control panel. 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.
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Features
Despatch Protocol Plus microprocessor-based digital programmable control, with simultaneous digital readout of both setpoint and actual temperatures.
CE 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. 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. Indicator lights on the sterile side showing cycle status, and alerting operator if
non-sterile door is open. Electrical door lock switch on each door prevents operator from opening chamber
door when cycle is in process or having both doors open at the same time. Door
lock switch has manual override for authorized maintenance personnel to release
door in case of power failure.
Options
Beacon light option on control panel provides visual cycle process indication to
operator (red/amber/green) High-limit alarm/alarm silence switch option Recorder option Modbus RS422/485 communications option to Protocol Plus controller
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VOLTS
AMPS
PHASE
HERTZ
HEATER
208
50.5
3
50/60
16 kW
240
44.5
3
50/60
16 kW
415
25.2
3
50
16 kW
480
22.2
3
60
16 kW
NOTE that this oven is not intended to process solvents or other volatile or
flammable materials. The oven’s forced exhaust is intended for cooling
purposes ONLY.
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.
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Physical Specifications
ENGLISH
METRIC
CHAMBER VOLUME
14 cubic feet
396 liters
INTERNAL DIMENSIONS *
25.5” W x 26”D x 37” H
65 cm W x 66 cm D x 94 cm H
EXTERNAL DIMENSIONS
48” W x 40 “ D x 71 “ H
122 cm W x 102 cm D X 180 cm H
SHELF SUPPORTS
Quantity 11 on 3” centers
Quantity 11 on 7.6 cm centers
SHELF LOAD CAPACITY
50 pounds
22.6 kg
CHAMBER LOAD CAPACITY
400 pounds
181 kg
NET WEIGHT
955 pounds
433 kg
SHIPPING WEIGHT
1050 pounds
476 kg
RECIRCULATION FAN
950 cfm
27 cmm
MODEL
ATMO-
SPHERE
OPERATING
RANGE
HEATING TIME TO TEMP
(minutes, w/no load)
COOLING TIME TO TEMP
(minutes, w/no load)
TEMPERATURE
UNIFORMITY AT
CONTROL STABILITY
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
LCC/LCD 2-14 PT3
AIR
60°C - 260°C
3 9 15
35
41
82
95
117
±1°C
±2°C
±3°C
±3.5°C
±0.5°C
* Clear width reduced to 24” (61cm) by shelf supports.
Functional Specifications
1. Uniformity figures are based on a nine-point test conducted in an empty oven
with thermocouples positioned at 3” from walls, and after the oven temperature
has reached stabilization (typically 30 – 60 minutes). Uniformity can vary slightly
depending on unit and operating conditions.
2. Operating temperatures and cooling times are based on a 20°C ambient temperature measured at the fresh air inlet.
3. Exhaust fan specification is 85 cfm.
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INSTRUCTIONS
The INSTRUCTIONS section provides directions on unpacking, installation, operation and maintenance of the Despatch LCC/LCD2-14PT Series pass-through 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. (Use a hollow point torx tip tool
and rotate 90 degrees counterclockwise the manual override in the safety switch. It must be turned back to the locked position to allow electrical 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.
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WARNING: Do not use the oven in wet, corrosive or explosive atmospheres unless this oven is specifically designed for a special atmosphere.
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.
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.
3. This oven has been designed for use in a clean room environment (sterile and non-sterile rooms).
4. The oven has a four (4) inch diameter exhaust opening and is located on the left side 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.
5. (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. 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 (recommended amount of flow).
6. (Water Cooled Models) Make the drain connection at the side 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. Check for leaks.
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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.
Clean Dry Air Inlet. 70 to 80 PSI (4.83 to
5.52 Bar). Used 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, 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 flow at 55 F (13 C) to meet published cooling rates.
MAXIMUM PRESSURE 100 PSI (6.89 Bar)
LCC/LCD2-14-3 WITH WATER COOLING UTILITY
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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 84”
(2.13 meters) of wire length is required from the entrance on left side of oven to these connections.
Power wires are routed through this unused conduit to main equipment panel.
Power wires are routed through this compartment.
Hole for conduit fitting provided on side of oven for customer power.
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 left side of the lower oven compartment to the front equipment panel, through which the line voltage power wiring can be connected to the disconnect switch labeled LINE CONNECTION 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)
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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.
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WARNING: Make certain that power is disconnected from the oven before removing or replacing the HEPA 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. 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 six nuts alternately for even tightness. Be careful not to over tighten. Correct installation torque is 28 +/- 3 in-lbs. 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.
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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.
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.
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LCC2-14 HEPA 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.
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.
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OVEN OPERATION
Oven
The LCC/LCD2-14PT-3 Series pass-through 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 prior to filter burn-off.
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.
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.
Non-sterile side controls are mounted on the front of the oven for easy operation and readability. The EMO (emergency off) switch and indicator lights are mounted on the control panel on the sterile side. Two electropolished stainless steel wire shelves are provided. The shelves are removable and adjustable on three inch centers.
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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, and
door lock switch/door release pushbuttons.
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.
Indicator lights on the sterile side provides visual indication of the cycle status, as
follows:
Red (pilot light) – Non-Sterile Door Open Yellow (pilot light) – Cycle On Green (illuminated push button) – Cycle Complete (depress push button after
unloading and sterile door closed)
Indicator Lights
Optional MODBUS RS422/485 serial communications hardware may be installed
on the Protocol Plus controller, with two 9-pin communications ports located on the front of the oven. This provides the ability to network the oven(s) with a host PC.
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