Despatch LFD Installation Manual
C-186
PN 143378
REVISION H
3/2009
LFD SERIES OVEN
WITH PROTOCOL
PLUS
INSTRUCTION MANUAL
™
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
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, a list of Accessories and a Warranty.
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.
i
Revision B: Corrected Sensor Calibration Page instruction
Revision C: Added definitions and sample profile to Program Page description
Revision D: Modified per Rev C Protocol Plus software
Revision E: Update to Protocol Plus software version 4.0.
Revision F: Revised Protocol Plus times. Updated Despatch Address.
Revision G: Updated Warranty
Revision H: Updated Controller Section
ii
TABLE OF CONTENTS
INTRODUCTION .......................................................................................................................... 1
Special Features ............................................................................................................... 1
Specifications .................................................................................................................... 2
Dimensions ............................................................................................................ 2
Capacities .............................................................................................................. 2
Temperature .......................................................................................................... 3
Power .................................................................................................................... 4
THEORY OF OPERATION ........................................................................................................... 5
Damper Control ................................................................................................................. 6
Determining Damper Settings ............................................................................... 6
Full Closed Position ................................................................................... 6
Full Open Position ..................................................................................... 7
Other Damper Settings .............................................................................. 7
OVEN INSTRUCTIONS ................................................................................................................ 8
Unpacking and Inspection ................................................................................................. 8
Set-up ................................................................................................................................ 9
Operating ........................................................................................................................ 10
Loading the Oven ................................................................................................ 10
Pre-Startup Checklist .......................................................................................... 11
Startup ................................................................................................................. 11
CONTROL .................................................................................................................................. 13
Theory of Control Operation ............................................................................................ 13
Operating Modes ................................................................................................. 15
Setup Mode ......................................................................................................... 15
Fast Start Mode ................................................................................................... 15
High Limit ............................................................................................................ 16
Indicators ............................................................................................................. 16
Displays ............................................................................................................... 17
Key Functions ...................................................................................................... 17
Outputs ................................................................................................................ 18
Relay (Continued) ............................................................................................... 19
Communication ................................................................................................... 19
Optional Software ................................................................................................ 19
INSTRUCTIONS ......................................................................................................................... 20
Start-Up ........................................................................................................................... 20
Operation ........................................................................................................................ 21
Manual Mode ....................................................................................................... 21
Timer Mode ......................................................................................................... 22
Profile Mode ........................................................................................................ 23
Auto Start Mode .................................................................................................. 23
Setup Mode ......................................................................................................... 24
Instructions for Setup Mode Pages ................................................................................. 25
Program Page ..................................................................................................... 25
Profile # ................................................................................................... 27
Sample Profile ..................................................................................................... 28
Auto Start Page ................................................................................................... 29
PID Page ............................................................................................................. 31
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Control Page ....................................................................................................... 32
Communication Page (optional) .......................................................................... 33
Real Time Clock Page ......................................................................................... 33
Relay Outputs Page (optional) ............................................................................ 34
Test Page ............................................................................................................ 35
Zone Calibration Page ......................................................................................... 36
Sensor Calibration Page ..................................................................................... 38
Enable Page ........................................................................................................ 40
Digital Inputs (optional) ........................................................................................ 41
Error Messages and Alarms ............................................................................................ 42
Quick Reference and Default Values .............................................................................. 43
Technical Specifications .................................................................................................. 50
MAINTENANCE .......................................................................................................................... 51
Checklist .......................................................................................................................... 51
Tests ............................................................................................................................... 52
Replacement ................................................................................................................... 53
Parts .................................................................................................................... 53
Protocol Plus™ Instrument ............................................................................................. 54
Fan Motor ........................................................................................................................ 55
TROUBLESHOOTING ................................................................................................................ 57
APPENDIX .................................................................................................................................. 59
Temperature Scale Conversion (C/F) ............................................................................. 59
Optional MRC5000 Recorder Setup ............................................................................... 60
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1
INTRODUCTION
This section provides an overview of the Despatch LFD Series forced air oven. The
LFD Series Ovens have the most effective heat distribution and the fastest processing
time of any lab oven their size. Air is discharged from the left side wall of the oven and
circulates through the chamber.
Special Features
The sturdy construction and three inch insulation of the Despatch LFD Series ovens
contribute to excellent temperature uniformity.
Other special features include the following:
Class A design features forced exhaust with airflow switch, pressure relief panel,
and purge timer.
Unique Despatch design to combine higher fan volume of forced recirculated air with
a system of perforated stainless steel walls for the ultimate in temperature
uniformity.
Welded double wall construction and fiberglass insulation to reduce heat loss.
Silicone rubber gaskets further minimize heat leakage.
Rapid response heater.
Scratch-resistant baked enamel exterior and stainless steel interior for easy
cleaning.
2
Specifications
Model
Chamber Size
in (cm)
Capacity
feet3
(liters)
Overall Size
in (cm)
Maximum
Number of
Shelf
Positions
Exhaust
Dimension
inches (cm)
W D H W D
H
LFD 1-42
LFD 2-11
LFD 2-24
20
(50)
38
(96)
48
(122)
18
(46)
20
(50)
24
(61)
20
(51)
26
(66)
36
(91)
4.2
(120)
11.0
(310)
24.0
(680)
33
(84)
54
(137)
66
(166)
41
(104)
35
(88)
38
(98)
45
(114)
78
(198)
89
(226)
9
6
9
1.75 x 2.75
(4.5 x 7.0)
3.5 x 8.5
(8.9 x 21.6)
3.5 x 8.5
(8.9 x 21.6)
Model
LFD 1-42
LFD 2-11
LFD 2-24
Maximum Load Lbs
Maximum Shelf Load Lbs
Exhaust at 177°C (350°F) CFM
HP
Recirculating Fan CFM
HP
Approximate Weight Net Lbs.
KG
Approximate Shipping Weight Lbs.
KG
Solvent Handling Capabilities
at 177°C (350°F)
150
30
25 to 93
1/50
300
1/4
380
173
510
232
0.025 GPH
of VM and P
Naptha
180
60
38 to 300
1/3
1,000
1
795
361
1,095
498
0.042 GPH
of VM and P
Naptha
300
100
122 to 300
1/3
1,500
2
1,065
484
1,465
666
0.14 GPH
of VM and P Naptha
Dimensions
Capacities
3
Temperature
Model
LFD 1-42
LFD 2-11
LFD 2-24
Time to Temperature 25°C - 100°C
(approximate minutes with 25°C - 200°C
no load) 25°C - 343°C
4
10
35
4
10
30
2
10
40
Recovery Time Door Open 1 Min. 100°C
(approximate minutes with 200°C
no load) 343°C
<1
2
4
<1
3
8
<1
3
7
Temperature Uniformity at 100°C*
200°C*
343°C*
±1°C
±2°C
±4°C
±1°C
±2°C
±4°C
±1°C
±2°C
±4°C
Minimum Operating Temperature dampers open
(Approximate w/20 C ambient) dampers closed
40°C
50°C
30°C
40°C
30°C
55°C
Control Stability
±0.3°C
±0.3°C
±0.3°C
Repeatability
±0.5°C
±0.5°C
±0.5°C
Cooldown Time 343 - 50°C dampers open
(approximate 343 - 75°C dampers closed
minutes with no load)
46
110
40
120
27
85
* Figures are based on actual tests in an empty oven. Uniformity can vary slightly
depending on unit and operating conditions.
4
Power
Model
Volts
Amps
Hertz
Phase
Heater KW
LFD 1-42
LFD 2-11
LFD 2-24
240*
208
240
480
208
240
480
28.7
39.7
34.9
17.5
76.2
66.8
33.4
50/60
60
60
60
60
60
60
1
3
3
3
3
3
3
6
12
12
12
24
24
24
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.
Power Requirements
* Oven designed for 240 volts (see name plate 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. An option is available to regain
the full heater power when operating on 208V.
5
THEORY OF OPERATION
Fresh
Air
This section details the function and operation of assemblies and subassemblies on the
Despatch LFD Series Ovens. These ovens have the most effective heat distribution
system and the fastest processing time of any lab ovens their size. They are especially
useful for testing, preheating, sterilizing, drying, aging and curing as well as other
production applications. Horizontal airflow with precision digital control delivers uniform,
fast processing. The overall result is efficient productivity under strenuous conditions.
Figure 1. Horizontal Airflow
The unique Despatch computerized design, moves forced convected heat through
perforated stainless steel walls. The air is recirculated with a high volume fan.
Despatch LFD Series Ovens employ higher volume fans than any competitive model.
The chamber can be densely loaded without interfering with the process. The LFD
series air delivery temperature is within 1/2° C of the number appearing on the digital
display. Also, fresh air intake is regulated by a panel-mounted damper control. The
exhaust rate is regulated by an adjustable control on the exhaust stack.
6
Damper Control
The oven is equipped with a manually adjustable damper mechanism. The damper
control arm is located on the front panel of the oven. The damper adjustment controls
the flow of fresh air into the chamber. If the damper is in the full open position, the
maximum amount of fresh air is distributed into the chamber. An additional adjustable
damper is provided on the exhaust.
In the full closed position of an LFD oven, a pre-determined amount of fresh air is
allowed into the chamber due to cutaways provided in the fresh air and exhaust
dampers. This minimum amount of fresh air is required by NFPA86 safety guidelines
for Class A ovens.
Determining Damper Settings
The optimum setting for the amount of fresh air that should be distributed into the
chamber depends on several factors. These factors include ambient environment
temperature, load conditions, load distribution, heat up rates, cool down rates, desired
temperature uniformity and most importantly the desired operating temperature. To
consider all of these variables at any one point in time is not practical and there are
engineering tradeoffs that should be considered. Therefore guidelines should be used
to determine the fresh air damper setting.
In general, the damper should be set so that the amount of fresh air flowing into the
chamber agrees with the desired operating temperature conditions. The following
outline shows the considerations involved with various damper position settings.
Full Closed Position
When the fresh air damper is in the full closed position, the chamber will be able to
achieve the maximum attainable heat up rates for the chamber. In addition, the
chamber will use the minimum amount of power to operate at the desired temperature.
In almost all cases, the fresh air damper should be in the full closed position in order to
efficiently operate at the maximum operating temperature for the chamber.
7
Full Open Position
When the fresh air damper is in the full open position, the chamber will operate at its
minimum operating temperature.
Friction heat from the air recirculation system builds up in the chamber. This causes
chamber temperature to rise slightly even though the heating system is not turned on.
After the recirculation motor has been on for an extended period of time, the chamber
will reach a thermal equilibrium temperature.
When the damper is not set to the full open position, the chamber has no way to readily
dissipate the heat generated by the friction. With the fresh air damper fully open, the
thermal equilibrium temperature is the minimum operating temperature of the chamber.
Other Damper Settings
The damper can be set to several other distinct operating positions. In most cases the
damper setting is influenced by two specific performance factors. The two performance
factors are uniformity and cool down rates.
The uniformity of the chamber is influenced by the inside chamber pressure of the
system. The pressure inside the chamber is dependant on the amount of fresh air
flowing into the chamber. When a large volume of fresh air is flowing into the chamber,
the chamber becomes slightly pressurized and the overall temperature uniformity
improves. The slightly pressurized chamber produces the effect of "pushing" the air to
the corners of the chamber. Typically the corners of the chamber will improve with
respect to temperature distribution while the core of the chamber will maintain excellent
uniformity characteristics regardless of the damper position. Therefore, the
pressurization of the chamber typically is a factor when the chamber is loaded heavily.
Adjusting the exhaust damper will aid in pressurizing the chamber. The best uniformity
results, with respect to the product, are achieved when no more than two-thirds of any
inside chamber dimension are used. The best overall results are achieved when the
product(s) are located in the center of the chamber.
8
OVEN INSTRUCTIONS
The INSTRUCTIONS section provides directions for unpacking, installation, operation
and maintenance of the LFD Series oven.
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.
If there is damage that may have occurred 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. Send a copy of your filed damage claims to Despatch.
4. Next, check to make sure you have received all the required materials. Your
shipment should include:
One (1) Despatch oven,
One (1) Instruction manual,
One (1) Warranty card,
Two (2) Shelves
One (1) Package containing four rubber feet (LFD1-42 only).
5. If any of these items are missing from the packaged contents, contact Despatch
Industries to have the appropriate materials forwarded to you.
6. Finally, to protect the warranty on your new LFD Series Oven, complete the
warranty card and mail it to Despatch within 15 days after receipt of the
equipment.
9
Set-up
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 the oven in wet,
corrosive or explosive
atmospheres unless this oven is
specifically designed for a
special atmosphere.
1. Select the location for installing your oven.
If solvents are going to be used in the oven,
you must install an exhaust stack to the
outside of the building. Go to step 2.
If no exhaust stack is necessary, go to step 3.
2. Install an exhaust stack from the rectangular exhaust fan discharge stack to the
outside of the building.
If a round exhaust stack is used, a minimum area greater than the area of
the exhaust stack is required.
The flashing through the roof or wall must be capable of handling an
exhaust stack temperature up to 343°C (650°F).
All stacks must comply with state and local building codes to insure that
surrounding combustible surfaces are below 71°C (160°F).
Design the exhaust stack to limit the amount of restrictions to insure
proper airflow. If more than two (2) elbows are used in the stack, over all
airflow will be reduced. If airflow is reduced, the amount of solvent that
can be safely used with the equipment must also be reduced.
3. Place oven on a bench top or an optional cabinet base, or directly on the floor.
The oven must have a minimum 2 inch clearance in the rear to provide proper
ventilation. When placed next to another cabinet, or next to another oven, a 3
inch clearance is required. The doors will still open.
4. Make sure oven is level and plumb; this will assure proper heat distribution and
operation of all mechanical components.
5. Identify correct power source indicated on the
specification plate.
6. On the larger units, remove the control panel
and the filler panel to expose the equipment
mounting area.
7. Hardwire the oven directly to the electric supply. On larger units the oven line
connection is located on the equipment mounting panel.
10
Operating
WARNING:
Do not use the oven in wet,
corrosive or explosive
atmospheres unless this oven is
specifically designed for a
special atmosphere.
WARNING:
This equipment is designed for
a specific amount of solvent.
Exceeding this amount could
result in explosion.
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.
11
Pre-Startup Checklist
Know the system. Read this manual carefully. Make use of its instructions and
explanations. Safe, continuous, satisfactory, trouble-free operation depends
primarily on your understanding of the system and your willingness to keep all
parts in proper operating condition.
Check line voltage. Voltage must correspond to nameplate requirements of
motors and controls. Refer to the section on power connections in the
INTRODUCTION of this manual.
Fresh air and exhaust. 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 appreciably reduce the air quantity. The
proper ventilation clearances should be fulfilled at all times. Refer to the Set-up
instructions in this manual.
Helpful hints
For drying ovens, open vent to prevent buildup of moisture.
For sample heating, close the vent when no ventilation is required.
Startup
For fastest oven heat-up time, close the fresh-air vent. After the desired temperature is
reached, the vent may be adjusted as needed.
1. Start Fan.
a. Open oven door.
b. Press Power switch to the On position. You will hear the exhaust and
recirculating fans start.
c. Shut oven door.
d. Check that the control display turns on.
2. Operate the temperature control as desired by following the control operation
instructions that follow.
12
Note that in a Class A oven, the heater can not be energized until the forced exhaust
system has brought in a minimum amount of fresh air into the chamber. The purge
timer provided prevents the heater from energizing until the oven has had enough time
to bring in the amount of fresh air required. The purge timer is energized by the airflow
switch which closes when the exhaust system is running.
The pre-determined purge time is two minutes for the LFD1-42 and LFD2-24 and three
minutes for the LFD2-11.
13
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.
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