Despatch LND User Manual

C-187 PN 143377 REVISION I
2/2009
LND 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 1-952-469-8193.
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, pages 38-39 Revision C: Modified per Rev C Protocol Plus software Revision D: Update Despatch Warranty Revision E: Update to Software Revision 4.0 Revision F: Revised Protocol Plus times. Updated Despatch address Revision G: Revised warranty Revision H: Revised Unpacking and Inspection Instructions Revision I: Updated Control section.
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TABLE OF CONTENTS
INTRODUCTION .......................................................................................................................... 1
Special Features ............................................................................................................... 1
Specifications .................................................................................................................... 2
Dimensions ............................................................................................................ 2
Capacities .............................................................................................................. 2
Temperature .......................................................................................................... 3
Power .................................................................................................................... 4
THEORY OF OPERATION ........................................................................................................... 5
Inert Atmosphere Theory .................................................................................................. 6
OVEN INSTRUCTIONS ................................................................................................................ 7
Unpacking and Inspection ................................................................................................. 7
Set-up ................................................................................................................................ 8
Operating ........................................................................................................................ 11
Loading the Oven ................................................................................................ 11
Pre-Startup Checklist .......................................................................................... 12
Startup ................................................................................................................. 12
Automatic Nitrogen and Water Cooling ............................................................... 15
CONTROL .................................................................................................................................. 16
Theory of Control Operation ............................................................................................ 16
Operating Modes ................................................................................................. 18
Setup Mode ......................................................................................................... 18
Fast Start Mode ................................................................................................... 18
High Limit ............................................................................................................ 19
Indicators ............................................................................................................. 19
Displays ............................................................................................................... 20
Key Functions ...................................................................................................... 20
Outputs ................................................................................................................ 21
Relay (Continued) ............................................................................................... 22
Communication ................................................................................................... 22
Optional Software ................................................................................................ 22
INSTRUCTIONS ......................................................................................................................... 23
Start-Up ........................................................................................................................... 23
Operation ........................................................................................................................ 24
Manual Mode ....................................................................................................... 24
Timer Mode ......................................................................................................... 25
Profile Mode ........................................................................................................ 26
Auto Start Mode .................................................................................................. 26
Setup Mode ......................................................................................................... 27
Instructions for Setup Mode Pages ................................................................................. 28
Program Page ..................................................................................................... 28
Profile # ................................................................................................... 30
Sample Profile ..................................................................................................... 31
Auto Start Page ................................................................................................... 32
PID Page ............................................................................................................. 34
Control Page ....................................................................................................... 35
Communication Page (optional) .......................................................................... 36
Real Time Clock Page ......................................................................................... 36
Relay Outputs Page (optional) ............................................................................ 37
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Test Page ............................................................................................................ 38
Zone Calibration Page ......................................................................................... 39
Sensor Calibration Page ..................................................................................... 41
Enable Page ........................................................................................................ 43
Digital Inputs (optional) ........................................................................................ 44
Error Messages and Alarms ............................................................................................ 45
Quick Reference and Default Values .............................................................................. 46
Technical Specifications .................................................................................................. 53
MAINTENANCE .......................................................................................................................... 54
Checklist .......................................................................................................................... 54
Tests ............................................................................................................................... 55
Nitrogen Supply ............................................................................................................... 55
Replacement ................................................................................................................... 56
Parts .................................................................................................................... 56
Protocol Plus™ Instrument ............................................................................................. 57
Heater Unit ...................................................................................................................... 57
Fan Motor ........................................................................................................................ 58
TROUBLESHOOTING ................................................................................................................ 60
APPENDIX .................................................................................................................................. 62
Temperature Scale Conversion (C/F) ............................................................................. 62
Optional MRC5000 Recorder Setup ............................................................................... 63
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1
INTRODUCTION
This section provides an overview of the Despatch LND Series forced air oven. The LND 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 LND Series ovens contribute to excellent temperature uniformity.
Other special features include the following:
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.
Purge and maintain valves and flowmeters for creating an inert gas atmosphere in the oven chamber
Water cooling coil for dissipating heat from the oven chamber
2
Specifications
Model
Chamber Size
in (cm)
Capacity
feet3
(liters)
Overall Size
in (cm)
Maximum
Number of
Shelf
Positions
W D H W D
H
LND 1-42
LND 2-11
LND 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)
40.5
(103)
44.5
(113)
45
(114)
63
(160)
74
(188)
9
6
9
Model
LND 1-42
LND 2-11
LND 2-24
Maximum Load Lbs Maximum Shelf Load Lbs Recirculating Fan CFM
HP Approximate Weight Net Lbs.
KG Approximate Shipping Weight Lbs.
KG
150 30 300
1/4 380
173 510
232
180 60 1,000
1 745
339 1,045
475
300 100 1,500
2 1,065
484 1,465
666
Dimensions
Capacities
3
Temperature
Model
LND 1-42
LND 2-11
LND 2-24
Time to Temperature 25°C - 100°C (approximate minutes with 25°C - 200°C no load) 25°C - 343°C
6 25 56
5 14 32
3 12 30
Recovery Time Door Open 1 Min. 100°C (approximate minutes with 200°C no load) 343°C
<1 3 10
<1 2 7
<1 2 4
Temperature Uniformity at 100°C* 200°C* 343°C*
±1°C ±2°C ±3°C
±1°C ±2°C ±3°C
±1°C ±2°C ±3°C
Minimum Operating Temperature** with water cooling (Approximate w/20 C ambient) without water cooling
55°C 97°C
55°C 100°C
60°C 110°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 - 60°C (approximate minutes with no load)
30
35
45
* Figures are based on actual tests in an empty oven. Uniformity can vary slightly depending on unit
and operating conditions.
** 60°F Supply water temperature at 120 GPH for LND1-42, 210 GPH for LND2-11 and LND2-24.
Minimum operating temperature is also affected by inert gas flow rate and temperature.
4
Power
Model
Volts
Amps
Hertz
Phase
Heater KW
LND 1-42 LND 2-11
LND 2-24
240* 208 240 480 208 240 480
15.6
29.8
26.1
13.1
52.4
46.0
23.0
50/60
60 60 60 60 60 60
1 3 3 3 3 3 3
3 9 9
9 16 16 16
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
Inert Gas
This section details the function and operation of assemblies and subassemblies on the Despatch LND 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 LND Series Ovens employ higher volume fans than any competitive model. The chamber can be densely loaded without interfering with the process. The LND series air delivery temperature is within 1/2° C of the number appearing on the digital display. Nitrogen intake is regulated by separate purge and maintain panel-mounted flowmeters. The cooling water flow is controlled by an adjustable valve and monitored by a flowmeter located on the rear of the oven.
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Inert Atmosphere Theory
WARNING:
This oven is not designed for use with flammable material. If your process involves flammable material see the LFD series.
The goal of the inert atmosphere oven is to reduce oxygen concentration levels to an acceptable level. This is accomplished by injecting an inert gas into the sealed chamber. As the flow rate of inert gas into the chamber is increased, the chamber becomes pressurized and gas is exhausted out the pressure relief valve located on the back of the oven. Since oxygen is repelled by inert gas flow, the overall oxygen concentration in the chamber is reduced.
However, there is a limit to the desired inert gas flow rate into the chamber. To minimize the oxygen concentration level, you must minimize the number of exhaust outlets. The only desired outlet is through the pressure relief valve. If the inert gas flow rate is too high, other exhaust outlets will be formed (usually the door seal). In this situation oxygen can penetrate back through the leak or outlet even though the chamber is pressurized. This process is called diffusion. As diffusion is minimized, oven performance is maximized.
7
OVEN INSTRUCTIONS
The INSTRUCTIONS section provides directions for unpacking, installation, operation and maintenance of the LND 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
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 LND Series Oven, complete the warranty card and mail it to Despatch within 15 days after receipt of the equipment.
8
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:
Use only inert gases.
WARNING:
All grounding and safety equipment must be in compli­ance with applicable codes, ordinances and accepted safe practices.
1. Select the location for installing your oven. The oven must have a minimum 2 inch
clearance in the rear to provide proper ventilation. The oven may be placed next to another cabinet, or next to another oven, with a 3 inch clearance to insure proper ventilation. Make sure oven is level and plumb; this will assure proper heat distribution and operation of all mechanical components.
2. Connect the nitrogen supply line to the inlet located on the oven rear panel and marked nitrogen supply. The nitrogen supply to the oven must not exceed 80 PSI. (40 PSI on LND 1-42)
3. Check for leaks in the nitrogen supply line. a. Turn the three-way nitrogen valve
switch to the OFF position.
b. Turn the PURGE flowmeter knob
clockwise to the OFF position. c. Turn the MAINTAIN flowmeter knob clockwise to the OFF position. d. Open tank valve on the nitrogen supply. e. Set pressure regulator to about 40 PSI. f. Check the nitrogen plumbing for leaks with 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. Gas from a nitrogen leak might leak might displace much of the oxygen in the atmosphere.
4. If cooling is required, install water connection for cooling coils.
9
Flowmeter
3-way Valve
Drain
Flow Valve
Cooling Water Supply
Cooling Coil
Vacuum Breaker
Check Valve
Drain
WARNING:
NEVER use the water cooling coil without a gas flow into the chamber. Not using inlet gas during cooldown creates a vacuum pressure which could cause extensive damage to the oven.
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 or warning labels installed that a hazard exists.
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.
Figure 2. Recommended Water Connection on Despatch LND Series Ovens
a. Make drain connections at the check
valve and 3-way valve.
b. Connect cooling water supply to the
flow valve.
c. Open 3-way valve and adjust flow
control valve for maximum flow.
d. Check for leaks.
10
e. Adjust flowmeter for desired flow rate. Consult the following chart for
300
200
100
0
0 10 20 30 40 50
Time
(minutes)
LND2-24
LND2-11
LND1-42
NOTE:
Cooldown rates are approximate. Load mass, inert gas flow and exhaust rates affect cool down times.
cooldown rates.
f. Close 3-way valve. Make sure check valve is working properly by
monitoring water flow back through the cooling coil and out the drain port of the 3-way valve.
Figure 3. Cool Down Rate with Water Cooling Coil (unit without a load).
5. Identify correct power source indicated on the specification plate.
6. On larger units, remove the control panel and the filter panel to expose the
7. Hard wire oven directly to the electric supply. On larger units the line connection
equipment mounting area.
is located on the equipment mounting panel.
11
Operating
WARNING:
Do not use oven in wet, corrosive or explosive atmospheres unless this oven is specifically designed for a special atmosphere.
WARNING:
Do not use flammable solvent or other flammable material in this oven. Do not process closed containers of any substance because they may explode under heat.
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.
12
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 recirculating fan
start. c. Shut oven door. d. Check that the control display turns on.
2. Adjust nitrogen flow rate. a. Determine the desired oxygen level. b. Use the following chart to determine the time to achieve the desired
oxygen level.
13
c. Turn the nitrogen valve switch to the PURGE position for the time to
20
12
8
4
0
16
0 4 8 12 16 20 24 28 32
achieve oxygen level as determined in step 2b.
Figure 4. Oxygen Level vs. Time at Maximum SCFH Purge Flow
d. When the purge is complete, turn the nitrogen valve switch to the
MAINTAIN position.
e. Use the charts on the next page to determine the MAINTAIN flowmeter
value to maintain the oxygen stabilization level.
f. Adjust the MAINTAIN flowmeter to the value determined in step 2e.
3. Operate the temperature control as desired by following the control operation instructions that follow.
14
Figure 5. Nitrogen Leakage Rate vs. Oven Pressure
Figure 6. Oxygen Stabilization Level vs. Flow of Nitrogen
15
Automatic Nitrogen and Water Cooling
Your oven may be fitted with optional automatic water cooling and/or nitrogen control features. These features replace the manual on/off valves with solenoid valves which can be operated either by switches in the control panel or programmed event outputs on the temperature control instrument.
The additional switches in the control panel have AUTO and MANUAL positions. Placing the switch in MANUAL energizes the appropriate solenoid valve. Leaving the switch in the AUTO position allows the solenoid valve to be operated by the control event outputs.
Refer to the following section on the control instrument for more information on programming the event outputs. The standard configuration for these optional features is for event relay 1 to operate water cooling, event relay 3 to operate nitrogen purge, and event relay 4 to operate nitrogen maintain. In addition, if the optional door lock feature is also installed, it will be in the locked position any time the nitrogen maintain solenoid is energized.
Typically, the control is programmed so that the purge and maintain valves are energized at the beginning of a program in a segment of long enough duration to purge the oven (see the oxygen level chart discussed earlier). The next program segment then de-energizes the purge valve while leaving the maintain valve energized. The maintain valve should be left energized for as long as the nitrogen level is desired to be maintained.
The water cooling solenoid valve is energized in the last segment(s) of the program to bring the chamber temperature down to a safe unloading temperature.
16
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.
17
Protocol Plus Faceplate and Wiring Diagram
18
Operating Modes
The Protocol Plus control has five modes of operation available: Stopped Mode: All control and relay outputs are off. Stopped Mode is integrated
into each of the following four modes of operation.
Manual Mode: Control operates as a single setpoint control until Stopped mode is
accessed
Timer Mode: Control operates as a single setpoint control until preset time period
has expired.
Profile Mode: Control operates as a ramp/soak profiling control until the end of
the profile. 8 profiles are available with up to 8 ramp/soak segments in each profile.
Auto Start Mode: Control may automatically start Manual, Timer, or Profile mode
based on a preset time and day.
The optional event outputs can be utilized during Manual, Timer, or Profile modes.
Setup Mode
The control has a Setup Mode which provides access to control configuration and programming of profiles. The Setup Mode contains ten separate electronic Pages where the configuration and programming parameters (Menu items) are found. The Setup Mode Pages are described in detail elsewhere in this manual.
Fast Start Mode
The Protocol Plus control has the ability to automatically start an operating mode when power is applied. This feature may be useful if the same mode of operation is used everyday. The user can turn on the power and the oven will start the desired process automatically. The Fast Start Mode is controlled by the Power-Up Start parameters on the Control page (see Setup Mode).
19
High Limit
The control has an integrated high limit function which will disable the heater output when tripped. If the high limit does trip, the relay will need to be manually reset. When the high limit relay is tripped, the Hi-Limit indicator will be lit. Allow the oven to cool several degrees (or increase the high limit setpoint) and then press the Reset key. The indicator will turn off.
High-Limit temperature readout is provided on LCD Line #2 in all Modes (Stop, Run, Hold, and Standby) except Setup Mode. High-Limit temperature is displayed for 10 seconds, alternating with current Mode and Status display for 10 seconds.
The control will not allow the high limit setpoint to be set below the current setpoint value.
Indicators
The Protocol Plus control has 12 indicating LEDs that provide operational information to the user.
Power LED: Indicates that power is supplied to the instrument. Heater LED: Indicates that the heater output is active. Profile LED: Indicates that the Profile Mode is in operation. Timer LED: Indicates that the Timer Mode is in operation. Manual LED: Indicates that the Manual Mode is in operation. Cycle Complete LED: Indicates that the control is in Stopped mode. Hi-Limit Alarm LED: Indicates that the high limit relay has tripped
(de-energized).
Soak Alarm LED: Indicates that the guaranteed soak deviation is in alarm
condition.
Outputs 1 through 4: Indicate that the optional relay outputs are in the ON
state. These outputs may be configured as timed event outputs, process temperature trip point outputs, alarm outputs, or as an end of cycle relay output. The ON state can be configured as energized or de-energized.
20
Displays
The Protocol Plus control has two displays. A dedicated LED upper display shows the oven temperature. A two-line LCD lower display provides information on control status, high limit temperature, and allows changes to be made to the control settings.
Key Functions
The Protocol Plus control has seven keys that provide operation.
Select key: Press to select mode of operation. In Setup Mode, to select profile
number or relay. In Profile/Run Mode, press simultaneously with the UP key to advance a segment.
Run/Hold key: Press to activate a mode of operation. If a Profile (or Timer)
Mode is running, pressing the Run/Hold key will place the Profile (or Timer) in Hold status. A subsequent press will resume the Profile (Timer).
Stop key: Press to stop any mode of operation. Page/Reset key: While in Setup Mode, press to access different Pages of
configuration, Press this key to silence an alarm if the instrument alarm sounds during operation. In an operating mode, if an alarm or error condition occurs, press this key to return the instrument to normal operation once the condition is cleared.
Menu/View key: While running any operating mode, pressing this key will
display the high limit setpoint. While in Setup Mode, pressing this key will provide access to each Menu parameter.
keys: Press these keys to adjust parameter settings. In Profile/Stopped
Mode, press to select profile to run. In Profile/Run Mode, press key simultaneously with the Select key to force the program to advance one segment.
21
Outputs
The Protocol Plus control has seven different outputs available.
Heating output: The control output is a DC voltage open-collector output which
is time-proportioned and designed to control a heat control device such as a solid state relay.
High limit: The high limit output is a form C relay which is energized under
normal operating conditions. If the control senses a temperature higher than the high limit setpoint, or if there is a sensor error, the high limit relay will de-energize until the condition is cleared and the Reset key is pressed. When the high limit relay is de-energized, the heater is disabled.
Retransmission: The retransmission output is a DC 1 to 5 volt or 4 to 20 ma
(DC) signal that is proportional to the process temperature. The signal can be an input to other devices such as a chart recorder.
Relay (four optional outputs): The four form A dry contact relay outputs can be
configured to function as alarms, events, or end of cycle. These outputs can be utilized in Manual, Timer, or Profile Mode.
Layout for Optional Components
22
Relay (Continued) Use the Relay Card Optional Ay p/n 144562 to add relays to the standard controller. Each relay card contains two relays (maximum of two cards Ay’s allowed).
Communication
The Protocol Plus control has optional MODBUS communication available which can communicate via RS232, RS422, or RS485 to a computer. See communications option assembly p/n 161957 for board and cable assembly. Please refer to the MODBUS communications manual which comes with this option.
Optional Software
The Protocol Manager program allows the operator to start/stop multiple ovens (32 maximum) from a personal computer. A data log can also be used to record process information (p.n. 140008).
23
INSTRUCTIONS Start-Up
These instructions are provided as a quick reference for operating the Protocol Plus control. If the Profile Mode is to be used, or the configuration of the control needs to be changed, please refer to the Setup Mode instructions before operating the control. For more detailed operating instructions refer to the Operation instructions for the mode you wish to use.
Upon initial power-up the control is in Manual/Stopped Mode (unless the Autostart or Fast Start Modes are active). To activate any operating mode from Stopped Mode, press the Select key until the desired mode is displayed, then press the Run key. If the proper Profile number is not displayed when the Profile Mode is accessed, press the or keys until the desired Profile number is displayed, then press the Run key. If no profile numbers can be displayed (display only reads NONE) then no profiles are currently programmed (see Setup Mode).
The Hi-limit thermocouple actual temperature reading is displayed, when the lower LCD display reads HL Temp. Note: This is not a error message.
The temperature setpoint can be adjusted while Manual or Timer Mode is running by pressing the UP or DOWN key.
To momentarily hold the Timer or Profile Mode, press the Hold key. To continue the Timer or Profile Mode, press the Run key.
To return to Stopped Mode at any time, press the Stop key and the cycle complete LED will illuminate.
Note that the control can be configured to automatically activate Manual, Timer or Profile Mode when power is applied (power switch turned on). See Control Page in the Setup Mode to utilize the Fast Start mode.
24
Operation
Manual Mode
Press the Select key until Manual is displayed (note you can press the Run key at any time to activate Manual Mode).
1. Press the Menu key to display the Process Temperature Setpoint (setpt). You can change the Setpoint with the keys.
Note: If the SPChange parameter on the Enable page in Setup Mode has been set to DISABLED, it must be changed to ENABLED before any changes to the process temperature and high limit setpoints can be made.
2. Press the Menu key a second time to display current high limit setpoint (Hi-Lim SP). The value can be adjusted by pressing the keys. If Band is displayed, the high limit band feature is activated (see Control page) and the high limit can not be adjusted.
3. (optional feature) Press the Menu key a third time to display Event1. Press the key to turn on the event or to turn off the event. Repeat for all events which are enabled (up to 4).
4. To start Manual Mode, press the Run key.
The display will change from Stop to Run. To return to Stopped Mode, press the Stop key. While in operation, the process setpoint can be adjusted by using the
keys to change the value while the mode is running. Pressing the Menu key
will display the High Limit Setpoint (HLSP) setting.
If changes to the high limit setpoint or event output configuration are needed, they must be done from the stopped mode.
25
Timer Mode
1. Press the Select key until Timer is displayed (note you can press the Run key at any time to activate Timer Mode).
2. Press the Menu key to display the Process Temperature Setpoint (Setpt). You can change the Setpoint with the keys.
Note that if the SPChange parameter on the Enable page in Setup Mode has been set to DISABLED, it must be changed to ENABLED before any changes to the process temperature and high limit setpoints can be made.
3. Press the Menu key a second time to display current high limit setpoint (Hi-lim SP). The value can be adjusted by pressing the keys. If Band is displayed, the high limit band feature is activated (see Control page) and the high limit can not be adjusted.
4. Press the Menu key a third time to display Time Set. You can change the time setting with the keys.
5. (optional feature) Press the Menu key a fourth time to display Event1. Press the
key to turn on the event or to turn off the event. Repeat for all events which
are enabled (up to 4).
6. Press the Menu key a fifth time to display the current guaranteed soak band (TmrGuarSoak) value. If the process temperature deviates from the setpoint by more than this value, the timer is placed in a hold condition. The timer continues when the process temperature falls within range. Reference the Quick Reference and Default Values section for available settings.
7. To start Timer Mode, press the Run key. The display will change from Stop to Run and the time remaining will be
displayed. To return to Stopped Mode, press the Stop key. While in operation, the process setpoint can be adjusted by using the keys to change the value while the mode is running. Pressing the Menu key will display the High Limit Setpoint.
Pressing the Run/Hold key while the Timer Mode is in operation will put the control in Hold status. The Timer LED will flash to indicate the held status. Press the Run/Hold key again to continue timing. The Timer LED will return to lit status.
26
Profile Mode
1. Press the Select key until Profile is displayed. “None” may be displayed if a profile has not been selected or no profiles entered.
2. Press the key to display the desired profile to run.
3. To start Profile Mode, press the Run key.
The display will change from Stop to Run and the segment time remaining, Temperature Setpoint, Profile #, along with the current segment number, will be displayed. To return to Stopped Mode, press the Stop key.
Pressing the Run/Hold key while the Profile Mode is in operation will put the control in Hold status. Press the Run/Hold key again to continue the mode. The Profile LED will flash to indicate the hold status.
To advance to the next segment while running a profile, press the Select and UP arrow keys at the same time.
If Link To is set to Standby in the Program Page, at the End of Program/Profile,
1. Cycle Complete LED indication goes ON.
2. Controller beeps if End of Cycle beep is enabled.
3. Heater/control output keeps controlling oven temperature at last Soak setpoint.
4. All events programmed (if relay cards installed and programmed as an event) for the last Soak Segment stays active.
Note that ramping down too fast may cause the high limit relay to trip unexpectedly if the high limit band feature is used. This can be avoided by using a separate cooling profile that does not utilized the high limit band and then jumping to that profile to perform rapid cooling.
Auto Start Mode
The Auto Start Mode allows the control to start Manual, Timer, or Profile mode automatically at a preset time and day. See the Auto Start Page in Setup Mode for the time, day, and operating mode settings.
To activate the Auto Start Mode,
1. On Auto Start page, Enable is set to Yes.
2. LCD reads Active on line 1 in Auto Start Mode.
3. On Auto Start page Enable set to No, will deactivate Auto Start Mode.
27
Note that once you activate Auto Start, you can continue to use all operating modes as normal. If an operating mode is running at the time of a preset Auto Start function, and Auto Start is activated, the existing operating mode will override the auto Start function and the Auto Start will not turn on.
Note: All process Set to Run in Auto Start Mode must be at least one minute long for all Run Modes (Manual, Timer, and Profile).
Setup Mode
Configuration of the control and programming of the ramp/soak profiles must be done in the Setup Mode. To access Setup Mode, the control must first be in Stopped Mode.
1. Press the Select key until Setup is displayed.
2. Press the Page key and Security will be displayed.
3. Press the Menu key and Password will also be displayed. Use the keys to enter the proper password.
4. Once the proper password is displayed, press the Page key twice to enter the Setup Mode.
To exit Setup Mode, press and hold the Page key for three seconds. The control has two levels of password-protected security. Level one provides access
only to those menu pages that are enabled on the Enable page. Level two provides access to all menu pages, including the Enable page. The default security password values are 1 for level one and 2 for level two.
If an improper password has been entered, the control will remain at the Security display. To enter the proper password, press the Menu key. To exit Setup Mode, press and hold the Page key for three seconds.
Mapping of the Setup Mode is provided in the following sections. To access each parameter Page, which are described in detail in the following sections, press the Page key until the desired page heading is displayed. Press the Menu key to access each Menu parameter. Press the keys to change Menu parameter settings.
Refer to the Quick Reference and Default Values section for available settings for each Menu parameter.
Press the Page key to continue with each Page, or press and hold the Page key for three seconds to exit Setup Mode.
28
Instructions for Setup Mode Pages
Program Page
Programming of the profiles is provided on the Program Page. Eight profiles are available with up to eight ramp and soak segments per profile.
If the optional relay outputs are installed, they must be configured as alarms or events on the Relay Outputs Page before they can be utilized. If configured as event outputs, these relays can be used as time or temperature events.
When entering the Program Page, press the Select key to select the profile you wish to enter/edit, then press the Menu key. The first parameter (Profile #, Segment 1, Ramp Time) will display. Adjust the time value with the keys. Once the proper value is displayed, press the Menu key to continue. Continue with the Menu key to adjust/view each parameter.
If the ramp time value of the current segment is left at 0:00, the next press of the Menu key will advance the control to the High Limit Setpoint parameter for that profile. Continue entering / verifying all parameters until you get to the last parameter (Guaranteed Soak Band). Once all parameters have been properly entered, press the Page key to return to the top of the Profile Page. You can press the Select key to enter/edit another profile, press the Page key to access another page, or press and hold the Page key to exit Setup mode.
While editing any profile, pressing the Select key will advance the control to the time value for the next segment, until the last segment has been reached. This allows faster editing of the profile rather than pressing the Menu key to advance past each parameter.
If Link To is set to Standby in the Program Page, at the End of Program/Profile,
1. Cycle Complete LED indication goes ON.
2. Controller beeps if End of Cycle beep is enabled.
3. Heater/control output keeps controlling oven temperature at last Soak setpoint.
4. All events programmed (if relay cards installed and programmed as an event)
for the last Soak Segment stays active.
To run a profile indefinitely, link the profile to itself.
29
Menu Item
Display
Description
Ramp Time Seg 1
Pro-1 Seg-1 Ramp Time
Ramp time for segment 1 of profile
Event 1 Set Value*
Pro-1 Seg-1 Ramp Event 1
Event 1 setting for segment 1 ramp of profile
Event 2 Set Value*
Pro-1 Seg-1 Ramp Event 2
Event 2 setting for segment 1 ramp of profile
Event 3 Set Value*
Pro-1 Seg-1 Ramp Event 3
Event 3 setting for segment 1 ramp of profile
Event 4 Set Value*
Pro-1 Seg-1 Ramp Event 4
Event 4 setting for segment 1 ramp of profile
Soak Temp Seg 1
Pro-1 Seg 1 Soak Temp
Soak temperature for segment 1 of profile
Soak Time Seg 1
Pro-1 Seg 1 Soak Time
Soak time for segment 1 of profile
Event 1 Set Value*
Pro-1 Seg-1 Soak Event 1
Event 1 setting for segment 1 soak of profile
Event 2 Set Value*
Pro-1 Seg-1 Soak Event 2
Event 2 setting for segment 1 soak of profile
Event 3 Set Value*
Pro-1 Seg-1 Soak Event 3
Event 3 setting for segment 1 soak of profile
Event 4 Set Value*
Pro-1 Seg-1 Soak Event 4
Event 4 setting for segment 1 soak of profile
(repeat for segments 2-8, until ramp or soak time = 00:00)
High Limit Setpoint
Pro-1 Hi-Lim SP
High limit setpoint for profile**
Loop From
Pro-1 Loop From Seg
To start a loop action in a profile
Loop To
Pro-1 Loop To Seg
To end a loop action in a profile
Loop Count
Pro-1 Loop Number
Number of times to execute loop
Profile Link
Pro-1 Link To Pro
To jump from this profile to another
Guaranteed Soak
Pro-1 Guar Band
Guaranteed soak band for profile
See the definitions on the following pages for parameter ranges.
* only available if optional relay outputs are installed (repeat all for profiles 2-8) ** Set to Band to use the high limit band feature
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Profile #
There are eight profiles available.
Segment#
Recipe segments 1 through 8 may be programmed, each with its own set of events, ramp and soak times, and soak temperature.
Ramp Time
The time required to ramp from one setpoint up to another setpoint. Values between 0 and 99:59 are allowable. In the Protocol Plus controller, the profile ramp and soak times are stored without units. Units are set as either hours and minutes (HH:MM) or minutes and seconds (MM:SS). The setpoint will automatically increment from the actual temperature to the soak temperature.
EV1 through 4
From 1 to 4 events may be programmed into the ramp time portion of each segment here. These typically involve actuating/disabling relays to close/open valves or perform other relay-controlled functions. NOTE: These will only actuate when the controller has the relay cards installed and programmed for an event.
Soak Temp.
The temperature setpoint of a particular segment is entered here; it can range from -18 to 540 degrees C (0 to 1000 degrees F).
Soak Time
The duration of soak is entered here; the value can range from 0 to 99:59.
EV1 through 4
From 1 to 4 events may be programmed into the soak portion of each segment here. These typically involve actuating/disabling relays to close/open valves or perform other relay-controlled functions. NOTE: These will only actuate when the controller has the relay cards installed and programmed for an event.
Hi Limit SP
The high limit setpoint may be entered here; if the temperature exceeds this value, the hi-limit will alarm and shut off the heater.
Loop From
Values are No, Seg-1 to Seg-8.
Loop To
Values are No, Seg-1 to Seg-8.
Loop Number
Values are 0 - 99. These values enable the operator to jump from a certain step to another step of the recipe a preset number of times.
Profile Link
Values are STANDBY/STOP/HOLD/1 - 8. When the profile ends, the profile can hold the temperature setpoint while keeping the events active, turn the heater off, hold the temperature setpoint at the end of the profile, or jump to another specified profile.
Guaranteed Soak Band
If the process temperature deviates from the setpoint by more than this value, the soak timer is placed in a hold condition. The timer continues when the process temperature falls within range.
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Sample Profile
Seg-
ment
Ramp
Soak
Time
Events
Temp-
erature
Time
Events
1 2 3 4 1 2 3
4
1
01h00
100
01h00
2
02h00
50
00h01
3
00h00
4 5
6
7 8
High Limit Setpoint
115
Loop From Seg
No
Loop To Seg
No
Loop Number
0
Link To Pro
No
Guar Soak Band
10
Programming Table Profile Number____1______ Profile Name__________
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Auto Start Page
The Auto Start Page can be configured to automatically start Manual, Timer or Profile Mode at a specified time and day. Note that if Auto Start Enable is set to Yes in the Setup Mode, the Auto Start feature is not turned on - it is available to the operator to be activated in Stopped Mode.
To configure the Auto Start feature:
1. Access the Setup Mode.
2. Press the Page key until Auto Start is displayed.
3. Press the Menu key. If there is no change in the display, the controller may not have the realtime clock option.
4. Set Auto Start Enable to Yes.
5. Using the Menu key, scroll through the options available and use the keys to set the mode desired for each day of the week. You may select from Manual, Timer, or Profile 1 through 8.
6. When the mode is set press the Menu key.
7. Enter the time of day you wish the mode to activate.
8. Continue through the rest of the week by pressing the Menu key, or press the Page key when done.
One Auto Start mode can be set for each day of the week. Exit the Setup mode by pressing and holding the Page key for three seconds. Press the Select key until Auto Start is displayed. Make sure the correct time and day is displayed. If not proper, set it to the correct time on the Real Time Clock Page in the Setup mode.
To activate the Auto Start Mode,
1. On Auto Start page, Enable is set to Yes.
2. LCD reads Active on Line 1 in Auto Start Mode.
3. On Auto Start page Enable set to No, will deactivate Auto Start Mode.
Note that once you activate Auto Start, you can continue to use all operating modes as normal. If an operating mode is running at the time of a preset Auto Start function, and Auto Start is activated, the existing operating mode will override the Auto Start function and the Auto Start will not turn on.
Note: All process Set to Run in Auto Start Mode must be at least one minute long for all Run Modes (Manual, Timer, and Profile).
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Menu Item
Display
Description
Range
Enable Autostart
Auto Start Enable
Enable (yes) or disable (no) the Autostart function
No, Yes
Sunday mode
Auto Start Sun Mode
Set mode on Sunday to activate
Off, Manual, Timer, Pro-1 to Pro-8
Sunday time
Auto Start Sun Time
Set time on Sunday for mode to activate
00:00 to 23:59
Monday mode
Auto Start Mon Mode
Set mode on Monday to activate
Off, Manual, Timer, Pro-1 to Pro-8
Monday time
Auto Start Mon Time
Set time on Monday for mode to activate
00:00 to 23:59
Tuesday mode
Auto Start Tue Mode
Set mode on Tuesday to activate
Off, Manual, Timer, Pro-1 to Pro-8
Tuesday time
Auto Start Tue Time
Set time on Tuesday for mode to activate
00:00 to 23:59
Wednesday mode
Auto Start Wed Mode
Set mode on Wednesday to activate
Off, Manual, Timer, Pro-1 to Pro-8
Wednesday time
Auto Start Wed Time
Set time on Wednesday for mode to activate
00:00 to 23:59
Thursday mode
Auto Start Thu Mode
Set mode on Thursday to activate
Off, Manual, Timer, Pro-1 to Pro-8
Thursday time
Auto Start Thu Time
Set time on Thursday for mode to activate
00:00 to 23:59
Friday mode
Auto Start Fri Mode
Set mode on Friday to activate
Off, Manual, Timer, Pro-1 to Pro-8
Friday time
Auto Start Fri Time
Set time on Friday for mode to activate
00:00 to 23:59
Saturday mode
Auto Start Sat Mode
Set mode on Saturday to activate
Off, Manual, Timer, Pro-1 to Pro-8
Saturday time
Auto Start Sat Time
Set time on Saturday for mode to activate
00:00 to 23:59
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PID Page
Menu Item
Display
Description
Range
Display units
PID Temp Unit
Set display units to °C or °F
°C or °F
Proportional band
PID Prop Band
Set proportional band for tuning
1 to 56°C (1 to 100°F)
Integral reset
PID Reset/Rep/Min
Set integral reset for tuning
0.0 to 100 seconds/repeat
Derivative Rate
PID Rate In Sec
Set derivative rate for tuning
0.0 to 500 seconds
AutoTune
PID AutoTune
Enable auto tuning function
Disable, Enable
The PID Page contains parameters which control the response to the setpoint and process variable input. To access the PID Page, enter the Setup Mode. Press the Page key until PID is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the
keys to change the value.
The AutoTune parameter disables or enables the AutoTune function. To utilize AutoTuning:
1. Access the Setup Mode.
2. Press the Page key until the display reads AutoTune. Press the key to enable the AutoTune.
3. Press the Page key for three seconds to exit Setup Mode.
4. Cycle power to the instrument.
5. Set Manual Mode to run. The display will alternately display AutoTune and Manual.
If the Manual Mode setpoint is less than 50 degrees higher than the actual process temperature, the AutoTune function will create an error condition. This can be cleared by either cooling off the process temperature or increasing the setpoint until there is more than 50 degrees between them. Once the AutoTune function is allowed to complete tuning, the AutoTune parameter will disable by itself.
If you wish to cancel the AutoTune function, press the STOP key, access the PID page in Setup Mode, and set the AutoTune parameter to Disable.
35
Menu Item
Display
Description
Range
Cycle Time
Control Cycle Time Sec
Set cycle time in seconds for control output
1 to 60 seconds
High limit setpoint
Control Hi-Lim SP***
Maximum value for all high limit setpoints
MinHiLimSP - MaxHiLimSP*
High limit band
Control Hi-Lim Band
If=0, high limit setpoint= Control Hi-Lim SP If>0, high limit setpoint= Control SP* + Band
Off, 3°C to 11°C (5°F to 20°F)
Power fail recovery
Control PwrFRec
Controls response to loss of power
Stop, Restart, Hold, Resume
Recovery time limit
Control PFRTime
Control aborts to Stopped mode if power is lost for time period longer then set value
00m00s to 99m59s
Powerup start enable
ControlPwrUpStrt
Allows mode to automatically start when power is first applied
Disable, Enable
Powerup Start Mode
Control StrtMode
Operating mode for powerup start
Off, Manual, Timer, Pro-1 to Pro-8
Hysteresis
Control Hysteresis
Hysteresis for all alarms and temperature events
1°C to 56°C (1°F to 100°F)
Process out low
Control RetOutLo
Process value for retransmit output = 1VDC
-73°C to 760°C (-100°F to 1400°F)
Process out high
Control RetOutHi
Process value for retransmit output = 5VDC
-73°C to 760°C (-100°F to 1400°F)
Time scale
Control TimeScale
Time scale setting for program and timer mode**
hh:mm or mm:ss
Key press beep
Control KeyBeep
Internal beeper sounds when key is pressed
On or Off
End of cycle beep
Control EOCBeep
Internal beeper sounds at end of cycle
On or Off
Alarm beep
Control AlarmBeep
Internal beeper sounds for alarms
On or Off
Control Page
The Control Page contains various parameters which control miscellaneous functions. To access the Control Page, enter the Setup Mode. Press the Page key until Control is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.
* includes ramping setpoints during profiles and controlled ramps ** power fail recovery time limit is always MM:SS regardless of time scale setting *** high limit setpoint is a read-only item which is calculated on Enable page
36
Communication Page (optional)
Menu Item
Display
Description
Range
Address
Communication CommAddr
Sets address node for control
1 to 247
Mode
Communication Mode
Turns on/off communications
OFF, Modbus
Baud Rate
Communication BaudRate
Sets interface speed
2400, 4800, 9600, 19.2K,
38.4K
Parity
Communication Parity
Sets parity for interface
None, Odd, Even
Menu Item
Display
Description
Range
Day of the week
Clock Day
Setting for current day of the week
Sun, Mon, Tue, Wed, Thu, Fri, Sat
Time of day
Clock HH:MM
Setting for current time of the day
00:00 to 23:59
Reset clock
Clock UP to Reset CLK*
Press the key to set the clock to entered values
Ready, Done
The Communication Page contains parameters for the communications feature. To access the Communications Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Communication is displayed. Press the Menu key. (NOTE: If there is no change in the display, the controller does not have the communications board installed.) Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.
Real Time Clock Page
The Real Time Clock Page allows the control to be configured to have an operating mode begin automatically at a specific time on a specific day of the week. The real time clock feature is also used for using the Power Failure Recovery mode Time Limit feature (see Control Page). The real time clock is a seven day, 24 hour clock with battery backup.
To access the Real Time Clock Page, enter the Setup Mode. Press the Page key until Clock is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.
* If the key is not pressed, the clock values will retain their original values. The display will change to Done if the clock is reset
37
Relay Outputs Page (optional)
Menu Item
Display
Description
Range
Type of relay
Relay 1 RelayType
Set function of relay
Off, Alarm, Cycl, Ev1 to Ev4
Action of relay
Relay 1 RelayAction
Set coil and contact state of relay
NDE, NE, NDEL, NEL*****
Type of alarm*
Relay 1 AlarmType
Set alarm type for relay
High, Low, Plus, Minus, Band
Alarm setpoint*
Relay 1 AlmHi/Lo SP
Setpoint for alarm
-73°C to 760°C (-100°F to 1400°F)
Alarm deviation*
Relay 1 AlmDevBand
Deviation band for alarm
1 to 56°C (1 to 100°F)
Inhibit alarm*
Relay 1 ALMInhibit
Inhibits alarm until "safe" condition is reached
En or Dis
Type of event**
Relay 1 EventType
Set event type for relay
Time or Temp
Event setpoint***
Relay 1 Event SP
Setpoint for temperature event
SPLoLim to SPUpLim****
The Relay Outputs Page configures the four alarm/event outputs. Each output has a dedicated indicator light and can be configured as a temperature alarm, profile event, or end of cycle output. Temperature alarms can be of type process high, process low, deviation high, deviation low, or deviation band.
To access the Relay Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Relay is displayed. Press the Select key until the desired relay output is selected. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value. To configure a specific relay, press the Select key until the desired relay appears.
NOTE: If Relay 0 appears, then no relays are installed (see relay kit assembly p.n.
144562).
(repeat for relay outputs 2-4, if available) * appears only for alarm types
** appears only for time or temperature event types *** appears only for temperature event types
Turning on the Alarm Inhibit function disables the alarm output on power up until the process temperature has reached a non-alarming condition ("safe").
If the relay output has been configured as latching, the RESET key must be pressed to return the output to the non-alarm state once the alarm condition has cleared.
38
Test Page
Menu Item
Display
Description
Range
Heater output
Test HeatOut
Activate SSR output 100%
On
High limit relay
Test HiLimOut
Activate high limit alarm (de-energize relay)
On
Relay 1 output
Test Rly1 Out
Energize relay output 1
On
Relay 2 output
Test Rly2 Out
Energize relay output 2
On
Relay 3 output
Test Rly3 Out
Energize relay output 3
On
Relay 4 output
Test Rly4 Out
Energize relay output 4
On
HiLim Sensor
Test HL Temp (push and hold up)
Displays sensor reading*
The Test Page contains parameters which allow manual control of the heat control and optional relay outputs and should be used only for testing the functionality of the control instrument. Do not operate the oven for processes using the Test Page.
To access the Test Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Test is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.
*Push key to refresh display When the Test Page is entered, all outputs are automatically set to off. When exiting
the Test Page, all outputs will return to their previous condition regardless of the Test Page settings.
39
Zone Calibration Page
Menu Item
Display
Description
Range
Zone 1 actual
Zone Cal Zone1Act
Point at which Zone 1 is set (center of chamber)
-73°C to 760°C (-100°F to 1400°F)
Zone1 displayed
Zone Cal Zone1Dis
Desired displayed value for Zone 1 setting
-73°C to 760°C (-100°F to 1400°F)
Zone 2 actual
Zone Cal Zone2Act
Point at which Zone 2 is set (center of chamber)
-73°C to 760°C (-100°F to 1400°F)
Zone2 displayed
Zone Cal Zone2Dis
Desired displayed value for Zone 2 setting
-73°C to 760°C (-100°F to 1400°F)
Factory calibration*
Zone Cal FactCal
Restores the factory calibration values
Ready or Done (push- key)
The Zone Calibration Page allows adjustment of the displayed temperature versus the actual temperature measured by the control thermocouple. This may be desirable in certain conditions where the center of the oven chamber is not the same temperature as the control thermocouple. This may occur when the oven is not allowed to soak at a constant temperature for long periods of time, or the oven is being used at high temperature.
There is also a Factory Calibration Recovery which will restore the factory calibration values when the control was first shipped by the manufacturer. This may be helpful if the calibration has been lost and a calibration instrument is not readily available. To use the Factory Calibration Recovery feature only, bypass the Zone 1 and Zone 2 calibration parameters by pressing the Menu key.
To access the Zone Calibration Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Zone Cal is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.
*Only use when no calibration instrument is available, push key to restore factory values.
Press the Page key to exit the Zone Calibration Page. Two points of display calibration (temperature offset) are available. The Zone 1 Actual
and Zone 2 Actual parameters are the two temperature points where the offset is to take effect. These values are adjustable. The Zone 1 and Zone 2 Displayed parameters are the values the user wishes to have displayed at the Actual temperatures, and are also adjustable.
40
As an example, the control is displaying 400°F with the setpoint being 400°F, but the center of the oven chamber is actually 395°F. This can occur due to oven wall losses and product loading variations. The operator may change the zone calibration so that the center of the oven is 400°F when the display reads 400°F. In this case operate the oven in manual mode with a setpoint of 400°F. Record the center of the chamber (as measured with an independent sensor). Access the Zone Calibration Page and enter this measured value as the Zone 2 Actual value, with 400° as the Zone 2 Displayed value.
Zone 1 can be adjusted using the same method at a lower temperature. The instrument will then create a linear offset based on the Zone1 and Zone 2 Actual temperature values. Note that the oven does not have to be heated to adjust the zone parameters if the zone values are known based on prior experience.
41
Sensor Calibration Page
The Sensor Calibration Page has parameters which can change the internal calibration of the temperature sensor input signal. There is a low and high calibration point for both the control sensor and the high limit sensor. To calibrate the instrument, allow the control to warm up for at least 30 minutes.
To access the Sensor Calibration Page, enter the Setup Mode (see description earlier in this manual). Press the Page key until Control Sensor is displayed. Press the Menu key.
The control may have the optional process value retransmission output feature. The output is a 1 to 5VDC signal. To calibrate the retransmit signal, the RetOutLo and RetOutHi values from the Control Page must be known. You may bypass calibrating the control and high limit sensor input to access only the retransmit calibration by pressing the Menu key until RetCalLo is displayed (skip steps 4-17).
To re-calibrate the instrument:
1. Disconnect the control and high limit sensor thermocouples.
2. Connect a calibration instrument with a type J thermocouple output to the
control sensor input. Allow the control to warm up at least 30 minutes.
3. Access Setup Mode.
4. Press Page key until -100F is displayed.
5. Press Menu key until Ctrl Sens -100F is displayed.
6. With Ctrl Sens -100F displayed, adjust the calibration instrument to Type J
thermocouple, -100 degrees Fahrenheit output.
7. Wait 30 seconds. Press the key.
8. With Ctrl Sens 1400F displayed, adjust the calibration instrument to 1400
degrees Fahrenheit output (Type J thermocouple).
9. Wait 30 seconds. Press the key.
10. When the control displays Ctrl Sens Done, disconnect the calibration
instrument from the control sensor input and connect it to the high limit sensor input. Reconnect the control sensor thermocouple.
11. Press the Menu key until HL Sens -100F is displayed.
12. With the control displaying HL Sens -100F, adjust the calibration instrument
to -100 degrees Fahrenheit output (Type J thermocouple).
13. Wait 30 seconds. Press the key.
14. With the control displaying HL Sens 1400F, adjust the calibration instrument
to 1400 degrees Fahrenheit output (Type J thermocouple).
15. Wait 30 seconds. Press the key.
16. When the control displays HL Sens Done, disconnect the calibration
instrument from the high limit sensor input. Re-connect the high limit sensor thermocouple.
17. To skip calibration of the retransmit signal, press the Page key twice to exit the
Sensor Calibration Page.
18. To calibrate the retransmit signal, press the Menu key until RetCalLo is
displayed.
42
19. Connect a calibration instrument with a type J thermocouple output to the
Menu Item
Display
Description
Range
Control Sensor Cal
Ctrl Sens -100F Ctrl Sens 1400F Ctrl Sens Done
Calibrate Sensor Low End Calibrate Sensor High End Control Sensor Cal Complete
-100 to 1400°F
-100 to 1400°F (read only)
HiLim Sensor Cal
HL Sens -100F HL Sens 1400F HL Sens Done
Calibrate HiLim Sensor Low End Calibrate HiLim Sensor High End HiLim Sensor Cal Complete
-100 to 1400°F
-100 to 1400°F (read only)
Retransmit Cal
RetCalLo XXXX * RetCalHi XXXX *
Calibrate Retransmit Output Low Calibrate Retransmit Output High
0 to 4096** 0 to 4096***
control sensor input.
20. Connect a voltage measurement device to the retransmit output terminals.
21. Set the calibration instrument output to the temperature value of the RetOutLo
parameter from the Control Page.
22. Adjust the RetCalLo * value using the keys until the voltage measurement
device reads 1VDC.
23. Press the Menu key.
24. Set the calibration instrument output to the temperature value of the RetOutHi
parameter from the Control Page.
25. Adjust the RetCalHi * value using the keys until the voltage measurement
device reads 5VDC.
26. Press the Menu key.
27. Press the Page key to exit the Sensor Calibration Page.
28. Calibration is now complete. Disconnect the calibration instrument and voltage
measurement device (if used).
29. Verify that the control and high limit sensor thermocouples are connected.
*Note that the actual RetCalLo and RetCalHi values displayed are of no importance.
43
Enable Page
Menu Item
Display
Description
Range
Profiles
Enable Profile 1-8
Controls access to Program Page
Yes or No
Autostart
Enable Auto Start
Controls access to AutoStart Page
Yes or No **
PID
Enable PID
Controls access to PID Page
Yes or No
Control
Enable Control
Controls access to Control Page
Yes or No
Communication
Enable Communication
Controls access to Communication Page
Yes or No **
Real Time Clock
Enable Clock
Controls access to Real Time Clock Page
Yes or No **
Relay outputs
Enable Relay 1-4
Controls access to Relay Page
Yes or No **
Test
Enable Test
Controls access to Test Page
Yes or No
Zone Calibration
Enable Zone Cal
Controls access to Zone Calibration Page
Yes or No
Sensor Calibration
Enable Sensor Cal
Controls access to Sensor Calibration Page
Yes or No
Setpoint lower limit
Enable SPLowerLim
Sets minimum setpoint allowed
-73°C to 759°C (-100°F to 1399°F)
Setpoint upper limit
Enable SPUpperLim
Sets maximum setpoint allowed
-73°C to 760°C (-100°F to 1400°F)
High limit overhead
Enable HiLimOH
Sets maximum high limit setpoint allowed*
3 to 11°C (5 to 20°F)*
Password level 1
Enable Password 1
Sets password for access level 1
0 to 999
Password level 2
Enable Password 2
Sets password for access level 2
0 to 999
Setpoint Change
Enable SPChange
Set to DISABLE to lock out setpoint and high limit setpoint changes in Manual and Timer Modes
Yes or No Analog Output
Type
Enable Analog Type
Sets Analog Output type
Ctrl or Proc
The Enable Page controls access to the other Setup Pages. The setpoint minimum and maximum values, and the security passwords are also set on the Enable Page. To access the Enable Page, enter the Setup Mode using a level 2 access code (see description earlier in this manual). Press the Page key until Enable is displayed. Press the Menu key. Each parameter can be changed by pressing the Menu key until the desired parameter is displayed, and then pressing the keys to change the value.
NOTE: Changing the enable to “yes” for each page will allow access to the page in
Level 1 security.
* Maximum high limit setpoint = SPUpperLim + HiLimOH ** If the controller does not have this feature, “No” is the only option.
44
Digital Inputs (optional)
Input 1
Input 2
Input 3
Profile Selected
ON
OFF
OFF
1
OFF
ON
OFF
2
ON
ON
OFF
3
OFF
OFF
ON 4 ON
OFF
ON 5 OFF
ON
ON 6 ON
ON
ON 7 OFF
OFF
OFF
none
The Protocol Plus control can be run by external inputs wired to the control from an external source such as a PLC or control panel switches. The external run operation can Run, Hold or Stop profiles 1 through 7 (profile 8 can not be operated externally). Refer to the table below for the inputs required for the desired operation. NOTE: A profile must be created in the program page before trying to run a profile number.
To start the selected profile, set Input 1, 2, 3 or 4 to ON. To hold a profile, set Input 4 to OFF. To stop a profile, set all inputs to OFF.
Digital Inputs
45
Error Messages and Alarms
The Alarm Status Hi-limit LED is flashing. This indicates a problem with the thermocouple, or the Hi-limit setpoint has been exceeded. Once the problem has corrected, press the Reset pushbutton.
The Alarm Status Soak LED is flashing. This indicates that the oven temperature has not entered or dropped out of the soak band and the soak timer has stopped.
The top LED Display reads OPEN and the lower LCD display reads CONTROL SENS ERR. This indicates that the Control thermocouple is disconnected or broken. Repair or replace the thermocouple.
The lower LCD display reads HI-LIM SENS ERR. This indicates that the Hi-limit thermocouple is disconnected or broken. Repair or replace the thermocouple.
The lower LCD display reads HIGH LIMIT ALARM. This indicates that the Hi-limit temperature setpoint has been exceeded. Determine if the setting is set too close to the setpoint, the SSR is defective, or the calibration is incorrect.
Note: The lower LCD display intermittently reads HL Temp. This is not an error message, but the Hi-limit thermocouple temperature reading.
46
Quick Reference and Default Values
Menu Item
Display
Default
Range
Setting
Ramp Time Seg 1
Pro-1 Seg-1 Ramp Time
00:00
00m00s to 99h59s
Event 1 Set Value
Pro-1 Seg-1 Ramp Event 1
Off
Off, On
Event 2 Set Value
Pro-1 Seg-1 Ramp Event 2
Off
Off, On
Event 3 Set Value
Pro-1 Seg-1 Ramp Event 3
Off
Off, On
Event 4 Set Value
Pro-1 Seg-1 Ramp Event 4
Off
Off, On
Soak Temp Seg 1
Pro-1 Seg 1 Soak Temp
68°F
SPLowerLim to SPUpperLim *
Soak Time Seg 1
Pro-1 Seg 1 Soak Time
00:00
00m00s to 99h59s
Event 1 Set Value
Pro-1 Seg-1 Soak Event 1
Off
Off, On
Event 2 Set Value
Pro-1 Seg-1 Soak Event 2
Off
Off, On
Event 3 Set Value
Pro-1 Seg-1 Soak Event 3
Off
Off, On
Event 4 Set Value
Pro-1 Seg-1 Soak Event 4
Off
Off, On
(repeat for segments 2-8)
High Limit Setpoint
Pro-1 Hi-Lim SP
Max HiLimSP
MinHiLimSP to MaxHiLimSP *, Band **
Loop From
Pro-1 Loop From XX
No
No, Seg-1 to Seg-8
Loop To
Pro-1 Loop To XX
No
No, Seg-1 to Seg-8
Loop Count
Pro-1 Loop Number
0
0 to 99
Profile Link
Pro-1 Link To XX
Stop
Standby***, Stop, Hold, Pro-1 to Pro-8
Guaranteed Soak
Pro-1 Guar Band
Off
Off, 1 to 778°C (1400°F)
(repeat for profiles 2-8)
Program Page
* See Enable Page ** Band value is set on Control Page
*** If Standby
1. Cycle Complete LED indication goes ON.
2. Controller beeps if End Of Cycle beep is enabled.
3. Heater/control output keeps controlling oven temperature at last Soak setpoint.
4. All events programmed (if relay cards installed and programmed as an event) for the last Soak Segment stays active.
47
Programming Table
Seg-
ment
Ramp
Soak
Time
Events
Temp-
erature
Time
Events
1 2 3 4 1 2 3
4
1 2 3 4 5 6 7 8
High Limit Setpoint
Loop From Seg
Loop To Seg
Loop Number
Link To Pro
Guar Soak Band
Profile Number__________ Profile Name__________
48
Autostart
Menu Item
Display
Default
Range
Setting
Enable Autostart
Auto Start Enable
No
No, Yes
Sunday mode
Auto Start Sun Mode
Off
Off, Manual, Timer, Pro-1 to Pro-8
Sunday time
Auto Start Sun Time
00:00
00:00 to 23:59
Monday mode
Auto Start Mon Mode
Off
Off, Manual, Timer, Pro-1 to Pro-8
Monday time
Auto Start Mon Time
00:00
00:00 to 23:59
Tuesday mode
Auto Start Tue Mode
Off
Off, Manual, Timer, Pro-1 to Pro-8
Tuesday time
Auto Start Tue Time
00:00
00:00 to 23:59
Wednesday mode
Auto Start Wed Mode
Off
Off, Manual, Timer, Pro-1 to Pro-8
Wednesday time
Auto Start Wed Time
00:00
00:00 to 23:59
Thursday mode
Auto Start Thu Mode
Off
Off, Manual, Timer, Pro-1 to Pro-8
Thursday time
Auto Start Thu Time
00:00
00:00 to 23:59
Friday mode
Auto Start Fri Mode
Off
Off, Manual, Timer, Pro-1 to Pro-8
Friday time
Auto Start Fri Time
00:00
00:00 to 23:59
Saturday mode
Auto Start Sat Mode
Off
Off, Manual, Timer, Pro-1 to Pro-8
Saturday time
Auto Start Sat Time
00:00
00:00 to 23:59
Menu Item
Display
Default
Range
Setting
Display units
PID Temp Unit
°C
°C or °F
Proportional band
PID Prop Band
6°C
1 to 56°C (1 to 100°F)
Integral reset
PID Reset
2
0 to 100 seconds/repeat
Derivative Rate
PID Rate
0
0 to 500 seconds
AutoTune
PID AutoTune
Disable
Disable, Enable
PID
49
Control
Menu Item
Display
Default
Range
Setting
Cycle Time
Control Cycle Time
1
1 to 60 seconds
High limit setpoint
Control Hi-Lim SP
Max HiLimSP
MinHiLimSP - MaxHiLimSP*
High limit band
Control Hi-Lim Band
Off
Off, 3°C to 11°C (5°F to 20°F)
Power fail recovery
Control PwrFRec
Stop
Stop, Restart, Hold, Resume
Recovery time limit
Control PwrFTime
00m00s
00m00s to 99m59s
Powerup start enable
Control EPwrStrt
Dis
Dis, En
Powerup Start Mode
Control StrtMode
Off
Off, Manual, Timer, Pro-1 to Pro-8
Hysteresis
Control Hyst
3°C
1°C to 56°C (1°F to 100°F)
Process out low
Control RetOutLo
80°C
-73°C to 760°C (-100°F to 1400°F)
Process out high
Control RetOutHi
400°C
-73°C to 760°C (-100°F to 1400°F)
Time scale
Control TimeScale
hh:mm
hh:mm or mm:ss
Key press beep
Control KeyBeep
On
On or Off
End of cycle beep
Control EOCBeep
Off
On or Off
Alarm beep
Control AlarmBeep
Off
On or Off
Menu Item
Display
Default
Range
Setting
Address
Communication CommAddr
1
1 to 247
Mode
Communication CommMode
OFF
OFF, Modbus
Baud rate
Communication Baud Rate
19.2K
2400, 4800, 9600,
19.2K, 38.4K
Parity
Communication Parity
None
None, Odd, Even
*see Enable Page
Communication (optional)
50
Real Time Clock
Menu Item
Display
Default
Range
Setting
Day of the week
Clock Day
Mon
Sun, Mon, Tue, Wed, Thu, Fri, Sat
Time of day
Clock HH:MM
00:00
00:00 to 23:59
Reset clock
Clock UP to Reset CLK*
Ready
Ready, Done
Menu Item
Display
Default
Range
Type of relay
Relay 1 RelayType
Off
Off, Alarm, Cycl, Ev1 to Ev4
Action of relay
Relay 1 RelayAction
NDE
NDE, NE, NDEL, NEL*****
Type of alarm*
Relay 1 AlarmType
High
High, Low, Plus, Minus, Band
Alarm setpoint*
Relay 1 AlmHi/Lo SP
538°C
-73°C to 760°C (-100°F to 1400°F)
Alarm deviation*
Relay 1 AlmDevBand
3°C
1 to 56°C (1 to 100°F)
Inhibit alarm*
Relay 1 ALMInhibit
On
En or Dis
Type of event**
Relay 1 EventType
Time
Time or Temp
Event setpoint ***
Relay 1 Event SP
SPUpLim
SPLoLim to SPUpLim****
Relay
Type
Action
Alarm/ Event Type
Setpoint
Alarm Deviation
Alarm Inhibit
* if the key is not pressed, the clock values will retain their original values, the display will change to Done if the clock is reset
Relay Outputs (optional)
Push Select key to select relay. If Relay 0 appears, no relays are installed
(repeat for relay outputs 2-4, if available) * appears only for alarm types
** appears only for time or temperature event types *** appears only for temperature event types **** see enable page ***** Normally de-energized and non-latching, normally energized and non-latching,
normally de-energized and latching, normally energized and latching
Table of Settings
51
Test
Menu Item
Display
Default
Range
Setting
Heater output
Test HeatOut
Off
On
High limit relay
Test HiLimOut
Off
On
Relay 1 output
Test Rly1 Out
Off
On Relay 2 output
Test Rly2 Out
Off
On
Relay 3 output
Test Rly3 Out
Off
On
Relay 4 output
Test Rly4 Out
Off
On High Limit Sensor
Test HL Temp
(sensor reading)
Menu Item
Display
Default
Range
Setting
Zone 1 actual
Zone Cal Zone1Act
38°C
-73°C to 760°C (-100°F to 1400°F)
Zone1 displayed
Zone Cal Zone1Dis
38°C
-73°C to 760°C (-100°F to 1400°F)
Zone 2 actual
Zone Cal Zone2Act
260°C
-73°C to 760°C (-100°F to 1400°F)
Zone2 displayed
Zone Cal Zone2Dis
260°C
-73°C to 760°C (-100°F to 1400°F)
Factory calibration*
Zone Cal FactCal
Ready
Ready or Done (push- key)
Menu Item
Display
Default
Range
Setting
Control Sensor Cal
Ctrl Sens 0F Ctrl Sens 1000F Ctrl Sens Done
-100°F 1400°F Done
-100 to 1400°F
-100 to 1400°F (read only)
HiLim Sensor Cal
HL Sens 0F HL Sens 1000F HL Sens Done
-100°F 1400°F Done
-100 to 1400°F
-100 to 1400°F (read only)
Retransmit Cal
RetCalLo XXXX * RetCalHi XXXX *
0 4096
0 to 4096** 0 to 4096***
Zone Cal
*only use when no calibration instrument is available
Sensor Cal
* note that the actual RetCalLo and RetCalHi values displayed are of no importance. ** press keys until retransmission output = 1VDC *** press keys until retransmission output = 5VDC
52
Enable Page
Menu Item
Display
Default
Range
Setting
Profiles
Enable Profile 1-8
Yes
Yes or No
Autostart
Enable Auto Start
No
Yes or No **
PID
Enable PID
Yes
Yes or No
Control
Enable Control
No
Yes or No
Communication
Enable Communication
No
Yes or No **
Real Time Clock
Enable Clock
No
Yes or No **
Relay outputs
Enable Relay 1-4
No
Yes or No **
Test
Enable Test
No
Yes or No
Zone Calibration
Enable Zone Cal
No
Yes or No
Sensor Calibration
Enable Sensor Cal
No
Yes or No
Setpoint lower limit
Enable SPLowerLim
20°C
-73°C to 759°C (-100°F to 1399°F)
Setpoint upper limit
Enable SPUpperLim
260°C
-73°C to 760°C (-100°F to 1400°F)
High limit overhead
Enable HiLimOH
5°C
3 to 11°C (5 to 20°F)*
Password level 1
Enable Password 1
1
0 to 999
Password level 2
Enable Password 2
2
0 to 999
Manual/Timer mode setpoint change
Enable SPChange
Yes
Yes or No
Analog Output Type
Enable Analog Type
Proc
Ctrl or Proc
* Maximum high limit setpoint (MaxHiLimSP) = SPUpperLim + HiLimOH Minimum high limit setpoint (MinHiLimSP) = SPLowerLim + HiLimOH
** If the controller does not have this feature, “No” is the only option.
53
Technical Specifications
UL, cUL listed:
UL file E136675
CE compliance to:
EMC Directive 89-366/EEC European Standard EN55011/1991 European Standard EN50082-2/1995
Power supply:
100 to 240 VAC +10% -15%, 50-60Hz, 30VA Maximum 12 to 24 VAC/VDC +/-10%, DC to 60Hz, 30VA Maximum
Temperature:
Storage -20 to 60°C Operating 0 to 50°C
Humidity:
90% or less, non-condensing
Sensor inputs:
Type J thermocouple -73°C to 760°C (-100°F to 1400°F) Input impedance 1M ohm or greater Common mode noise rejection of 140db@60Hz Common mode input voltage of +/-12.0VDC Sample rate of at least 1 sample per second
Stability of +/- 0.5°C per 5°C change in ambient temperature Repeatability of +/- 0.5°C, or +/-0.1% of sensed temperature (whichever is
greater)
Accuracy (@ 77°F +/-0.2 percent of span (+/-3°F) Supply Voltage Influence of +/-0.5°C per 10% change in nominal line voltage
Temperature display:
1 degree resolution (C or F) Accuracy after calibration of +/- 1°C, or +/-0.2% of sensed temperature
(whichever is greater) @25°C
Four-digit seven-segment LCD, 0.43 inches high (11mm) Readout Stability (+/-1°F/10°F Change in ambient temperature)
Message display:
Two-line, 16 alpha-numeric 5x7 dot matrix characters per line
0.2 inches high (5mm)
Time base:
+/- 4 seconds accuracy in 24 hours
Heat control output:
SSR Drive 24VDC nominal @ 70mA
Relay output: (plug-in module)
Form A dry contact, rated 3 amps @ 24-264VAC
Retransmit output:
1 to 5 VDC into > 100K ohm load
Communications: (plug-in module)
RS232 Single drop, isolated RS422 Multi-drop, isolated RS485 Multi-drop, isolated
Remote inputs: (plug-in module)
Dry-contact closure type with less than 250 ohm ON resistance
Front panel:
NEMA 4X (with gasket)
Dimensions:
3.57H x 7.24W x 2.84D inches (91H x 184W x 72D mm)
Panel opening:
3.63H x 7.30W inches (92H x 185W mm)
54
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.
55
Tests
WARNING:
Disconnect the main power switch or power cord before attempting any repair or ad­justment.
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 the functions of the temperature control. Test the control every 40 hours. Check that the heater LED is cycling on and off, indicating that the heater is working. Also check the high limit function to make sure it is working properly.
To test the high limit:
1. Go to Manual Mode and enter control setpoint value at least 20°F (11°C) lower than the current process temperature.
2. Press the Menu key and lower the high limit setpoint to a value just below the current process temperature.
3. The high limit alarm indicator should flash and a high limit alarm message should be displayed. Verify that the heater relay has been disabled by checking that 2LED on the control panel circuit board is not lit.
4. Return the control setpoint and high limit setpoint values to their original values.
5. Press the Reset key.
Nitrogen Supply
Turn the three-way valve on the control panel to the OFF position and screw the adjusting knob clockwise on both PURGE and MAINTAIN flowmeter all the way to the OFF position. Then open the tank valve on the nitrogen supply and set the pressure regulator to about 40 PSI. Check the nitrogen plumbing for leaks with a soapy water solution. As nitrogen gas is odorless, all leaks should be stopped to prevent the possibility of suffocation in a small work areas. Gas from a nitrogen leak might displace much of the oxygen in the atmosphere.
56
Replacement
WARNING:
Disconnect the main power switch or power cord before attempting any repair or ad­justment.
Parts
To order or return parts, contact the Service Products Division at Despatch. The Service Products features our Response Center for customer service. When returning parts, a Despatch representative will provide you with an MRA (Material Return Authorization) number. The MRA number must be attached to the returned part for identification. When you are ordering parts, be sure to give the model number, serial number and the part number. This will expedite the process of obtaining a replacement part.
When you have a service need, contact the Response Center at 1-800-473-7373: FAX 612-781-5353.
57
Protocol Plus™ Instrument
(Tools needed: 1/4" socket driver with #1 bit, #2 Phillips screwdriver)
1. Disconnect the power.
2. Remove the screws from the control panel and slide it forward.
3. Unplug all terminals on the rear of the control, noting the proper connections.
4. Remove the four retaining clips for the control.
5. Remove the control.
6. Insert the new control into the panel.
7. Fasten the four retaining clips.
8. Re-plug all terminals.
9. Fasten the control panel.
Heater Unit
(Tools needed: 3/8" wrench, square recess driver with #1 bit for LND1-42, one-quarter inch socket set for LND2-11 and LND2-24)
1. Remove the chamber floor plate. a. Remove the screws from the floor plate. b. Lift the floor plate out of the oven.
2. Disconnect the heater leads from heater element with wrench. Note which wires go on which terminals.
3. Unscrew the screws holding the heater frame to the oven body.
4. Remove the heater and discard.
5. Screw down the new heater frame.
6. Attach the heater leads to appropriate terminals.
7. Replace the interior floor and screws.
58
Fan Motor
(Tools needed: Screwdriver, 5/32 inch Allen wrench, one quarter (¼) inch socket set)
1. Remove the chamber floor plate. a. Remove the screws from the floor plate. b. Lift the floor plate out of the oven.
2. Remove the left side wall.
3. Remove the fan inlet plate.
4. Loosen the set screws (2) on fan wheel in middle of oven bottom. You can reach the fan wheel by going through the heater or by disconnecting and removing the heater. Refer to the Heater Unit instructions.
5. Place the oven on its back (LND1-42 only).
6. Remove the bottom plate on the LND1-42, or remove the control panel on the LND2-11 and 2-24. This will reveal the fan motor.
7. Remove the fan motor. a. Unscrew the screws (4) holding motor mounts to the body. b. Disconnect the motor leads from the terminal strip on the power panel. c. Lift the fan motor from the oven body.
After the fan wheel has run at temperature for awhile, it will stick to the shaft. Some force may be required to separate the fan wheel from the fan motor shaft.
8. Take the motor mounts off old motor.
9. Put the motor mounts onto new motor.
10. Replace the fan motor. a. Insert the shaft into shaft collar. Put the fan wheel onto shaft from inside
oven.
b. Reattach the motor mounts to the oven body, making sure grommets are
in place.
59
c. Reattach the motor lead wires to the terminal strip.
11. Replace the oven bottom (LND1-42) or control panel front (LND2-11 or 2-24).
12. Turn the oven right side up.
13. Adjust the fan wheel for 3/16 inch clearance between the wheel and the inlet ring.
14. Tighten the set screws on the fan wheel.
15. Check that the set screws hit the flats machined into the motor shaft.
16. Replace the chamber floor plate.
60
TROUBLESHOOTING
Difficulty
Probable Cause
Suggested Remedy
Failure to heat
No power Burned out heater Protocol™ malfunction Loose wire connections
Purge timer not timed out or failed
Heater relay failure Airflow switch not closed
Door switch failure (if installed)
Check power source and/or oven and wall fuses. Replace heater (see warranty.) Replace controller. Disconnect power and check connections behind
control panel. Wait 3 minutes. If still not heating, replace purge
timer. Replace circuit board. Check exhaust system for proper operation and
ventilation. If airflow switch still does not close, replace switch.
Replace door switch.
Slow heat up
Improperly loaded Low line voltage
Heating element(s) are burned out
240 volt oven is connected to a 208V line (LND1-42 only)
Fan motor failure
Reduce load or redistribute load in chamber. Supply sufficient power and proper connections.
Check for circuit overload. Replace burned out element (see warranty
statement.) Raise line voltage to a 240 volt line or modify oven
for 208V operation (consult factory). Replace fan motor.
Frequent heater element out
Harmful fumes generated by load
Spillage or splattering of material on heater elements
Overheating oven
Increase vent opening or discontinue process.
Disconnect power and clean oven chamber and elements.
Check the Hi-limit.
Equipment which operates for long periods of time may develop 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.
61
Difficulty
Probable Cause
Suggested Remedy
Erratic temp. or inaccurate temp.
Protocol™ malfunction Improper tuning parameters Protocol™ miscalibration
Hi-limit setting Improper offset
Replace Protocol™. Check tuning parameters. Recalibrate Protocol™ (see section on Calibration
mode.) Hi-limit should be 10-25 C higher than setpoint. Check zone calibration.
Excess surface or door temp.
Door seal deterioration
Replace door seal.
Improper airflow
Fan motor failure Fan wheel seated too low on
fan shaft Unbalanced fan wheel
Replace fan motor. Adjust fan wheel for 3/16" clearance between
wheel and inlet ring. Replace fan wheel.
Excessive vibration
Dirty fan wheel Unbalanced fan wheel
Clean fan. Replace fan wheel.
Oven will not control at setpoint
Hi-limit set too low Protocol malfunction SSR malfunction
Air friction of recirculation fan
Set the Hi-limit higher Replace control. Replace SSR and/or check control output voltage. Open exhaust air vent. Unit will not control below
minimum operating temperature with vent closed.
Heater does not shut down until temp. reaches the Hi-limit setting
Protocol malfunction SSR malfunction
Replace Protocol Replace SSR
NOTE: The circuit board mounted on the control panel has three status LED indicators to help troubleshoot if the oven is not heating (LND1-42 only).
A. If LED 1 is not lit, check 2F and 3F (control fuses), or power switch. B. If LED 1 and LED 3 are lit but not LED 2, check high limit (and optional door
switch, if installed).
C. If all three LEDs are lit, check 1F and 4F (heater fuses), SSR, heater, and heater
relays.
62
APPENDIX Temperature Scale Conversion (C/F)
The Protocol Plus controller can be operated in either C or F. The default setting for the controller is C. Changing from one to the other is as follows:
1. Go into the Setup Mode on the controller.
2. Press the Select Key until Setup is displayed.
3. Press the Page key and Security will be displayed.
4. Press the Menu Key and Password will be displayed. Use the arrow keys to enter the proper password. The default password is 2 for level two.
5. Once the proper password is displayed, press the Page key until PID is displayed.
6. Press the Menu key and Temp Unit along with C or F will be displayed. Use the arrow keys to change the setting.
7. Once the proper setting is displayed, press and hold the Page key for approximately three seconds to exit the Setup Mode.
63
Optional MRC5000 Recorder Setup
Parameter Code
Degrees C
Degrees F
Inps
17
17
Icor
0 0 diSP
On
On
dPOS
0
0
EUU **
400
752
EUL **
0
32
ChUP
400
800 *
ChLO
0 0 DFF
1
1
The temperature is retransmitted to the Recorder from the Controller. Set up the Recorder as follows:
1. Make sure that jumper JU1 is setup for the 5 VDC setting (see MRC Manual).
2. Move the Mode switch to the PROG/TEST/CAL position, and Prog will be displayed.
3. Press the down arrow key twice and Inps will be displayed. Make sure the settings are per the table below.
4. Once all the settings have been changed, move the Mode switch to the RUN position. The display on both the Recorder and controller should read the same.
* Note: The 0 - 400 chart paper must be changed to the 0 - 800 chart paper.
** Note: These values must mach the setting sRetOutLo and RetOutHi on the Control
Depending on the equipment, 0 - 600 paper can be used if the maximum temperature is 500 degrees F.
page on the Protocol Plus controller (example: RetOutLo is 32, then EUL must read 32).
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