Despatch RAD1-42-2E Installation Manual

RAD1-42-2E Oven Owner’s Manual PREFACE

ULTRAFLEX DRYING AND FIRING FURNACE

MODELS 1000, 3615, 3630, 3640

C-204 VERSION 27

10/2008

RAD1-42-2E WITH PROTOCOL 3

TM

CONTROLLER

OWNER’S MANUAL

C-246 PN 320296 VERSION 1 5/2012

Version 1 1

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

PREFACE RAD1-42-2E Oven Owner’s Manual

Revision

Date

Author

Description

1

5/2012

Livingston

Revised for Protocol 3 and revised format.

2 Version 1

Revision History

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

RAD1-42-2E Oven Owner’s Manual PREFACE Version 1 3

Table of Contents

1. About This Manual ............................................................................................................. 5

1.1. Important User Information ..................................................................................... 5

1.2. Manufacturer & Service .......................................................................................... 6

1.3. Organization of this Manual .................................................................................... 6

1.4. Conventions ............................................................................................................. 7

1.5. Specifications .......................................................................................................... 7

1.5.1. Dimensions .......................................................................................................... 7

1.5.2. Capacities ............................................................................................................ 7

1.5.3. Temperatures ....................................................................................................... 8

1.5.4. Power ................................................................................................................... 9

2. Safety ................................................................................................................................ 10

2.1. Safety Information ................................................................................................. 10

2.1.1. Lockout .............................................................................................................. 10

2.1.1.1. Lockout Requirements ................................................................................... 10

2.1.1.2. Lockout Procedure ......................................................................................... 10

2.2. Maintenance .......................................................................................................... 11

2.3. Electrical Power ..................................................................................................... 11

2.4. Fire ......................................................................................................................... 11

2.5. Equipment Lockout Requirements ........................................................................ 11

2.5.1. Optional Disconnect Switch .............................................................................. 12

3. Theory of Operation ......................................................................................................... 13

3.1. The RAD1-42-2E Oven ......................................................................................... 13

3.2. Damper Control ..................................................................................................... 13

3.2.1. Determining Damper Settings ........................................................................... 13

3.2.1.1. Damper Full Closed Position ......................................................................... 14

3.2.1.2. Damper in Full Open Position ....................................................................... 14

3.2.1.3. Other Damper Settings .................................................................................. 14

3.3. The Protocol 3 Controller ...................................................................................... 15

3.3.1. Optional High Limit Audible Alarm ................................................................. 16

3.3.2. Optional Modbus Communications Hardware .................................................. 16

4. Assembly & Setup ............................................................................................................ 17

4.1. Unpack & Inspect The RAD1-42-2E Oven ........................................................... 17

4.1.1. If Damaged During Shipping ............................................................................ 17

4.2. Setup The RAD1-42-2E Oven ............................................................................... 17

4.2.1. Select Oven Location ........................................................................................ 17

4.2.1.1. Single Oven Placement Requirements........................................................... 18

4.2.1.2. Multiple Oven Placement Requirement......................................................... 18

4.2.2. Exhaust Connections ......................................................................................... 18

4.2.3. Wiring & Power Connections ........................................................................... 19

5. Operation .......................................................................................................................... 20

5.1. Load Oven ............................................................................................................. 20

5.2. Pre-Startup Checklist ............................................................................................. 20

5.3. Operating Procedure .............................................................................................. 22

5.3.1. Start Oven .......................................................................................................... 22

5.3.2. Working with Protocol 3 Operating Modes ...................................................... 22

6. Maintenance ..................................................................................................................... 23

6.1. Checklist ................................................................................................................ 23

6.2. Lubrication ............................................................................................................ 23

means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

PREFACE RAD1-42-2E Oven Owner’s Manual 4 Version 1

6.3. Replacement Parts ................................................................................................. 23

6.4. Repairs ................................................................................................................... 24

6.4.1. Protocol 3 Controller ......................................................................................... 24

6.4.2. Heater Unit ........................................................................................................ 24

6.4.3. Fan Motor .......................................................................................................... 24

7. Troubleshooting................................................................................................................ 26

7.1. Possible Problems and Suggested Solutions ......................................................... 26

7.2. Error Messages and Alarm .................................................................................... 29

8. Appendices ....................................................................................................................... 30

8.1. Standard Products Warranty .................................................................................. 30

8.2. MRC5000 Setup (Optional) .................................................................................. 31

8.3. Electrical Schematics ............................................................................................. 31

Figures

Figure 1. Disconnect Switch.......................................................................................................... 12

Figure 2. RAD1-42-2E Oven. ....................................................................................................... 13

Figure 3. RAD1-42-2E Oven Damper Control. ............................................................................ 13

Figure 4. Protocol 3 Operator Interface. ........................................................................................ 16

Figure 5. RAD1-42-2E LED Circuit Board Lights. ...................................................................... 28

Figure 6. RAD1-42-2E (Drawing 320211-01). ............................................................................. 32

Figure 7. RAD1-42-2E (Drawing 320211-02). ............................................................................. 32

Figure 8. RAD1-42-2E (Drawing 320211-03). ............................................................................. 32

Figure 9. RAD1-42-2E (Drawing 320212-01). ............................................................................. 32

Figure 10. RAD1-42-2E (Drawing 320212-02). ........................................................................... 32

Figure 11. RAD1-42-2E (Drawing 320212-03). ........................................................................... 32

Tables

Table 1. Exhaust Connection Requirements.................................................................................. 18

Table 2. Possible Problems and Suggested Solutions. .................................................................. 26

Table 3. Troubleshooting with Control Panel Mounted Circuit Board. ........................................ 28

Table 4. Error Messages and Next Steps. ...................................................................................... 29

Table 5. MRC 5000 Settings. ........................................................................................................ 31

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

RAD1-42-2E Oven Owner’s Manual ABOUT THIS MANUAL



Values displayed on screens are examples only. Though those values may be typical, contact Despatch Industries for the final value.



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 5 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.

Danger!

Only fully-trained and qualified personnel should setup and maintain this equipment. Improper setup and operation of this equipment could cause an explosion that may result in equipment damage, personal injury or possible death.

Version 1 5

1. About This Manual

1.1. Important User Information

All rights reserved. No part of the contents of this manual may be reproduced, copied, or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of the publisher, unless it is for the purchaser's personal use.

Printed and bound in the United States of America.

The information in this manual is subject to change without notice and does not represent a commitment on the part of Despatch Industries. Despatch Industries does not assume any responsibility for any errors that may appear in this manual.

In no event will Despatch Industries be liable for technical or editorial omissions made herein, nor for direct, indirect, special, incidental, or consequential damages resulting from the use or defect of this manual.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

ABOUT THIS MANUAL RAD1-42-2E Oven Owner’s Manual

Global Headquarters

Contact

Service & Technical Support

Despatch Industries

8860 207th Street Lakeville, MN 55044 USA

International/Main: 1-952-469-5424 US toll free: 1-888-337-7282 Fax: 1-952-469-4513 info@despatch.com www.despatch.com

Service: 1-952-469-8230 US toll free: 1-800-473-7373 Service @despatch.com

Danger!

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

6 Version 1

The information in this document is not intended to cover all possible conditions and situations that might occur. The end user must exercise caution and common sense when installing or maintaining Despatch Industries products. If any questions or problems arise, call Despatch Industries at 1-888-DESPATCH or 1-952-469-5424.

1.2. Manufacturer & Service

The RAD1-42-2E oven is manufactured by Despatch Industries.

Despatch has specialized in thermal processing for over 100 years. Technical expertise gained over those years helps provide innovative solutions to critical applications in vertical markets and cutting edge technology worldwide. Despatch products are backed by a drive for long-term customer satisfaction and a strong sense of responsibility. The worldwide network of factorytrained Service Professionals is available to support your Despatch equipment. From full service preventive maintenance to routine repair and certified calibration and uniformity, the Despatch service network is positioned to respond to your business needs. Our service programs are customized to meet your specific needs using our Advantage Service Assurance Program (ASAP). For more information on ASAP, visit www.despatch.com.

1.3. Organization of this Manual

This owner’s manual contains the most comprehensive set of information for the Despatch RAD1-42-2E oven, including installation instructions, theory of operation, and operating instructions, among other things.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

RAD1-42-2E Oven Owner’s Manual ABOUT THIS MANUAL

This icon signifies information that describes an unsafe condition that may result in death, serious injury, or damage to the equipment.

Danger!

Danger is the signal word used to indicate a hazardous situation that, if not avoided, will result in death or severe injury.

Warning!

Warning is the signal word used to indicate a hazardous situation that, if not avoided, could result in death or severe injury.

Caution!

Caution is the signal word used to indicate a hazardous situation that, if not avoided, could result in moderate or minor injury.

Notice

Notice is the signal word used to indicate a hazardous situation that, if not avoided, could result in property damage.



This icon signifies supplemental important information.

LOG OUT

Bold, 10 point sans-serif typeface indicates a specific key or button on screen to click.

Models

Chamber Size

inches (cm)

Capacity

ft3 (liters)

Overall Size inches (cm)

Maximum

number

of

Shelves

Exhaust

Outlet

Diameter in

(cm)

W D H W D

H

RAD 1-42-2E

20

(50.8)

18

(45.7)

20

(50.8)

4.2

(119)

46

(116.8)

31.5 (80)

37.5

(95.3)

8

2.5

(6.4)

Capacity

Model RAD1-42-2E

Maximum load

(Lbs) (KG)

200

91

Maximum shelf capacity

(Lbs)

30

Version 1 7

1.4. Conventions

1.5. Specifications

1.5.1. Dimensions

1.5.2. Capacities

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

ABOUT THIS MANUAL RAD1-42-2E Oven Owner’s Manual

Capacity

Model RAD1-42-2E

(KG)

13.6

Exhaust Capacity

Adjustable to 12 CFM (5.6 lps)

Recirculating fan

(CFM)

425 (200 lps)

(H.P.)

1/2

Net weight (Approximate)

(Lbs)

350

(KG)

159

Shipping weight (Approximate)

(Lbs)

480

(KG)

218

Feature

Range

Model RAD1-42-2E

Time to Temperature

Minutes

(No Load)

40°C to 177°C

10

40°C to 260°C

20

40°C to 343°C

38

Recovery Time Door Open 1 Min

100°C

<1

200°C

3

343°C

10

Cooling Time to Temperature

Minutes

(No Load)

343 - 50°C (damper open)

180

343 - 75°C (damper closed

130

Temperature Uniformity at*

177°C

+/- 2.3° C

260°C

+/- 3.4° C

343°C

+/- 4.2° C

Minimum Operating Temperature

above ambient

(Approximate w/20°C ambient)

20°C

Control Stability (∆ represents the

change in ambient temperature)

+/- 0.5ºC/5ºC ∆

Repeatability

+/- 0.5ºC

*

8 Version 1

1.5.3. Temperatures

Uniformity figures are based on a nine-point test conducted in an empty oven after stabilization period. Uniformity can vary slightly depending on unit and operating conditions. Minimum operating temperature and cooling times are based on 20ºC ambient temperature measured at the fresh air inlet with the fresh air and exhaust dampers fully open. Specifications are subject to change without notice.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

RAD1-42-2E Oven Owner’s Manual ABOUT THIS MANUAL

Warning!

This oven is not designed for use with flammable material. If your process involves flammable material, see the RFD Class A series.

†

Model

Volts †

Amps

Hertz

Phase

KW

RAD1-42-2E

240

30

50/60 1 6-

RAD1-42-2E

208

33.7

50/60 1 6-

Version 1 9

1.5.4. Power

Line voltages may vary in some geographies. If the line voltage for your RAD1-42-2E oven varies more than 10% from the oven voltage rating, electrical components such as relays and temperature controls may operate erratically.  If the line voltage is lower than the oven voltage rating, heat-up time may be significantly

longer and motors may overload or run hot.

 If the line voltage is higher than the nameplate rating, motors may run hot and draw excessive

amperage.

An oven designed for 240 volts (see oven nameplate) will operate satisfactorily on a minimum of 208 Volts, but will result in 25% reduced heater output. If your power characteristic is lower, contact Despatch Industries.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

SAFETY RAD1-42-2E Oven Owner’s Manual

Danger!

An accidental start-up, while working on the RAD1-42-2E oven, can result in serious injury or death.

Danger!

Electrical panels contain high voltage. Disconnect and lock out the power supply before working inside any electrical panels. Failure to lock out the power supply can result in death or injury.

10 Version 1

2. Safety

2.1. Safety Information

Do not work on the RAD1-42-2E oven without reading and understanding this section which contains important information and warnings. Ignoring these warnings can result in death, serious injury or damage to the machine and product.

2.1.1. Lockout

Machine lockout places the RAD1-42-2E oven into a zero energy state and prevents accidental machine start up. Always follow the Lockout Procedure described in this section before cleaning, maintaining or repairing the RAD1-42-2E oven.

2.1.1.1. Lockout Requirements

1. Every power source that can energize any element of the RAD1-42-2E oven must be shut off

at the closest possible power source. This includes air, water, electricity, and the Disconnect Switch (if applicable).

2. After energy sources are locked out, test to ensure circuits are de-energized.

2.1.1.2. Lockout Procedure

Personnel authorized to lockout equipment must have the necessary locks to perform the lockout.

1. Physically disconnect all electrical power to the machine or lockout the appropriate breaker

or disconnects.

2. Close all valves and bleed off any pressure.

3. Test for power by attempting a start with the machine controls.

4. Identify the Lockout Condition with a tag on the electrical disconnect and pneumatic shut off

valve.

5. When work is complete, remove all tags and restore the machine to its working state.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

RAD1-42-2E Oven Owner’s Manual SAFETY

Danger!

Contact with energized electrical sources may result in serious injury or death.

Danger!

Always disconnect all power before extinguishing a fire. Attempting to extinguish a fire in a machine connected to electrical power can result in serious injury or death.

Version 1 11

2.2. Maintenance

Only qualified and trained personnel should perform maintenance or repair.

2.3. Electrical Power

Only qualified and trained personnel should perform electrical maintenance or electrical repair.

 Before performing maintenance, disconnect all electrical power from the machine. Use a

padlock and lockout all disconnects feeding power to the machine.

 Never clean or repair the oven when in operation.  Unauthorized alterations or modifications to RAD1-42-2E oven are strictly forbidden. Never

modify any electrical circuits. Unauthorized modifications can impair the function and safety of the RAD1-42-2E oven.

2.4. Fire

Keep the RAD1-42-2E oven clean and free of scrap materials, oil or solvents to prevent the possibility of fire.

1. Leave the door as it is.

2. De-energize the machine immediately by turning OFF the DISCONNECT SWITCH (if

applicable).

3. Turn off the remote main disconnect (customer supplied disconnect).

4. Shut off fuel.

5. Call the fire department.

6. Stay away.

2.5. Equipment Lockout Requirements

To prevent injury or equipment damage during inspection or repair, the RAD1-42-2E oven must be locked out.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

SAFETY RAD1-42-2E Oven Owner’s Manual

Figure 1. Disconnect Switch.

12 Version 1

2.5.1. Optional Disconnect Switch

The RAD1-42-2E oven has an optional Disconnect Switch (Figure 1). This Disconnect Switch is located on the front of the oven and connected to the load break switch behind the panel that disconnects or connects power from the main line. When a risk of personal injury or damage to the RAD1-42-2E oven exists, turn off the Disconnect Switch. This shuts off all electrical power to the oven.

All rights reserved. No part of the contents of this manual may be reproduced, copied or transmitted in any form or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information storage and retrieval systems without the written permission of Despatch Industries, unless for purchaser's personal use.

Despatch RAD1-42-2E Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual