Despatch RBC1-50 Specifications

C-197
P/N 157413
REVISION H
11/2007
RBC1-50
WITH PROTOCOL PLUS
INSTRUCTION MANUAL
Model Volts Heater watts Amps HZ Phase RBC1-50 208 3,000 23 60 1 220 3,360 24 50 1 240 4,000 24 60 1
Prepared by: Despatch Industries 8860 207th St. West Lakeville, MN 55044 Customer Service 800-473-7373
Notice
Users of this equipment must comply with operating procedures and training of operation personnel as required by the Occupational Safety and Health Act (OSHA) of 1970, Section 6 and relevant safety standards, as well as other safety rules and regulations of state and local governments. Refer to the relevant safety standards in OSHA and National Fire Protection Association (NFPA), section 86 of 1990.
Caution
Setup and maintenance of the equipment should be performed by qualified personnel who are experienced in handling all facets of this type of system. Improper setup and operation of this equipment could cause an explosion that may result in equipment damage, personal injury or possible death.
Dear Customer, Thank you for choosing Despatch Industries. We appreciate
the opportunity to work with you and to meet your heat processing needs. We believe that you have selected the finest equipment available in the heat processing industry.
At Despatch, our service does not end after the purchase and delivery of our equipment. For this reason we have created the Service Products Division within Despatch. The Service Products Division features our Response Center for customer service. The Response Center will direct and track your service call to ensure satisfaction.
Whenever you need service or replacement parts, contact the Response Center at 1-800-473-7373: FAX 612-781-
5353. Thank you for choosing Despatch.
Sincerely, Despatch Industries
i
PREFACE
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 on air atmosphere and nitrogen atmosphere Burn-In ovens, a Troubleshooting Table, a list of Accessories and a Warranty.
The parts are listed in the corner of the attached prints, the electrical items on the electrical print and the mechanical items on the mechanical prints.
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.
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.
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Revision B (1-02): Updated drawings Revision C (4-02): Modified per Rev 3.0 Protocol Plus software Revision D (5-03): Updated drawings and Despatch Industries Product Warranty Revision E (2-04): Update drawings Revision F (3-04): Update drawings Revision G (8-06): Revised Protocol Plus numbers. Updated Despatch address Revision H (11-07) Updated warranty
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TABLE OF CONTENTS
PREFACE........................................................................................................................ i
INTRODUCTION.............................................................................................................1
Special Features.......................................................................................................... 1
Specifications .............................................................................................................. 2
Dimensions .............................................................................................................. 2
Capacities ................................................................................................................2
Temperature ............................................................................................................ 3
Power.......................................................................................................................4
Power Requirements............................................................................................ 4
THEORY OF OPERATION .............................................................................................5
Temperature Control.................................................................................................... 5
Power Switch............................................................................................................... 6
Air Circulation ..............................................................................................................6
Chamber Design.......................................................................................................... 6
Airflow Switch ..............................................................................................................6
Alarm...........................................................................................................................6
Chamber Door Handle................................................................................................. 7
Damper Control ...........................................................................................................7
Determining Damper Settings..................................................................................7
Full Closed Position.............................................................................................. 7
Full Open Position................................................................................................ 8
Minimum Opening for Dissipation of Live Load ....................................................8
Other Damper Settings......................................................................................... 8
OVEN INSTRUCTIONS................................................................................................ 10
Unpacking and Inspection ......................................................................................... 10
Warning Signs Missing.............................................................................................. 11
Set-up........................................................................................................................12
Power Connection ..................................................................................................... 13
Operating...................................................................................................................14
Loading the Oven...................................................................................................14
Oven Temperature Limit ........................................................................................ 14
Product Temperature Limit..................................................................................... 15
Operator Training Requirements............................................................................ 15
Pre-Startup Checklist.............................................................................................16
Startup ...................................................................................................................16
PROTOCOL PLUS CONTROLLER ..............................................................................18
Theory of Control Operation ...................................................................................... 18
Operating Modes....................................................................................................20
Setup Mode............................................................................................................20
Fast Start Mode......................................................................................................20
High Limit...............................................................................................................21
Indicators ...............................................................................................................21
Displays .................................................................................................................22
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Key Functions ........................................................................................................ 22
Outputs ..................................................................................................................23
Relay (Continued)..................................................................................................24
Communication......................................................................................................24
Optional Software...................................................................................................24
INSTRUCTIONS ........................................................................................................... 25
Start-Up.....................................................................................................................25
Operation...................................................................................................................26
Manual Mode ......................................................................................................... 26
Timer Mode............................................................................................................27
Profile Mode...........................................................................................................28
Auto Start Mode.....................................................................................................28
Setup Mode............................................................................................................29
Instructions for Setup Mode Pages............................................................................ 30
Program Page........................................................................................................30
Profile # ..............................................................................................................32
Sample Profile........................................................................................................33
Auto Start Page (optional)......................................................................................34
PID Page................................................................................................................36
Control Page..........................................................................................................38
Communication Page (optional)............................................................................. 39
Real Time Clock Page (optional)............................................................................ 39
Relay Outputs Page (optional)...............................................................................40
Test Page...............................................................................................................41
Zone Calibration Page ........................................................................................... 42
Sensor Calibration Page ........................................................................................44
Enable Page ..........................................................................................................46
Digital Inputs (optional) .......................................................................................... 47
Error Messages and Alarms ......................................................................................48
Quick Reference and Default Values......................................................................... 49
Technical Specifications ............................................................................................56
Maintenance..............................................................................................................57
Checklist ................................................................................................................57
Inspection and Cleaning.........................................................................................58
Vents..................................................................................................................58
Chamber.............................................................................................................58
Control Cabinet and Fan .................................................................................... 58
Chamber Door Gasket........................................................................................59
Recirculation Motor.............................................................................................59
Oven Exterior......................................................................................................59
Oven Chamber Interior.......................................................................................59
Door Hinges and Latches...................................................................................59
Automatic Damper..............................................................................................60
Controls and Indicators.......................................................................................60
Loose Screws, Bolts and Fasteners ...................................................................60
Lubrication..........................................................................................................60
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Tests......................................................................................................................61
OPTIONAL ACCESSORIES .........................................................................................62
Door Switch ...............................................................................................................62
Recorder....................................................................................................................62
Redundant High-Limit................................................................................................ 62
Disconnect Switch ..................................................................................................... 63
Stacking Option ......................................................................................................... 63
Replacement .............................................................................................................64
Parts.......................................................................................................................64
Nitrogen and Liquid Nitrogen..................................................................................... 64
Theory of Operation...............................................................................................64
Operator Training Requirements............................................................................ 65
Operation...................................................................................................................65
Nitrogen Atmosphere.................................................................................................67
Purge Rate.............................................................................................................67
Maintain Rate.........................................................................................................68
Troubleshooting.........................................................................................................69
Circuit Board Check...............................................................................................71
DRAWINGS .................................................................................................................. 72
APPENDIX: Temperature Scale Conversion and Optional MRC5000 Setup................75
Temperature Scale Conversion (C/F)........................................................................75
Optional MRC5000 Recorder Setup.......................................................................... 76
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vii
INTRODUCTION
This instruction manual covers the operation and maintenance of the Despatch RBC1-50 Burn-In oven.
NOTE: Read the entire INTRODUCTION and THEORY OF OPERATION before installing the oven.
Special Features
The sturdy construction and three-inch insulation top and bottom and four-inches of insulation on the sides of the Despatch RBC1-50 Burn-In 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.
1
Specifications
Dimensions
Model Chamber Size
in (cm)
W D H W D H RBC1-50 18
(46)
25
(64)
(46)
Capacities
Maximum Load 150 Lbs Fresh Air/ Exhaust Capacity at
125 °C (255 °F) Recirculating Fan 600 CFM 1 HP
Capacity
feet3
(liters)
18
4.7
(133)
RBC1-50
Air Atmosphere
51 CFM N/A
Overall Size
in (cm)
46
(117)
36
(91)
MODEL
RBC1-50
Nitrogen Atmosphere
31.50 (80)
Fresh Air Inlet 2.5” Diameter N/A Exhaust outlet 2.18” Diameter N/A # of Doors 1 Approximate Weight 470 Lbs. (213 KG)
2
Temperature
RBC1-50
Time to Temperature 25°C - 80°C (approximate minutes with 25°C - 125°C no live load) 25°C - 260°C
Recovery Time to 125°C with door open 1 Min. Temperature Uniformity at
260°C* Operating Temperature Range
(Based on 25°C ambient, and dampers fully open)
(1)
25°C - 150°C
(2)
125°C*
RBC1-50
Air Atmosphere
4 10 14 34
>1 Min. >1 Min.
<±1°C
±1°C
50° - 260°C 15° - 260°C
Nitrogen Atmosphere
4 10 14 30
<±1°C
±1°C
Control Stability Repeatability ±0.5°C Cooldown Time 125° - 60°C
Dissipation/Mean Temperature Rise 125°C 150°C
(1)
Time to temperature will be slightly longer for lower voltages due to heater kW derating (empty oven).
(2)
Figures are based on a nine-point survey in an empty oven. Uniformity can vary slightly depending
on unit and operating conditions.
(3)
In control stability figures represent the change in ambient temperature.
(4)
Dissipation is reduced by 17% on 50-Hertz operation. Temperature gradient/mean temperature rise is
with an evenly distributed live load.
(3)
40 Min. 11 Min.
(4)
80°C
±0.5°C per 5°C ∆
800 Watts/4°C 1,300 Watts/6°C 1,400 Watts/6°C
Note: Testing performed on 240V-1PH-60HZ.
3
Power
Line voltages may vary in some geographical locations. If your line voltage is much lower than the oven voltage rating, warm up time will be longer and motors may overload or run hot. If your line voltage is higher than nameplate 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
WARNING:
All grounding and safety equipment must be in compliance with applicable codes, ordinances and accepted safe practices.
WARNING: Failure to read this warning can result in death, serious bodily injury or property damage. All conductors must be copper unless the specific terminal is marked for use with aluminum conductors.
Volts Amps Hertz Phase Heater KW
208 23 60 1 3 220 24 50 1 3.4 240 24 60 1 4
4
THEORY OF OPERATION
Despatch RBC1-50 Burn-In ovens are made for the accelerated life testing of microcircuit electronic devices to identify early mortality. The Despatch RBC1-50 ovens are ideally suited for:
high-dissipation forward-bias burn-in,
high temperature reverse-bias burn-in,
stabilization baking of integrated circuits and other semiconductor devices.
Air atmosphere ovens recirculate air through the chamber. They can add heat and remove dissipated heat. Air is taken from the burn-in room and circulated through the oven. Heat is added by electric resistance elements, or removed through automatically controlled exhaust.
Temperature Control
A Despatch Protocol Plus™ modular microprocessor based digital temperature controller regulates the process. The Protocol Plus™ operates as a dual functioning controller/high limit instrument. The control portion utilizes a time-proportioning voltage signal to control heating, and a milliamp signal to control cooling with minimal temperature fluctuations.
The controller temperature-sensing element, located in the air return plenum area, senses the median air temperature of the oven. The controller automatically controls heat dissipated by sending a signal to the automatic damper modulator. This automatic damper controls the amount of fresh air drawn into the chamber, preventing excessive cooling and conserving energy.
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. When the high limit trips, the alarm horn will signal.
Please refer to the Protocol Plus™ instruction section located in this manual for more detailed information.
5
Power Switch
The POWER switch controls power to the control circuit, chamber recirculating fan motor relay, control cabinet fan, and any options that were included at the time of purchase.
Air Circulation
A Despatch centrifugal fan draws air through the heater section, moves it evenly across the chamber, past the temperature sensors and back to the heater. The fresh air is controlled manually and a modulating damper controls the exhaust.
Chamber Design
The chamber (in which the load is processed) has air supply and exhaust ducts on opposite sides. The ducts and perforated panels provide uniform airflow and temperature distribution throughout the chamber.
Airflow Switch
The airflow switch senses the differential pressure between the inlet and outlet side of the recirculating fan. If there is no air pressure, the switch disconnects power to the heater, and the alarm horn will signal. An On/Off indicator is visible through a window on the switch. The switch is located in the upper equipment compartment, behind the equipment panel and next to the recirculating motor.
Alarm
When there is a high limit condition, or when there is no air pressure sensed by the airflow switch, an alarm will sound and a red pilot light will be lit. To silence the alarm, depress the momentary ALARM SILENCE switch. The red light will remain on until the alarm condition is cleared.
6
Chamber Door Handle
The door handle positively engages a cam with a catch in one-quarter turn. The silicone rubber gasket provides a seal around the door as the handle is moved to the latched position.
Damper Control
The oven is equipped with a manually adjustable fresh air damper. The damper blade located on the rear of the oven. The damper adjustment controls the flow of fresh air into the chamber. If the damper is in the full open position, the maximum amount of fresh air is distributed into the chamber.
The exhaust has a modulating damper motor, which is automatically controlled by the Protocol Plus™ controller. No adjustments are necessary.
Determining Damper Settings
WARNING: This oven is not
designed for use with flammable material. If your process involves flammable material, contact Despatch Industries.
The optimum setting for the amount of fresh air that should be distributed into the chamber depends on several factors. These factors include ambient environment temperature, load conditions, load distribution, heat up rates, cool down rates, desired temperature uniformity and most importantly the desired operating temperature. To consider all of these variables at any one point in time is not practical and there are engineering tradeoffs that should be considered. Therefore guidelines should be used to determine the fresh air damper setting.
In general, the damper should be set so that the amount of fresh air flowing into the chamber agrees with the desired operating temperature conditions. The following outline shows the considerations involved with various damper position settings.
Full Closed Position
When the fresh air damper is in the full closed position, the chamber will be able to achieve the maximum attainable heat up rates for the chamber. In addition, the chamber will use the minimum amount of power to operate at the desired temperature. In almost all cases, the fresh air damper should be in the full closed position in order to efficiently operate at the maximum operating temperature for the chamber.
7
Full Open Position
When the fresh air damper is in the full open position, the chamber will operate at its minimum operating temperature.
Friction heat from the air recirculation system builds up in the chamber. This causes chamber temperature to rise slightly even though the heating system is not turned on. After the recirculation motor has been on for an extended period of time, the chamber will reach a thermal equilibrium temperature.
When the damper is not set to the full open position, the chamber has no way to readily dissipate the heat generated by the friction. With the fresh air damper fully open, the thermal equilibrium temperature is the minimum operating temperature of the chamber.
Minimum Opening for Dissipation of Live Load
To determine the minimum setting for the fresh air damper, only open the damper so that the fresh air dissipates the heat from live load. To conserve energy, the cooling output should be trying to control the setpoint temperature with minimal fluctuations. Close the damper if the heater continues to be cycled on and off. If the cooling is full on and the chamber temperature is over the setpoint, open the damper.
Other Damper Settings
The damper can be set to several other distinct operating positions. In most cases, the damper setting is influenced by specific performance factors. Some of these performance factors are uniformity; cool down rates and required dissipation.
The uniformity of the chamber is influenced by the inside chamber pressure of the system. The pressure inside the chamber is dependant on the amount of fresh air flowing into the chamber. When a large volume of fresh air is flowing into the chamber, the chamber becomes slightly pressurized and the overall temperature uniformity improves. The slightly pressurized chamber produces the effect of "pushing" the air to the corners of the chamber. Typically the corners of the chamber will improve with respect to temperature distribution while the core of the chamber will maintain excellent uniformity characteristics regardless of the damper position. Therefore, the pressurization of the chamber typically is a factor when the chamber is loaded heavily. The best uniformity results, with respect to the product, are achieved when the chamber is loaded uniformly.
8
NOTE: Overpressurizing the chamber can cause hot air to blow out around the door seal and cause the area around the door to be hot to the touch. To stop this hot air from entering the room, close the damper slightly until the air stops blowing.
9
OVEN INSTRUCTIONS
Failure to heed warnings in this instruction manual and on the oven could result in death, personal injury or property damage.
WARNING: Do not use oven in wet, corrosive or explosive atmospheres.
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
Any special options that were ordered at time of purchase
10
Warning Signs Missing
If it appears that any warning, danger, caution or information label or sign has been damaged or lost, contact Despatch Industries for replacements. Call or write:
Service Products Division Despatch Industries P.O. Box 1320 Minneapolis, MN 55440 Call Toll Free 800-473-7373
11
Set-up
1. Select the location for installing your oven.
2. Install an exhaust stack from the exhaust discharge stack to the outside of the building, if required.
If a round exhaust stack is used, a minimum area greater than the area of the exhaust stack is required.
The flashing through the roof or wall must be capable of handling an exhaust stack temperature up to 260°C (500°F).
All stacks must comply with state and local building codes to insure that surrounding combustible surfaces are below 71°C (160°F).
Design the exhaust stack to limit the amount of restrictions to insure proper airflow. If more than two (2) elbows are used in the stack, over all airflow will be reduced.
a. The exhaust could be vented into a burn-in room atmosphere or
other exhaust system capable of handling the total rated heat dissipation in:
BTUH
×
b. We recommend that the ovens be vented to the outside or to an
area that could use the heat. The maximum exhaust temperature could reach the maximum operating temperature of the oven.
3. Place oven on a bench top or directly on the floor. The oven must have a minimum 2-inch clearance in the rear to provide proper ventilation. When placed next to another cabinet, or next to another oven, a 3-inch clearance is required. The doors will still open.
4. Make sure oven is level and plumb; this will assure proper heat distribution and operation of all mechanical components.
5. The atmosphere where the oven is used should be clean, free of solvent vapors. Good results depend on a clean workspace.
3,412 KW ×
 
KW
 
WARNING:
Do not use the oven in wet, corrosive or explosive atmospheres.
BTUH
+
2,500
 
KW
 
HP Fan ionRecirculat
12
Power Connection
Be sure the oven is connected to the power source shown on the nameplate. Connect the oven directly to your electric supply, with all grounding and safety equipment, according to applicable codes, ordinances and accepted safe practices.
Line voltages may vary in some geographical locations. If your line voltage is much lower than the oven voltage rating, the warm up time will be longer and the motors may overload or run hot. If the line voltage varies more than ±10% from the oven voltage rating, the temperature control may operate erratically.
WARNING
Failure to read this warning can result in death, serious bodily injury or property damage. All conductors must be copper unless the specific terminal is marked for use with aluminum conductors.
WARNING
All grounding and safety equipment must be in compliance with applicable codes, ordinances and accepted safe practices.
:
:
13
Operating
Users and operators of this oven must comply with operating procedures and training of operating personnel as required by the Occupational Safety and Health Act (OSHA) of 1970, Section 5 and relevant safety standards, and other safety rules and regulations of state and local governments. Refer to the relevant safety standards in OSHA and National Fire Protection Association (NFPA), Section 86 of 1990.
Loading the Oven
Despatch Industries cannot be responsible for either the process or process temperature used, or for the quality of the product being processed. It is the responsibility of the purchaser and operator to see that the product undergoing processing in a Despatch oven is adequately protected from damage.
Carefully following the instructions in this manual will help the purchaser and operator in fulfilling that responsibility.
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 the cross-sectional air-delivery area.
WARNING
Do not use oven in wet, corrosive or explosive atmospheres.
WARNING
Do not heat any closed containers, flammable solvents or other flammable material in this oven. (Examples: spray can, sealed jar of water, alcohol, kerosene, oil, paper, etc.)
:
:
Oven Temperature Limit
Do not attempt to exceed the maximum or minimum operating temperature of this oven.
14
Product Temperature Limit
If the product has a critical high temperature limit, the HIGH-LIMIT control should be used as a process HIGH-LIMIT. When used as a process HIGH-LIMIT, the control should be set to a temperature somewhat below the temperature at which the product would be damaged. A pyrometer could be used to determine the process HIGH-LIMIT setting. If the destructive temperature of the product is already known, this could be used as a point below which the process HIGH-LIMIT could be set.
NOTE
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 Industries burn-In oven is adequately protected from damage. Carefully following the instructions in this manual will assist the purchaser and operator in fulfilling that responsibility.
:
Operator Training Requirements
All users must be thoroughly trained under the supervision of experienced personnel. The operator must be aware of the possible dangers of:
Suffocation from nitrogen,
Frostbite from nitrogen as a liquid or as a frozen gas,
Fire.
Users must demonstrate an understanding of the equipment and its operation to assure knowledge of and practice of safe and proper operating procedures. Users should receive regular retraining and testing as required to maintain a high level of proficiency and effectiveness.
Training should include the:
function of controls and safety devices,
handling of special atmospheres (on units with LN2 or GN2).
15
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 the degree of 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.
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.
Open oven door.
Press Power switch to the ON
position. You will hear the recirculating fan start.
Shut oven door.
Check that the control display turns on.
2. Operate the temperature control as desired by following the Protocol Plus™ instruction section located in this manual for more detailed information.
3. When the oven nears temperature set on the control, the heater will start cycling on and off.
4. When the chamber temperature is above setpoint on control, the cooling output of the control will start driving the damper open, which will exhaust air from the chamber.
WARNING
Do not heat any closed containers, flammable solvents or other flammable material in this oven. (Examples: spray can, sealed jar of water, alcohol, kerosene, oil, paper, etc.)
:
WARNING
Hot surfaces may exist around door, inside cabinet, product, and fixtures. Handle with care.
:
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