1

BARNSTEAD|THERMOLYNE CORPORATION

High Temperature

Muffle Furnace

 OPERATION MANUAL

AND PARTS LIST

Model Numbers

F46110CM F46230CM Automatic

F46110CM-33 F46230CM-33 Automatic

F46118CM F46238CM Automatic

F46120CM F46240CM Multi-Programmable

F46120CM-33 F46240CM-33 Multi-Programmable

F46128CM F46248CM Multi-Programmable

F46120CM-75 F46240CM-75 Multi-Programmable

F46120CM-33-75 F46240CM-33-75 Multi-Programmable

F46128CM-75 F46248CM-75 Multi-Programmable

LT1078X2 • 5/9/97
2

IMPORTANT INFORMATION

 This manual contains important operating and safety information. The user must carefully read and understand

the contents of this manual prior to the use of this equipment.

Table of Contents

Safety Information ..........................................................................................................................................4

Alert Boxes .....................................................................................................................................................4

Warnings ........................................................................................................................................................5

Description .....................................................................................................................................................7

Intended Use .............................................................................................................................................7

General Usage ......................................................................................................................................... 7

Principles of Operation ..............................................................................................................................7

Types of Controllers.................................................................................................................................. 8

General Specifications ...................................................................................................................................9

General Specifications .................................................................................................................................10

Environmental Conditions........................................................................................................................10

Declaration of Conformity ........................................................................................................................ 11

Unpacking ....................................................................................................................................................12

Installation ....................................................................................................................................................13

Furnace Connection ................................................................................................................................13

Initial heat-up procedure: .........................................................................................................................13

General Operation of Furnace ......................................................................................................................14

Power Switch ...........................................................................................................................................14

Cycle Indicator .........................................................................................................................................14

Circuit Breaker .........................................................................................................................................15

Fans ........................................................................................................................................................15

Controllers ...............................................................................................................................................15

Operation of Automatic Models ....................................................................................................................16

Control Parameters .................................................................................................................................16

Tuning Your Furnace ...............................................................................................................................17

 Single Set Point Operation ...................................................................................................................18

Program Ramp Rate................................................................................................................................19

Program Ramp Reset ..............................................................................................................................19

Operation of Programmable Models.............................................................................................................20

Control Parameters .................................................................................................................................20

Tuning Your Furnace ...............................................................................................................................22

Operating the Controller ......................................................................................................................... 23

 Single Set Point Operation ...................................................................................................................23

Programming Controller ..........................................................................................................................23

 Multi-Programmable Controller Program Entry (Models F46120CM,

 F46120CM-33, F46120CM-33-75, F46120CM-75, F46128CM, F46128CM-75, F46240CM,

 F46240CM-33, F46240CM-33-75, F46240CM-75, F46248CM, F46248CM-75) ..................................24

Program Entry (all models) ......................................................................................................................25

 Implementing Programs ..............................................................................................................................27

Program Execution ................................................................................................................................. 27

Parameter Change While Running ..........................................................................................................27

Loop Count ..............................................................................................................................................27

Program Hold ........................................................................................................................................ 27

Program Reset ....................................................................................................................................... 28

Table of Contents
3

Furnace Loading: .........................................................................................................................................29

Furnace Atmospheres .............................................................................................................................30

Preventive Maintenance .............................................................................................................................. 31

 General Cleaning Instructions ............................................................................................................... 32

Problem Solving Guide.................................................................................................................................33

Maintenance and Servicing ..........................................................................................................................34

Wiring Diagram............................................................................................................................................ 38

Wiring Diagram.............................................................................................................................................39

Wiring Diagram.............................................................................................................................................40

Wiring Diagram.............................................................................................................................................41

Replacement Parts List ............................................................................................................................... 42

Ordering Procedures ....................................................................................................................................43

Material Safety Data Sheet ..........................................................................................................................44

Warranty .......................................................................................................................................................47

TABLE OF CONTENTS
4

Safety Information

Your Thermolyne furnace has been designed with function,

reliability, and safety in mind. It is the user’s responsibility to

install it in conformance with local electrical codes. For safe

operation, please pay attention to the alert boxes throughout the manual.

Because of the nature of this product, considerably more

care is required in operating and servicing this furnace than

for lower temperature laboratory furnaces. For maximum

safety and longest furnace life, be sure to observe the

various cautions and warnings throughout this manual.

Alert Boxes

WARNING

Warning alerts apply when there is a

possibility of personal injury.

CAUTION

 Caution alerts apply when there is a

possibility of

 damage to the equipment.

NOTE

Notes alert the manual user to

pertinent facts and

conditions.

HOT SURFACE

Hot surfaces alert you to a possibility

of personal

injury if you come in contact with a

surface during use or for a period of

time after use.

Safety Information
5

WARNING

To avoid electrical shock, this furnace must:

1. Be installed by a competent, qualified electrician who

insures compatibility among furnace specifications,

electrical source and grounding code requirements.

2. Always be disconnected from the electrical supply

prior to maintenance and servicing.

To avoid personal injury:

1. Do not stand directly in front of the chamber without

wearing a heat resistant face shield, gloves and apron.

2. Do not operate or clean furnace without proper eye

protection.

3. Do not use in the presence of flammable or combustible materials; fire or explosion may result. This

device contains components which may ignite such

materials.

4. Refer servicing to qualified personnel.

5. Caution: Hot Surface. Avoid Contact.

6. To AVOID EYE DAMAGE in operating or cleaning

furnace, proper eye protection must be worn.

7. To AVOID BURNS, do not stand directly in front of the

chamber without wearing a heat resistant faceshield,

gloves and apron.

8. To AVOID FIRE, do not place combustible materials

where exposed to heat from open door.

 HOT SURFACE

Caution: Hot Surface. Avoid Contact.

SAFETY INFORMATION
6

Please note the following WARNINGS:

WARNING

This warning is presented for compliance with California Proposition 65 and other regulatory agencies and only

applies to the insulation in this product. This product contains refractory ceramic, refractory ceramic fiber or

fiberglass insulation, which can produce respirable dust or fibers during disassembly. Dust or fibers can cause

irritation and can aggravate pre-existing respiratory diseases. Refractory ceramic and refractory ceramic fibers

(after reaching 1000°C) contain crystalline silica, which can cause lung damage (silicosis). The International

Agency for Research on Cancer (IARC) has classified refractory ceramic fiber and fiberglass as possibly

carcinogenic (Group 2B), and crystalline silica as carcinogenic to humans (Group 1).

The insulating materials can be located in the door, the hearth collar, in the chamber of the product or under the

hot plate top. Tests performed by the manufacturer indicate that there is no risk of exposure to dust or respirable fibers resulting from operation of this product under normal conditions. However, there may be a risk of

exposure to respirable dust or fibers when repairing or maintaining the insulating materials, or when otherwise

disturbing them in a manner which causes release of dust or fibers. By using proper handling procedures and

protective equipment you can work safely with these insulating materials and minimize any exposure. Refer to

the appropriate Material Safety Data Sheets (MSDS) fo information regarding proper handling and recommended protective equipment. For additional MSDS copies, or additional information concerning the handling

of refractory ceramic products, please contact the Customer Service Department at Barnstead|Thermolyne

Corporation at 1-800-553-0039.

WARNING

REFER SERVICING TO QUALIFIED PERSONNEL.

SAFETY INFORMATION
7

Intended Use

 Types 461 and 462 are general purpose laboratory

furnaces

 intended for applications requiring temperatures from

800-1700

 degrees C.

General Usage

Do not use this product for anything other than its

intended usage.

Principles of Operation

The chamber section is heated by six (in type F46100

urnaces) or eight (in type F46200 furnaces) Super

Kanthal 33 heating elements suspended in a chamber

made of alumina and silica high temperature refractory

fiber.

This high temperature refractory fiber is in the form of

blocks which line the inside of the chamber. Because of

the

stresses caused by extremely high temperature operation, these blocks will show some surface cracking. This

cracking is not detrimental to the operation of the furnace.

A precious metal type B thermocouple senses the

temperature in the chamber and transmits this information to the temperature control in millivolts.

NOTE

The fans operate continuously, even

when the circuit breaker is OFF, to assure

that the control section and the terminals

of the heating elements are continuously

ventilated. Without ventilation, residual

heat from the furnace chamber can cause

overheating after the furnace is turned off.

CAUTION

Do not completely remove electricity from

the furnace until chamber temperature

falls below 500°C. Do not touch exposed

elements.

Description
8

The control section consists of a temperature controller, a

 current controller, a transformer, a contactor (relay), a

circuit breaker, and a pilot light.

The temperature controller senses the furnace temperature

(by means of the thermocouple) and adjusts electricity to

the heating elements by means of the current controller.

The current controller controls electricity to the heating

 elements by adjusting the magnitude of the electrical

current (rather than turning the electricity completely on or

off). This is the preferred method of controlling electricity to

molybdenum disilicide heating elements.

The transformer supplies the proper electrical voltage to the

heating elements.

The contactor removes electricity from the heating elements

if the furnace temperature equals or exceeds the high limit

set point of the controller

The circuit breaker is used to turn the furnace on and off

and also protects the electrical supply in the event that the

furnace draws too much electrical current.

The pilot light indicates that the circuit breaker is ON and

that the controller is being supplied with electricity.

A fan is provided in each section of the furnace to provide

forced air cooling.

Types of Controllers

1. The automatic (single set point) digital model enables the

user to program a single set point temperature which the

furnace will heat and hold.

2. The 4 program, programmable digital model enables the

operator to program up to 8 ramp segments (heat-up or

cool-down rate) and 8 dwell segments (soak) for applications that require time and temperature relationship for

up to 4 separate or linkable programs.

3. The 15 program, programmable digital model enables

the operator to program up to 8 ramp segments (heat-up

or cool-down rate) and 8 dwell segments (soak) for up to

15 separate or linkable programs.

DESCRIPTION
9

General Specifications

Model# F46110CM, F46118 F46120CM F46128 F46120CM-75 F46128CM-75

F46110CM-33 F46120CM,-33 F46120CM-33-75

Dimensions Overall-in Width 28-1/8 28-1/8 28-1/8 28-1/8 28-1/8 28-1/8

(cm) (71.4) (71.4) (71.4) (71.4) (71.4) (71.4)

Height 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2

(47) (47) (47) (47) (47) (47)

 Depth 19 19 19 19 19 19

(48.3 (48.3) (48.3) (48.3) (48.3 (48.3)

Chamber- Width 6 6 6 6 6 6

in (cm) (15.2) (15.2) (15.2) (15.2) (15.2) (15.2)

 Height 6-1/2 6-1/2 6-1/2 6-1/2 6-1/2 6-1/2

(16.5) (16.5) (16.5) (16.5) (16.5) (16.5)

 Depth 6-1/4 6-1/4 6-1/4 6-1/4 6-1/4 6-1/4

(15.9) (15.9) (15.9) (15.9) (15.9) (15.9)

Weight LBS.(kg) 156 (70.9) 156 (70.9) 156 (70.9) 156 (70.9) 156 (70.9) 156(70.

Electrical Volts 240 208 240 208 240 208

Rating Amps 40*/10.4# 40*/12# 40*/10.4# 40*/12# 40*/10.4# 40*/12#

Watts 9600* 8320* 9600* 8320* 9600* 8320*

2500# 2500# 2500# 2500# 2500# 2500#

Phase 1 1 1 1 1 1

Temp. Range Cont. 1700°C 1700°C 1700°C 1700°C 1700°C 1700°C

Controller Automatic Automatic 4-Program. 4-Program. Multi-Prog. Multi-Prog.

NOTES:*Inrush power and current.

# Power and current required to maintain maximum temperature after stabilization.

The maximum current is determined by the limiting factor set by the current controller. In the event that 40 amperes is not available, the

current controller may be set to limit the current to some smaller value at the expense of a somewhat longer heat-up time.

The variation in current is a result of molybdenum disilicide heating elements

having a large decrease in resistance with increasing temperature.

NOTES: The maximum ramp rates for this furnace for heat-up are: 100°C per minute from 25°C-1000°C and

15°C per minute from 1000°C-1700°C.

General Specifications
10

 Model# F46230CM, F46238 F46240CM F46248 F46240CM-75 F46248CM-75

F46230CM-33 F46240CM,-33 F46240CM-33-75

Dimensions Overall-in Width 34-1/8 34-1/8 34-1/8 34-1/8 34-1/8 34-1/8

(cm) (86.7) (86.7) (86.7) (86.7) (86.7) (86.7)

Height 22-1/2 22-1/2 22-1/2 22-1/2 22-1/2 22-1/2

(57.2) (57.2) (57.2) (57.2) (57.2) (57.2)

 Depth 23 23 23 23 23 23

(58.4) (58.4) (58.4) (58.4) (58.4) (58.4)

Chamber- Width 10 10 10 10 10 10

in (cm) (25.4) (25.4) (25.4) (25.4) (25.4) (25.4)

 Height 10-1/4 10-1/4 10-1/4 10-1/4 10-1/4 10-1/4

(26) (26) (26) (26) (26) (26)

 Depth 9-3/4 9-3/4 9-3/4 9-3/4 9-3/4 9-3/4

(24.8) (24.8) (24.8) (24.8) (24.8) (24.8)

Weight LBS.(kg) 234 (106.3) 234 (106.3) 234 (106.3) 234 (106.3) 234 (106.3) 234 (106.3)

Electrical Volts 240 208 240 208 240 208

Rating Amps 40*/20.8# 40*/24# 40*/20.8# 40*/24# 40*/20.8# 40*/24#

Watts 9600* 8320* 9600* 8320* 9600* 8320*

5000# 5000# 5000# 5000# 5000# 5000#

Phase 1 1 1 1 1 1

Temp. Range Cont. 1700°C 1700°C 1700°C 1700°C 1700°C 1700°C

Controller Automatic Automatic 4-Program. 4-Program. Multi-Prog. Multi-Prog.

# Power and current required to maintain maximum temperature after stabilization.

The maximum current is determined by the limiting factor set by the current controller. In the event that 40 amperes is not available, the

current controller may be set to limit the current to some smaller value at the expense of a somewhat longer heat-up time.

The variation in current is a result of molybdenum disilicide heating elements

having a large decrease in resistance with increasing temperature.

NOTES: The maximum ramp rates for this furnace for heat-up are: 100°C per minute from 25°C-1000°C and

15°C per minute from 1000°C-1700°C.

Environmental Conditions

Operating:17°C-27°C; 20% to 80% relative humidity,

non-condensing. Installation Category II (over- voltage) in accordance with IEC 664.

Pollution Degree 2 in accordance with IEC 664. Altitude limit: 2,000

meters.

Storage: -25°C to 65°C; 20% to 80% relative humidity.

GENERAL SPECIFICATIONS
11

Declaration of Conformity

(-33 models only)

Barnstead|Thermolyne hereby declares under its sole

responsibility that this product conforms with the technical requirements of the following standards:

EMC: EN 50081-1 Generic Emission Standard;

EN 50082-1 Generic Immunity Standard;

Safety: IEC 1010-1-92 Safety requirements for

electrical equipment for measurement,

control, and laboratory use; Part I:

General Requirements

IEC 1010-2-010 Part II: Particular

requirements for laboratory equipment

for the heating of materials

per the provisions of the Electromagnetic Compatability

Directive 89/336/EEC, as amended by 92/31/EEC and

93/68/EEC, and per the provisions of the Low Voltage

Directive 73/23/EEC, as amended by 93/68/EEC.

The authorized representative located within the European Community is:

European Manager

Barnstead|Thermolyne

Saarbrückener Str. 248

D-38116 Braunschweig

Germany

Copies of the Declaration of Conformity are available

upon request.

NOTE

The Type 46100 and 46200 furnaces do

not come with an electrical cord because

current requirements are too great to be

handled by ordinary electrical cords and

standard wall electrical outlets.

Declaration of Conformity
12

Unpacking

Visually check for any physical damage to the shipping

container. Inspect the equipment surfaces that are adjacent

to any damaged area. Open the furnace door and remove

packing material from inside the furnace chamber. Vacuum

the chamber prior to use to remove the insulation dust due

to shipment. A hearth plate is supplied with the furnace to

be placed on bottom of furnace chamber.

Retain the original packaging material if re-shipment is

foreseen or required.

CAUTION

 Be sure ambient temperature does

not exceed 104°F (40°C). Ambient

temperatures above 104°F (40°C)

may result in damage to the controller.

Allow at least six inches (15 cm) of

space between the furnace on all

sides and the top. This permits the

heat from the furnace case to escape.

WARNING

To avoid electrical shock, this furnace

must be installed by a competent,

qualified electrician who insures

compatibility among furnace specifications, electrical source and grounding code requirements. Ensure unit is

properly grounded.

CAUTION

For supply connections, use 8 AWG or

larger wires suitable for at least 90°C.

Failure to observe this caution could

result in damage to furnace.

Unpacking
13

Installation

 Site Selection: Install furnace on a sturdy surface and

allow space for ventilation.

The electrical specifications are located on the specification

plate on the back of the furnace. Consult Barnstead/

Thermolyne if your electrical service is different than

those listed on the specification plate. Prior to connecting

your Type 46100 or 46200 furnace to your electrical

supply, be sure the front circuit breaker is in the OFF

position.

Furnace Connection

Remove cover plate for access to the electrical connections. Connect electricity to the three terminals found

behind this plate; one side of the 208 or 240 volt service

to the top terminal, L1; the other side of the 208 or 240

volt service to the bottom terminal, L2, and the ground

(usually green wire) to the center terminal marked GND.

For 220 volt service,connect the neutral to the top

terminal (marked L1); the 220 volt line to the bottom

terminal, L2, and the ground to the center terminal

marked GND. Electricity must be brought to the furnace

through an appropriate conduit system, through the hole

in the back panel at the bottom left rear of the furnace,

and connected as described. Be sure to observe local

wiring codes in connecting.

Initial heat-up procedure:

The elements may bend slightly sideways due to electromagnetic forces generated between the element shanks.

To prevent this bending, heat the furnace up to 1650°C

for 10-20 minutes. Then let furnace cool to ambient

temperature. See Operation for your particular controller

for information on setting temperature setpoints.

Installation
14

General Operation of Furnace

Observe these Warnings before operating your furnace:

 WARNING

To avoid electrical shock, this furnace must:

1. Be installed by a competent, qualified electrician who

 insures compatibility among furnace specifications, electrical source and grounding code requirements.

 2. Always be disconnected from the electrical supply

prior to maintenance and servicing.

To avoid personal injury:

1. Do not stand directly in front of the chamber without

wearing a heat resistant faceshield, gloves and apron.

2. Do not operate or clean furnace without proper eye

protection.

3. Do not use in the presence of flammable or combustible

materials; fire or explosion may result. This device contains

components which may ignite such materials.

4. Refer servicing to qualified personnel.

5. Caution: Hot Surface. Avoid Contact.

6. To AVOID EYE DAMAGE in operating or cleaning

furnace, proper eye protection must be worn.

7. To AVOID BURNS, do not stand directly in front of the

chamber without wearing a heat resistant faceshield, gloves

and apron.

8. To AVOID FIRE, do not place combustible materials

where exposed to heat from open door.

 HOT SURFACE

 Caution: Hot Surface. Avoid Contact.

Power Switch

Controls power to the furnace. Switch to the “ON” position

to energize the elements and the controller.

Cycle Indicator

The amber cycle light will illuminate when electricity is

being supplied to the elements.

CAUTION

Remember that when the power switch

is turned “ON”, the furnace will begin to

heat to the set point temperature that

was previously set in the controller. This

value will remain unchanged for up to a

year without electricity being supplied to

the controller.

CAUTION

If the electrical supply must be disconnected from the furnace at any time, be

sure the chamber temperature is 500°C

or less before doing so.

General Operation of Furnace
15

Circuit Breaker

A double pole circuit breaker is located at the bottom of

the control section. It serves to turn electricity ON and

OFF and to protect the electrical circuit.

Fans

The fans, located in the rear of the heating section and

the control section, will run continuously as long as

electricity is supplied to the furnace, even when the

furnace panel circuit breaker is OFF. This serves to

remove residual heat after the furnace is turned OFF so

the heat does not cause damage to the controls.

Controllers

Your furnace’s controller consists of a microprocessor

based three-mode (Proportional, Integral, Derivative),

programmablecontrol with overtemperature protection

and appropriate output switching devices to control the

furnace. The digital readout continuously displays

chamber (upper display) and set point (lower display)

temperatures unless the scroll button is depressed.

If the scroll button is depressed and released, the lower

display will indicate output power (OP) or set point (SP).

This is referred to as the “short scroll”. Continued single

step depression of scroll button will cause lower display

to alternate between set point (SP) and output power

(OP).

To enter the main scroll list (list of all controller parameters that are accessed through front keyboard), the

scroll button should be held depressed. On the Automatic

Models, PR (program ramp rate) will appear. On the

Programmable Models, PR1 (program ramp rate 1) will

appear. To progress through the parameter list, the scroll

button must first be released, subsequent single step

depression will advance you through the list. Rapid

progression through the parameter list is achieved by

holding the scroll button depressed. (See Control Parameters for your particular controller for a list of parameters.)

NOTE

When performing operations on the

controller, remember that if you depress

and release either the “scroll”, “up”, or

“down” push buttons and more than 8

seconds elapse before the buttons are

used again, the display screen will

automatically switch back to displaying

set point temperature. If this happens,

you will have to step through each

parameter until you reach the point at

which the interruption occurred. The

parameter values you

adjusted earlier, however, will not be lost

or altered.

NOTE

Due to the High Temperature design of

the thermocouple, the controller will

indicate a temperature of 70°-90°C at

ambient temperature.

GENERAL OPERATION OF FURNACE
16

Operation of Automatic Models

(Models F46110CM, F46110CM-33, F46118CM,

F46230CM, F46230CM-33, F46238CM)

Control Parameters

PR = program ramp rate, the rate of heat increase or

decrease in °C/minute. Pushing the up or down button will

give the current setting of this ramp. Push up or down

button to set.

SP2. SP2 is not configured into control and nonfunctional.

Set to 20.

ST = Self-tune automatically loads PID values on initial

start up. This function does not have a value, it is

either “ON” or “OFF”. (See Furnace Operation for

function of Self-tune).

AT = Adaptive Tune, which analyzes and inputs optimum

PID values when temperature has reached set point. This

function does not have a value, it is either “ON” or

 “OFF”. (See Furnace Operation for function of Adaptive

Tune).

SAT = Self-Adaptive Tune when engaged starts controller in

self-tune mode then automatically switches to Adaptive

Tune (AT). This function does not have a value, it is either

“ON” or “OFF”. (See Furnace Operation for function of

Adaptive Tune).

ATR = Adaptive Tune Range setting determines the

operational band width of the adaptive tuning function.

Self-tuning automatically determines this setting.

AL1 = Alarm 1 is a full scale alarm which protects load

and furnace when temperature exceeds preset value.

Furnace will control temperature at the preset

temperature value, it will not shut off furnace.

The next five parameters: proportional (PB), integral (+i),

derivative (+d), cutback low (cbl) and cut back high (cbh)

are for high accuracy control. These parameters are set

during Self-Adaptive Tune. (See Tuning Your Furnace.)

NOTE

Thermolyne recommends that you set

the value of AL 1 either at 1710°C

(3092°F) or at a value of 20 degrees

above your working temperature if you

desire to provide protection for your

workload.

NOTE

“OR” will be displayed if an open thermocouple condition exists.

NOTE

To change from °C indication to °F

indication, contact Barnstead/

Thermolyne.

NOTE

The automatic control has automatic

tuning features which install optimum

tuning parameters to give the best

temperature accuracy. No manual

loading of tuning parameters is needed.

We recommend that you tune the

furnace to your specific application to

obtain the best

results. To provide the best temperature

accuracy possible, use these features

when you install yourfurnace and

whenever you change your application

orprocedure.

Operation of Automatic

Controls
17

HL = Output Power limits the average maximum percentage

of electricity that is applied to the heating elements.

Depress and release up or down button, if 100 is not

displayed, contact Barnstead/Thermolyne.

Sbr = the power that is required to indicate an open

thermocouple condition exists. Push up or down button, if

0.0 is not displayed, contact Barnstead/Thermolyne.

Tuning Your Furnace

 The SAT Self and Adaptive Tuning feature starts the

controller in the Self-tune mode, then automatically

switches over to the Adaptive Tuning mode. Self-Tuning

is a one-time function which permits the user to tune the

instrument control parameters to suit new process

conditions.

Adaptive tuning takes over when the self-tune is completed and continuously evaluates tuning parameters.

Adaptive tuning automatically installs new values if better

accuracy is

possible.

To Tune Your Furnace:

1. Load your furnace with a load characteristic of those

you intend to heat in it.

2. Depress scroll button until SAT is displayed. Depress

the up and down buttons simultaneously to start selftuning.

During Tuning, the A-T indicator is illuminated (upper

right hand corner) and the lower display indicates the set

point at which the self-tune sequence will occur. The “SP”

indicator will flash for 1 minute, during which time the set

point may be changed (use temperature set point that

your application requires). At the end of one minute, the

“SP” indicator will stop flashing, indicating that the set

point can no longer be changed. The A-T indicator will

start flashing and continue to flash until the self-tune is

completed. After the self-tune is completed, adaptive

tune takes over and the A-T indicator will remain illuminated.

NOTE

The self-tune feature will be inactive if you

implement a ramp to setpoint. If your

implement a ramp to setpoint, the adaptive

tune feature will be active only after you

reach your setpoint. See Program Ramp

Rate for more information on ramping to

setpoint.

CAUTION

Minimize operation of furnace under

800°C. Element life is reduced when

operating below 800°C because the

protective layer of silica glass takes

longer to form.

NOTE

Once the desired parameter has been

selected, depressing either the raise or

lower button will cause the parameter to

be replaced with the new value. At this

point, the “top dot” of the least significant

digit of the secondary display will flash on

and off. Any further use of up or down

buttons will change parameter value. In all

cases, the value shown on the display is

the current working

 NOTE

The two center push buttons are nonfunctional.

NOTE

The program ramp rate is designed to

reduce the heat-up rate or cooling rate

that the furnace normally exhibits. When

not using this feature, the furnace will

operate at its maximum heating and

cooling capability.

OPERATION OF AUTOMATIC CONTROLS
18

3. To stop tuning function, scroll until SAT is displayed

and simultaneously push up and down buttons.

Single Set Point Operation

The automatic control is used as a single set point control,

which includes one ramp to set point capability. To use as a

single set point control, simply push up or down buttons to

choose a specific temperature. The control will cause the

furnace chamber to heat to the chosen temperature and

hold it at this temperature until you turn off the front circuit

breaker switch or select another temperature.

To operate the control:

1. Turn power switch to the “ON” position. The set point

temperature presently set in the control will appear on

the lower display.

2. To change this set point, depress the “UP” or “DOWN”

push button until the desired set point value is displayed

then release the button.

3. The furnace will begin to heat if the new set point

temperature you have chosen is higher than the present

chamber temperature.

4. The upper display indicates actual chamber temperature.

NOTE

When the program ramp has ended or

has been reset, the furnace will

continue to maintain set point temperature. It will not cool to ambient

temperature unless set point is set to

ambient temperature.

OPERATION OF AUTOMATIC CONTROLS
19

Program Ramp Rate

If you desire to ramp to the set temperature at a specified

rate, depress scroll button until “PR” appears. (“PR” =

program ramp rate, which is the rate of heat increase or

decrease in °C/minutes). Depress up or down button to

give current setting of ramp rate. Depress up or down

button again until you achieve desired setting.

To start the temperature ramp, push the run button. With

the run initiated, the program will commence and the

legend on the display will indicate “RAMP”. While a

program is running, the short scroll will contain three

parameters. SP = set point. OP = output power. Time =

time remaining in program ramp to reach set point

temperature. Single depression of the scroll button will

allow you to view each of these parameters.

When the program ramp has ended, an “E” will appear

on the display.

Program Ramp Reset

A running or finished program can be reset by depressing the run/hold button.

After depressing the run/hold button, the parts of the

display associated with programming will be extinguished

and the controller will operate as a single set point

control as described before.

OPERATION OF AUTOMATIC CONTROLS
20

Operation of Programmable Models

(F46120CM, F46120CM-33, F46120CM-33-75, F46120CM75, F46128CM,

F46128CM-75, F46240CM, F46240CM-33, F46240CM-33-

75, F46240CM-75,

F46248CM, F46248-75)

Control Parameters

PR1 = program ramp rate is the rate of heat increase or

decrease in °C/minute. Pushing the up or down button to

set.

PL1 = program level is the temperature which the furnace

needs to attain. Push up or down button to set.

PD1 = program dwell “1” is amount of time, in minutes, to

hold the PL1 program temperature level entered. Push up

or down button to set.

The remaining Program Ramp Rates PR2 - PR8, Program

Levels PL2 - PL8, and Program Dwells PD2 - PD8 follow in

the same manner as PR1, PL1 and PD1. (After PD8).

HB = “Holdback” automatically places the programmer into

“Hold” if the measured value deviates more than a specified

amount from programmer setpoint. When measured value

re-enters the holdback band, the timing for the segment

resumes. (Parameter is expressed in °C and only functions

when running a program). Push up or down button to set.

PLC = Program Loop Count is the number of times a

program will be repeated. Push up or down button to set.

SP1 = setpoint one which indicates current setpoint. Push

up or down button to set.

SP2=Setpoint two. Not configured into control and

nonfunctional. Set to 20.

Operation of Programmable

Models

NOTE

Once the desired parameter has been

selected, depressing either the raise

or lower button will cause the parameter to be replaced with the new

value. At this point, the “top dot” of the

least significant digit of the secondary

display will flash on and off. Any

further use of up or down buttons will

change parameter value. In all cases,

the value shown on the display is the

current working value of that parameter

MODELS F46120CM, F46120CM-33,

F46120CM-33-75, F46120CM-75,

F46128CM, F46128CM-75,

F46240CM, F46240CM-33,

F46240CM-33-75, F46240CM-75,

F46248CM, F46248CM-75

NOTE

These models have two additional

parameters at the beginning of the

parameter list;

Pnr is the program number selected.

By pushing the up or down button,

you can select a program from 1 to

15. On the F46120CM, F46120CM33, F46128CM, F46240CM,

F46240CM-33 and F46248CM

models, this is selected between 1-4.

Cnt is used to allow linking of programs. Cnt (continued) may be

selected as “y” (yes) or “n” (no) by

pushing the up or down button. The

remaining parameters will follow in the

sequence listed.
21

ST = Self Tune automatically loads PID values on initial

start up. This function does not have a value, it is either

ON or OFF. (See Furnace Operation for function of Self

Tune.)

AT = Adaptive Tune analyzes and inputs optimum PID

values when temperature has reached setpoint. This

function does not have a value, it is either “ON” or “OFF”.

(See Furnace Operation for function of Adaptive Tune).

SAT = Self Adaptive Tune when engaged starts controller

off in self-tune mode, then automatically switches to

Adaptive Tune (AT). This function does not have a value,

it is either “ON” or “OFF”. (See Furnace Operation for

function of Adaptive Tune).

ATR = Adaptive Tune Range setting determines the

operational band width of the adaptive tuning function.

Self-tuning

automatically determines this setting.

AL1 = Alarm 1 is a full scale alarm which protects load

and

furnace when temperature exceeds preset value. Furnace will control temperature at the preset temperature

value, it will not shut off furnace.

The next five parameters, proportional (PB), integral (+i),

derivative (+d), cutback low (cbl) and cutback high (cbh),

are for high accuracy control. These values cannot be

changed by the user; the controller automatically installs

optimum values when in Self and Adaptive Tuning.(See

Tuning Your Furnace for more information.).

HL = Output Power limits the average maximum percentage of electricity that is applied to the heating elements.

Depress and release up or down button. If “100” is not

displayed, contact Barnstead/Thermolyne.

Sbr = the percent of power that is supplied to the control

output terminals if an open thermocouple condition

exists.

Push up or down button. This parameter cannot be

changed, if 0.0 is not displayed, contact Barnstead/

Thermolyne.

NOTE

Barnstead|Thermolyne recommends

that you set the value of AL1 either at

maximum operating temperature of the

furnace or at a value of 20 degrees

above your working temperature if you

desire to provide protection for your

workload.

NOTE

The upper display will flash “OR” if an

open thermocouple condition exists.

NOTE

To change from °C indication to °F

indication, contact Barnstead/

Thermolyne.

OPERATION OF PROGRAMMABLE MODELS
22

Tuning Your Furnace

The SAT Self and Adaptive Tuning feature starts the

controller in the Self Tune mode, then automatically

switches over to the Adaptive Tuning mode. Self Tuning is a

one-time function which permits the user to tune the

instrument control parameters to suit new process conditions.

Adaptive tuning takes over when the self tune is completed

and continuously evaluates the tuned parameters. Adaptive

tuning automatically install new values if better accuracy is

possible.

To Tune Your Furnace:

1. Load your furnace with a load characteristic of those

you intend to heat in it.

2. Depress scroll button until SAT is displayed. Depress

the up and down buttons simultaneously to start self-tuning.

During Tuning, the A-T indicator is illuminated (upper right

hand corner) and the lower display indicates the set point at

which the self-tune sequence will occur. The “SP” indicator

will flash for 1 minute, during which time the set point may

be changed. (If you will be using the controller as a single

Setpoint Controller, set the furnace’s setpoint to the temperature you intend to use for your application. If you will be

running a multi-step program, set the furnace’s setpoint to

the value of PL1 (Program Level #1).) At the end of one

minute, the “SP” indicator will stop flashing, indicating that

the set point can no longer be changed. The A-T indicator

will start flashing and continue to flash until the self-tune is

completed. After the self-tune is completed, adaptive tune

takes over and the A-T indicator will remain illuminated.

4. To stop tuning function, scroll until SAT is displayed

 and simultaneously push up and down buttons.

5. Operate your controller normally as described in

 Operating the Controller.

NOTE

The automatic control has automatic

tuning features which install optimum

tuning parameters to give the best

temperature accuracy. No manual

loading of tuning parameters is

needed. We recommend that you tune

the furnace to your specific application

to obtain the best results. To provide

the best temperature accuracy possible, use these features when you

install your furnace and whenever you

change your application or

procedure.

NOTE

The self-tune feature is inactive while

running a program. The adaptive tune

feature is active only in the dwell segments of a program.

OPERATION OF PROGRAMMABLE MODELS
23

CAUTION

Minimize operation of furnace under 800°C.

Element life is reduced when operating below

800°C because the protective layer of silica

glass takes longer to form.

NOTE

Temperature setpoint or output power is

indicated on lower display, single depression

of scroll button will alternate between these

two parameters. The control will cause the

furnace chamber to heat to the chosen

temperature and hold it at this temperature

until you turn off the front circuit breaker

switch or select another temperature.

CAUTION

Remember that whenever the power switch

is turned “ON”, the furnace will begin to

heat to the setpoint temperature that was

previously programmed. This value will

remain unchanged for up to a year without

electricity being applied to the control.

NOTE

The two center push buttons are non-functional.

Operating the Controller

The programmable control can be used as a single

setpoint control or as a programmable control.

Single Set Point Operation

To use as a single set point control simply push up or

down

buttons to choose a setpoint temperature.

To operate the control as a single set point control:

1. Turn front circuit breaker switch to the “ON” position.

The setpoint temperature presently set in the control

will appear on the lower display.

 2. To change this set point, depress the “UP” or

“DOWN” push button until the desired setpoint value is

displayed,

then release the button.

3. At this point, the furnace will begin to heat if the new

 set point temperature you have chosen is higher than

the

present chamber temperature.

4. The upper display indicates actual chamber temperature.

Programming Controller

To run a program, first determine your ramp rate, dwell

times, program levels. It is helpful to graph your program

for ease of loading program into controller. Observe

maximum ramp rates (heat up time) on the general

specifications page before programming ramp rates.

A maximum of 8 ramp and 8 dwell segment combinations

are available, thus enabling eight different setpoint levels

to be achieved. Each ramp is programmed by specifying

the program level (PL) and the required ramp rate (PR).

The control automatically calculates the time that is

required to attain the program level (PL) based on

OPERATION OF PROGRAMMABLE MODELS
24

desired ramp rate (PR). Dwell segments (PD) can be

attached to each program level (PL) to hold that temperature for a specified number of minutes.

Multi-Programmable Controller Program Entry

 (Models F46120CM, F46120CM-33, F46120CM-33-75,

F46120CM-75, F46128CM, F46128CM-75, F46240CM,

F46240CM-33, F46240CM-33-75, F46240CM-75,

F46248CM, F46248CM-75)

The multi-programmable controller in the F46120CM-75,

F46128CM-75, F46240CM-75 and F46248CM-75 units

provides up to 15 separate programs of 8 ramps and 8

dwells each. The F46120CM, 46128CM, F46240CM and

F46248CM models have four separate programs These

controllers allow you to link programs together. These

functions are governed by the controller’s first two programming parameters, “Pnr” and Cnt.”

To select program number

Push scroll button until “Pnr 1” is displayed. Push the up or

down button to select a program number from 1 to 15. On

the F46120CM, F46120CM-33, F46128CM, F46240CM,

F46240CM-33 and F46248CM models, this is selected

between 1-4.

To link programs together

Push scroll button until “Cnt n” is displayed. Press and

release the up and down buttons to switch between

“Cnt y” (continue yes) and “Cnt n” (continue no). The effect

of selecting “Cnt y” is to continue the program to the next

program number. For example, if in program #3 you select

“Cnt y,” when program #3 is complete, program #4 will run

automatically. Setting “Cnt y” in program #15 will initiate the

start of program #1 upon the completion of program

#15.Each program will complete the selected number of

loops before continuing (see Loop Count).

These two parameters (“Pnr” and “Cnt”) are the only ones

that differ from the single program 8 ramp and 8 dwell

control. Program entry for the multi-programmable models

continues with the following instructions, which are applicable to both the multi-programmable and single programmable models.

OPERATION OF PROGRAMMABLE MODELS
25

Program Entry (all models)

Set Ramp Rates

1. With the controller not operating, indicated by the

bottom right hand side of the display extinguished,

depress scroll button until PR1 is displayed. Push the up

or down button to scroll to the desired value, which is

degrees per minute.

Scrolling down below zero will give three other options

for the ramp: NONE-which will force the program to skip

to the next segment; END-which will cause the program

to stop or restart if loops remaining is not zero; STEPwhich will cause the program to ramp as quickly as

possible to the next temperature level.

All other ramps in the program are set in a similar fashion

by selecting ‘PR’ followed by the relevant ramp number.

Set Level Temperatures

2. The level to which the first ramp is aiming is entered

by scrolling through the main scroll list until “PL1” is

displayed. By pressing either the up or down button the

present value of this level is indicated in display units.

Using the up or down button will scroll the present value

to the new value required.

All other levels in the program are set in a similar fashion

by selecting ‘PL’ followed by the relevant number.

Set Dwell Times

3. To set the dwell time for the first level, scroll through

the main scroll list until “PD1” is displayed. Pressing the

up or down button will reveal the current value of time in

minutes. Using the up or down button will scroll the

present value to the new value required. Scrolling this

value downscale will allow a setting of “END.” A setting of

“END” will terminate the program,or force it to restart if

loops remaining are not zero at the beginning of that

dwell.

NOTE

Be sure to select the program number

before pressing “Run/Hold.” (Models

F46120CM, F46120CM-33,

F46120CM-33-75, F46120CM-75,

F46128CM, F46128CM-75,

F46240CM, F46240CM-33,

F46240CM-33-75, F46240CM-75,

F46248CM and F46248CM-75)

OPERATION OF PROGRAMMABLE MODELS
26

All other dwells in the program can be set in a similar

fashion by selecting “PD” followed by the relevant dwell

number.

Set the Number of Times to Repeat the Program

4. Scrolling through the main scroll until the parameter

“PLC” is displayed and then depressing the up or down

button will reveal the present setting of the loop count. This

is the number of times that the entered program will be

repeated before a continuous setpoint at the last level of the

program is achieved. By pushing the up or down button the

number of loops can be set at any value from 1 to 999.

Set the Holdback Feature

5. Scroll through the main scroll list until “HB” is displayed.

Push the up or down button to reveal the current value of

holdback. The up or down button can now be depressed to

scroll to the required value. Holdback is set in display units

and represents the allowable excursion of measured value

away from the current setpoint, either above or below,

before the program is forced into hold. The program will

remain in hold until the measured value comes within

holdback limits. This feature is active the whole time that

the program is running. When hold is forced onto the

program by holdback, the “HOLD’”legend is not illuminated

but either the “RAMP” or “DWELL” legend will flash.

NOTE

The temperature control in these

models is a programmable “and”

automatic single setpoint device.

When the program has ended, the

controller will maintain the chamber

temperature at a value equal to the

last programmed level (PL) until the

program is cancelled. It will not

automatically cool to ambient unless

last programmed level (PL) is set at

ambient. When a program is cancelled, the controller will maintain the

chamber temperature at a value equal

to the main setpoint (SP1 or SP). To

cancel a program, depress and

release the “UP” and “DOWN” push

buttons simultaneously. Be sure single

set point mode is set to 20 or below

degrees as described earlier in this

manual.

OPERATION OF PROGRAMMABLE MODELS
27

Implementing Programs

Program Execution

Once the program has been entered it can be set

running by depressing the ‘RUN/HOLD’ push button on

the front.

With the run initiated, the program will commence and

the legend on the display will indicate if a ramp or dwell

is being performed. While a program is running the short

scroll will contain a third parameter “TIME.” Push scroll

button once; time remaining for the current segment,

either ramp or dwell will be indicated. If the loop counter

has been set to any value other than one, then the

above procedure will be repeated for each loop.

At the end of the complete program, an “E” will appear

on the display.

Parameter Change While Running

The previous parameters can be inspected but not

changed while a program is running. If it is necessary to

alter a parameter while a program is running, the program must be placed into the hold condition. To put

program into hold, push run/hold button once. After

modification of the parameter, returning the program to

the run state will cause the program to continue with the

changed value(s) installed. Push run/hold button again to

restart program.

Loop Count

If the loop count is set to values other than one, then the

number of loops remaining in a running program can be

displayed. To determine which loop is being performed

depress scroll button until LR’ is displayed and by

pushing either the up or down button the remaining

number of loops, excluding the one being executed, is

displayed.

Program Hold

A running program can be forced into hold at any stage

by depressing the “RUN/HOLD” push button on the front.

When a running program is forced into hold, “HOLD”

legend will appear on the display together with the

Implementing Programs
28

segment type and will be flashing. Pushing “RUN/HOLD”

button again will return the program to a run situation and

extinguish the “HOLD” legend.

Program Reset

A running, held or finished program can be reset by depressing the up and down push buttons together.

When the reset has been enabled, the parts of the display

associated with programming will be extinguished and the

controller will operate as a single setpoint control.

IMPLEMENTING PROGRAMS
29

Furnace Loading:

Be sure to use care in loading and unloading the furnace

chamber. Molybdenum disilicide heating elements are

extremely fragile and can crack or break with just a slight

bump. Be sure not to block the flow of radiant heat from

the heating elements to the thermocouple. The thermocouple must be able to respond directly to the heating

elements. Failure to observe this will permit the heating

elements to overheat and possibly burn out. Poor

temperature control can also result from improper

loading.

Because of the possibility of erosion of the insulation on

the floor of the furnace chamber, a separate hearth plate

should be used when possible.

In general, space should be left on all sides of a load or

on all sides of individual components of a load so that

heat can penetrate through the surfaces. The load should

not occupy more than two-thirds of the inside dimensions

of the chamber.

The extent to which a furnace may be loaded depends

upon such factors as operating temperature, desired

accuracy, and type of material. A furnace may be loaded

more heavily at lower temperatures, if highest accuracy

is not needed, and if the material of the load absorbs

heat easily.

Furnace Loading
30

Furnace Atmospheres

This furnace is designed to be used to 1700°C in pure air

only. It may be used with nitrogen, argon, or helium

atmospheres to 1600°C. Reducing atmospheres are not

recommended.

The heating elements in this furnace are attacked by

fluorine, chlorine, sodium and potassium compounds and

also by molten metals. This furnace may be used for metal

melting if care is taken not to splash molten metal on the

heating elements.

FURNACE LOADING
31

 WARNING

This warning is presented for compliance with California Proposition 65 and other regulatory agencies and only

applies to the insulation in this product. This product contains refractory ceramic, refractory ceramic fiber or

fiberglass insulation, which can produce respirable dust or fibers during disassembly. Dust or

fibers can cause irritation and can aggravate pre-existing respiratory diseases. Refractory ceramic and refractory ceramic fibers (after reaching 1000°C) contain crystalline silica, which can cause lung damage (silicosis).

The International Agency for Research on Cancer (IARC) has classified refractory ceramic fiber

and fiberglass as possibly carcinogenic (Group 2B), and crystalline silica as carcinogenic to humans (Group 1).

The insulating materials can be located in the door, the hearth collar, in the chamber of the product or under the

hot plate top. Tests performed by the manufacturer indicate that there is no risk of exposure to dust or respirable fibers resulting from operation of this product under normal conditions. However, there may be a

risk of exposure to respirable dust or fibers when repairing or maintaining the insulating materials, or when

otherwise disturbing them in a manner which causes release of dust or fibers. By using proper handling procedures and protective equipment you can work safely with these insulating materials and minimize any exposure. Refer to the appropriate Material Safety Data Sheets (MSDS) for information regarding proper handling

and recommended protective equipment. For additional MSDS copies, or additional information concerning the

handling of refractory ceramic products, please contact the Customer Service Department at

Barnstead|Thermolyne Corporation at 1-800-553-0039.

WARNING

To avoid electrical shock, this furnace must always be

disconnected from the electrical supply prior to

maintenance and servicing.

Do not clean furnace without proper eye protection.

Refer servicing to qualified personnel.

Preventive Maintenance
32

General Cleaning Instructions

Wipe exterior surfaces with lightly dampened cloth containing mild soap solution.

A few simple procedures will help insure that your furnace

will give you long service.

1. Keep the chamber clean; this furnace is capable of

achieving temperatures which will cause vaporization

of many materials. In turn, these vapors can react with the

heating elements, the insulation, or other materials you

have placed in the chamber. In many instances this

reaction is detrimental to operation.

2. Clean exterior surfaces with lightly dampened cloth

containing mild soap solution.

3. Occasionally check the electrical connections in the

control section. Repeated heating and cooling can cause

terminals to loosen.

4. The type B thermocouple used in this furnace is

matched to the temperature controller. It is possible that its

calibration can drift, particularly when operated near

the upper temperature limit, and especially in the

presence of contaminants. It is a good idea to inspect it

at regular intervals or when its accuracy is suspect.

5. Check the cooling fans at regular intervals to be sure

they are functioning properly and are not obstructed.

PREVENTIVE MAINTENANCE
33

The following pages are intended to help you resolve functional problems with your furnace.

Thermolyne is always available to assist you with problems. If this guide does not direct you to your specific

problem, call or write Barnstead/Thermolyne at (1-800-553-0039).

 PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION

Inaccurate temperatures. Contaminated themocouple. Replace thermocouple.

Repeated element burn-out. Continuous operation Do not continuously

below 800°C. operate below 800°C.

Contact Barnstead/Thermolyne

Heating element

 contamination.

“OR” displayed. Open thermocouple. Replace thermocouple.

Slow heat-up. Operating 240V furnace Increase voltage to

on 208V supply. proper level.

Furnace chamber overloaded. Lighten load.

Building or laboratory Fuses or breakers not Install service line of sufficient

main fuses blow or properly rated to size to match furnace

circuit breakers trip. furnace electrical electrical requirements. Contact

 requirements. Barnstead|Thermolyne for

assistance.

CH. C, CH.. H, Err-r Contact

displayed. Barnstead/Thermolyne

Probelm Solving Guide
34

 WARNING

 To avoid electrical shock, this furnace must always be disconnected from the electrical supply prior to

 maintenance and servicing. Refer servicing to qualified personnel.

 WARNING

This warning is presented for compliance with California Proposition 65 and other regulatory agencies and only

applies to the insulation in this product. This product contains refractory ceramic, refractory ceramic fiber or

fiberglass insulation, which can produce respirable dust or fibers during disassembly. Dust or fibers can cause

irritation and can aggravate pre-existing respiratory diseases. Refractory ceramic and refractory ceramic

fibers (after reaching 1000°C) contain crystalline silica, which can cause lung damage (silicosis). The International Agency for Research on Cancer (IARC) has classified refractory ceramic fiber and fiberglass as possibly

carcinogenic (Group 2B), and crystalline silica as carcinogenic to humans (Group 1).

The insulating materials can be located in the door, the hearth collar, in the chamber of the product or under the

hot plate top. Tests performed by the manufacturer indicate that there is no risk of exposure to dust or respirable fibers resulting from operation of this product under normal conditions. However, there may be a risk of

exposure to respirable dust or fibers when repairing or maintaining the insulating materials, or when otherwise

disturbing them in a manner which causes release of dust or fibers. By using proper handling procedures and

protective equipment you can work safely with these insulating materials and minimize any exposure.

Refer to the appropriate Material Safety Data Sheets (MSDS) for information regarding proper handling and

recommended protective equipment. For additional MSDS copies, or additional information concerning the

handling of refractory ceramic products, please contact the Customer Service Department at

Barnstead|Thermolyne Corporation at 1-800-553-0039.

CAUTION

To avoid breakage of a replacement heating

element, be sure that the slot into which the

replacement heating element slides is free of all

debris so that the element goes in very easily.

Forcing an element into a slot, however slightly,

can result in its breakage.

Maintenance and Servicing
35

To avoid premature burnout of a replacement heating

element, be sure that the insulation tail supplied with the

replacement element is inserted between the two legs of

the element as shown in the drawing. Also be sure that

the heating element projects sufficiently into the chamber. Insert element until welded portion (where large

diameter meets small diameter) projects approximately

1/4" into inside of furnace chamber.

To replace a heating element: (refer to Fig. 1A).

a. Remove top cover from heating chamber side of

furnace.

b. Remove the clips holding the connector cable (4) to

the defective heating element. Unwrap the connector

cable from the element.

c. Slide the heating element with element ceramic holder

attached upward, out of the slot in the insulation.

Save the blanket insulation for reuse.

d. Remove the element ceramic holder, noting its exact

position on the heating element.

e. Fasten the element ceramic holder on the new element in exactly the same position it was on the old

element.

f. Begin inserting the new element with element ceramic

holder attached into the slot in the insulation; stop

when there is just enough room left to insert the new

element insulation.

g. Continue sliding the element with the element insulation tail into the slot. DO NOT FORCE - even slight

pressure can fracture the heating element.

h. When the element ceramic holder is nearly seated

against the main insulation, check the top of the

element insulation tail. In its final position, the top

should be about 1/8 inch below the surface of the

main insulation.

i. Position the blanket insulation piece from step c in the

cavity over the insulation tail. Complete insertion of

MAINTENANCE AND SERVICING
36

the heating element until the element ceramic holder

rests on top the main insulation. Check the heating

element on the inside of the chamber. The large diameter

section of the element must be flush with or slightly

projecting from the surface of the insulation (if not,

reposition element ceramic holder). Carefully wrap the

connector cable around the element ends; fasten with

clips. Replace top cover.

To replace thermocouple:

a. Remove top cover from the heating chamber side of

furnace.

b. Loosen diagonal screw holding ceramic connection

block.

c. Lift connection block.

d. Loosen connection block screws holding thermocouple;

noting which side of block the side of the

thermocouplewith the colored bead is connected to.

e. Remove thermocouple.

f. Install new thermocouple with colored bead in same

position.

g. With thermocouple through the hole in the insulation,

replace block in its holder and retighten diagonal screw.

h. Turn furnace ON for a few minutes; check to be sure the

temperature displays upscale.

i. Replace cover.

MAINTENANCE AND SERVICING
37

 Figure 1A Element Replacement
38

Wiring DiagramWiring Diagram

 F46110CM, F46118CM, F46120CM, F46128CM, F46120CM-75, F46128CM-75

Wiring Diagram

CONTROLLER

NOTES:FUSE AND FUSE HOLDER ARESUPPLIED WITH CURRENT CONTROLLER.

INDICATOR LAMPHEATING ELEMENT

DS1HR1 toHR6

3

7

BO

1317

INTERNAL COMMUNICATION CABLE WIRING

CONNECTOR

2

1 R

W

215

CONTROLLER, TEMPERATURECONTROLLER, CURRENTCIRCUIT BREAKERCONTACTOR, MECHANICALTRANSFORMERTHERMOCOUPLE

PART NO. DESCRIPTION

DIAGRAM COMPONENT LIST

CN2CB1B1B2K1T1TC1

FANFAN

CN1

K1 FUSE

SERIES ELEMENTS

208 VOLTS240 VOLTS

HR1 HR2

T1

HR3

56

HR4 HR5

CN2

3

4

12

HR6 GND

L1

DS1

B2

B1

L2

28 1 10

18

17

16 7

89

252627

+-

14

111213

5

6

234

2930313233

CN1

CB1

BLACKRED

TC1

DOOR SWITCH SW1

SW1
39

 Wiring DiagramWiring Diagram

 F46110CM-33, F46120CM-33, F46120CM-33-75

WIRING DIAGRAM

DIAGRAM COMPONENT LIST

PART NO. DESCRIPTIONCN1CN2CB1B1B2K1T1TC1DS1HR1 toHR6

CONTROLLER, TEMPERATURECONTROLLER, CURRENTCIRCUIT BREAKERFANFANCONTACTOR, MECHANICALTRANSFORMERTHERMOCOUPLEINDICATOR LAMPHEATING ELEMENT

208 VOLTS240 VOLTS

1 10 28

2 11 293 12 304 13 315 14 32

6 337 168 17 26

+

9 18 27

-

BLACKRED

GND

GND

L1 L2

123

45

6

T1

K1

CN2

HR1 HR2 HR3 HR4 HR5 HR6

DS1

CB1

B1

B2

TC1

CN1

SERIES ELEMENTS

25

2151317

RWBO 7

3

2

1

CONNECTOR CONTROLLER

INTERNAL COMMUNICATION CABLE WIRING

FUSE

NOTES:FUSE AND FUSE HOLDER ARESUPPLIED WITH CURRENT CONTROLLER.

EMI LINE FILTER C

C

DOOR SWITCH SW1

SW1
40

 Wiring Diagram Wiring Diagram

 F46230CM, F46238CM, F46240CM, F46248CM, F46240CM-75, F46248CM-75 DIAGRAM COMPONENT LIST PART NO. DESCRIPTION CN1 CN2 CB1 B1B2 & 3 K1T1TC1 DS1 HR1 to HR8 CONTROLLER, TEMPERATURE CONTROLLER, CURRENT CIRCUIT BREAKER FAN FAN CONTACTOR, MECHANICAL TRANSFORMER THERMOCOUPLE INDICATOR LAMP HEATING ELEMENT 208 VOLTS 240 VOLTS

1 10 282 11 293 12 304 13 315 14 326 33

7 168 17 26

+

9 18 27

-

BLACKRED

GND

L1 L2

1

2

3

456

T1

K1

CN2

HR1 HR2 HR3 HR4 HR5 HR6

DS1

CB1

B2

B3

TC1

CN1

SERIES ELEMENTS

25

2151317

RWBO 7

3

2

1

CONNECTOR CONTROLLER

INTERNAL COMMUNICATION CABLE WIRING

B1

HR7 HR8

FUSE

NOTES:FUSE AND FUSE HOLDER ARESUPPLIED WITH CURRENT CONTROLLER.

SW1

DOOR SWITCH SW1

WIRING DIAGRAM
41

 Wiring Diagram Wiring Diagram

 F46230CM-33, F46240CM-33, F46240CM-33-75

SERIES ELEMENTS

CONTROLLER

NOTES:FUSE AND FUSE HOLDER ARESUPPLIED WITH CURRENT CONTROLLER.

INDICATOR LAMPHEATING ELEMENT

DS1HR1 toHR8

3

7

BO

1317

INTERNAL COMMUNICATION CABLE WIRING

CONNECTOR

2

1 R

W

215

EMI LINE FILTERCONTROLLER, TEMPERATURECONTROLLER, CURRENTCIRCUIT BREAKERCONTACTOR, MECHANICAL

PART NO. DESCRIPTION

DIAGRAM COMPONENT LIST

FANFANTRANSFORMERTHERMOCOUPLE

CCN1CN2CB1B1B2 & 3K1T1TC1

C

HR6 HR1

208 VOLTS240 VOLTS

HR2

T1

HR3 HR4

6

HR5

CN2

3

45

1

2

HR7

GND

HR8

L1

DS1

B1 B3

B2

L2

FUSE K1

16

252627

78

9

17

18

-

56

14

2

34

111213

+

2930313233

1 10

CN1

28

CB1

RED

TC1

BLACK

GND

SW1

SW1 DOOR SWITCH

WIRING DIAGRAM
42

Description SERIES 1077 SERIES 1078

(Chamber) Small (Models) Large (Models)

(6"X6"X6") (10"X10"X10")

Circuit breaker switch SWX54 SWX54

Connector cable 30" long CE557X1 (2 req’d) CE557X1 (1 req’d)

Connector cable 36" long CE558X1 (1 req’d)

Current controller CNX125 CNX125

Elements EL461X1 (6 req’d) EL462X1 (8 req’d)

Element ceramic holder HRX2 (6 req’d) HRX2 (8 req’d)

Element connector clips CEX135 (12 req’d) CEX135 (16 req’d)

Element connector cable 4" lg CE461X1 (4 req’d) CE461X1 (6 req’d)

Element connector cable 10" Ig CE461X3

Element connector cable 14" lg CE462X1

Element connector cable 19" lg CE462X2

Element Insulation tail JN461X8 (6 req’d) JN461X8 (8 req’d)

Fans FAX7 (2 req’d) FAX7 (3 req’d)

Fuse, Thyristor, Fast Blow, 250V, 45 Amp FZX42 FZX42

Fuse Holder FZX62 FZX62

Hearth Plate PH461X1 PH462X1

Injection Port w/plug JC633x1 JC633x1

& JC633X2 (plug) & JC633X2 (plug)

Insulation - door JN461X3 JN462X4

Insulation Kit - chamber JN461X9A JN462X7A

Multi-programmable control CN71X46 CN71X46

(8 ramp & 8 dwell, 15 programs, -75 models) (F46120CM-75, (F46240CM-75,

F46120CM-33-75, F46240CM-33-75,

F46128CM-75) F46248CM-75)

Relay RYX62 RYX62

Temperature Control Automatic CN71X59 CN71X59

(F46110CM, (F46230CM,

F46110CM-33, F46230CM-33,

F46118CM) F46238CM)

Temperature Control Programmable CN71X59 CN71X59

(8 ramp and 8 dwell 4 program) (F46120CM, (F46240CM,

F46120CM-33, F46240CM-33,

F46128CM) F46248CM)

Thermocouple TCX5 TCX5

Thermocouple terminal block TRX137 TRX137

Transformer TNX79 TNX80

NOTE: Service on control units - contact Barnstead/Thermolyne Corp (1-800-553-0039).

Replacement Parts List
43

WARNING

Replace fuses with the same type and rating.

Please refer to the Specification Plate for the complete model number, serial number, and series number when

requesting service, replacement parts or in any correspondence concerning this unit. All parts listed herein may

be ordered from the Barnstead|Thermolyne dealer from whom you purchased this unit or can be obtained

promptly from the factory. When service or replacement parts are needed we ask that you check first with your

dealer. If the dealer cannot handle your request, then contact our Customer Service Department at 319-556-

2241 or 800-553-0039. Prior to returning any materials to Barnstead|Thermolyne Corp., please contact our

Customer Service Department for a “Return Goods Authorization” number (RGA). Material returned without a

RGA number will be refused.

Ordering Procedures
44

Date Revised: 7/2/91

PRODUCT IDENTIFICATION

Trade Name(s): CERAFIBER

Generic Name: REFRACTORY CERAMIC FIBER INSULATION CAS #: 65997-17-3

Chemical Name: ALUMINA SILICA Formula: MIXTURE

Manufacturer: Thermal Ceramics Telephone: (404) 796-4200

Address: P.0. BOX 923, 2102 Old Savannah Road

City: Augusta State: Georgia Zip: 30903

PRODUCT INGREDIENTS

INGREDIENT NAME CAS NUMBER % PEL and TLV (except as noted)

REFRACTORY CERAMIC FIBER 65997-17-3 100 1 FIBER/CC

EXPOSURE GUIDELINE

5mg/M- NUISANCE RESPIRABLE - OSHA

10mg/M- NUISANCE TOTAL - ACGIH

CRYSTALLINE SILICA (CRISTOBALITE) WILL FORM “AFTER SERVICE” AT TEMPERATURES >1000°C.

14464-46-1 >20 0.05 mg/M- OSHA Respirable Dust

PHYSICAL DATA

Appearance and Odor: WHITE FIBER-NO ODOR.

Boiling Point: NA Evaporation Rate (NA = 1): NA

Vapor Pressure: NA Specific Gravity (water = 1 ): 2.6

Water Solubility (%): NIL Melting Point: >3000°F

Vapor Density (Air= l): NA % Volatile by Volume: 0

FIRE AND EXPLOSION DATA

Flash Point (Method): NONFLAMMABLE

NFPA Flammable/Combustible Liquid Classification:

NAFlammable Limits: LEL: NA % UEL: NA %

Auto-Ignition Temperature:

NA

HEALTH HAZARDS

Summary/Risks

Summary: EXPOSURE TO DUST FROM THIS PRODUCT SHOULD BE MINIMIZED. ANIMAL INHALATION AND ARTIFICIAL IMPLANTATION STUDIES HAVE REPORTED THE DEVELOPMENT OF TUMORS. BASED ON PRELIMINARY RESULTS, A NOTICE OF

SUBSTANTIAL RISK HAS BEEN FILED WITH THE EPA ACCORDING TO SECTION 8(e) OF THE TOXIC SUBSTANCES CONTROL

ACT. BASED ON ANIMAL STUDIES, IARC HAS CLASSIFIED RCF AS POSSIBLY CARCINOGENIC FOR HUMANS (2B). DATA

FROM HUMAN EPIDEMIOLOGICAL STUDIES IS INSUFFICIENT. THIS SUBSTANCE OR MIXTURE HAS NOT BEEN CLASSIFIED

A CARCINOGEN BY NTP OR OSHA.

Medical conditions which may be aggravated: AS WITH ANY DUST, PRE-EXISTING UPPER RESPIRATORY AND LUNG DISEASES

Thermal Ceramics

Material Safety Data Sheet

Material Safety Data Sheet
45

MAY BE AGGRAVATED.

Target Organ(s): LUNGS, SKIN AND EYES .

Acute Health Effects: PRODUCT IS A MECHANICAL IRRITANT TO SKIN, EYES AND UPPER RESPIRATORY SYSTEM.

Chronic Health Effects: EXCESSIVE EXPOSURE TO RCF DUSTS AND AFTER SERVICE FIBERS MAY CAUSE LUNG DAMAGE (FIBROSIS). IARC STATES THERE IS SUFFICIENT EVIDENCE IN ANIMALS AND LIMITED EVIDENCE IN HUMANS TO CLASSIFY

CRYSTALLINE SILICA AS A PROBABLE CARCINOGEN (2A) AND RCF AS A POSSIBLE CARCINOGEN (2B).

Primary Entry Route(s): INHALATION, SKIN AND EYE CONTACT.

Signs/Symptoms of Overexposure

Inhalation: IRRITATION OR SORENESS IN THROAT & NOSE. IN EXTREME EXPOSURES SOME CONGESTION MAY OCCUR.

Skin Contact: TEMPORARY IRRITATION OR RASH.

Skin Absorption: NA

Ingestion: NOT HAZARDOUS WHEN INGESTED. MAY CAUSE TEMPORARY IRRITATION TO GI TRACT.

Eyes: TEMPORARY IRRITATION OR INFLAMMATION

First Aid/Emergency Procedures

Inhalation: REMOVE TO FRESH AIR. DRINK WATER TO CLEAR THROAT AND BLOW NOSE TO EVACUATE FIBERS.

Skin Contact: WASH AFFECTED AREAS GENTLY WITH SOAP AND WARM WATER.

Skin Absorption: NA

Ingestion: NA

Eyes: FLUSH EYES WITH COPIOUS QUANTITIES OF WATER. IF IRRITATION PERSISTS CONSULT A PHYSICIAN.

REACTIVITY DATA

MATERIAL IS STABLE. HAZARDOUS POLYMERIZATION CANNOT OCCUR.

Chemical Incompatibilities: HYDROFLUORIC ACID

Conditions to Avoid: NONE IN DESIGNED USE.

Hazardous Decomposition Products: NONE

SPILL OR LEAK PROCEDURES

Procedures for Spill/Leak: VACUUM CLEAN DUST WITH EQUIPMENT FITTED WITH HEPA FILTER. IF SWEEPING IS NECESSARY

USE A DUST SUPPRESSANT.

Waste Management: WASTES ARE NOT HAZARDOUS AS DEFINED BY RCRA (40 CFR PART 261 ) . COMPLY WITH FEDERAL,

STATE & LOCAL REGULATIONS. METHOD OF DISPOSAL - LANDFILL. RQ - N/A.

SPECIAL PROTECTION INFORMATION

Goggles: GOGGLES OR SAFETY GLASSES WITH SIDE SHIELDS ARE RECOMMENDED.

Gloves: GLOVES ARE RECOMMENDED.

Respirator: <1 F/CC, USE 3M 9900; <10 F/CC, USE MSA COMFO II WITH H FILTER; <50 F/CC, USE MSA ULTRA-TWIN H FILTER; OR

EQUIVALENTS. SEE SECTION IX-OTHER.

Ventilation: USE SUFFICIENT NATURAL OR MECHANICAL VENTILATION TO KEEP DUST LEVEL TO BELOW PEL/TLV/WEG (WORKPLACE EXPOSURE GUIDELINE) USE DUST COLLECTION WHEN TEARING OUT.

Other: WEAR LOOSE FITTING, LONG SLEEVED CLOTHING. WASH EXPOSED AREAS WITH SOAP & WARM WATER AFTER HANDLING. WASH WORK CLOTHES SEPARATELY FROM OTHER CLOTHING; RINSE WASHER THOROUGHLY.

Special Considerations for repair/maintenance of contaminated equipment: CRISTOBALITE RESPIRATOR: <10X PEL, USE 3M

9900; <100X PEL, USE MSA ULTRA-TWIN H FILTER; OR EQUIV. SEE SEC IX-OTHER.

MATERIAL SAFETY DATA SHEET
46

SPECIAL PRECAUTIONS

*** ALWAYS SEGREGATE MATERIALS BY MAJOR HAZARD CLASS ***

THIS PRODUCT CONTAINS A CHEMICAL KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER.

Storage Segregation Hazard Classes: IRRITANT

Special Handling/Storage: KEEP MATERIAL DRY.

Special Workplace Engineering Controls: ADEQUATE VENTILATION TO KEEP DUST LEVEL TO BELOW PEL/TLV/WEG (WORKPLACE

EXPOSURE GUIDELINE).

Other: ADDITIONAL INFORMATION ON THE HEALTH AND SAFETY ASPECTS OF REFRACTORY CERAMIC FIBERS IS AVAILABLE.

† Copyright© 1980, National Fire Protection Assoc., Quincy, MA 02269. This reprinted material is not the complete and official position of

the NFPA on the referenced subject, which is represented only by the standard in its entirety. MSSM/226-21:26/00030

As of the date of preparation of this document, the foregoing information is believed to be accurate and is provided in good faith to comply

with applicable federal and state law(s). However, no warranty or representation with respect to such information is intended or given.

MSDS/MSD3 FORM REV. 7/2/91

MATERIAL SAFETY DATA SHEET
47

Barnstead|Thermolyne Corporation warrants that if a product manufactured by

Barnstead|Thermolyne and sold by it within the continental United States or Canada

proves to be defective in material or construction, it will provide you, without charge, for a

period of ninety (90) days, the labor, and a period of one (1) year, the parts, necessary to

remedy any such defect. Outside the continental United States and Canada, the warranty

provides, for one (1) year, the parts necessary to remedy any such defect. The warranty

period shall commence either six (6) months following the date the product is sold by

Barnstead|Thermolyne or on the date it is purchased by the original retail consumer,

whichever date occurs first.

All warranty inspections and repairs must be performed by and parts obtained from

an authorized Barnstead|Thermolyne dealer or Barnstead|Thermolyne. Heating elements, however, because of their susceptibility to overheating and contamination, must be

returned to our factory, and if, upon inspection, it is concluded that failure is not due to excessive high temperature or contamination, warranty replacement will be provided by

Barnstead|Thermolyne. The name of the authorized Barnstead|Thermolyne dealer nearest you may be obtained by calling 1-800-446-6060 or writing to:

Barnstead|Thermolyne

P.O. Box 797

2555 Kerper Boulevard

Dubuque, IA 52004-0797

USA

FAX: (319) 556-0695

Barnstead|Thermolyne’s sole obligation with respect to its product shall be to repair

or replace the product. Under no circumstances shall it be liable for incidental or consequential damage.

THE WARRANTY STATED HEREIN IS THE SOLE WARRANTY APPLICABLE TO

Barnstead|Thermolyne PRODUCTS. Barnstead|Thermolyne EXPRESSLY DISCLAIMS

ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR USE.

Special Two Warranty on Control Module

There are no other warranties, expressed or implied, made in connection with the sales

of this product. Barnstead|Thermolyne expressly disclaims any implied warranty of merchantability or fitness for specific use.

One Year Limited Warranty
48

Barnstead Thermolyne

2555 Kerper Blvd.

P.O. Box 797

Dubuque, IA 52004-0797 USA

PHONE: 319-556-2241 • 800-553-0039

FAX: 319-556-0695

Web Address: http://www.barnsteadthermolyne.com

a subsidiary of

9001

ISO

REGISTERED