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Temperature Controller

Thermolyne

LT2416DX1

2

2

Table of Contents:

3

3

Introduction

The 16 segment, four programmable, furnace (Group D1) consists of a microprocessor-based dual-mode PID (Proportional, Integral, Derivative) temperature controller with over-temperature protection and appropriate output switching devices to control the chamber temperature. The digital readout continuously displays the measured chamber temperature (upper display) and the setpoint chamber temperature (lower display) while in user run mode. The display reverts to showing the mnemonic (upper display) and corresponding set value or parameter value (lower display) in the set up mode. These programmable controller modules can be utilized as either single setpoint controllers or as a single program controllers defined by 16 segments of programming capability. A special feature, the cALL segment type, can be utilized to link segments from one program to another. This translates to a maximum of 1 program consisting of 64 segments.

The controller discussed in this manual is used in a variety of Thermolyne furnace model types. Thermolyne has assigned a unique controller part number that corresponds with a specific Thermolyne furnace model. The control group of these furnace models described in sales literature is D1.

A list of the Thermolyne replacement controller part numbers within group D1 are as follows:

CN71X75 CN71X84 CN71X87 CN71X90 CN71X92 CN71X98

LT2416DX1

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4

Understanding The Controller:

252416

OP1

25AUT O

MAN

RUN

HOLD

Understanding The Controller: Controller Terminology Mnemonic - Mnemonic is a term used to reference what is shown in the upper display of the controller. Mnemonics will consist of numbers, such as the measured chamber temperature as well as letters, such as list headers. Whether the mnemonic is a group of letters or numbers will depend upon what display you have navigated to. Mnemonics cannot be altered using the arrow keys. Parameter - Parameter is a term used to reference what is shown in the lower display of the controller. Parameters will consist of numbers, such as deviation alarm setpoint as well as letters, such as the holdback function setting. Whether the parameter is a group of letters or numbers will depend upon what display you have navigated to. Unlike mnemonics, parameters can be altered using the arrow keys. Value - Value is a term used to describe a parameter, particular a parameter that is associated with numbers. For example, the setpoint temperature, deviation alarm setting, segment number, ect.

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5

Understanding The Controller: Levels of Operation The controller has four levels of operation.

1. Operator Level: Select mnemonics & corresponding parameters can be viewed and/or altered at the operation level. Controllers are factory installed in the furnace with the intent to be operated at this level. The operator level is also commonly referred to as the user run mode.

2. Full Level: All mnemonics & corresponding parameters can be viewed

at the operator level, however only select parameters can be altered pending the edit level setting. The full level of operation is password protected.

3. Edit Level: Like the full level, the edit level is password protected. All

mnemonics & corresponding parameters are defined in the edit level as either:

- Alterable (ALtr) = Mnemonic & corresponding parameter can be

viewed as well as altered at the operator or full level. - Promoted (PrO) = Mnemonic & corresponding parameter are

promoted to the HOME DISPLAY list & can be altered at the operator or full level.

- Read Only (rEAd) = Mnemonic & corresponding parameter can be

viewed at the operator or full level, but cannot be altered.

- Hidden (HidE) = Mnemonic & corresponding parameter cannot be viewed at the operator or full level and cannot be altered.

4. Configuration Level: This special level is double password protected.

The fundamental characteristics of the controller are set up at the configuration level. Extreme caution must be used if an operator enters the configuration level. The configuration level may also be referred to as the configuration mode of operation.

For more information on how to access the various levels of operations see Access List Section.

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6

16 Segment Programmable Models w/OTP

250.02416

OP1

OP2

SP2

REM 250.0AUT O

MAN

RUN

HOLD

1234

97

10

13 14 15 16

12

811

6

5

Button/Indicator Name Description 1. OP1 LED Output 1 Illuminates when controller energizes elements. 2. OP2 LED Output 2 Not activated for furnace operation. 3. SP2 LED Setpoint

2 Not activated for furnace operation.

4. REM LED Remote Setpoint

Not activated for furnace operation.

5. Upper Display Display Indicates measured chamber temperature or mnemonic value (parameter).

6. Lower Display Display Indicates set point chamber temperature or mnemonic.

7. Auto/Man Button Not activated for furnace operation. 8. Run/Hold Button Press once to initiate a program.

Press twice to place a program in hold state. Press & hold button for 2 seconds to cancel a program in the run state.

9. Auto Mode LED Illuminates to indicate furnace is in operating in auto mode.

10. Manual Mode LED Not activated for furnace operation. 11. Run LED Illuminates to indicate controller is executing a

program. 12. Hold LED Illuminates to indicate controller has paused

program execution. 13. Page Button Press to select a new list header. 14. Scroll Button Press to view a mnemonic and parameter setting

within a list header. 15. Down Button Press to decrease the value in the lower display. 16. Up Button Press to increase the value in the lower display.

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7

HOME DISPLAY

The controller is powered ON when the furnace is powered ON. The controller will perform a short power on self-test sequence and automatically revert to the home display of the operator level or user run mode.

The home display indicates the measured chamber temperature (also known as the process variable) in the upper display window and the chamber set point temperature in the lower display window.

252416

OP1

25AUT O

MAN

RUN

HOLD

From the home display you can perform one of five functions:

1. Adjust the chamber single set point temperature indicated in the lower

display using the or

keys. (NOTE: Can not adjust single set point temperature if a program is being executed or in a hold/pause state.)

2. Cycle through the mnemonic parameter/values promoted to the HOME

LIST by using the key.

3. Cycle through the mnemonic list headers using the key.

4. Initiate a program by using the RUN button. 5. Place a program in pause mode or canceling a program using the

HOLD button. (Press HOLD button once to pause a running program. Press & hold the HOLD button to cancel a program.)

NOTE: This is what the home display appears like.

Measured Chamber Temp

Set Point Temp

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HOME DISPLAY list of mnemonics and parameter settings:

By pressing the key, the mnemonics promoted to the home display will appear in the upper or lower display window. The corresponding mnemonic parameter/value will be displayed in the lower window. Some parameters/values can be altered using the or keys when displayed and others cannot. The following pages include detailed controller drawings showing the various mnemonics of the home list.

252416

OP1

CAUT O

MAN

RUN

HOLD

Press to advance

OP2416

OP1

0.0AUT O

MAN

RUN

HOLD

Press to advance

C.id2416

OP1

75AUT O

MAN

RUN

HOLD

Press to advance

PrG2416

OP1

1AUT O

MAN

RUN

HOLD

Chamber Measured Temperature

Indicates all temperature values are expressed in degrees C. Cannot be altered in the HOME DISPLAY.

Output Power Level

Number is a % value of the output power being applied to the heating elements. Cannot be altered in the HOME DISPLAY.

Parameter Explanation/Action


Controller Identification Number


This number may not be set to 75 on all control modules this manual is written for. The value has no impact on controller operation. Cannot be altered in the HOME DISPLAY.

Program Number


Press or

to change

1 - 4 Number presents the program. (4 programs total)

9

9

IdHi2416

OP1

50AUT O

MAN

RUN

HOLD

Press to advance

tunE2416

OP1

OFFAUT O

MAN

RUN

HOLD

High Deviation Alarm

The parameter number displayed represents the current alarm setpoint.

Tune Feature

Status of tunE feature/function is OFF. Can be altered from HOME DISPLAY to initiate a tune.


Press or

to change


50

OFF

NOTE: Tuning matches the characteristics of the controller to that of the process to eliminate temperature undershoot and/or overshoot of setpoint. Tuning should be initiated with the furnace at room temperature. For more information on this feature, please see the Tuning & PID Sections of this manual.

Press or

to change

NOTE: The deviation alarm is intended for load protection and should never be set lower than 10 degrees. Setting a lower deviation alarm may interfere with the PID control process.

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10

Mnemonic List Headers

From the home display, the controller can also be cycled through the

various mnemonic list headers by using the key. The various lists contain mnemonics and parameters or set values that dictate how the controller operates.

252416

OP1

25AUT O

MAN

RUN

HOLD

Press to advance

252416

OP1

CAUT O

MAN

RUN

HOLD

Press to advance

run2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

ProG2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

Measured chamber temperature

Set point temperature

Measured chamber temperature

Indicates all temperature values are expressed in degrees C.

Run List. The run list contains mnemonics that correspond to a program. You can start, end, or place a program in check in the run list. You can also check the status of a running program.

- What segment is currently being executed - How much program time has elapsed

Program List. The program list contains mnemonics that are used specifically to enter a program into the controller.

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11

AL2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

Atun2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

Pid2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

cmS2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

ACCS2416

OP1

LiStAUTO

MAN

RUN

HOLD

Alarm List. The alarm list contains mnemonics that define the alarm setting of the controller.

Auto Tune List. The auto tune list contains mnemonics that pertain to the tuning feature or functions of a controller

Pid List. The Pid list contains mnemonics that define how well the controller responds to change in order to keep a stable chamber temperature. The proportional bands, integral, and derivative time bands as well as gain scheduling are listed in the Pid.

Access List. The Access list is used to enter the configuration mode as well as define mnemonic access levels. The Access list is password protected.

Communication List (Comms). The communication list contains the address mnemonic that is utilized for RS232 communications.

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Run List Section

The Run list contains mnemonics that detail a program. The run list is considered part of the set up mode of at the operator level.

When a program is not being executed you can perform two functions in the Run List.

1. Initiate a program (StAt = run) 2. Activate the display segment feature (SEG.d = YES) or

Deactivate the display segment feature (SEG.d = no)

If you activate the display segment by altering SEG.d to YES, the lower home display will indicate which segment type is being executed in the lower home display window when the program is actually being executed. The segment type will cycle on and off with the temperature.

When a program is being executed you can perform three functions in the Run List.

1. Suspend or Pause the program (StAt = hold) 2. Terminate and Reset the program (StAt = OFF) 3. Activate the display segment feature (SEG.d = YES)

Deactivate the display segment feature (SEG.d = no) When a program is being executed (run) you can also check the following:

1. Programmer Set Point (PSP = Setpoint temperature of the active segment)

2. Cycles Remaining (CYC = Number of times the cycle has to repeat itself) 3. Segment (SEG = Active segment number of the program being executed) 4. Segment Type (StyP = Active segment type of the program being

executed) 5. Segment Time (SEG.t = Amount of time [Expressed in min/hours/sec as

defined by ramp and dwell units in the program list] remaining in the active segment in the program.)

6. Target Set Point (tGt = Setpoint temperature of the active segment) 7. Ramp Rate (rATE = ramp rate of the active segment [only appears if the

active segment type is defined as a ramp rate in the program list]) 8. Program Time (PrG.t = Amount of time [Expressed in hours] remaining in

the active program. The following pages will step you through the various displays you will see in the run list.

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Run List Mnemonics (run LiSt) (When a program is NOT being executed)

run2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

PrG2416

OP1

1AUT O

MAN

RUN

HOLD

Press to advance

StAt2416

OP1

OFFAUT O

MAN

RUN

HOLD

Press to advance

FASt2416

OP1

noAUT O

MAN

RUN

HOLD

Press to advance

Run List Header

Current Status of Program


OFF Program reset & not being executed

Program being executed (running)

Program paused

Fast Run through program (Factory preset to no)


no This feature is not activated for furnace operation, all though the parameter can be changed when a program is not being executed.

Press or

to change parameter

Press or

to change parameter

Program Number

Paramete Explanation/Action

Press or

to change parameter

Number presents the program. (4 programs total)

1 - 4

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14

SEG.d2416

OP1

noAUT O

MAN

RUN

HOLD

Run List Mnemonics (run LiSt) (While a program is being executed)

run2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

PrG2416

OP1

1AUT O

MAN

RUN

HOLD

Press to advance

StAt2416

OP1

runAUT O

MAN

RUN

HOLD

Press to advance

Status of program


Program reset & not being executed

run Program being executed (running)

Program paused

Run List Header

Active Segment Displayed (Factory preset to no) Parameter Explanation/Action

no Active segment is not flashed in the lower display during program execution.

Active segment flashes in the lower display during program execution.

Press or

to change parameter

Press or

to change parameter

Program Number


Program number currently being executed. Parameter cannot be adjusted.

1 - 4

15

15

PSP2416

OP1

235AUT O

MAN

RUN

HOLD

Press to advance

CYC2416

OP1

0AUT O

MAN

RUN

HOLD

Press to advance

SEG2416

OP1

1AUT O

MAN

RUN

HOLD

Press to advance

StyP2416

OP1

rmP.rAUT O

MAN

RUN

HOLD

Press to advance

SEG.t2416

OP1

7.1AUT O

MAN

RUN

HOLD


Programmer Set Point

235 This number will increase and decrease as a program is being executed. The oscillation is dictated by the program segment. Cannot be adjusted in this display.

Cycles Remaining in the Program


0 The parameter number displayed represents the number of times the program will repeat itself. Cannot be adjusted in this display.


1 This number represents what segment of the program is currently being executed. . Cannot be adjusted in this display.

Active Segment Number


rmP.r This parameter represents the segment type that is currently being executed by the controller. Cannot be adjusted in this display.

Active Segment Type

Segment Time Remaining


7.1 This number represents the amount of time remaining in the current segment of the program being executed. Defined in minutes, hours, or seconds by the program setup. Cannot be adjusted on this display.

16

16

Press to advance

tGt2416

OP1

500AUT O

MAN

RUN

HOLD

Press to advance

rATE2416

OP1

1.0AUT O

MAN

RUN

HOLD

Press to advance

PrG.t2416

OP1

0.1AUT O

MAN

RUN

HOLD

Press to advance

FASt2416

OP1

noAUT O

MAN

RUN

HOLD

Press to advance

Target Set Point [this window appears only if the segment type is defined as a ramp rate or ramp time]


500 This number represents the segment setpoint temperature currently being executed by the controller. Cannot be adjusted on this display.


1.0 This parameter represents the ramp rate of the segment that is currently being executed by the controller. Defined in degrees C per min/hour/sec in the program setup. Cannot be adjusted on this display.

Ramp Rate [this window appears only if the segment type is defined as a ramp rate or ramp time]

Program Time Remaining


0.1 This parameter number represents the amount of time remaining in the current program. Expressed in hours. Cannot be adjusted in this display.

Fast Run Through Program (Factory preset to no)


no This feature is not activated for furnace operation, all though parameter can be changed.

Press or

to change parameter

NOTE: Pending the segment type currently being executed will dictate what display(s) will appear next.

17

17

SEG.d2416

OP1

noAUT O

MAN

RUN

HOLD

Program List Section The Program list contains mnemonics that are used to define a custom

program. This section explains how to enter a custom program into the controller.

A program can only consist of up to 16+ segments with the cALL feature. Each segment is defined as one of five types.

1. Ramp = Measured chamber temperature ramps linearly from it's

current value at either a defined rate or within a defined amount of time to a defined setpoint chamber temperature. Note: Measured chamber temperature can be ramped up (temperature increase) or ramped down (temperature decrease).

If a segment type is set as a ramp rate, mnemonics appear as follows:

A) Ramp Rate (rmP.r) = Ramp rate B) Setpoint Temp (tGt) = Defined setpoint temperature. C) Rate of change (rATE) = Defined rate of temperature increase

or decrease. Ramp units (rmP.U) define the time associated (hour, minutes, or seconds) with rate of change.

If a segment type is set as a ramp time, mnemonics appear as follows:

A) Ramp Time (rmP.t) = Ramp time B) Setpoint Temp (tGt) = Defined setpoint temperature. C) Duration (dur) = Defined amount of time in which the measured

chamber temp is allowed to reach the setpoint temp.

2. Dwell = A defined amount of time or duration that is required to hold the chamber measured temperature constant.

If a segment type is set as a dwell, mnemonics appear as follows:

A) Dwell (dwEll)= Dwell time

Active Segment Displayed (Factory preset to no)


no Active segment is not flashed in the lower display during program execution.

Active segment flashes in the lower display during program execution.

Press or

to change parameter

18

18

B) Duration (dur) = Amount of defined time in which the measured chamber temperature is to be controlled at the setpoint temperature for this segment only. Dwell units (dwL.U) define the time associated (hours, minutes, or seconds) with the duration parameter.

3. Step = Step segment allows a new setpoint temperature to be defined.

The control module will attempt to achieve the new setpoint temperature instantaneously with no ramping.

If a segment type is set as a step, mnemonics appear as follows:

A) Step (StEP) = Step Instantaneously. B) Setpoint (tGt) = Defined setpoint temperature

4. End = Defines or signals the end of a program.

If a segment type is set end, mnemonics appear as follows: A) End (End) = End program. B) End Type (End.t) = Defines what the controller is supposed to

do now that the program is done running. There are three settings or choices:

1. Dwell (dwEll) = Controller holds the last programmed setpoint temp (tGt) of the program.

2. Reset (rSEt) = Controller resets and reverts to single setpoint operation/mode.

3. Segment Output Power (S OP) = Controller reverts from auto mode of operation to manual mode of operation and controls power to the heating element as expressed in a percentage of output power. WARNING: S OP end type should never be selected! Due to the configuration of the controller Thermolyne could not remove this option from the list of choices of the end type. Selecting S OP will result in uncontrollable chamber temperature and will shorten element and thermocouple life span.

NOTE: If you desire the chamber temperature to cool down to ambient temp (25C) at completion of the program, you will need to step the setpoint to 25 in the 2nd to last segment of the program and select (dwEll) as the end type OR you will need to reset the single setpoint temperature to 25C prior to initiating the program and select (rSEt) as the end type.

19

19

5. Call = The call segment links segment(s) from another program, as a subroutine, to the existing program.

If a segment type is set call, mnemonics appear as follows: A) Program number (PrG.n) = Program number linking to. B) Cycle number (cYc.n) = How many times controller is to repeat

the linked segment during program execution. The following pages of this section will step you through the various displays you will see in the program list. There is also an example program and spreadsheet you can use to help define your custom program.

Program List Mnemonics (ProG LiSt)

Programming the Controller

The following section explains how to enter a program into the control module with use of an example program.

Program protocol: (example) Our example program calls to heat from ambient to 500C at a rate of 10C per minute. Once the furnace reaches 500C, we need to hold the temperature at 500C for 2 hours. After two hours of holding at 500C, we need to increase the chamber temperature to 800C at a rate of 5C per minute. Once the furnace reaches 800C, we need to hold the temperature at 800C for 3 hours. After three hours, we need the chamber temperature to go back to ambient as quickly as possible.

100°200°300°400°500°600°700°800°900°

1000°1100°1200°

1 Hr 2 Hr 3 Hr 4 Hr 5 Hr 6 Hr 7 Hr 8 Hr 9 Hr 10 Hr(600 Min)(540 Min)(480 Min)(420 Min)(360 Min)(300 Min)(240 Min)(180 Min)(120 Min)(60 Min)

Segment 1rmP.r

Segment 2dwEll

Segment 3rmP.r

Segment 4dwEll

Segment 5 & 6 End

To help visualize our example program we chart the chamber temperature (temperature versus time) in a graph.

20

20

The Program List (ProG LiSt) contains the mnemonics that are used to define the program. The keystroke procedures required to enter a program, such as the example program are as follows:

From the HOME DISPLAY, Press repeatedly to advance to the Program List window.

ProG2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

Hb2416

OP1

HiAUT O

MAN

RUN

HOLD

Press to advance

Hb U2416

OP1

10AUT O

MAN

RUN

HOLD

Press to advance

Program List Header

Holdback


Disables holdback feature for all segments in a program

Holds the program when the measured chamber temperature deviates below set point minus the hold back unit value.

Hi Holds the program when the measured chamber temperature deviates above set point plus the hold back unit value.

Holds the program when the measured chamber temperature deviates below or above the setpoint by more than the holdback unit value.

Hold Back Units


10 The parameter number represents the deviation tolerance from the setpoint temperature for the holdback feature. (value should never be adjusted below 10 for optimal furnace results)

Press or

to change parameter

Press or

to change parameter

21

21

rmP.U2416

OP1

minAUTO

MAN

RUN

HOLD

Press to advance

dwL.U2416

OP1

minAUT O

MAN

RUN

HOLD

Press to advance

CYC.n2416

OP1

1AUT O

MAN

RUN

HOLD

Press to advance

Dwell Units


min Dwell units defined in minutes.

Dwell units defined in hours.

Dwell units defined in seconds.

Cycles of Program


1 The parameter number displayed represents the number of time(s) the program will repeat itself.

If set to "cont" the program will repeat itself continuously indefinitely

Ramp Units


min Ramp units defined in minutes.

Ramp units defined in hours.

Ramp units defined in seconds.

Press or

to change parameter

Press or

to change parameter

Press or

to change parameter

NOTE: The previous mnemonics will need to be set for each and every program. They apply to the entire program. NOTE: The following mnemonics actually define the ramp and dwells of our program.

22

22

SEG.n2416

OP1

1AUTO

MAN

RUN

HOLD

Press to advance

tYPE2416

OP1

rmP.rAUT O

MAN

RUN

HOLD

Press to advance

tGt2416

OP1

500AUTO

MAN

RUN

HOLD

Press to advance

Segment Number


1 This parameter number represents the 1st segment of the program.

Segment Type


rmP.r Ramp to setpoint at defined rate. Our program calls for a ramp rate of 10C per minute.

Ramp to a new setpoint within a defined amount of time

Hold a desired setpoint temperature for a defined amount of time

Steps temperature to a new setpoint as quickly as possible.

Ends the program.

Target Temperature [this window appears only if the segment type is defined as a ramp rate]


500 Setpoint temperature. Our program calls for setpoint of 500C.

Press or

to change parameter

Press or

to change parameter

Press or

to change parameter

Links segment(s) from one program as a subroutine to the existing program. [This feature allows for more than 16 segments of programmability.]

23

23

rATE2416

OP1

10AUTO

MAN

RUN

HOLD

Press to advance

SEG.n2416

OP1

2AUT O

MAN

RUN

HOLD

Press to advance

tYPE2416

OP1

dwEllAUT O

MAN

RUN

HOLD

Press to advance

Rate of temperature change [this window appears only if the segment type is defined as a ramp rate]


10 Parameter number represents the rate of temperature change. Our program calls for a rate of 10C per minute. (We defined the time units in rmP.U)

Segment Number


2 This parameter number represents the 2nd

segment of the program.

Segment Type


Ramp to a new setpoint at defined rate of increase or decrease


dwEll Hold a desired setpoint temperature for a defined amount of time. Our program calls to hold the temperature at 500C for 2 hours.


Ends the program.

Press or

to change parameter

Press or

to change parameter

Press or

to change parameter


24

24

dur2416

OP1

120AUT O

MAN

RUN

HOLD

Press to advance

SEG.n2416

OP1

3AUT O

MAN

RUN

HOLD

Press to advance

tYPE2416

OP1

rmP.rAUT O

MAN

RUN

HOLD

Press to advance


120 Represents the amount of time allowed for the temperature to hold at the 1st setpoint of 500C (Remember: we set dwL.U to min, which means 2 hours = 120 minutes)

Segment Number


3 This parameter number represents the 3rd segment of the program.

Press or

to change parameter

Press or

to change parameter

Segment Type


rmP.r Ramp to a new setpoint at defined rate of increase or decrease


Hold a desired setpoint temperature for a defined amount of timeSteps temperature to a new setpoint as quickly as possible.

Ends the program.

Press or

to change parameter

Duration [this window appears only if the segment type is defined dwell]


25

25

tGt2416

OP1

800AUT O

MAN

RUN

HOLD

Press to advance

rATE2416

OP1

5AUTO

MAN

RUN

HOLD

Press to advance

SEG.n2416

OP1

4AUTO

MAN

RUN

HOLD

Press to advance

Target Temperature [this window appears only if the segment type is defined as a ramp rate]


800 Parameter number represents the target (set point) temperature of 800C.

Segment Number


4 This parameter number represents the 4th segment of the program.

Press or

to change parameter

Press or

to change parameter

Rate of temperature change [this window appears only if the segment type is defined as a ramp rate]


5 Parameter number represents the rate of temperature change. Our program calls for a rate of 5C per minute. (We defined the time units in rmP.U)

Press or

to change parameter

26

26

tYPE2416

OP1

dwEllAUT O

MAN

RUN

HOLD

Press to advance

dur2416

OP1

180AUT O

MAN

RUN

HOLD

Press to advance

SEG.n2416

OP1

5AUT O

MAN

RUN

HOLD

Segment Type




dwEll Hold a desired setpoint temperature for a defined amount of time. Our program calls to hold the temperature at 500C for 2 hours.


Ends the program.

Press or

to change parameter



180 Represents the amount of time allowed for the temperature to hold at the 2nd setpoint of 800C (Remember: we set dwL.U to min, which means 3 hours = 180 minutes)

Press or

to change parameter

Duration [this window appears only if the segment type is defined dwell]

Segment Number


5 This parameter number represents the 5th segment of the program. .

Press or

to change parameter

27

27

tYPE2416

OP1

StEPAUT O

MAN

RUN

HOLD

Press to advance

tGt2416

OP1

25AUT O

MAN

RUN

HOLD

Press to advance

SEG.n2416

OP1

6AUT O

MAN

RUN

HOLD

Press to advance

Target Temperature [this window only appears if the segment type is set to step]


25 Setpoint temperature. By "stepping" the setpoint from 800C to 25C in segment 5, the controller will attempt to achieve the new setpoint as quickly as possible as the program calls for.

Segment Number


6 This parameter number represents the 6th segment of the program. .

Segment Type





StEP Steps temperature to a new setpoint as quickly as possible.

Ends the program.

Press or

to change parameter

Press or

to change parameter

Press or

to change parameter


28

28

tYPE2416

OP1

EndAUT O

MAN

RUN

HOLD

Press to advance

End.t2416

OP1

rSEtAUTO

MAN

RUN

HOLD

This completes entering the example program into the controller and hopefully gives you an ideal as to how the programmer list functions.

End Type


rSEt Ends & resets the program. Controller will automatically revert to single setpoint operation.

Ends & resets the program. However, the controller will hold the chamber temperature at the last setpoint (target) of the program.

Ends & resets the program. However, chamber temperature is controlled by an output power percentage.

Segment Type






End Ends the program.

Press or

to change parameter

Press or

to change parameter

WARNING: DO NOT SET THE END TYPE OF A PROGRAM TO THE "S OP" PARAMETER. THIS CHOICE COULD NOT BE ELIMINATED AT THE OPERATOR LEVEL HOWEVER. ELEMENT FAILURE IS LIKELY TO OCCUR. THERMOLYNE FURNACES ARE NOT DESIGNED TO OPERATE OFF A PERCENTAGE OF POWER.


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Call Segment type: Our example program did not execute a "cALL" segment. The cALL segment feature allows you to enter custom programs, which consist of more than 8 segments. The following displays are what you can expect to see when you "cALL" a segment from another program as a subroutine.

tYPE2416

OP1

cALLAUT O

MAN

RUN

HOLD

Press to advance

PrG.n2416

OP1

2AUT O

MAN

RUN

HOLD

Press to advance

cYc.n2416

OP1

1AUT O

MAN

RUN

HOLD

Press to advance

Segment Type






Ends the program.

Press or

to change parameter


cALL

Program Number


2 Parameter represents the program number the controller will call a segment from within.

Press or

to change parameter

Number of Cycles for the Called Program


1 Parameter number represents the number of times the called subroutine segment will repeat itself

Press or

to change parameter

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30

SEG.n2416

OP1

9AUT O

MAN

RUN

HOLD

Press to advance This completes the list of windows you can expect to see if your custom

program requires the cALL feature to be used as subroutine.

Segment Number


Parameter number represents the segment number of the called program that will be executed next in the program. (The segment number displayed will be in chronological order coinciding with the previous segments of the program.)

9

Press or

to change parameter

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31

Alarm List Section

Understanding Alarm Types: Process Alarms The control module has two process alarms: A process alarm warns there is a problem with the chamber temperature the controller is trying to control.

1. Deviation High Alarm (IdHi) = A deviation alarm can be reset by the operator. Factory preset to 50, means if the chamber measured temperature exceeds the set point temperature at any given time during furnace operation by more than 50 degrees, the controller will alarm. The alarm code will flash on the home display to alert operators and the controller will attempt to remove all power from the heating elements to stop the thermal runaway condition. The deviation alarm is intended for load protection and should never be set lower than 10 degrees. Setting a low deviation alarm (below 10 degrees) may interfere with the PID control process.

2. Full Scale High Alarm (2FSH) = The full scale high alarm is factory

preset in the configuration mode and is not visible in the alarm list at the operator level. Unlike the deviation alarm, no attempts by operators to reset this alarm value should be made. This alarm is factory preset to a temperature value that exceeds the maximum recommended operating temperature of the unit. If a thermal runaway condition should occur this alarm protects the furnace from further damage by attempting to remove power from the elements. If the deviation alarm is set properly for the application, this alarm will never be activated in a thermal runaway condition as the deviation alarm will be tripped first.

Understanding Process Alarms: What happens when an alarm condition occurs: Events that occur during a process alarm condition: - The home display will flash the alarm error mnemonic with the measured chamber temperature in the lower display to alert operators of the condition. - The controller will stop sending AC power to a mechanical relay contactor. As a result the contactor will open, effectively de-energizing the heating elements. - Both process alarms are non-latching, which means the controller will reset automatically when the measured chamber temperature is no longer over the defined alarm temperature value. Ultimately this means the controller will cycle power to the mechanical relay and re-energize the elements creating more heat. The controller essentially cycles power to the elements through the mechanical relay instead of the solid-state relay. Thus, the chamber temperature is controlled at the alarm temperature value.

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Understanding Process Alarms: Troubleshooting

In the event of a deviation high alarm (IdHi) condition, operators should first check the alarm value. In some situations, the alarm is merely set to low for the process of the PID control, taking into consideration program parameters and load type/mass. Resetting this alarm to a higher value often times corrects the problem. If this alarm condition occurs after the alarm setting has been increased, please call Barnstead International technical support for additional troubleshooting procedures. Please obtain the model and serial number of your furnace prior to calling tech support.

In the event of a full-scale high alarm (2FSH) condition, operators should

power off the furnace immediately to avoid further damage and call Barnstead International technical support for troubleshooting procedures. Please obtain the model and serial number of your furnace prior to calling tech support. Understanding Alarm Types : Diagnostic Alarms The control module has ten diagnostic alarms. A diagnostic alarm warns there this a fault within the controller or input module (thermocouple or RTD). Please be aware combinations of alarm types can exist simultaneously. If such an occurrence should happen, alarm mnemonics will alter with each other on the display of the controller. The following diagnostic alarms are listed.

1. "S.br" (Sensor Break Alarm): The home display will flash "S.br" indicating the thermocouple input is open. In this error state, the controller will not cycle power to the elements to generate any heat. Thermocouple replacement is usually required to resolve this alarm condition.

2. "EE.Er" (Electrically Erasable Memory Alarm): The home display will flash

"EE.Er" indicating a mnemonic value in either the operator or configuration mode has been corrupted. In this error state, the controller will not cycle power to the elements to generate any heat. Controller replacement is usually required to resolve this alarm condition.

3. "TU.Er" (Tune Error Alarm): The home display will flash "TU.Er" indicating

the tune procedure has failed. This error condition can only occur during a tune procedure. In this error state, the controller will stop submitting power to the heating element and chamber temperature will drop to ambient conditions. In most situations, the one-shot tune procedure was interrupted resulting in the error. Re-running the one-shot auto tune usually resolves the problem. However, thermocouple and/or controller replacement may be necessary to resolve this alarm condition.

4. "LLLL" (Out of Range Low Reading): The home display will flash "LLLL"

indicating the input signal is out of range low. If the thermocouple was

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33

recently replaced, it may not be connected properly or connected in reverse polarity causing the error message. If you have verified the thermocouple is the connected properly, controller replacement may be necessary to resolve this alarm condition.

5. "HHHH" (Out of Range High Reading): The home display will flash

"HHHH" indicating the input signal is out of range high If the thermocouple was recently replaced, it may not be connected properly or connected in reverse polarity causing the error message. If you have verified the thermocouple is the connected properly, controller replacement may be necessary to resolve this alarm condition.

6. "Err1" (ROM Failure): The home display flashes "Err1". Controller

replacement is usually required to resolve this alarm condition.

7. "Err2" (RAM Failure): The home display flashes "Err2". Controller replacement is usually required to resolve this alarm condition.

8. "Err3" (Watchdog Failure): The home display flashes "Err3". Controller

replacement is usually required to resolve this alarm condition.

9. "Err4" (Keyboard Failure): The home display flashes "Err4". Controller replacement is usually required to resolve this alarm condition.

10. "Err5" (Internal Communication Failure): The home display flashes "Err5".

Controller replacement is usually required to resolve this alarm condition.

Understanding Diagnostic Alarms: What happens when an alarm condition occurs? When a diagnostic alarm is active, the controller will flash the alarm until the error condition has been corrected. The controller will not attempt to cycle power to the heating elements, however the elements may generate heat if a double fault exists in the furnace. Obtain the model and serial number of the furnace and contact Barnstead International technical support if a diagnostic alarm condition should occur.

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34

Alarm List Mnemonics (AL LiSt)

AL2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

IdHi2416

OP1

50AUT O

MAN

RUN

HOLD

Alarm List Header

Deviation High Alarm


50 The parameter number displayed represents the current alarm setpoint.

Press or

to change parameter

NOTE: The deviation alarm is intended for load protection and should never be set lower than 10 degrees. Setting a lower deviation alarm may interfere with the PID control process.

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35

Auto Tune List Section The controller incorporates a self-tuning feature, which determines the

optimum control parameters (PID values) for best temperature accuracy with your load type. This feature should be used to eliminate temperature under-shoot, over-shoot, or oscillation conditions.

There are two types of automatic tuning.

1. One Shot Auto Tune: The one-shot tuner functions by switching the heating elements on and off as a means to induce temperature oscillation. From the amplitude and period of the temperature fluctuation, the controller can calculate the optimal tuning parameters to help reduce or totally eliminate such oscillation. The tuning parameters of the following mnemonics are automatically set for optimal operation as a result of a one shot tune:

2. Adaptive Tune: Adaptive tuning is a background algorithm, which continuously monitors the error from the setpoint and analyses the control respond during process disturbances. Adaptive tune is triggered whenever the error from setpoint exceeds a defined trigger level (drA). The tuning parameters changed as a result of an adaptive tune are the Proportional Band (Pb), Integral Time Band (ti), and Derivative Time Band (td) only.

Mnemonic Parameter Meaning/Function

Proportional Pb The bandwidth, in display units, over which the output Band power us proportioned between minimum & maximum.

Integral ti Determines the time taken by the controller to remove Time steady-state error signals

Derivative td Determines how strongly the controller will react to the Time rate of change of the measured chamber temperature.

High Hcb The number of display units above set point at which Cutback the controller will cutback the output power, in order to prevent undershoot on cool down.

Low Lcb The number of display units below set point at which Cutback the controller will cutback the output power, in order to Prevent overshoot on heat up.

WARNING: While we may have not disabled the adaptive tune capability of the controller, it is strongly advised not to attempt this method of tuning, with a Thermolyne box furnace. There are very few applications with a laboratory furnace that require this type of tuning. The process is too sensitive, usually causing more problems rather than correcting them.

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36

Auto Tune List Mnemonics (Atun LiSt) Atun

2416OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

tunE2416

OP1

OFFAUT O

MAN

RUN

HOLD

Press to advance

drA2416

OP1

OFFAUT O

MAN

RUN

HOLD

Press to advance

drA.t2416

OP1

20AUT O

MAN

RUN

HOLD

Auto Tune List Header

Auto Tune (one shot)


OFF Auto tune off/terminated

Auto tune on/initiated

Auto Tune (adaptive tune)


OFF Auto tune off/terminated

Auto tune on/initiated

Adaptive Tune Trigger Level


20 Adaptive tune trigger level. Adaptive tune is triggered whenever the error from the setpoint exceeds this trigger level setting. (Only active if drA is set to on).

Press or

to change parameter

NOTE: The following feature may not be present on all control types. As a result the following windows will not appear.

Press or

to change parameter

Press or

to change parameter

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37

Suggested Tuning Procedure: 1. Load the furnace chamber with material that exhibits similar

characteristics as your normal loads you will be using the furnace to process. Please note: the material may not be of salvageable at completion of this process, however loading the furnace for the tune procedure will result in more accurate tune parameters given the characteristics of the load.

2. Power on the furnace. 3. Set the desired single set point temperature using the arrow keys. (If

more than one known single set point temperature is going to be used over the course of time, average the set points together, and enter the average single set point into the controller.)

4. Page key to the atun list. 5. Scroll key to the one-shot tune mnemonic. 6. Use the arrow key to change the OFF to ON. 7. The furnace will heat from ambient to the set point temperature while

tuning. The lower display will toggle the set point temperature with the word "tune" to indicate the process is being executed.

8. When the furnace reaches the set point temp and the word "tune" stops flashing in the lower display, the tune is complete and the tuner parameters have been automatically set for optimum results.

NOTE: Initiating a one-shot tune while the chamber is at ambient usually results in obtaining the optimal PID values for the process, however with some applications, initiating a tune when the furnace actually reaches set point, may produce better results.

NOTE: Programs cannot be tuned, only single set points. If you wish to set your PID tuning parameters for program operation, select the mean temperature of the program or calculate the average temperature. Enter the mean or the average as a single set point and initiate the one-shot auto tune with a mock load in the chamber. The PID tuning values the controller calculates at this value will work best for the entire program.

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38

PID List Section

The PID list contains mnemonics that define the control module's ability to maintain set point with minimal deviation process error from set point. PID Control: What is PID Control?

The control algorithm is based on proportional gain, an integration action, and a derivative action. Gain, more commonly called, proportional band, simply amplifies the error between set point and measured chamber temperature to establish a power level. The term, proportional band, is one that expresses the gain of the controller as a percentage of the span of the instrument. It determines the magnitude of the response to an error. If the prop band is too small, meaning a high gain, the furnace temperature will oscillate through being over-responsive. If the prop band is too large, meaning low gain, the measured chamber temperature will oscillate due to the lack of response or will be slow to react to disturbances.

Having the proper gain alone will not allow for accurate control however. The integral action, expressed as the integral band, slowly shifts the output power level as a result of an error between set point and measured chamber temperature. If the measured chamber temperature is below set point the integral action will gradually increase the output power level in an attempt to increase the chamber temperature to meet the set point requirement. Likewise, if the measured chamber temperature is above the set point, the integral action will gradually decrease the output power level in an attempt to lower the chamber temperature to meet the set point requirement. The integral band is expressed as a time constant, meaning the longer the integral band (time constant) the more slowly the power level shift will occur. If set too large, the controller response time may be too slow and sluggish. If the integral band is set to smaller value, the controller essentially shifts the power level more quickly resulting in a faster response. However, if the power level is shifted too quickly it can cause unwanted temperature oscillation due to the load type.

The last constant is referred to as the derivative band and like the integral band is expressed as a time constant. The derivative band provides a sudden shit in output power level as a result of a quick change in the measured chamber temperature (for example, opening the chamber door). It also aids the PI control process in dampening chamber temperature oscillation near set point. The derivative time band is typically set to a value equal to one sixth of the integral band.

No matter how thorough or discrete the explanation of PID control and the function of each of the three tuning parameters, it is a difficult concept to understand. When the PID tuning parameters are set to optimal values, the controller will heat to set point with minimal temperature overshoot or undershoot. Unlike past control models, in which PI values needed to be

39

39

calculated long form by end-users as well as manually entered into the controller, the new versions of PID controllers automatically calculate and set by the values into the controller as a result of a one-shot auto tune discussed in the previous section entitled Auto Tune List Section.

Dual PID Control: What does this mean?

The control module installed your laboratory furnace has dual PID control

capability. Due to the wide range of controllable temperatures, one set of PID values can be used for chamber set points below a defined level while a second set can be used for chamber set point above the defined level. The defined level is referred to as the gain set point (G.SP). Factory preset at 700C, means if the chamber set point temperature is below 700C, the controller will activate and use the 1st set of PID values. If the chamber set point temperature is above 700C, the controller will automatically use the 2nd set of PID values. The advantage of dual PID control lies in the fact controllers do not require re-tuning as often, saving you time.

PID Control & Tuning: When should I tune or re-tune my controller?

Controllers should be re-tuned from ambient when one of the following

events occur: - When the application changes. For example if a the furnace is

being used to ash small samples of waste material one day and having a large piece of metal placed in the chamber to heat treat the following day. The mass of the load will exhibit characteristic differences as it absorbs heat generated by the furnace. This can cause unwanted temperature over or undershoot.

- If chamber set point temperature is changed by a significant difference. For example, running at an average set point of 350C to running at an average set point of 900C.

- If you are experiencing chamber measured temperature oscillation on the control display. The PID values may drift over time as a result of electrical interference and need to be reset.

- If a thermocouple or heating element is replaced in the furnace, the controller should be re-tuned.

For instructions on how to properly initiate a tune please refer to the Tune List Section of this manual.

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40

PID List Mnemonics (Pid LiSt)

Pid2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

G.SP2416

OP1

700AUT O

MAN

RUN

HOLD

Press to advance

Pb2416

OP1

9AUT O

MAN

RUN

HOLD

Press to advance

ti2416

OP1

159AUTO

MAN

RUN

HOLD

Press to advance

Proportional Band 1


1-9999 Proportional Band 1 value. Factory preset to 9.

Gain Setpoint


700 Gain setpoint level. Level at which PID control switches from the 1st set of PID values to the 2nd set.

PID List Header

Integral Time Band 1


1-9999 Integral time band 1 value. Factory preset to 159.

Press or

to change parameter

Press or

to change parameter

Press or

to change parameter

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41

td2416

OP1

26AUTO

MAN

RUN

HOLD

Press to advance

Pb22416

OP1

5AUT O

MAN

RUN

HOLD

Press to advance

ti22416

OP1

44AUT O

MAN

RUN

HOLD

Press to advance

td22416

OP1

7AUT O

MAN

RUN

HOLD

Proportional Band 2


1-9999 Proportional Band 2 value. Factory preset to 5.

Derivative Time Band 1


1-9999 Derivative time band 1 value. Factory preset to 26.

Integral Time Band 2


1-9999 Integral time band 2 value. Factory preset to 44.

Derivative Time Band 2


1-9999 Derivative time band 2 value. Factory preset to 7.

Press or

to change parameter

Press or

to change parameter

Press or

to change parameter

Press or

to change parameter

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42

Communication List Section The communication list contains only one mnemonic that defines the location of the controller when connected to a computer via RS232.

cmS2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

Addr2416

OP1

1AUT O

MAN

RUN

HOLD

Address


1-99 Parameter number defines the address location of the controller.

Press or

to change parameter

Communication List Header

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43

Access List Section

The access list is the gateway, so to speak of, to the configuration level as well as the Edit & FuLL modes of operation. Configuration Level:

This special level is double password protected. The fundamental characteristics of the controller are set up in the configuration level. For this reason we have chosen not to supply the password necessary to enter the configuration level. If you feel you are required to enter the configuration level of your Thermolyne furnace controller, please obtain the model & serial number of your furnace & call our customer service technical support at 800-446-6060 for further assistance. Full & Edit Levels:

The password required to enter the FuLL or Edit level is the number {25}. FuLL Level: All mnemonics & corresponding parameters can be viewed at the operator level, however only select parameters can be altered pending the edit level setting. Access to the FuLL level of operation is required to change the calibration-offset value (if necessary).

Edit Level: All mnemonics & corresponding parameters are defined in the Edit level as either:

- Alterable (ALtr) = Mnemonic & corresponding parameter can be

viewed as well as altered at the operator or full level. - Promoted (PrO) = Mnemonic & corresponding parameter are

promoted to the HOME DISPLAY list & can be altered at the operator or full level.

- Read Only (rEAd) = Mnemonic & corresponding parameter can be viewed at the operator or full level, but cannot be altered.

- Hidden (HidE) = Mnemonic & corresponding parameter cannot be viewed at the operator or full level and cannot be altered.

Access to the Edit level of operation is required if you wish to lock out select mnemonics and corresponding parameter settings to prevent unwanted tampering.

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44

Access List Mnemonics (ACCS LiSt)

ACCS2416

OP1

LiStAUT O

MAN

RUN

HOLD

Press to advance

codE2416

OP1

0AUT O

MAN

RUN

HOLD

Access List Header

Code Number


0-9999 Password

Press or

to change parameter

45

45

2416 Eurotherm: Offset Calibration

1

5252416

OP1

900AUTO

MAN

RUN

HOLD

Press

repeatedly

to goto 2

ACCS2416

OP1

LiStAUTO

MAN

RUN

HOLD

Press

to goto 3

codE2416

OP1

0AUTO

MAN

RUN

HOLD

Press

repeatedly

to goto

4

codE2416

OP1

25AUTO

MAN

RUN

HOLD

Automatic

5

codE2416

OP1

PASSAUTO

MAN

RUN

HOLD

Press

to goto 6

Goto2416

OP1

FuLLAUTO

MAN

RUN

HOLD

Press

repeatedly

to goto

7

iP2416

OP1

LiStAUTO

MAN

RUN

HOLD

Press

to goto 8

OFS.12416

OP1

0AUTO

MAN

RUN

HOLD

**Press

or

to set offset

9

OFS.12416

OP1

5AUTO

MAN

RUN

HOLD

Press

repeatedly

to goto

10

ACCS2416

OP1

LiStAUTO

MAN

RUN

HOLD

Press

to goto 11

codE2416

OP1

PASSAUTO

MAN

RUN

HOLD

Press

to goto 12

Goto2416

OP1

FuLLAUTO

MAN

RUN

HOLD

Press

to goto

13

Goto2416

OP1

OPErAUTO

MAN

RUN

HOLD

Press

to goto

14

ACCS2416

OP1

LiStAUTO

MAN

RUN

HOLD

Press

to goto 15

5252416

OP1

900AUTO

MAN

RUN

HOLD

**Calibration offset value must be calculated. See following instructions on how to properly calculate this value.

NOTE: There are three important aspects you need to know when performing this procedure: 1. If you do not press a key within a defined amount of time, the display will automatically revert

back to the home display. 2. When you press the key, you must wait until the parameter in the lower display "blinks"

before pressing the next instructed key. The "blink" indicates the parameter change has been accepted by the controller.

3. If you press and hold the key, the parameter value in the lower display will toggle quicker.

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46

Calculating a Temperature Offset Value

Equipment Required For All Thermolyne Furnace Model Types: - N.I.S.T. traceable type K thermocouple with digital pyrometer. (Thermolyne Cat #

AY589X1)

Equipment Required For Select Thermolyne Model Types: - Tools necessary to remove the back cover of the furnace chamber (Screwdriver set) - Drill with 3/8" bit.

1. Route the N.I.S.T. traceable type K thermocouple probe into the geometric center of the

chamber. a) Route the probe through a 3/8" diameter access port located on the back wall of

select Thermolyne furnace model types [select models must have the chamber back wall insulation drilled out through the access port] See Pic A.

b) Route the probe through a 1" diameter access/vent port located on the roof of select Thermolyne furnace model types [select models must have the chamber roof insulation drilled out through the access port] See Pic B.

A) B)

2. Power on the furnace. 3. Set the desired single set point temperature. 4. Allow the furnace to heat to set point & stabilize. Stabilization allows the interior surfaces to

reach thermal equilibrium resulting in a more accurate response. Pending Thermolyne furnace model type as well as the set point temperature, the time required for stabilization to occur will fluctuate. Please allow two additional hours for stabilization to occur once the set point temperature has been achieved.

5. Record the measured chamber temperature from the display of the furnace controller. 6. Record the measured chamber temperature from the digital pyrometer. 7. Subtract the displayed furnace controller temperature from the N.I.S.T. digital pyrometer

temperature. The difference becomes the calibration offset value that is to be entered in step 11 of the procedure.

EXAMPLE 1 (Negative offset value): 495ºC (N.I.S.T digital pyrometer reading) - 500ºC (Furnace controller measured chamber temp reading) - 5ºC (Calculated calibration offset value) EXAMPLE 2 (Positive offset value): 505ºC (N.I.S.T digital pyrometer reading) - 500ºC (Furnace controller measured chamber temp reading) 5ºC (Calculated calibration offset value)

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