User Manual
Contents
1. Serial Number as well as contact data for the MELLEN Company The furnace plate also contains wattage and voltage information zone configuration and any special adaptations on this furnace Important Safety Information e Never place any part of the body in the furnace or touch the furnace while acti vated or while cooling e Use proper ventilation at all times do not inhale fumes from a bake out proce dure or arun Do not approach the furnace without a mask e Never have food or drink near the furnace e Apply proper voltage to the heaters e Provide at least Y clearance between furnace surface and any conductive parts e Take necessary precautions when handling high temperature materials e Do NOT exceed the recommended temperature ratings e Do not modify or drill holes to the heaters without consulting MELLEN 603 228 2929 e Do NOT support the furnace by any electrical parts e Do NOT bury any electrical interconnections between the furnace and any equip ment e Furnace should be level and free from vibrations e Furnace should be installed and grounded in accordance with national and local codes e Avoid contact between furnace and any metallic object e Always wash hands after coming in contact with furnace and components e Do not place any combustible components inside the furnace e Do not hold furnace by the knobs used to open and close the furnace page 3 Unpacking Instructions Remove furnace from b2. Thermocouples wear out through normal use and should be replaced as needed Thermocouples placed inside the furnace improperly will most likely be damaged and need to be replaced sooner than expected the TC en but rn grasp the gt TC and ey connect fhe TC prongs to the plug of the wire The connection will be flush when fully connected Connect the controller power out to the furnace or immediate trans fer input whichever is applicable see wiring diagram Be sure that the furnace and controller are properly grounded Observe local and National Codes for wiring and electrical page 12 Controller Overview The controller is set up at MELLEN and the instruments are ready to operate upon set up If you wish to change the set setpoint please follow these proce dures Further instruction is included in the OMEGA controller manual To turn the unit on switch the white ON OFF switch as illustrated in the photo above To change the setpoint on the controller use the instrument on the left hand side Press and hold the star button far left and while holding it down press the up or down arrow keys to change the setpoint To shut the unit off simply shut the ON OFF switch The Over temperature OT setpoint is set at the maximum temperature for your unit MELLEN 7 recommends setting this no more than 1000 over the operating temperature of your furnace NEVER to exceed the maximum operating temperature of the furnace O
3. bore is empty Check the furnace power leads for possible shorts On the first firing the power should be applied to every other zone never to two adjoining zones at the same time It is recommended that in a three zone furnace that the middle zone zone 2 be fired or baked out first Then upon completion of zone 2 bake out procedure that zones 1 and 3 can be baked out together 7 Raise the temperature of the zones being fired to a minimum of 1000 C in four steps 200 C for one hour 400 C for one hour 800 C for one hour 1000 C for one hour OD o1 amp After this bake out has been completed turn off the zones The remaining zones may now be baked out following the same procedure zones 1 and 3 It is recommended that this procedure be done in succession that is baking out the remaining zones before the furnace cools In the case that this is achieved skip to step 3 800 C for 1 hour and begin baking zones 1 and 3 at this step Then continue as normal and bake at 1000 C for 1 hour The bake out is now complete After the initial drying out run the furnace should be run approximately 10 C 40 C above the normal operating temperature without exceeding the rated temperature to fully stabilize the furnace Under no circumstances should the rated temperature of the furnace be exceeded WARNING Multi zone furnaces SERIOUS DAMAGE may result if steps 6 7 are not followed when baking out multi zone furnace
4. in the furnace with the leads inserted through to the back of the furnace 1 Slide an element clip between the element and the insulation 2 Repeat with three remaining clips 3 Replace insulation on the side of the furnace between element and furnace skin 4 Replace screw on the side of the furnace 5 Gently close the furnace 5 Attach leads in the back of the furnace by crimping with a buttsplice to the wire 6 Replace perforated cage on the back of the furnace To Replace the element on the TOP of the furnace follow the same procedure for replacing the bottom element but remove the cage on the top of the furnace Remove the two screws on the top of the furnace to remove the cage Clip the wires as shown before removing element clips and insulation Open the furnace and remove insulation then element clips then slide out element To replace element slide element leads amp through the furnace and replace clips and insulation then attach PA the leads page 11 Thermocouple Care TC s should be handled with care The ceramics are fragile and thus can be broken easily A broken ceramic can lead to broken or twisted wires which may cause a second junction to be formed resulting in incorrect temperature readings Exposing the TC to arsenic or any other corrosive material may contaminate the TC The TC should be cleaned or replaced if the TC appears to be cor roded or attacked in any way
5. thermocouple or TC is in serted in the backside of the furnace in the TC holder Insert the thermocouple carefully as thermocouples are fragile Loosen the bolt on the top of the TC and hold the washer to the top of the bolt away from the TC holder Slide the thermocouple into the furnace keeping the washer outside the holder Using a screwdriver gently tighten the bolt to hold the ther The thermocouple slides into the furnace and just barely protrudes from the inside of the furnace page 8 Element Replacement Tools Required 1 8 Allen wrench replacement element s needle nose pliers Wire cutters Be certain that furnace and elements are completely cool and at room temperature before replacing any MELLEN elements Wear a protective mask when handling elements To replace the BOTTOM element 1 Remove the screw using the Allen wrench located on the side of the fur nace as shown in the photo above 2 Gently slide out the insulation on the side of the element as shown in the photos on the right Gently set aside 3 Using the needle nose pliers slide the metal clip sideways holding the element in place 4 Remove all 4 clips following the same procedure and set clips aside _ 5 Gently close the furnace 6 Remove two screws holding the perforated screen onto the furnace Set screws aside 7 Cut the wire connections on the leads of the element Replace new element
6. The MELLEN Company Inc www MELLENCompany com MTSCR Furnace MAX 100092 Congratulations on your purchase of a MELLEN Furnace In order to assist in your scientific procedures please consult this manual prior to unpacking and in stallation Please contact technical support at the MELLEN Company 40 Chenell Drive Concord NH 03301 phone 603 228 2929 Fax 603 228 5727 E mail info mellencompany com with additional questions Contents Contact Information sure 1 Furnace lhformaliofi en ns 3 Safety A chndecetiamecdatwer ion 3 Unpacking Instructions sr4s40s sense 4 Initial Run Bake Out Instructions 5 7 Basic OPS ana 1 Thermocouples Installation 8 Element Replacemenit 4440040s seen een 9 11 Thermocouple INFO c cccssssccecesseessseeeeesessseneeees 12 Wiring INFO 12 Troubleshooting Guide 404404 Hs en 13 Safety Data Sheets are attached to printed copies from MELLEN Diagrams Spare Parts List etc are in the back pocket of hard copies from MELLEN Furnace Information All MELLEN furnaces are labeled with an information sticker allowing the user to ac cess necessary information concerning the furnace The serial number for the MELLEN Furnace is located on a MELLEN furnace plate primarily located on the cage on the furnace Attached to this plate you will conve niently find the Furnace Model Number
7. UCCESS ococccccccccnccnncnnccnnoos Single Zone Bake Out Procedure 1 If your furnace is a horizontal furnace please raise one end to up to 30 de grees and not less than 5 degrees If you can not raise one end of the fur nace contact MELLEN to verify that it is OK to run the bakeout in its fixed position 2 At the furnace ends place the furnace plugs slightly inserted in order for fur nace to reach required temperature Be sure to leave a gap an opening for the smoke to escape during bake out Vent the smoke outside through the use of a hood or exhaust collector Make certain that the bore is empty Check the furnace power leads for possible shorts Raise the temperature of the furnace to 800 in three steps STEPA 200 C for one hour STEP B 400 C for two hours STEP C 800 C for one hour DU w The furnace may now be cooled down and is ready for use Multiple Zone Bake Out Procedure 1 If your furnace is a horizontal furnace please raise one end to up to 30 de grees and not less than 5 degrees If you can not raise one end of the fur nace contact MELLEN to verify that it is OK to run the bakeout in its fixed position 2 At the furnace ends place the furnace plugs slightly inserted in order for furnace to reach required temperature Be sure to leave a gap an opening for the smoke to escape during bake out Vent the smoke outside through the use of a hood or exhaust collector Make certain that the
8. ely TC NEEDS REPLACEMENT Call MELLEN 603 228 2929 ELEMENTS NEED REPLACEMENT Call Mellen 603 228 2929 page 15
9. ox or crate Inspect furnace for any damage Report any damage to the delivering carrier immediately to insure a proper claim Remove any packaging material from the bore paying attention not to damage the insulation Do not drop box or furnace page 4 Initial Run and Bake Out Instructions Please follow the appropriate Bake Out Instructions either Single Zone Bake Out Procedure for furnaces with one heating zone or Bake Out Procedure for Multiple Zone Furnaces for furnaces with more than one heating zone The furnace contains carefully selected insulation to permit the best possible operation This insulation inherently contains moisture that must be slowly and completely removed before the furnace can be fully utilized During this drying period a small quantity of smoke and vapors from the binders in the embedding cement will also be emitted The smoke will have a bad odor so provide ad equate ventilation Please inspect the furnace prior to the bake out procedure Please be sure that the furnace core is empty that nothing is inside of it ie no papers office sup plies tools etc Please be sure that nothing is on the exterior of the furnace as well Remove plastic protective wrap adhering to furnace skins This protective layer is intended for shipping purposes only and must be removed prior to op eration Please follow the recommended procedure s to properly dry out the furnace insulation for maximum operating S
10. s WARNING Due to the possibility of combustible gases being given off by the refractory cement binders as the furnace is heated Mellen recommends operat ing the furnace in a tilted or vertical position prevent local hot spots an possible damage to the heating elements or element Both ends of the bore should be open or slightly ajar with furnace plugs and the bore empty After the initial run the furnace can be operated normally Basic Operation The furnace should be brought to temperature as slowly as is practical for your applications During prolonged periods of inactivity the furnace should be shut off or idled at approximately 1000 F 538 C The furnace should be level and free from vibrations Check the furnace for shorts from inputs to ground Check the resistance of the heating element s to see that the connections are tight and free of oxides The resistance should be checked across the two end terminals Although the furnace has a nominal rating the furnace should never be connect ed to a line without an automatic or manual voltage control in front of it CAUTION The furnace transformer if required and control cabinet should be installed and grounded in accordance with National and local codes Multi Zone Furnaces are supplied with one grounding wire and two power leads for each zone page 7 Thermocouple Installation The furnace can use various thermocouples depending on application type K S or R The
11. ver Temperature Controller If you wish to change the OT setpoint follow y eos a gt these instructions 1 2 P the UP amp the SETUP key at th i o nn OVERTEMP Use the A or Y to scroll through 4 choices on the screen OPTR SETP CONF INFO en Stop scrolling when you see SETP Press the SETUP key ULOC will show up on the screen Using the A and Y keys press until the number 10 appears onscreen This is the unlock code Once you have the number 10 onscreen press the SETUP key and the SET POINT will be displayed Using the A and Y keys choose your new setpoint Once you have your desired number onscreen press RESET Press the SETUP key to scroll to the next screen 0 1 Press SETUP amp A at the same time to return to the main menu Select OPTR by scrolling with the Akey Press SETUP and you will now be in operator mode OPTR and the new setpoint will be active page 14 Troubleshooting Guide LED Display doesn t light up Check to make sure unit is plugged in Check power connections FURNACE DOESN T HEAT Heating element burned out SCR burned out Call MELLEN for technical support 603 228 2929 info mellencompany com FURNACE EMITS SMOKE after bake out Shut unit off Check for combustible substances inside furnace bore Determine if smoke is coming from controller or furnace bore If coming from controller call MELLEN technical support immediat
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