PCR2007-12 Automatic heat treatment console
Contents
1. RaPID Controllers only Figure 3 DIN DIN Series Link Jumpers UNIVERSAL INPUT S Linear Linear T C RTD mA V mV Figure 5 DIN A DIN Universal Input Connections PC2007 12 Automatic Heat Treatment Console REV 0 07 wnt marntimadtraco nam DIN 4 DIN amp DIN Temperature Controllers Input Calibration Procedure 5 To calibrate all inputs repeat Steps 1 to 4 for each of the other input types see Table 1 until all five input types have been successfully calibrated NOTE Input Type 5 should be calibrated using the appropriate Type K compensating lead between Terminals 2 amp 3 on DIN DIN Controllers Terminals 4 amp 5 on DIN Controllers The Controller should be powered up and remain powered up for at least 30 minutes with this lead connected before the input is calibrated The universal input calibration procedure is now complete CALIBRATING THE SECONDARY ANALOGUE INPUT RaPID CONTROLLERS ONLY Equipment Required 1 DC linear input source 0 5V and 0 20mA with an accuracy better than 0 05 of reading 2 Appropriate case assembly 4 DIN or DIN wired for appropriate input supply 90 264V AC 50 60Hz 20 50V AC 50 60Hz or 22 65V DC Calibration Procedure 1 Ensure that the Controller is powered off and that the mains line lead is disconnected On the CPU PCB configure link jumpers LJ10 and LJ11 see Table 2 and Figure 3 Connect the remote set point input2. gt Maritime Stress PO Box 2898 30 Estates Road Dartmouth NS B2W 4Y2 Canada Toll Free 1 877 468 1781 Phone 902 468 7873 Fax 902 468 2304 Website www maritimestress com E mail info maritimestress com OPERATION MANUAL PC2007 12 AUTOMATIC 12 WAY HEAT TREATMENT CONSOLE INDEX PC2007 12 HEAT TREATMENT 12 WAY CONSOLE PC2007 12 Basic Six Way Heat Treatment Console Description Page 3 Specifications PC2007 12 Basic Heat Treatment Console Page 4 Maintenance Requirements Page 5 PC2007 12 Operating Instructions Page 6 7 amp 8 P256 6 Channel Programmer Calibration Instructions Page 9 10 6600 Temperature Controller Calibration Instructions Page 11 12 13 amp 14 PC2007 12 Heat Treatment Console System Connections Page 15 To change secondary and primary connections follows these instructions Page 16 Spare parts PC2007 12 Way Heat Treatment Console Page 17 PC2007 12 Automatic Heat Treatment Console REV 0 07 mr marntimadtraco nnam PC2007 6 Twelve Way Heat Treatment Console DESCRIPTION The PC2007 12 automatic heat treatment console is designed to control various heat treatment processes by closely monitoring and adjusting the temperature rate of rise and fall the soak temperature set point and duration on up to 12 zones It incorporates the latest microprocessor based technology and is simple to set up and operate Control setting is by means of push switches and an LCD screen provides vis
3. Circuit 5 amp circuit breaker gt Heater Power Isolation contactor for each zone gt Console Power 200 250 amp main circuit breaker gt Power Transformer 392 F 200 C over temperature thermostat per phase gt Cooling fan 2 x 340 CFM Thermally protected PC2007 12 Automatic Heat Treatment Console REV 0 07 mr marntimadtraco nnam Inspection and Cleaning Maintenance Requirements ITEM INSPECTION FREQUENCY ACTION Contactors Burned or Pitted Every 6 months Clean or replace contacts Temperature Controllers Calibration Every 12 months Check accuracy and adjust 6600 Programmer P256 if required Recorder OPTIONAL Calibration Every 12 months Check accuracy and adjust if required Recorder OPTIONAL Main shaft Lubrication Every 6 months Refer to page 19 2 in and cleaning AH3000 Series manual System Cleanliness Every 6 months Vacuum with power disconnected System Electrical Loose connections Every 6 months Tighten all terminal connections Air Vents and fan Dust or dirt build up Every 3 months Clean with vacuum with power disconnected Check bolts and screws Loose Every 6 months Tighten PC2007 12 Automatic Heat Treatment Console REV 0 07 mr marntimadtraco nnam Note PC2007 6 Twelve Way Heat Treatment Console Operating Instructions Switch 200 amp main circuit breaker to the ON position Make sure zones used are indicating the actual tem
4. DC V 10V DC Parked Fitted 9 Remote Setpoint Linear DC mA 20mA DC Fitted Parked NOTE No calibration is required if the secondary analogue input is to be used as a Remote Setpoint Potentiometer input or for Dual Setpoint switching PIL ae REMOTE V mA mV SETPOINT INPUT V mA mV Figure 6 DIN DIN Controllers Secondary Analogue Input EXIT FROM CALIBRATION MODE To exit from Calibration Mode press the Lower and Function keys simultaneously NOTE An automatic exit is made from Calibration Mode if there is no key activity for two minutes CALIBRATION CHECK 1 Set the Controller to the required configuration using link jumpers and front panel entry as de scribed in the appropriate Product Manual 3 Power up the Controller and leave it powered up for at least five minutes for RTD and DC linear in puts or at least 30 minutes for thermocouple inputs 2 After the appropriate delay for stabilisation has elapsed check the calibration by connecting the appropriate input source and checking a number of cardinal points PC2007 12 Automatic Heat Treatment Console REV 0 07 ummy marntimadtraco nnam 13 Thermocouple Cable lt Secondary gt Cable Note 3 way splitter y 3 way splitter The PC2007 12 connections for circuit number 1 shown Circuit numbers 2 12 are connected in the same manner CP10 CP10 CP10 Parallel connection of heaters Thermocouple Wire Maritime Stress Contracting Limited
5. Toll Free 1 877 468 1781 Phone 902 468 7873 Fax 902 468 2304 Website www maritimestress com E mail info maritimestress com PC2007 12 Automatic Heat Treatment Console REV 0 07 171 martimactraco nam TO CHANGE PRIMARY CONNECTIONS FOLLOWS THESE INSTRUCTIONS 1 Switch off main breaker and disconnect primary power cable supply 2 Loosen the primary power cable clamp 3 Remove panel labelled Back Panel to change secondary and primary connections 4 Change connections as per requirements and make sure the connections are tight 5 Make sure nothing is left inside the enclosure 6 Put the Back Panel back on 7 Tighten the primary power cable clamp 8 Hook up primary power cable supply and then switch on main breaker when ready SEC VOLTAGE OPEN DELTA x01 xo X01x1 X02x2 x03 x3 85 a 1 1 PH 110 VOLT O 1650 VA At 2 H1 H3 X3 X03 ae 0 07 Pe 17 MS Part No Description Of Part 900Wheel Wheels Swivel Caster 900 lb Capacity with brake Simultaneous 12 12 Channel Chino Digital Temperature Recorder Optional 6600 Digital Temperature Controller P256 6 Channel P256 programmer 130KVA 9 130 KVA 3 Phase Isolated copper wound power transformer Primary 480 575 600 60 Hz Secondary 0 85 Thermal trips per phase to prevent overload Amp Meter Digital Amp Meter 0 200 amps Selector Switch Six Channel Selector Switch with Plate amp Knob CT Current Transformer 0 200 amps A10 300 amp Fe
6. are sure that the zero calibration is correct then press button 1 and the screen will change back to the operating screen You should repeat the above sequence at least once since any changes that you make to the zero constant will alter the value displayed at span Similarly any changes made to the span constant may have a small effect on the value displayed at zero Before you make any changes to the constants you must leave sufficient time for the value to settle after you have set the calibrator The 256 takes several seconds to achieve a steady reading after a step change to its input Note that the above values of 0 and 1000 are for instruments set for degrees C instruments set for degrees F use the corresponding values of 32 and 1800 When you are sure that the calibration is correct it is wise to make a note of both constants a record is kept of the original constants at FGH You may then leave calibration mode by going to the opening screen and then pressing the down button whereupon normal operation will resume Note that there is no time out in calibration mode so the instrument will remain in this mode indefinitely until you deliberately exit from it PC2007 12 Automatic Heat Treatment Console REV 0 07 ur mantimadtraco nam 11 6600 CONTROLLER CALIBRATIONINSTRUCTIONS DIN DIN amp DIN Temperature Controllers Input Calibration Procedure 1 DIN DIN amp 4 DIN TEMPERATURE CONTROLLERS INPUT CALIBRATION PROCEDURE Septemb
7. e Step 4 For heating or cooling turn the Final Set Point up or down and adjust Ramp Rate rP as per requirements Step 5 Turn percentage timer between 7 10 on scale if equipped NOTE When the controller is turned on it automatically sets the SPrP set point ramp Initial Set Point from the thermocouple t c temperature At this point in time it starts to count up or down to the Final Set Point The SPrP set point ramp Initial Set Point cannot be changed manually except by turning the controller off then on ALWAYS Change the Ramp Rate before changing the Final Set Point when changing stages The controller cannot be paused held at a temperature during the ramp stage except by changing the Final Set Point PC2007 12 Automatic Heat Treatment Console REV 0 07 ET mantimadtraco nam to the desired temperature Step 1 Press the scroll key O until rP appears then set degrees per hour Ramp Rate by using the up or down key v Step 2 Press the up to down key v to set the Final Set Point ic the bottom display Note When the controller temperature reaches the Final Set Point it will hold that temperature continuously Step 3 Make sure the SPrP set point ramp Initial Set Point is the same as the actual temperature of the controller If not turn controller off then back on by toggling the rocker switch to off position then back on CONT position This will change the SPrP Initial Set Point to the actual t
8. eir function Push No 1 button to display heating rate adjust to requirements with up down buttons Push No 1 again to revert to Profile Push No 2 button to display Soak Temperature adjust to requirements with up down buttons Push No 2 again to revert to Profile Push No 3 button to display Soak Time adjust to requirements with up down buttons Note this display indicates dwell time in hours 1 e 1 1 1 hour 6 minutes 1 5 1 hour 30 minutes Etc Push No 3 again to revert to Profile Push No 4 button to display Cooling Rate adjust to requirements with up down buttons Push No 4 again to revert to Profile Push No 5 button to display program End Temperature adjust to requirements with up down buttons Push No 6 button to display Ready and then press the up button to start the program PC2007 12 Automatic Heat Treatment Console REV 0 07 ET mantimadtraco nam 7 Note P256 Programmer has a reverse thermocouple alarm feature which will turn off the zone if a thermocouple is accidentally reversed this is a safety feature built in to the P256 programmer controller Note Any zone in manual mode will control to its set point regardless of the program profile Starting the program will cause any zone set in automatic to follow the profile The start temperature will be from the highest actual temperature of any zone in automatic Any zo
9. emperature Step 4 For heating or cooling turn the Final Set Point up or down and adjust Ramp Rate rP as per requirements Step 5 Turn percentage timer between 7 10 on scale 1f equipped NOTE When the controller is turned on it automatically sets the SPrP set point ramp Initial Set Point from the thermocouple t c temperature At this point in time it starts to count up or down to the Final Set Point The SPrP set point ramp Initial Set Point cannot be changed manually except by turning the controller off then on ALWAYS Change the Ramp Rate before changing the Final Set Point when changing stages The controller cannot be paused held at a temperature during the ramp stage except by changing the Final Set Point to the desired temperature PC2007 12 Automatic Heat Treatment Console REV 0 07 ur mantimadtraco nam P256 PROGRAMMER CALIBRATION INSTRUCTIONS The P256 programmer has one common measuring circuit which is used by all six of its thermocouple inputs The measuring circuit is factory calibrated by the adjustment of two numbers that are held in the 256s non volatile memory One of the numbers the zero constant adjusts the measuring and cold junction circuits zero offset The other number the span constant adjusts the measuring circuits gain The measuring circuit uses high stability components and so should not need any further adjustment for many months From time to time however it will be necessary to perfo
10. er 1996 NOTE Calibration should be attempted only on Controllers on which calibration errors have been encountered see CALIBRATION CHECK and should only be performed by personnel who are technically competent and authorised to do so CALIBRATING THE UNIVERSAL INPUT Equipment Required 1 Input source with an accuracy better than 0 05 of reading a Thermocouple inputs complete with 0 C reference facility appropriate thermocouple functions and compensating leads or equivalent b DC linear inputs O 5V and 0 20mA c RTD inputs decade resistance box with connections for three wire input or equivalent 2 Appropriate case assembly DIN DIN or DIN wired for appropriate input supply 90 264V AC 50 60Hz 20 50V AC 50 60Hz or 22 65V DC Calibration Procedure 1 Ensure that the Controller is powered off and that the mains line lead is disconnected On the CPU PCB fit the appropriate link jumpers see Table 1 and Figure 1 Figure 2 or Figure 3 as appropri ate to the type of Controller Connect the appropriate input lead see Figure 4 or Figure 5 2 Connect the mains line lead to the Controller Power up the Controller and leave switched on for five minutes for RTD and DC Linear inputs or 30 minutes for thermocouple inputs then power down 3 Put the Controller in Calibration Mode by powering up the Controller and within 30 seconds of power up holding down the Lower and Function keys si
11. lead see Figure 6 2 Connect the mains line lead to the Controller Power up the Controller and leave switched on for five minutes then power down 3 Put the Controller in Calibration Mode by powering up the Controller and within 30 seconds of power up holding down the Lower and Function keys simultaneously for approximately five sec onds The upper display will then show Input Type Number in the form and the lower display will show LAL Using the Raise Lower keys change the input type number as required see Table 2 NOTE If required only one input type may be calibrated 4 Press the Auto Manual key to change the upper display to show After a few seconds the upper display will either a return to the intial Input Type Number display if calibration was successful or b display FH IL In the latter case the link jumpers and wiring should be checked 5 To calibrate all inputs repeat Steps 1 to 4 for each of the other input types see Table 2 until all three secondary analogue input types have been successfully calibrated PC2007 12 Automatic Heat Treatment Console REV 0 07 ummy marntimadtraco nnam 13 14 LDIN DIN 8 DIN Temperature Controllers Input Calibration Procedure Table 2 Secondary Analogue Input Type Selection Link Jumper Settings Calibration Input LJ10 LJ11 Input Type No Input Type 7 Remote Setpoint Linear DC mV 50mV DC Parked Parked 8 Remote Setpoint Linear
12. male Panel Mount Socket Complete PP 20 KX Thermocouple Extension Cable A37 EL 200 amp contactor 100 Duty Cycle A38 110 Volt Neon 52F7431 ON OFF On Rocker Switch Merlin 250 amp 250 amp 3 phase Circuit Breaker with 120 volt uv Release 56F877 15 amp Circuit Breaker 56F876 10 amp Circuit Breaker F A18 Female Thermocouple Panel Mount Type K Fan 340 CFM Cooling Fan 120 V 120 V Receptacle 96F4496 3 Pole Terminal Block 1 Tinned 1 Tinned Cable with lugs please specify length 90F7177 Lug 1 0 3 8 Hole 84F 1876 Aluminium Lugs 3 8 Hole for 250 amp circuit breaker PC2007 12 Automatic Heat Treatment Console REV 0 07 wir martimadtraco nnam
13. multaneously for approximately five sec onds The upper display will then show Input Type Number in the form and the lower display will show LAL Using the Raise Lower keys change the input type number as required see Table 1 NOTE If required only one input type may be calibrated Exception If it is required to calibrate the thermocouple input Input Type 5 it is necessary first to calibrate the DC 0 50mV input Input Type 1 4 Press the Auto Manual key to change the upper display to show After a few seconds the upper display will either a return to the intial Input Type Number display if calibration was successful or b display FA IL In the latter case the link jumpers and wiring should be checked E PC2007 12 Automatic Heat Treatment Console REV 0 07 wnt marntimadtraco nam 12 L DIN DIN amp 4 DIN Temperature Controllers Input Calibration Procedure Table 1 Universal Input Type Selection Link Jumper Settings Input Type No Input Type Calibration Input LJ1 LJ2 LJ3 1 DC 0 50mV 50mV DC Parked Parked Parked 2 DC O 10V 10V DC Fitted Parked Parked 3 DC O 20mA 20mA DC Parked Fitted Parked 4 RTD Three wire 2002 Parked Parked Parked 5 Thermocouple 0 C K Parked Parked Fitted Figure 1 DIN Link Jumpers Relay SSR Output 1 Figure 2 DIN Link Jumpers DC Output 1 Top of Controller 168178 18 J 7 on 4 INPUT Linear mA Linear V mV Thermocouple MN T
14. ne heating too slowly for the set heating profile will cause the program to go into a hold mode until that zone has caught up with the profile setting On delivery the hold band is set to 20 C so any zone running a profile that lags the set point by 20 C will start the hold Once the program has started the down button can be used to alternate between programs Profile Overview or the Controller Overview If a hold situation arises it will be displayed on either screen For more detailed instructions refer to User Manual for 256 Programmer 1 Make sure zones used are indicating the actual temperature on the controllers 6600 prior to start and then turn rocker switches to the MAN position 2 Decide on the heat treatment specification and set as follows 6600 Digital Temperature Controllers Step 1 Press the scroll key O until rP appears then set degrees per hour Ramp Rate by using the up or down key v Step 2 Press the up to down key v to set the Final Set Point ic the bottom display Note When the controller temperature reaches the Final Set Point it will hold that temperature continuously Step 3 Make sure the SPrP set point ramp Initial Set Point is the same as the actual temperature of the controller If not turn controller off then back on by toggling the rocker switch to off position then back on CONT position This will change the SPrP Initial Set Point to the actual temperatur
15. oth are OK Use V to exit cal mode Use 1 for more To exit calibration mode press the down arrow button and normal instrument operation will resume To continue with the calibration procedure press button 1 whereupon the screen changes to ZERO CALIBRATION Value Zk 00 7 05918 Set calibrator to 0 deg and Use v unit value 0000 0 Use 1 for more This shows the zero calibration screen for an instrument with a zero constant of 5918 which reads a temperature of 0 7 degrees for a calibrator input of 0 0 degrees If this error is unacceptable it may be corrected by using the up or down buttons to change the zero constant until the value is shown as 0000 0 Note that the zero constant can only be set within the range 5700 to 6100 When you are sure that the zero calibration is correct then press button 1 and the screen will change to PC2007 12 Automatic Heat Treatment Console REV 0 07 ET mantimadtraco nam 10 SPAN CALIBRATION Value Sk 999 1 33862 Set calibrator to 1000 deg and Use v until value 1000 0 Use 1 for more This shows the span calibration screen for an instrument with a span constant of 33862 which reads a temperature of 999 1 degrees for a calibrator input of 1000 degrees If this error is unacceptable it may be corrected by using the up or down buttons to change the span constant until the value is shown as 1000 0 Note that the span constant can only be set within a range 32250 to 35650 When you
16. perature on the programmer P256 prior to start and then turn rocker switches to the PRG position Decide on the heat treatment specification and set as follows for both programmers P256 Six Channel Digital Programmer a On start up The display shows Logo 256 and version number It then reverts to the Controller Overview The large number on the left hand side of each box shows the zone number The small letter a or m on the right hand side indicates if the zone is in AUTO of MANUAL mode The larger number below shows the temperature of the thermocouple in that zone b By pushing the zone button once that display shows the manual set point for that zone It is recommended that this is set at about 10 C if no manual operation is required The value is altered by use of the up down buttons c Push the zone button a second time the display will show if the zone is in AUTO or MANUAL mode this again can be altered by use of the up down button Set the zone in the AUTO mode d Pushing the button a third time reverts the screen back to Controller overview if no button is pushed for 20 seconds the screen automatically reverts to Controller overview Set each zone to be used in the Automatic mode e While in the Controller Display mode push the down button once and the display will change to show the Profile overview The six numbered buttons have now changed th
17. rm routine calibration checks and make adjustments to the instruments calibration The following procedure should be used to make these adjustments To calibrate the instrument on the bench you should connect a calibrator to thermocouple input 1 using type K compensating or extension wire To calibrate the instrument in situ you should disconnect thermocouple 1 and output 1 from the installation and connect the calibrator in its stead again using type K wire In both cases switch the instrument on and leave it energised for about fifteen minutes to reach its operating temperature Then briefly switch the instrument off for a few seconds and then switch back on It will then show the opening logo on the screen for twenty seconds During these twenty seconds you must enter the password using the front panel buttons The password is a fixed five digit number that cannot be changed by the user It would be wise to keep this password secret from all unauthorised persons The password at this time is 1 1 1 7 2 using the up arrow button for 7 If you have entered this correctly the logo will immediately disappear and be replaced with the calibration mode opening screen If you enter the wrong password there will be no effect and you will have to start over by switching the instrument off briefly again The calibration mode opening screen shows the following prompt CALIBRATION MODE Connect calibrator to I P1 Use comp cable Repeat zero And span cal till b
18. ual indication of program position and output status at any time SPECIFICATIONS PC2007 12 Heat Treatment 12 way Console Length 44 Width 36 Height 38 Weight Approx 1275 lbs Material 12 gauge stainless steel cabinet Wheels 900 Ibs capacity each with brake 4 SS mounting brackets available upon request Handling Forklift access Inputs gt Voltage 480 565 575 604 3 Phase gt Current 200 amp gt Power 130 KVA Isolated Copper Wound gt Frequency 60 Hz Output Per Zone gt Zones 12 gt Voltage 80 VAC single phase gt Current 135 amps 80V gt Power 10 8 KVA gt Activation 200 amp contactor gt Control per zone Digital temperature controller or P256 programmer Control Circuit gt Voltage 110 VAC single phase gt Current 10 amp circuit breaker gt Power 1650 VA winding on power transformer gt Auxiliary 110 VAC supply single phase PC2007 12 Automatic Heat Treatment Console REV 0 07 nar marntimadtraco nnam 6 x Digital Temperature Controller 6600 gt Temperature Range 0 2200 F or 0 1200 C gt Thermocouple Type K gt Resolution Measurement 0 1 degrees Display 1 0 degree 2 x 6 Channel Temperature Programmer Controller P256 gt Temperature Range 0 2000 F or 0 1200 C gt Thermocouple Type K gt Resolution Measurement 0 1 degrees Display 1 0 degree Amp Meter Supplied by client Protection gt 120 VAC Control
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