RP160000NA Rapid E Batch Oven Manual.book
Contents
1. Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service Before servicing equipment equipment must be locked out and tagged out at More than one disconnect switch may be disconnect required to disconnect electric from Do not operate fans without access panels equipment or fittings in place Equipment must be properly grounded WARNING Explosion Hazard Falling Hazard Burn Hazard Do not put combustible Use proper safety Do not come into contact items in equipment without equipment and practices to with inside surfaces of exhaust fan avoid falling equipment during and after operation Do not exceed maximum Do not use any part of solvent or volatile loading equipment as support Inside surfaces are hot as listed on Safety Design Form label Secure doors before entering equipment Doors can close Maintain safe clearance Failure to follow these instructions can result in death injury or property damage Installation Code and Annual Inspections All installations and service of equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Rapid Engineering LLC and conform to all requirements set forth in the RAPID manuals and all applicable governmental authorities pertaining to the installation service and operation of the equipment To help facilitate optimum performance and safety Rapid Enginee2. 26 12 5 Fil 5 L La uuu tere 26 SECTION 13 Replacement Parts 27 SECTION 14 Troubleshooting 28 14 1 Initial Checks sese 29 14 2 General 14 3 Temperature Controller SECTION 15 The RAPID E Series Warranty 2013 Rapid Engineering LLC All rights reserved No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Rapid Engineering LLC Printed in U S A TABLE OF FIGURES Figure 1 Label Placement Drawing for Batch Oven 2 Figure 2 Lifting the Batch Oven 10 Figure 3 Panel Layout 14 Figure 4 Interconnects 14 Figure 5 Wiring Diagram em 15 Figure 6 Wiring Diagram continued 16 Figure 7 Wiring Diagram continued 17 LIST OF TABLES Table 1 Recommended Torque Settings 5 Table 2 Specifications 8 Table 3 Spe
3. Defective thermocouple Replace thermocouple Burner purging light does not light up after fans come on Purging completes cycle heaters do not come on Heat on light does not come on All fans not running Check all fans High temperature limit controller is tripped Check temperature set point versus actual temperature and then push reset Recirculation fan or exhaust fan air flow switch not proving Check air flow switches on these fans for damaged or obstructed sensing lines Adjust sensing lines or switch as necessary Bad light bulb Heat Start Stop knob is in the stop position Replace light bulb Place to start position Solid state relay is bad Reset circuit breakers Replace relay Heating element circuit breakers are tripped 30 of 35 14 3 Temperature Controller 14 3 1 Display Error Messages SECTION 14 TROUBLESHOOTING DISPLAY DESCRIPTION ACTION REQUIRED PV b150 Display on Start Up No action required SV rr PV No No Input Probe Verify that sensor is wired to proper terminals Next check that the controller is programmed for the correct input type SV Cont Most commonly seen when controller is programmed for a RTD while a thermocouple is connected PV Err Input Error Verify that the input is wired to the proper terminals Next check to see if the input type is set to the proper value
4. Most commonly seen when controller is programmed for a SV inPt 4 to 20 mA input and 0 to 20 mA signal is wired to the con troller PV 2001 Process value flashes when outside Input signals may normally go above or below range limits 0 0 of range If no check input and correct the process temperature or SV increase temperature range limits using tP H and tP L PV Err Error EEPROM Call Rapid Engineering LLC SV Pron 14 3 2 Communication Error Messages ERROR STATUS PV READ BACK 102EH 4750H 1000H 4700H ERROR STATUS 0001H N A PV Unstable 0002H 8002H Re initialize no temperature at this time 0003H 8003H Input sensor did not connect 0004H 8004H Input Signal Error 0005H N A Over Input Range 0006H 8006H ADC fail 0007H N A EEPROM read write error 31 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL 32 of 35 SECTION 14 TROUBLESHOOTING Raps 70 START UP FORM 1100 Seven Mile Road NW BATCH OVEN WITH UAM Fax 616 784 1910 ELECTRIC HEAT www rapidengineering com Page 1 of 3 Customer Project Number Technician Model Number Date Serial Number Field start up should be performed by a qualified technician The technician is responsible for assuring that all of the items on this checklist are properly installed and operating Upon completion a copy of this form should be returned to Rapid Engineering LLC using the contact information listed in the header DANGER
5. 30 ftelb Bolt Head eo 00 Nut Grade Marking Bolt Size Grade 8 8 Grade 10 9 M5 6Nm 9Nm M6 10Nm 15Nm M8 25Nm 35Nm M10 50Nm 75Nm M12 85Nm 130Nm M16 215Nm 315Nm 5 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 4 NATIONAL STANDARDS AND APPLICABLE CODES 4 1 National Standards and Applicable Codes All appliances must be installed in accordance with the latest revision of the applicable standards and national codes This refers to the electric ventilation exhaust and installation Note Additional standards for installation in aircraft hangars etc may be applicable 4 2 Electrical Electrical connection to batch oven must be in accordance with the following codes United States Refer to National Electrical Code NFPA 70 latest revision Wiring must conform to the most current National Electrical Code local ordinances and any special diagrams furnished Canada Refer to Canadian Electrical Code CSA 22 1 Part 1 latest revision 6 of 35 SECTION 5 SPECIFICATIONS ho fo TOP VIEW FRONT VIEW SECTION 5 SPECIFICATIONS NOTE For dimensioning purposes Model E468 is composed of two Model E464 ovens mounted end to end Model G E444 in 4 3 cm E464 in 43 cm 7 of 35 E SERIES INSTALLATION
6. WARNING hOM Rapid Engineering Rapid E Series Keep all flammable objects liguids and Sta n d d rd E ctri C vapors the minimum required clear ances to combustibles away from equipment Batch Ove ns Some objects will catch fire or explode when placed close to equipment Installation Operation amp Failure to follow these instructions can result in death injury or property Se rvi C e M d n u a damage E444 E464 E468 Fire Hazard A WARNING Installer Please take the time to read and understand these instructions prior to any installation Installer must give a copy of this manual to the owner Improper installation adjustment alteration service or maintenance can result in death injury or property damage Read the installation operation and service manual thoroughly before Owner installing or servicing this equipment Keep this manual in a safe place in order to provide Installation must be done by a registered installer your service technician with necessary information contractor qualified in the installation and service of industrial process and finishing equipment NOT FOR RESIDENTIAL USE Rapid Engineering LLC 1100 Seven Mile Road NW Comstock Park MI 49321 Telephone 1 616 784 0500 Fax 1 616 784 1910 Toll Free 800 536 3461 www rapidengineering com www rapidbatchovens com O 2013 Rapid Engineering LLC P N RP160000NA Orig 12 13 TABLE OF CONTENTS SECTION 1 B
7. h exhaust fan is 5 12 7cm diameter pipe of a minimum 22 gauge galvanized steel Recommended vent pipe for a batch oven equipped with a 120 CFM 204 m h exhaust fan is 4 10 1cm diameter pipe of a minimum 22 gauge galvanized steel The installer must provide a rain cap or weather cap All joints must be sealed Do not support the weight of the vent pipe on the exhaust fan s flange Maximum vent pipe length horizontal or vertical of a 12 of 35 batch oven with an exhaust fan at 0 5 in wc external static pressure ESP is 30ft 9 1m with no more than two 45 elbows Total ESP must not exceed 0 5 W C Do not install dampers or other restrictive devices in the vent pipe The vent pipe should not be installed in such a manner that access to the components is obstructed The vent pipe shall have a minimum of at least 36 91 4 cm clearance to combustibles and be guarded to protect personnel from coming in contact Approved listed thimble is to be used wherever the vent pipe passes SECTION 9 ELECTRICAL DANGER Electrical Shock Hazard Disconnect electric before service More than one disconnect switch may be required to disconnect electric from equipment Equipment must be properly grounded Failure to follow these instructions can result in death or electrical shock Each batch oven is equipped with a wiring diagram See Page 15 Figure 5 through Page 17 Figure 7 Note Spark testing or shorting o
8. 1 2 1 2 5 3x5 8x5 1 6x1 8x1 5 64 18 1 550 703 450 232 30 12 E464 15 480 xx 4x6x4 1 2x1 8x1 2 5 3x7 8x5 1 6 24 15 96 27 1 700 771 450 232 15 6 E464 30 480 xx 4x6x4 1 2x1 8x1 2 5 3 7 8 5 1 6x2 4x1 5 96 27 1 700 771 450 232 30 12 E464 15 480 xx E 4x6x4 1 2x1 8x1 2 5 3x7 8x5 1 6 24 15 96 27 1 700 771 450 232 15 6 E464 30 480 xx E 4x6x4 1 2 1 8 1 2 5 3x7 8x5 1 6x2 4x1 5 96 27 1 700 771 450 232 30 12 E464 15 240 xx 4x6x4 1 2x1 8x1 2 5 3x7 8x5 1 6x2 4x1 5 96 27 1 700 771 450 232 15 6 E464 30 240 xx 4x6x4 1 2x1 8x1 2 5 3x7 8x5 1 6x2 4x1 5 96 27 1 700 771 450 232 30 12 E464 15 240 xx E 4x6x4 1 2 1 8 1 2 5 3x7 8x5 1 6x2 4x1 5 96 27 1 700 771 450 232 15 6 E464 30 240 xx E 4x6x4 1 2x1 8x1 2 5 3x7 8x5 1 6x2 4x1 5 96 27 1 700 771 450 232 30 12 E464 15 220 xx 4x6x4 1 2x1 8x1 2 5 3x7 8x5 1 6x2 4x1 5 96 27 1 700 771 450 232 15 6 E464 30 220 xx 4x6x4 1 2x1 8x1 2 5 3x7 8x5 1 6 24 15 96 27 1 700 771 450 232 30 12 E464 15 220 xx E 4x6x4 1 2x1 8x1 2 5 3x7 8x5 1 6x2 4x1 5 96 27 1 700 771 450 232 15 6 E464 30 220 xx E 4x6x4 1 2x1 8x1 2 5 3x7 8x5 1 6 24 15 96 27 1 700 771 450 232 30 12 E468 30 480 xx 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 30 12 E468 60 480 xx 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 60 24 E468 30 480 xx E 4x6x
9. Label Shock Hazard Mini 91070010 Label Burn Hazard 91070011 Label Fire Hazard Overheating 91070012 Label Explosion Hazard 91070013 Label Severe Injury Hazard 91070014 Label Noxious Fumes Hazard 91070016 Label Proposition 65 Air 91070023 Label Safety Design 91070024 Label Rating 91070025 ES Label Operating Instructions EN ES 91070025 FC Label Operating Instructions EN FC 91070026 Label Product Damage Hazard TOP VIEW CO 01 A N k E N E E A o _ E APPLIED TO PACKAGING ON OPPOSITE SIDES OF UNIT 2 of 35 SECTION 2 INSTALLER RESPONSIBILITY The installer is responsible for the following To install the batch oven as well as the electrical supply in accordance with applicable specifications and codes Rapid Engineering LLC recommends the installer contact a local building inspector or Fire Marshal for guidance To use the informat
10. 1 Wiring and Electrical Connections 13 9 2 Motor Current Draw 13 9 3 Control Current Draw 13 9 4 016 661 13 9 5 Safety Systems 13 9 6 Recirculating Fan Airflow Switch 13 9 7 Exhaust Fan Airflow Switch 13 9 8 High Temperature Limit Switch 13 SECTION 10 Sequence of Operation 18 10 1 Batch Oven Configuration 18 19 2 Gontrol Panel rn HH 18 10 3 Temperature Controller 18 10 4 Batch TU uu uuu ua 19 10 5 Basic Sequence of Operation 20 SECTION 11 Start up Procedures 21 11 1 Pre Start Up Checks 22 11 2 Blocca iconos 22 EU 22 11 4 Batch Oven Operation 22 11 5 Batch Timer Operation 23 SECTION 12 Maintenancoe 24 12 1 General nano 25 12 2 Unit Exterior ica acme nine 25 12 3 FANS c 26 12 4 Heater Elements
11. OPERATION AND SERVICE MANUAL Table 2 Specifications Physical Data Heat Data inside Quts de Interior Approxm ale Maximum Heat Model Dimensions Dimensions Size Shipping Temperature Output Element WxHxD W x Hx D Weight Qty ft m ft m f m Ib kg F C kW E444 15 480 xx 4x4x4 1 2x1 2x1 2 5 3 5 8 5 1 6x1 8x1 5 64 18 1 550 703 450 232 15 6 E444 30 480 xx 4x4x4 1 2x1 2x1 2 5 3x5 8x5 1 6x1 8x1 5 64 1 8 1 550 703 450 232 30 12 E444 15 480 xx E 4x4x4 1 2x1 2x1 2 5 3x5 8x5 1 6x1 8x1 5 64 1 8 1 550 703 450 232 15 6 E444 30 480 xx E 4x4x4 1 2x1 2x1 2 5 3 5 8 5 1 6x1 8x1 5 64 1 8 1 550 703 450 232 30 12 E444 15 240 xx 4x4x4 1 2x1 2x1 2 5 3x5 8x5 1 6x1 8x1 5 64 1 8 1 550 703 450 232 15 6 444 30 240 4x4x4 1 2 1 2 1 2 5 3x5 8x5 1 6x1 8x1 5 64 18 1 550 703 450 232 30 12 E444 15 240 xx E 4x4x4 1 2x1 2x1 2 5 3 5 8 5 1 6x1 8x1 5 64 18 1550 703 450 232 15 6 E444 30 240 xx E 4x4x4 1 2x1 2x1 2 5 3x5 8x5 1 6x1 8x1 5 64 18 1 550 703 450 232 30 12 E444 15 220 xx 4x4x4 1 2x1 2x1 2 5 3x5 8x5 1 6x1 8x1 5 64 1 8 1 550 703 450 232 15 6 E444 30 220 xx 4x4x4 1 2x1 2x1 2 5 3x5 8x5 1 6x1 8x1 5 64 1 8 1 550 703 450 232 30 12 E444 15 220 xx E 4x4x4 1 2x1 2x1 2 5 3x5 8x5 1 6x1 8x1 5 64 1 8 1 550 703 450 232 15 6 444 30 220 4x4x4 1 2
12. h HP kW HP kW HP kW FLA Exhaust Exhaust Fan A Fan A E444 15 480 xx 2 400 4077 05 037 1480 3 60 18 0 E444 30 480 xx 2 400 4077 05 037 N A 480 3 60 36 1 N A N A E444 15 480 xx E 2 400 4 077 0 5 0 37 0 03 0 02 0 02 0 01 480 3 60 18 0 211 214 E444 30 480 xx E 2 400 4077 05 0 37 0 03 0 02 0 02 0 01 480 3 60 36 1 39 2 39 5 E444 15 240 xx 2 400 4077 05 037 NA 240 3 60 36 1 N A N A E444 30 240 xx 2 400 4 077 05 037 240 3 60 72 2 N A N A E444 15 240 xx E 2 400 4077 05 0 37 0 03 0 02 0 02 0 01 240 3 60 36 1 42 6 42 9 E444 30 240 xx E 2 400 4077 05 037 0 03 0 02 0 02 0 01 240 3 60 72 2 78 7 79 0 444 15 220 2 400 4077 05 0 37 NA 220 1 60 68 2 E444 30 220 xx 2 400 4077 05 037 NA NA NA 220 1 60 136 4 N A N A E444 15 220 xx E 2 400 4 077 0 5 0 37 0 03 0 02 0 02 0 01 220 1 60 68 2 76 5 76 8 E444 30 220 xx E 2 400 4 077 0 5 0 37 0 03 0 02 0 02 0 01 220 1 60 136 4 144 7 145 0 E464 15 480 xx 2 400 4077 05 0 37 480 3 60 18 0 N A N A E464 30 480 xx 2 400 4077 05 0 37 480 3 60 36 1 N A N A E464 15 480 xx E 2 400 4 077 0 5 0 37 0 03 0 02 0 02 0 01 480 3 60 18 0 211 214 E464 30 480
13. recommends that a qualified contractor conduct at a minimum annual inspections of your RAPID equipment and perform service where necessary using only replacement parts sold and supplied by Rapid Engineering LLC Check installation site to ensure all codes and engineering specifications are correct This section of the manual is intended to be used as an instructional guide to the commissioning of the electric batch oven Fill out the attached start up sheet located at the back of the manual as each step of the procedure is performed This procedure should be completed by the commissioning contractor and returned to Rapid Engineering LLC 11 1 Pre Start Up Checks 11 2 Electrical 1 Check motor starter for proper overload set tings The overload setting should exceed the full load amps FLA of motor by 10 2 Measure the supply voltage with the batch oven off and then on For a system that is pow ered with three phase power measure the volt age of each phase 3 Verify correct blower rotation 4 While the blower is running and the heating elements are off measure the total system cur rent draw with an ammeter Measure the sys tem current draw again with the heating elements and blower both on 11 3 Airflow Factory calibrated the air flow switches are safety devices If an air flow switch does not close the problem may not be the air flow switch It could be an indication of an air flow problem incorrect blow
14. xx E 2 400 4077 05 0 37 0 03 0 02 0 02 0 01 480 3 60 36 1 39 2 39 5 E464 15 240 xx 2400 4077 05 037 NA 240 3 60 36 1 N A N A E464 30 240 xx 2400 4077 05 037 NA 240 3 60 72 2 N A N A E464 15 240 xx E 2 400 4 077 0 5 0 37 0 03 0 02 0 02 0 01 240 3 60 36 1 42 6 42 9 E464 30 240 xx E 2 400 4 077 0 5 0 37 0 03 0 02 0 02 0 01 240 3 60 72 2 78 7 79 0 E464 15 220 xx 2 400 4 077 05 0 37 NA N A 220 1 60 68 2 N A N A E464 30 220 xx 2 400 4 077 05 0 37 N A NA 220 1 60 136 4 N A N A E464 15 220 xx E 2 400 4 077 0 5 0 37 0 03 0 02 0 02 0 01 220 1 60 68 2 76 5 76 8 E464 30 220 xx E 2 400 4 077 0 5 0 37 0 03 0 02 0 02 0 01 220 1 60 136 4 144 7 145 0 E468 30 480 xx 4 800 8 155 1 0 75 N A N A 480 3 60 36 1 N A N A E468 60 480 xx 4 800 8 155 1 0 75 N A N A 480 3 60 72 2 N A N A E468 30 480 xx E 4 800 8 155 1 0 75 0 03 0 02 0 02 0 01 480 3 60 36 1 40 2 40 5 E468 60 480 xx E 4 800 8 155 1 0 75 0 03 0 02 0 02 0 01 480 3 60 72 2 78 7 79 0 E468 30 240 xx 4 800 8 155 1 0 75 N A 240 3 60 72 2 N A N A E468 60 240 xx 4 800 8 155 1 0 75 NA NA 240 3 60 144 3 N A N A E468 30 240 xx E 4 800 8 155 1 0 75 0 03 0 02 0 02 0 01 240 3 60 72 2 85 5 85 8 E468 60 240 xx E 4 800 8 155 1
15. 0 75 0 03 0 02 0 02 0 01 240 3 60 144 3 1576 1579 E468 30 220 xx 4 800 8 155 1 075 NA NA NA N A 220 1 60 136 4 N A N A E468 60 220 xx 4 800 8 155 1 075 NA NA NA N A 220 1 60 272 7 N A N A E468 30 220 xx E 4 800 8 155 1 0 75 0 03 0 02 0 02 0 01 220 1 60 136 4 153 3 153 6 E468 60 220 xx E 4 800 8 155 1 0 75 0 03 0 02 0 02 0 01 220 1 60 272 7 289 6 289 9 NOTE FLA ratings may vary depending on supply voltage Consult factory for more information 9 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 6 LIFTING A BATCH OVEN WARNING Crush Hazard Use proper lifting equipment and practices Failure to follow these instructions can result in death injury or property damage The batch oven must be installed in compliance with all applicable codes The qualified installation technician must use best building practices when installing the batch oven and any optional equipment 6 1 Lifting a Batch Oven 6 1 1 Preparing to Lift the Batch Oven Prior to lifting the batch oven the following steps must be performed 1 Remove all packaging or banding that attached the batch oven to the skid and ensure that the batch oven is no longer bound to the skid 2 Remove all packaging and blockers 3 Inspect the batch oven to e Verify that there is no damage as a result of shipping e Ensure that it is appropriately rated for the utilities available at the
16. 14 TROUBLESHOOTING DANGER Q Electrical Shock Severe Injury Hazard Disconnect electric before service Before servicing equipment equipment must be locked out and tagged out at More than one disconnect switch may be disconnect required to disconnect electric from Do not operate fans without access panels equipment or fittings in place Equipment must be properly grounded Failure to follow these instructions can result in death electrical shock or injury A WARNING Explosion Hazard Fire Hazard Falling Hazard Burn Hazard Do not put combus Do not overheat items Use proper safety Do not come into tible items in equip placed in equipment equipment and contact with inside ment without exhaust ins can practices to avoid surfaces of equipment fan catch fire falling during and after operation Do exceed Equipment Do not use any part of mum solvent or vola temperature setpoint equipment as support Inside surfaces are tile loading as listed ee hot on Safety Design temperature listed in Form label items Material Safety Secure doors before Data Sheets 505 entering equipment Doors can close Maintain safe clear ance between equip ment and trafficways to avoid contact with equipment Allow equipment to cool before service Failure to follow these instructions can result in death injury or property damage 28 of 35 14 1 Initial C
17. 8 1 2x1 8x2 4 5 3 7 8 9 1 6x2 4x2 7 192 54 3400 1 542 450 232 30 12 E468 60 480 xx E 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 60 24 E468 30 240 xx 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 30 12 E468 60 240 xx 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 60 24 E468 30 240 xx E 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 30 12 E468 60 240 xx E 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 60 24 E468 30 220 xx 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 30 12 E468 60 220 xx 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 60 24 E468 30 220 xx E 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 30 12 E468 60 220 xx E 4x6x8 1 2x1 8x2 4 5 3x7 8x9 1 6x2 4x2 7 192 54 3400 1 542 450 232 60 24 8 of 35 Table 3 Specifications SECTION 5 SPECIFICATIONS 120 CFM 230 CFM Recirculation Fan Data 209m 390 MT Electrical Data Exhaust Exhaust Model Fan Data Fan Data Airflow Motor Size Motor Size Motor Size Total FLA w Total FLA w V lHz Element 120 CFM 230 CFM m
18. Menu AL2H Alarm 2 High Set Point May not appear depending on ALA2 setting in Initial Setting Menu AL2L Alarm 2 Low Set Point May not appear depending on ALA2 setting in Initial Setting Menu LoC Set front panel security lock LOC1 Lock all settings LOC2 Lock all settings except the set point Display the output value for output 1 In manual mode oUt1 this value can be changed using the up and down arrows SECTION 10 SEQUENCE OF OPERATION 10 4 Batch Timer Output TIMER Current Indicator Valve Set Valve Preset Protection Valve Indicator Digit Keys Reset Key The batch timer interface consists of the following 1 Output Indicator red This lights when output is ON It flashes when alarm output is ON 2 Protection Indicator red This flashes when it is in key protect node only at the time of key ON 3 Current Value Indicator red It indicates the current value 4 Set Value Indicator red It indicates the set value h hour m minute s second 5 Preset Value Indicator green It indicates the preset value 6 Reset Key The current value is reset 0 when displaying the current time preset value when displaying the remaining time Z Digit Keys After changing the preset value the preset value becomes effective after a condi tion of no key input has lasted for about one second 19 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL 10 5 Basic Se
19. NING Electrical Shock Hazard Explosion Hazard Fire Hazard Use only genuine RAPID replacement parts per this installation operation and service manual Failure to follow these instructions can result in death electric shock injury or property damage Replacement parts list is general and MAY NOT BE APPLICABLE FOR your specific batch oven Before ordering replacement parts please contact factory to make sure that the replacement parts are the direct replacement for your specific batch oven Table 6 Replacement Parts Description Part Number Alarm Horn 20328 Backplate 36 x 24 702274 Bracket 99965 Contactor 30884 Contactor 25261 Control Panel 22766 Cooling Fan 14543 Distribution Block 115 3 18509 Fan Guard Wire 14545 Filter Kit 14544 Fuse 25099 Fuse 25135 Fuse 25902 Fuse 17989 Fuse 60 A 25053 Fuse Block 30 A 600 V 25179 Jumper 8 Position 25053 Light Amber 250 V 22550 Relay 25855 Solid State Relay 20326 Switch Airflow Recirculation Fan N A Switch High Temperature Limit 14546 Switch Selector 3 Position with Spring Return Center 17357 Switch Toggle DPDT 18668 Temperature Controller 8282 Thermocouple J with 5 Leads 20327 Timer Purge 16321 Timer Purge Base 8 Pin 16322 Timing Relay 26332 Transformer 220 480 V 120 VAC 500 VA 08127 27 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION
20. atch Oven Safety 1 1 1 Description 1 1 2 Inspection and Setup 1 1 3 Safety Labels and Their 1 1 4 California Proposition 65 1 SECTION 2 Installer Responsibility 3 2 1 Corrosive Chemicals 3 2 2 Required Equipment 4 SECTION 3 Critical Considerations 5 3 1 Required Clearances to Combustibles 5 3 2 eerte ERR er eh 5 SECTION 4 National Standards and Applicable Codes 6 4 1 National Standards and Applicable Codes 6 4 2 Electrical u een 6 SECTION 5 Specifications 7 SECTION 6 Lifting a Batch Oven 10 6 1 Lifting a Batch Oven 10 SECTION 7 Batch Oven Installation 11 SECTION 8 Venting 12 8 1 General Venting Requirements 12 8 2 Recommended Venting Practices 12 SECTION 9 Electrical 13 9
21. cedure at this time and check control settings 12 2 Unit Exterior Cabinet Exterior After installation touch up scratches Periodic painting should be done there after as required Caulk should be inspected annually Re apply caulk as needed to maintain integrity Unit Location oven Verify that no flammable objects liquids or vapors are present near the batch Do not hang anything from or place anything on the batch oven Keep the area under and around the batch oven free of all objects Maintain minimum clearances to combustibles at all times 25 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL 12 3 Fans Fan Blades Inspect fan blades and clean as necessary A small build up of dust can cause a significant decrease in fan performance Check for excessive vibra tion repair as required Motors Inspection 1 Inspect motor every months 500 hours of operation which ever occurs first Keep the motor clean and vent openings clear Lubrication 1 Motors with grease fittings must be lubricated based on the table below Table 5 Motor Lubrication Intervals NEMA Frame Size Motor HP Rated at 1800 RPM Hrs Up to 210 3 5 6 000 Over 210 to 280 7 5 20 4 750 Over 280 to 360 25 50 3 700 Note These intervals are based on severe duty Over lubricating bearings could result in reduced motor life 2 Ahigh grade ball or roller bearing grease must be use
22. cifications 9 Table 4 Safety 13 Table 5 Motor Lubrication Intervals 26 SECTION 1 BATCH OVEN SAFETY Your Safety is Important to Us This symbol is used throughout the manual to notify you of possible fire electrical or burn hazards Please pay special attention when reading and following the warnings in these sections Installation service and annual inspection of batch ovens must be done by a contractor qualified in the installation and service of industrial process and finishing equipment Read this manual carefully before installation operation or service of this equipment This batch oven is designed for use in non residential indoor spaces Do not install in residential spaces These instructions the layout drawing local codes and ordinances and applicable standards that apply to electrical wiring ventilation etc must be thoroughly understood before proceeding with the installation Protective gear is to be worn during installation operation and service Thin sheet metal parts have sharp edges To prevent injury the use of work gloves is recommended The equipment must be applied and operated under the general concepts of reasonable use and installed using best building practices This appliance is not intended for use by persons includi
23. d Recommended grease for standard service is Polyrex EM Exxon Mobil Other com patible greases include Texaco Polystar Rykon Premium 2 Pennzoil Pen 2 Lube and Chevron SRI 3 Motors without grease fittings are sealed for life and do not require re lubrication Instructions for Lubricating Before greasing be sure fittings are clean and free from dirt Remove grease relief plug or plate and using a low pressure grease gun pump in the required grease Do not over grease Relubrication intervals are specified in the table above After relubricating allow motor to run for 10 minutes before replacing relief hardware NOTE In general it is not recommended to mix greases of different brands The mixing of different types of thickeners may destroy the composition and physical properties of the grease In the event that a different grease is required by the end user the following steps can be taken Using the instruc tions for lubrication open grease outlet and purge the system as much as possible of the old or unwanted grease Repeat this same operation after 1 week of service Consult Rapid Engineering LLC or the motor manufacturer for further recommendations on grease compatibility 12 4 Heater Elements Check wire bus bar connections Tighten as required 12 5 Filters Check power box cooling fan filter Clean as required 26 of 35 SECTION 13 REPLACEMENT PARTS SECTION 13 REPLACEMENT PARTS A DANGER A WAR
24. ent so that the batch oven may be placed in a safe manner The qualified installing service technician is responsible for having the appropriate equipment for the safe installation and start up of a batch oven Tools required to commission the equipment include but are not limited to the following e Various screwdriver types and sizes Crescent wrench e Digital multi meter e Clamp style ammeter 4 of 35 SECTION 3 CRITICAL CONSIDERATIONS A WARNING Fire Hazard Keep all flammable objects liquids and vapors the minimum required clearances to combustibles away from equipment Some objects will catch fire or explode when placed close to equipment Failure to follow these instructions can result in death injury or property damage 3 1 Required Clearances to Combustibles Clearances are the required distances that combustible objects must be away from the batch oven to prevent fire hazards Combustibles are materials that may catch on fire and include common items such as wood paper rubber fabric etc Maintain clearances to combustibles at all times for safety Check the clearances on the batch oven being installed to make sure the product is suitable for your application and the clearances are maintained Minimum clearances for all models are as follows 36 91 4 cm Above the top of the equipment 36 91 4 cm Along the sides of the equipment 36 91 4 cm Around the exhaust piping Read and fo
25. er rotation duct restrictions etc 22 of 35 11 4 Batch Oven Operation 11 4 1 General 1 Close disconnect switch Alarm sounds 2 Reset alarm horn by pushing ALARM SILENCE push button 11 4 2 Oven Start 1 Place RUN AUTO toggle switch to RUN 2 Press RST on batch timer 3 Rotate FANS switch clockwise to START and hold for 3 seconds FANS ON and OVEN PURGING lights illuminate Oven recirculating power cabinet cooling and exhaust fans start 4 Rotate HEAT switch clockwise to START after OVEN PURGING light goes out HEAT light illuminates 5 Adjust temperature controller to desired set point 11 4 3 Oven Shutdown 1 Rotate HEAT switch counter clockwise to STOP HEAT ON light turns off and alarm sounds 2 Reset alarm horn by pushing ALARM SILENCE push button 3 Fans Shutdown Options a Automatic Place RUN AUTO toggle switch to AUTO Fans will shut off automatically when oven temperature drops below 125 F 51 7 C b Manual Rotate FANS switch counterclockwise to STOP 11 5 Batch Timer Operation 1 2 Set batch timer to the desired batch time Batch timer begins to count when desired oven temperature comes within 15 F 8 3 C of set point Time elapses heater shuts off and alarm horn sounds Reset alarm horn by pushing ALARM SILENCE push button Enter a new batch
26. f the control wires by any means will render the transformers inoperative 9 1 Wiring and Electrical Connections All electrical wiring and connections including electrical grounding must comply with United States Refer to National Electrical Code NFPA 70 latest revision Wiring must conform to the most current National Electrical Code local ordinances and any special diagrams furnished Canada Refer to Canadian Electrical Code CSA C22 1 Part 1 latest revision Check rating plate on batch oven for supply voltage and current requirements All heater element wiring and jumpers must be 14 AWG high temperature type TGGT braided wire or larger with nickel plated ring terminals Each electrical element is rated for 2 5 kW at 240 Volts See Page 14 Figure 3 through Page 14 Figure 4 Two heaters in series at 480 Volts will drop 240 Volts across each element with 18 Amps per phase leg 14 AWG is rated for 39 Amps at 104 F 40 SECTION 9 ELECTRICAL 9 2 Motor Current Draw For current requirements of the motor see rating plate located on the blower motor 9 3 Control Current Draw The maximum current draw for a batch oven s controls and accessories is 4 5 A 115 Vac 9 4 Disconnect Disconnect and suitable branch circuit protection must be provided by others 9 5 Safety Systems Safety systems are required for proper performance of the batch oven The batch oven shall not be
27. he controller to make any changes to the controller s parameters The LoC2 setting affects all parameters except the set point In order to change any other parameters the operator will have to unlock the control before making a change In order to unlock the control the operator must depress the ENTER and INDEX key simultaneously 10 3 2 Control Operation Description The HOME display is the normal display with the control is operating If no errors or functions are active the HOME display will indicate the Process Variable that is being measured on the top display and the Set Variable on the bottom display 10 3 3 Operation Menu Upon normal operation control will be in the Operation Menu Pressing the INDEX key will cycle through the below menu items The parameter will be displayed in the bottom display except for the set point which is displayed in the bottom display on the Home Display The UP and DOWN arrows change the values of the parameters The ENTER key must be pressed after any changes Adjust the set point value Can be any numerical value 1234 between the upper and lower limit of the temperature range r 5 Select Run Stop Output Control rUn Activates outputs StoP De activates outputs AL1H Alarm 1 Hight Set Point May not appear depending on ALA1 setting in Initial Setting Menu AL1L Alarm 1 Low Set Point May not appear depending on ALA1 setting in Initial Setting
28. hecks When encountering any abnormal operation or fault conditions of the equipment all troubleshooting should start with the following initial checks If a problem is discovered in these initial checks it must be corrected before moving on in the trouble shooting 1 Compare voltage and phase of supply power on site with rating plate information 2 Check for proper blower rotation on batch oven and any exhaust blowers Blowers powered with a three phase motor can be reversed by swapping any two incoming power legs For blowers powered by a single phase motor refer to the motor rating plate for reversing instructions SECTION 14 TROUBLESHOOTING 29 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL 14 2 General PROBLEM POSSIBLE CAUSE SOLUTION Fan s won t start Main power off or circuit breaker tripped Check main power amp circuit break ers reset as needed Control transformer circuit breaker tripped Check circuit breaker reset as needed Fan motor overload relay tripped Reset the overloads check the fan motor amps Auto Run switch is in the auto position Switch to the run position Temperature controller or high temperature limit con troller display reads OPEN or reads 0 for PLC controls Open circuit in thermocouple wiring Check for wiring errors reference electrical drawing amp thermocouple head drawing Check for broken thermocouple wire
29. installation site e Verify that the lifting lugs are intact undamaged and secured to the batch oven e Ensure factory installed hardware is torqued as specified 4 Prepare the installation location to be ready to accept the batch oven 5 Verify that the lifting equipment can handle the batch oven s weight and the required reach 10 of 35 6 1 2 Lifting the Batch Oven Lift the batch oven into place using all four lifting lugs on the batch oven Use spreader bars to ensure that the lifting cables clear the sides of the batch oven The batch oven must be kept level during the lift to prevent tipping twisting or falling If lifted improperly product damage may occur FIGURE 2 Lifting the Batch Oven Sling With Spreader Bars Lifting Source Vertical Lift Lifting Lugs SECTION 7 BATCH OVEN INSTALLATION A WARNING Crush Hazard Use proper lifting equipment and practices Failure to follow these instructions can result in death injury or property damage A WARNING Falling Hazard Use proper safety eguipment and practices to avoid falling Failure to follow these instructions can result in death injury or property damage Batch oven is shipped as one piece No field assembly is reguired The batch oven must be floor mounted on a flat level surface that is rated for the oven s weight See Page 8 Table 2 In certain municipalities the batch oven may need to be anchored to the floor
30. ion given in a layout drawing the manual together with the cited codes and regulations to perform the installation To furnish all needed materials furnished as standard equipment To provide access to batch oven for servicing To provide the owner with a copy of this Installation Operation and Service Manual To ensure there is adequate air circulation around the batch oven and to supply air for ventilation and distribution in accordance with local codes To assemble or install any accessories or associated vent pipe using best building practices SECTION 2 INSTALLER RESPONSIBILITY 2 1 Corrosive Chemicals CAUTION Product Damage Hazard Do not use equipment in area containing corrosive chemicals Refer to appropriate Material Safety Data Sheets MSDS Failure to follow these instructions can result in product damage Rapid Engineering LLC cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation this is entirely the responsibility of the installer It is essential that the contractor the sub contractor or the owner identifies the presence of combustible materials or corrosive chemicals anywhere in the premises 3 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL 2 2 Required Equipment When lifting of the equipment is required the installing contractor is responsible for supplying or arranging for the appropriate lifting equipm
31. lating Fan Checks Airflow switch tubing connected tightly Motor specifications HP FLA RPM 1 Circuit breaker size D Start Up Procedure Turn disconnect switch to the on position Start fans and measure the re circulating fan data See operating procedures Check fan rotation Check motor amps at ambient temperature Phase 1 Phase 2 Phase 3 Check motor amps at operating temperature Phase 1 Phase 2 Phase 3 Measure the the exhaust fan data Check fan rotation Check motor amps at ambient temperature Phase 1 Phase 2 Phase 3 E Force the heater into maximum heat by pushing the heater start switch and then setting the temperature controller to the maximum operating setpoint Observe that the oven temperature begins to increase Record the amperage in each conductor nos oaeQIOoIsT Force the heater to minimum heat zero output by adjusting the temperature controller setpoint to 32 Observe that the oven temperature begins to decrease Verify the amperage in each conductor to the air duct heater is zero Installation Code and Annual Inspections All installations and service of equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Rapid Engineering LLC and conform to all requirements set forth in the RAPID manuals and all applicable governmental authorities pertaining to the installation service and operati
32. llow the safety guidelines below Locate the batch oven so that the air intakes are not too close to any exhaust fan outlets gasoline storage or other contaminants that could potentially cause dangerous situations Keep gasolines or other combustible materials including flammable objects liquids dust or vapors away from this batch oven or any other appliance Maintain clearances from heat sensitive material equipment and workstations Clearances to combustibles do not denote clearances for accessibility Minimum clearance for access is 36 91 4 cm in front of control panel per National Electric Code NFPA 70 latest revision SECTIONS CRITICAL CONSIDERATIONS The stated clearances to combustibles represent a surface temperature of 160 F 71 1 C Building materials with a low heat tolerance i e plastics vinyl siding canvas tri ply etc may be subject to degradation at lower temperatures It is the installer s responsibility to assure that adjacent materials are protected from degradation Maintain clearances from heat sensitive material equipment and workstations 3 2 Hardware Unless specified otherwise all hardware must be torqued to settings on page Table 1 Recommended Torque Settings Bolt Head Grade Marking OQ Grade Marking Nut Grade Marking Bolt Size Grade 2 Grade 5 10 24 27 inelb 42 inelb 1 4 20 65 inelb 101 inelb 5 16 18 11 ftelb 17 ftelb 3 8 16 19
33. minimum annual inspections of your RAPID equipment and perform service where necessary using only replacement parts sold and supplied by Rapid Engineering LLC Further Information Applications engineering and detailed guidance on systems design installation and equipment performance is available through RAPID representatives Please contact us for any further information you may require including the Installation Operation and Service Manual This product is not for residential use This document is intended to assist licensed professionals in the exercise of their professional judgment 35 of 35 SECTION 15 THE RAPID E SERIES WARRANTY RAPID ENGINEERING LLC WILL PAY FOR Within 12 months from start up or 14 months from date of shipment by Rapid Engineering LLC whichever occurs first replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect Rapid Engineering LLC will require the part in question to be returned to the factory Rapid Engineering LLC will at its sole discretion repair or replace after determining the nature of the defect and disposition of part in question RAPID Replacement Parts are warranted for the later of 12 months from date of shipment from Rapid Engineering LLC or the remaining RAPID E Series warranty RAPID ENGINEERING LLC WILL NOT PAY FOR Service trips service calls and labor charges Shipment of replacemen
34. ng children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do no play with the appliance For additional copies of the Installation Operation and Service Manual please contact Rapid Engineering LLC This batch oven is not designed for use in atmospheres containing flammable vapors flammable dust or corrosive chemicals Recirculated room air may be hazardous if containing flammable solids liquids and gases explosive materials and or substances which may become toxic when exposed to heat i e refrigerants aerosols etc SECTION 1 BATCH OVEN SAFETY 1 1 Description of Operation This batch oven is an electric appliance It is designed for indoor installation Batch oven is designed to operate at temperatures as high as 450 232 C Be sure to read this entire manual before installation and start up 1 2 Inspection and Setup The batch oven was inspected and operated prior to shipment Immediately upon receipt of the batch oven check the electrical characteristics of the batch oven and verify that they match the electrical supply available Verify that the specifications on the batch oven rating plate match your order Check the batch oven for any damage that may have occurred during shipment If an
35. nty gives you specific legal rights and you may also have other rights which vary from jurisdiction to jurisdiction Rapid Engineering LLC shall not be responsible for failure to perform under the terms of this warranty if caused by circumstances out of its control including but not limited to war fire flood strike government or court orders acts of God terrorism unavailability of supplies parts or power No person is authorized to assume for Rapid Engineering LLC any other warranty obligation or liability LIMITATIONS ON AUTHORITY OF REPRESENTATIVES No representative of Rapid Engineering LLC other than an Executive Officer has authority to change or extend these provisions Changes or extensions shall be binding only if confirmed in writing by Rapid Engineering LLC s duly authorized Executive Officer 37 of 35 SECTION 15 THE RAPID E SERIES WARRANTY 39 of 35
36. nty is non transferable Rapid Engineering LLC is not permitted to inspect the damaged equipment and or component parts READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL SECTION 15 THE RAPID E SERIES WARRANTY If you have questions about your equipment contact your installing professional Should you need Replacement Parts or have additional questions call or write Rapid Engineering LLC 1100 Seven Mile Road NW Comstock Park MI 49321 Telephone 1 616 784 0500 Fax 1 616 784 01910 Toll Free 800 536 3461 On the web at www rapidengineering com Rapid Engineering LLC s liability and your exclusive remedy under this warranty or any implied warranty including the implied warranties of merchantability and fitness for a particular purpose is limited to providing replacement parts during the term of this warranty Some jurisdictions do not allow limitations on how long an implied warranty lasts so this limitation may not apply to you There are no rights warranties or conditions expressed or implied statutory or otherwise other than those contained in this warranty Rapid Engineering LLC shall in no event be responsible for incidental or consequential damages or incur liability for damages in excess of the amount paid by you for the RAPID E Series Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to you This warra
37. on of the equipment To help facilitate optimum performance and safety Rapid Engineering LLC recommends that a qualified contractor conduct at a minimum annual inspections of your RAPID equipment and perform service where necessary using only replacement parts sold and supplied by Rapid Engineering LLC Further Information Applications engineering and detailed guidance on systems design installation and equipment performance is available through RAPIDO representatives Please contact us for any further information you may require including the Installation Operation and Service Manual This product is not for residential use This document is intended to assist licensed professionals in the exercise of their professional judgment 34 of 35 SECTION 14 TROUBLESHOOTING Rapes START UP FORM 1100 Seven Mile Road NW BATCH OVEN WITH Comstock Park Michigan 49321 9782 USA Tel 616 784 0500 Toll Free Tel 1 800 536 3461 Fax 616 784 1910 ELECTRIC HEAT www rapidengineering com Page 3 of 3 F Safety Switch Setup and Testing Oven High Temperature Limit Switch The typical setpoint for this switch is 500 F Lower the setpoint below the actual oven temperature to test operation Re set to 500 F C Exhaust Fan Airflow Switch Switch opens on pressure fall Increase switch set point to test operation Typically this switch is set between 07 w c and 2 w c Switch setting Switch setting Re Circulating Fan Ai
38. operate fans without access panels equipment or fittings in place Equipment must be properly grounded Failure to follow these instructions can result in death electrical shock or injury A WARNING Explosion Hazard Falling Hazard Burn Hazard Do not put combustible Use proper safety Do not come into contact items in equipment without equipment and practices to with inside surfaces of exhaust fan avoid falling equipment during and after operation Do not exceed maximum Do not use any part of solvent or volatile loading equipment as support Inside surfaces are hot as listed on Safety Design Form label Secure doors before entering equipment Doors can close Maintain safe clearance between equipment and trafficways to avoid contact with equipment Allow equipment to cool before service Failure to follow these instructions can result in death injury or property damage 21 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL Installation Code and Annual Inspections All installation and service of RAPID equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Rapid Engineering LLC and conform to all requirements set forth in the RAPID manuals and all applicable governmental authorities pertaining to the installation service and operation of the equipment To help facilitate optimum performance and safety Rapid Engineering LLC
39. ors before entering equipment Doors can close Maintain safe clearance between equipment and trafficways to avoid contact with equipment Allow equipment to cool before service Failure to follow these instructions can result in death injury or property damage 24 of 35 Prior to any maintenance or service to the electric batch oven shut off lockout and tagout the electrical disconnectin accordance with OSHA regulations and allow ample time for the batch oven to cool After maintenance is performed or batch oven is serviced the unit shall be re commissioned to the start up procedure as outlined on Page 21 Section 11 12 1 General SECTION 12 MAINTENANCE Installation Code and Annual Inspections All installation and service of RAPID equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Rapid Engineering LLC and conform to all requirements set forth the RAPID manuals and all applicable governmental authorities pertaining to the installation service and operation of the equipment To help facilitate optimum performance and safety Rapid Engineering LLC recommends that a qualified contractor conduct at a minimum annual inspections of your RAPID equipment and perform service where necessary using only replacement parts sold and supplied by Rapid Engineering LLC Annual Fall Start Up and operation Follow the entire start up pro
40. p start knob heat start stop knob alarm horn and alarm silence button three status lights temperature controller and batch timer 18 of 35 10 3 Temperature Controller LOVE CONTROLS PV SERIES 16C AT OUT 1 OUT 2 ALM INDEX ENTER DOWN ARROW UP ARROW The temperature controller interface consists of a message screen and four key function buttons INDEX Pressing the INDEX key advances the display to the next menu item ENTER Stores the value or item change If not pressed the previously stored value or item will be retained When pressed during the Operation Mode the controller switches to the Regulation Mode If held for more than 3 seconds during the Operation Mode the controller switches to the Initial Setting Mode If pressed during the Regulation Mode or Initial Setting Mode the controller will return to the Operation Mode UP ARROW Increments a value or changes a menu item If pressed during the Operation Mode the set point value will be increased DOWN ARROW Decrements a vaue or changes a menu item If pressed during the Operation Mode the set point value will be decreased 10 3 1 Security Features The controller has two built in security lock settings to prevent unauthorized personel from changing parameter settings These parameters are set in the Operation Mode The LoC1 setting affects all parameters in the controller If LoC1 setting is enabled the operator will have to unlock t
41. permitted to operate with any safety system disabled If a fault is found in any of the safety systems then the system shall be repaired only by a contractor qualified in the installation and service of industrial process and finishing equipment using only components that are sold and supplied by Rapid Engineering LLC See Page 13 Table 4 for a description of each safety device and its switching voltage Table 4 Safety Systems Safety Controls Voltage Recirculating Fan Airflow Switch 120 Exhaust Fan Airflow Switch 120 High Temperature Limit Switch 120 9 6 Recirculating Fan Airflow Switch The recirculating fan airflow switch monitors differential pressure across the recirculating fan to ensure the production of proper airflow When the switch closes along with the exhaust fan airflow switch if applicable it permits the beginning of the heating sequence This switch is factory set at 0 4 in wc The pressure switch is a safety device which cannot be field adjusted or tampered with 9 7 Exhaust Fan Airflow Switch The exhaust fan airflow switch monitors differential pressure across the exhaust fan to ensure the production of proper airflow When the switch closes along with the recirculating fan airflow switch it permits the beginning of the heating sequence This switch is factory set at 0 2 in wc The pressure switch is a safety device which cannot be field adjusted or tampered with 9 8 High Tempera
42. quence of Operation ACAUTION Eguipment Damage Hazard Wait to turn fans off until eguipment temperature is below 125 F 51 7 C Turning fans off when equipment temperature is above 125 F 51 7 C could result in components failure Failure to follow these instructions can result in product damage When power is applied to the control panel power is applied to the alarm horn Pushing the alarm silence button will remove power from the horn When the fans start stop knob is placed in the start position the fan starter is energized to power the recirculating exhaust and cooling fans The recirculating fan moves air within the oven The exhaust fan pulls air out of the oven The cooling fan is used to keep the solid state relays cool during operation Power will pass through two air flow switches and the high temperature limit switch to the purge timer and the oven purging light Once the timer has timed out it will remove power from the oven purging light and pass power to the heat start stop knob When the heat start stop knob is placed in the start position power will be placed to the electric heater elements and the heat on light If air flow is interrupted or if the temperature limit of 500 F 260 C is exceeded the elements will be turned off and the fans will remain on The temperature is modulated to a user defined set point by the modulating temperature controller This controller controls the curren
43. ram continued HTL 1 HIGH LIMIT 500 F MAX O O 40 LINE 10 42 30 o 16 of 35 to line 63 EXHAUST FAN 0 85 MAXFLA COOLING FAN FANS ON OVEN PURGING PURGE TIMER 3 MINUTES 40 43 HEATERS ON HEATER CONTACTOR 7 8 9 LATCH 45 59 TEMP CONTROL OUTPUT 4 10 AUTO SHUTDOWN BELOW 125 F 27 TIMER ENABLED WITHIN 15 F OF SETPOINT 63 TEMPERATURE CONTROLLER FIGURE 7 Wiring Diagram continued ALARM SILENCE PB 5 E AUTO OFF 28 sw 2 NOTE TIMER DIP SWITCH SETTINGS ARE POSITIONS 1 5 ON 6 8 OFF SECTION 9 ELECTRICAL ALARM HORN BURNER TIMER LATCH 65 66 TIMER START TIMING TIMER POWER 60 69 BURNER TIMER TIMED OUT 44 17 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 10 SEQUENCE OF OPERATION A DANGER Electrical Shock Hazard Disconnect electric before service More than one disconnect switch may be reguired to disconnect electric from eguipment Eguipment must be properly grounded Failure to follow these instructions can result in death or electrical shock 10 1 Batch Oven Configuration Based on the application the batch oven may or may not be configured with an exhaust fan and motor 10 2 Control Panel The control panel will be factory mounted to the oven TEMPERATURE CONTROLER FANSON FANS STOP START The control panel includes an auto run switch fans sto
44. rflow Switch Switch opens on pressure fall Increase switch setpoint to test operation Typically this switch is set between 07 w c and 5 w c Switch setting G Temperature Controller Setup and Testing Note The temperature controller was programmed at the factory and no additional set up is necessary For PID adjustments see the temperature controller manual and parameters located in the Installation Operation and Service Manual After completing the start up of the oven set the temperature controller at 200 F Let the oven run at this temperature for 4 hours to bum off oils on oven panels and other components used in the construction of the oven After the burn off period the oven is ready for production H Final Review Review the Operation Installation and Service Manual Review the recommendations for spare parts Review the preventative maintenance schedule Review the warranty Comments Installation Code and Annual Inspections All installations and service of equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Rapid Engineering LLC and conform to all requirements set forth in the RAPID manuals and all applicable governmental authorities pertaining to the installation service and operation of the equipment To help facilitate optimum performance and safety Rapid Engineering LLC recommends that a qualified contractor conduct at a
45. ring LLC recommends that a qualified contractor conduct at a minimum annual inspections of your RAPID equipment and perform service where necessary using only replacement parts sold and supplied by Rapid Engineering LLC Further Information Applications engineering and detailed guidance on systems design installation and equipment performance is available through RAPID representatives Please contact us for any further information you may require including the Installation Operation and Service Manual This product is not for residential use This document is intended to assist licensed professionals in the exercise of their professional judgment Copyright 2013 Rapid Engineering LLC Printed in USA P N 91709121 Rev B 12 13 33 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL Rapid START UP FORM 1100 Seven Mile Road NW BATCH OVEN WITH Comstock Park Michigan 49321 9782 USA ELECTRIC HEAT Tel 616 784 0500 Toll Free Tel 1 800 536 3461 Fax 616 784 1910 www rapidengineering com Page 2 of 3 A Pre Start Checks General All wire connections are properly wired and tight All controls and electrical fittings are secure and tight Wiring specifications Volts Hz Phase Service supply voltage L1 L2 L3 B Pre Start Checks Exhaust Fan Checks Airflow switch tubing connected tightly Motor specifications HP FLA RPM Circuit breaker size C Pre Start Checks Recircu
46. t flow to the elements through solid state relays The temperature controller will also power a relay when the temperature is above 125 51 7 C This relay is used the automatic shutdown mode which allows the user to turn the heat off and allow the fans to shut off automatically when the oven cools down to 125 F 51 7 C The auto run switch must be in the auto position for this to occur Another output on the temperature controller will power the batch timing circuit to operate once the temperature of the oven is 20 of 35 within 15 F 8 3 C of the set point temperature Once this happens power is applied to a latching relay to allow the batch timer to run when the temperature drops This allows for the door to open and not disrupt the timing of the batch The batch timer is a digital timer with set point and output adjustments Once the batch timer is started the timer will time When the timer has elapsed power will be removed from the electric heater elements fans will stay on and place power to the alarm horn The heat cannot be turned on again until the batch timer is reset SECTION 11 START UP PROCEDURES SECTION 11 START UP PROCEDURES A DANGER A AN Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service Before servicing equipment equipment must be locked out and tagged out at More than one disconnect switch may be disconnect required to disconnect electric from Do not
47. t parts Claims where the total price of the goods have not been paid Damage due to Improper installation operation or maintenance e Misuse abuse neglect or modification of the RAPID E Series in any way Use of the RAPID E Series for other than its intended purpose Incorrect electrical supply accident fire floods acts of God war terrorism or other casualty Improper service use of replacement parts or accessories not specified by Rapid Engineering LLC e Failure to install or maintain the RAPID E Series as directed in the Installation Operation and Service Manual e Relocation of the RAPID E Series after initial installation Use of the RAPID E Series a corrosive atmosphere containing contaminants Use of the RAPID E Series in the vicinity of a combustible or explosive material Any defect in the RAPID E Series arising from a drawing design or specification supplied by or on behalf of the consumer Damage incurred during shipment Claim must be filed with carrier WARRANTY IS VOID IF The RAPID E Series is not installed by an contractor qualified in the installation and service of gas fired heating equipment You cannot prove original purchase date and required annual maintenance history The data plate and or serial number are removed defaced modified or altered in any way The ownership of the RAPID E Series is moved or transferred This warra
48. time or push RST on timer to reset previous value Heater turns on and HEAT ON light illuminates The AUTO OFF feature may be used to auto matically shut oven off when a batch has timed out To use this feature place RUN AUTO switch in AUTO position when oven tempera ture is above 125 F 51 7 C after batch has start This disables alarm horn After batch timer elapses heater shuts off and fans will continue to run until oven temperature drops below 125 F 51 7 SECTION 11 START UP PROCEDURES 23 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 12 MAINTENANCE A DANGER A AN Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service Before servicing equipment equipment must be locked out and tagged out at More than one disconnect switch may be disconnect required to disconnect electric from Do not operate fans without access panels equipment or fittings in place Equipment must be properly grounded A WARNING Explosion Hazard Falling Hazard Burn Hazard Do not put combustible Use proper safety Do not come into contact items in equipment without equipment and practices to with inside surfaces of exhaust fan avoid falling equipment during and after operation Do not exceed maximum Do not use any part of solvent or volatile loading equipment as support Inside surfaces are hot as listed on Safety Design Form label Secure do
49. to comply with local codes Rapid Engineering LLC recommends the installer contact a local building inspector for guidance SECTION 7 BATCH OVEN INSTALLATION 11 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 8 VENTING A WARNING Noxious Fumes Hazard Properly vent equipment per Installation Operation and Service Manual Items placed in equipment could release noxious flumes Refer to the Safety Data Sheets SDS for items placed in equipment Failure to follow these instructions can result in death injury or property damage 8 1 General Venting Requirements Batch ovens equipped with an exhaust fan must be vented in accordance with the rules contained in this manual and with any national state provincial or local codes which may apply United States Refer to NFPA 91 latest revision Standard for Exhaust Systems for Air Conveying of Vapors Gases Mists and Non Combustible Particulate Solids 8 2 Recommended Venting Practices All electric batch ovens are shipped without flue vent pipe components It is the responsibility of the installer to supply the venting components for electric batch ovens shipped with an exhaust fan Each batch oven must have an individual vent pipe and vent terminal Termination of the vent pipe must be located so that the vented fumes can not be drawn back into any outside air intakes Recommended vent pipe for a batch oven equipped with a 230 CFM 390 m
50. ture Limit Switch If for any reason the internal temperature of the batch oven exceeds 500 F 260 C the high temperature limit switch will open the circuit to the batch oven s heating elements and shut them down 13 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 3 Panel Layout OVEN REAR oFU 2 0 Colle e e e efe FIGURE 4 Interconnects Layout 14 of 35 ELEMENT 12 ELEMENT 11 ELEMENT 10 ELEMENT 49 ELEMENT 8 606560 ELEMENT 7 ELEMENT 6 ELEMENT 5 ELEMENT 4 ELEMENT 3 ELEMENT 2 ELEMENT 1 MINIMUM 14 AWG TYPE TGGT WIRE ONLY 30 SSR2 CTRL SOAMP LOAD LOAD DISTRIBUTION 0000000000090 1T2A 1T3A DISTRIBUTION HEATSINK HEATSINK OVEN FRONT FIGURE 5 Wiring Diagram BRANCH CIRCUIT PROTECTION TO BE PROVIDED BY INSTALLER 11 12 DISCONNECT BY OTHERS 240VAC 60Hz 32 43 2 FLA TO LINE 50 36 1_ AMPS 240 3 60 15 KW TO LINE 48 6 2 5KW PER ELELMENT 230 VAC H3 H2 HI H4 RECIRC AIR FLOW AFS 1 4 optional EXHAUST FAN AIR FLOW AFS 2 x 120VAC re AUTO OFF SECTION 9 ELECTRICAL BRN WHT RECIRCULATION 001 RECIRCULATION 002 FAN 001 FAN 002 4 1 FLA FANS ON 17 27 32 AIR FLOW 15 of 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 6 Wiring Diag
51. y damage is found file a claim with the transporting agency Do not refuse shipment Check the installation location to ensure proper clearances to combustibles See Page 5 Section 3 1 If the batch oven must be temporarily stored i e job site is not ready for installation of the batch oven the batch oven should be set indoors to protect it from the environment 1 3 Safety Labels and Their Placement Product safety signs or labels should be replaced by product user when they are no longer legible Please contact Rapid Engineering LLC to obtain replacement signs or labels See Page 2 Figure 1 1 4 California Proposition 65 In accordance with California Proposition 65 require ments a warning label must be placed in a highly visible location on the outside of the equipment i e near equipment s serial plate See label placement drawing on Page 2 Figure 1 for label location Avoid placing label on areas with extreme heat cold corro sive chemicals or other elements To order additional labels please contact Rapid Engineering LLC or your independent distributor 1 35 E SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 1 Label Placement Drawing for Batch Oven Part Number Description 19145 Label Logo 901010100 Label Installation Manual Inside 91070001 Label Shock Hazard Large 91070003 Label Crush Hazard 91070004 Label Fire Hazard Clearances 91070005 Label Falling Hazard 91070009
Download Pdf Manuals
Related Search