Ney Furnace manual ENG
Contents
1. er 0 a Pbi Hon hore ip uda Wn Kaum ze He Bessie a erre eniti MR 9 Coo haa dee a faut na rum sa N r i Tr warn i E i Ta 1 uw t reer Ar er EE a mie d der nro m ee tort igen u bi Ma CL s 0 AUX 1 OUTPUT MUFFLE THERMOCOUPL CONTROL PANEL NOTE 13504 KEY LOCATIONS ARE SLIGHTLY DIFFERENT BUT PERFORM THE SAME OPERATIONS POWER SWITCH DIGITAL DISPLAY DELAY START Turns main power on and off to furnace Does not start furnace operation Displays operating and programmed temperatu es times and status conditions The right most decimal point in the display is used to indicate a low battery conditign Changes temperature display from degrees Celsius to de grees Fahrenheit This key is only active when the current muffle temperature is being displayed It is loc 0 when displaying programmed parameters Turns the furnace on at a later time and runs the preselected cycle Also gives operator access to program the amount of delay time desired Pressing the DELAY START key causes the DELAY START LED to flash and the current alue to be displayed A new2. t _ SERVICE MANUAL Pao MEME MODELS 6 525 6 160A 6 1350 9014 9363014 m er Fee TTO SECTION VI VII VIII DESCRIPTION Safety Precaution and MSDS Receiving Information Installation Features Specifications Heating Curves Cooling Curves Furnace Description and Operation Control Panel Description Operating the Furnace Programming the Furnace Example Maintenance Service Troubleshooting Charts and Error Codes Schematics Disassembly Instructions Replacement Parts 6 525 Parts Exploded View 6 525 6 1350A Parts Exploded View 6 1350A 6 160A Parts Exploded View 6 160A Accessories Warranty PAGE NUMBER 3 1 4 1 5 1 5 3 5 4 6 1 6 3 6 6 6 8 6 16 7 1 8 1 8 2 8 4 8 6 9 1 9 1 9 2 9 3 9 4 9 6 9 7 10 1 Inside Back Cover SAF Please read and follow the safety precautions listed below These are intended for your safety and the safe operation of the equipment CAUTION NEVER OPERATE THE FURNACE WITH COMBUSTIBLE MATERIALS ABOVE ON TOP OF OR IN CLOSE PROXIMITY TO THE FURNACE DO NOT USE TONGS OR OTHER TOOLS TO OPERATE THE CONTROLS KEEP THE DOOR IN THE CLOSED POSITION WHILE NOT IN USE DO NOT USE SOLVENTS OR LIQUID CLEANERS ON THE CONTROL PANEL DO NOT PLACE HOT ITEMS REMOVED FROM THE FURNACE ON TOP ORIN FRONT OF THE FURNACE
3. UE RAR LL A pira AC ee agent tea hl MSE elf A O Oe AD a 9 4 EXPLODED VIEW 6 1350 MUFFLE Rear Muffle Pane Terminal Block Top Heating Plate Botiom Heating Plate Side Heating Plate Enclosure The furnace and its internal components assemblies are delicate need to be packed properly for return shipment Pack all parts or assemblies a in bag then foam and seal them in suitable boxes Use original packaging when it is available VOLTAGE DESCRIPTION 100V 120V 220V 240V Muffle 6 160A R947777 394727 942227 94772 Thermocouple H9491747 Triac 9303015 Power Switch Door Switch Control Power PC Board Assembly Display PC Board Assembly Membrane Switch and Switch Plate Air Exchange Fan R949227 Fan Supply PCB Assy R949277 Battery Lithium Obtain Locally Panasonic Part Number BR2032 Radio Shack Number CR2032 Fuse 1Amp 250V Obtain Locally 5mm x 20mm SR u 7 0 0 0 0 0 0 a t Tu po eu m to ARE a PERPE ETI ees LLL EL En ae Ae u ROH A ans Pla OU QN a tu Imm Tuan Ium EXPLODED VIEW 6 160A BACK PANEL THERMOCOUPLE DAMPER S p gt EXHAUST PORT ASSEMBLY DOOR FRONT DISPLAY PC BOARD CONTROL PANEL SWITCH PLATE MEMBRANE SWITCH CONTROL POWER PC BOARD P
4. ming not saved when power is turned off Did LO BATT inklicator flash Battery dead or not seated properly See 5 1 0 belo o A A Bo OME EC ea iy A A a NOAH O haust port ball plug if air exchange fan or compressed air fitting is being used 5 0 0 Abnormal Display Signals and Operation 5 1 0 5 2 9 5 3 0 Possible problems include themocouple disconnected at control power 5 4 0 5 5 0 Lower Right Decimal Point Flashes In Display LO BATT Battery is low or dead replace with a number 2032 Lithum coin type See MAINTENANCE SECTION 7 and SERVICE PARTS SECTION 9 ERR 1 is displayed The muffle temperature is above 1100C 2012F or overtemperature Possible problems include shorted output triac shorted optotriac U7 on control power pc board wiring shorted thermocouple pushed back out of muffle thermocouple shorted outside of muffie ERR 2 is displayed The control thermocouple is open or disconnected pc board themocouple weld inside muffle open or damaged ERR 3 is displayed The contro is attempting to go above the Program mable High Limit Cutoff Review the section on programming the Cutoff in the programming section 6 DOOR remains on display when door is closed Check door switch con tinuity Check door switch actuator tab by listening for switch click as door closes AUX RECEPTACLE 5 A
5. 53 3 0 0 54 STAGE 6 IS NOW PROGRAMMED After TIME 6 the contro will continue to hold the last temperature TEMP 6 until 1200 F TEMP 3 is now programmed Press key until the TIME 3 LED flashes 1 7 Hours TIME 3 is now programmed Press key until the RATE 4 LED flashes 10 0 F min RATE 4 is now programmed Press key untilthe TEMP 4 LED flashes 1760 F TEMP 4 is now programmed Press key until the TIME 4 LED flashes 3 0 Hours TIME 4 is now programmed Press key until the RATE 4 LED flashes 0 5 F min RATE 5 is now programmed Press key until the TEMP 4 LED flashes 1510 F TEMP 5 is now programmed Press key until the TIME 4 LED fiashes 0 1 Hour TIME 5 is now programmed Press key until the RATE 6 LED flashes 10 0 F min RATE 6 is now programmed Press key until the TEMP 6 LED flashes 1000 F TEMP 6 is now programmed Press key until the TIME 6 LED flashes 30 0 Hours TIME 6 is now programmed turned off while beeping every 6 minutes A ps a EE DU OA weni la A SURE In O In e TS TT PN O enne o Tu Ch A CLEANING Vacuum rather than blow any muffle dust found and around the furnace This will minimize the airborne dust SEE SECTION 1 SAFETY PRECAUTIONS and MSDS Ciean the control panel with a soft dry cloth Do not use water liquids or spray cleaners on the panel or on the cloth These cleaners can ent
6. THERMOCOUPLE MUFFLE SPRING DOOR FRONT SWITCH PANEL MUFFLE FURNA The furnace and its internal components and assemblies are delicate and need to be packed properly for return shipment Pack all parts or assemblies in a bag then foam and seal them in suitable boxes Use original packaging when it is available VOLTAGE DESCRIPTION 220V 240V Top Bottom Heating Plate R9492684 Side Heating Plate R9492683 Triac 89303015 Power Switch 49306021 Door Switch R9492666 Thermocouple R9491747 Control Power PC Board Assembly R9492573 Display PC Board 9492707 Assembly Membrane Switch and R9492659 Switch Plate Air Exchange Fan 12 VDC R9492455 Fan Supply PCB Assy H9492710 Battery Lithium Obtain Locally Panasonic Part Number BR2032 Radio Shack Number Cr2032 Fuse 1 Amp 250V 5mm x 20mm Obtain Locally A MS DRM 5 29 aaa LI par o QT a ENI O A a ee a 770 1 T D DODA of CK PANEL THERMOCOUPLE ZA SE d FAN DUCT DAMPER ASSY REAR ELECTRICAL 8 un AND LINE COR f 0 Ale Y Lal 9 SWITCH TRIAC CONTROL PANEL FAN SUPPLY PC BOARD CONTROL POWER PC BOARD DISPLAY MEMBRANE PC BOARD _ SWITCH
7. new battery with the positive side to the top The battery bracket should be opened only a small amount so that is not deformed Replace th control panel and reapply power The battery replacement will cause the dr ntrol to lose complete memory NOTE THE POWER MUST BE APPLIED S ORTLY AFTER BATTERY REPLACEMENT OR THE BATTERY WILL BE DEAD WITHIN SEVERAL HOURS Go to configuration setup below CONFIGURATION SETUP When powered up for the first time after battery replacement the opntrol will display a series of furnace model numbers 525 160A 1350A ress the EN TER key when the correct model number of the furnace being worked on ap pears A pattern similar to SELECT will appear to indicate configuration setup Pressing the 9 key followed by the ENTER key will place th control in the normal operating mode See the CONFIGURATION SETUP in tt e program ming section 6 for details on possible operating mode changes MUFFLE REPAIR The 6 525 furnace muffle is constructed of a lightweight fiber insul tion Exer cise caution to prevent punctures or tears in the muffle when loadif g and un loading the furnace Punctures exposing the heating elements embedded in the insulation may significantly shorten muffle life The accessory tray provided with the furnace should be used to protect the mutfle flodr Damage to the fiber insulation in the muffle or the door can be rep lred bottle of Fiber Ha
8. DO NOT ATTEMPT TO SERVICE THE FURNACE UNTIL YOU HAVE READ AND UN DERSTOOD THE SERVICE INSTRUCTIONS INCLUDED IN THIS MANUAL ALWAYS TURN OFF THE POWER AND REMOVE THE LINE CORD FROM THE WALL OUTLET BEFORE SERVICING THE FURNACE ALWAYS VERIFY THAT THE FURNACE CONTROL IS DISPLAYING door BEFORE ATTEMPTING TO LOAD UNLOAD REACH INTO THE FURNACE CHAMBER WITH ANY TOOLS OR INSTRUMENTS USE ONLY INERT GASES WITH THE AIR EXCHANGE FEATURE WARNING gt This furnace is not designed for use in hazardous Class Il or Ill locations as defined by the National Electric Code gt For personal safety this furnace must be grounded The furnace power cord is equipped with a three prong grounding plug for use with wall receptacles to minimize the possibility of electric shock hazard from the furnace The wali receptacles and circuit should be checked by a qualified electrician to make sure the receptacle is properly grounded O Two prong wall receptacles must replaced with three prong g wall r obte jtacles t to ensure proper operation and safety Two to three prong adaptors are nat considered reliable safe methods of electrical connection gt This furnace must be connected to a properly sized power circuit with the correct overcurrent protection for safe and reliable operation gt AS a routine working precaution always wear safety glasses and pratective gloves when operating loading and unloading
9. JOFF for each STAGE of each PROGRAM The AUX 1 is programmed to bei ON contacts closed by selecting a STAGE key of a program followed by the Al 1 key AUX1 ON will be displayed if it was previously programmed to Be off Press ing the AUX 1 key a second time turns it off AUX 1 OFF is displa led is displayed in the far right character of the display when AUX 1 is o and the cycle is running AUXILIARY OUTPUT 2 The AUX 2 output NOT APPLICABLE TO 6 525 controls the air ex phange fan feature The air exchange fan is located on the back of the furnac A vertical damper is provided to block fan air from entering the furnace whefi moved into the down position Putting the damper in this position also providks access to the compressed air fitting When the damper is in the up position ithe fan will force pre heated air into the furnace If the exhaust port is plugge when the fan is operating the exhaust gas will escape around the door and Hiscolor the paint The air exchange fan can be programmed to be OFF or ON ata pal ticular speed for each stage The fan is programmed to be ON by pressin ig a STAGE key of a program followed by the AUX 2 key With SELECT 0 belt 1g displayed a digit key 1 9 can be pressed to set that speed 1 is the slowestiand 9 is the fastest Entering a 0 turns the fan to the lowest speed the fan is always on ata slow speed to prevent its possible overheating A setting of 9 prat uces ap proxim
10. TIME key can be pressed to save the valge If an incorrect digit key is pressed while entering a parameter the corre Bt parameter should be reentered The incorrect digit will shift off the display tolthe left An alternate method to clear an incorrect entry is to press the DELAY second time PROGRAMS Any one of the four programs can be selected for operation or prog gramming independently Pressing a PROGRAM key activates that program and the associated LED lights Programs can be chained together run in groups by pressing ang holding the first program key in the chain While this key is held down press the additional programs to be chained to the first program The LED for each that is selected will light The group selected in the chained is not stored in memory and must be assigned each time it is requested Each Individual program is stored and can be operated independently STAGES Once a program has been selected the individual stage RATE s TIME s and AUX s can be programmed STAGE key has to jessed before the various parameters can be programmed After the key is pres jed the STAGE LED will remain on for 7 seconds if no other keys are pressed if one of 6 10 the parameter keys i is pressed i it t will remain c on a until the ENTER or r TIME T EMP key is pressed If the LED goes out the STAGE key must be pressed again RATES The RATE key sets h
11. maximum loads Programmable Parameter Ranges and Presets DELAY START 1Hour _ 0 1 deg min 0 C min 40 C min 0 F min 72 F min 1 deg 100 C 1100 C 212 F 2012 F End Of Cycle Operation Factory Preset 1 Hold last temperature and M every 6 Options 2 Hold last temperature no beep 3 Turn off after last TIME muffl off 4 Repeat cycle continuously Parameter eee Tua Tasa nme 4999Hou _ Programmable 1 deg 500 C 1100 High Limit Cutoff 832 F 201 minutes m mewe TT A Z 1000 LLL Z LL 42 2 2 s 4 Put UU PA Y 800 6 525 7 6 1350 FAN OFF M 4 7 6 0 E FAN HIGH 6 160A FAN HIGH U 6 160A R FAN OFF 10 20 3 40 50 60 70 80 90 100 110 TIME Minutes IT ES TN COOLING CURVES 1100 N A 1000 UN WKN IS N N x 6 1350 lt 6 1350A 800 AN 7 Z FAN OFF FAN HIGH x x UM N UM NN N mh M gt NN gt E 600 3 277 In A 6 160A vM FAN OFF lt U 6 160 E R FAN HIGH 4 7 6 525 E 400 a N Yasa 5 C x _ X lt 200 UL 0 00 10 20 30 40 50 60 70 80 90 TIME Min
12. value can be programmed or the START STOP key can be pressed to start a cycle after aidelay Displays the currently programmed RATE for the selected program and stage Gives the operator access fo program the desired value A un DU hs a VENIM ee eee tamm HHH _ RATE refers to th 6 TEMP 7 TIME 8 HOLD RESUME 9 TEMP CYCLE TIME saga NL LIP Nu teu Penge A T in e desired temperature increase or de crease in tenths of a degree per minute xx x min The decrease in temperature or cooling is limited by the natural cooling RATE of the furnace and its load The control can force it to be slower but not faster See the heating and cooling curves in Section 5 Programming a TEMP lower than the previous TEMP will cause a negative RATE Similarly starting the furnace with the muffie temperature higher than the first TEMP 1 will cause the control to cool at RATE 1 to TEMP 1 Programming a RATE to zero prevents that stage and the following stages from running For example if RATE 4 is set to zero only stages 1 2 and 3 will operate and the program will end after stage 3 Displays the currently programmed temperature for the selected program and stage Also gives the operator ac cess to program the desired temperature value When the corresponding LED is flashing that TEMP is being reviewed an
13. 6 525 15 Amp fuse or circuit breaker 100V units require 20 Amp 6 160A 6 1350 20 Amp fuse or circuit breaker with receptacle for furnace only Firing trays are supplied with the furnace Please place these in the muffle before the first firing These will prevent molten materials from flowing into the muffle 6 160A and 6 1350A ONLY The air exchange feature on these furnaces is accessible from the rear of the furnace If the integral fan is not to be used the rear damper panel must be lowered The compressed air fitting 1 8 female NPT is then acces sible behind the damper panel If the top exhaust port is to be plugged then it is recommended that the rear damper panel be lowered This will minimize the escape of hot air from around the door and resulting discolored paint 6 525 ONLY The exhaust port along with mounting screws are packed in the top packing insert Locate the port and install it on top of the furnace TELP Qa a OCH L Spe A O PCA We Dele R _ MC ee Ne eU ut eal Mutat ce atat a Blau PNP al DAMM Xu dc Xu au O dcm m Pa E E 3 9 Au 2 355 EA i e rt apps ELO D EATURES GENERAL gt Six Stages Segments Of Temperature Control gt Four User Definable Stored Progra
14. D OF CYCLE 1 Pressing the 1 key followed by the ENTER key will cause the c ntrol to continuous hold the last TEMP and beep every 6 minutes HOLD TEMP is displayed This is the factory preset 2 Pressing the 2 key followed by the ENTER key will cause the centro to continuous hold the Jast TEMP without beeping HOLD TEMP is dis played 3 Pressing the 3 key followed by the ENTER key will cause the c ntrol to end 1 the cycle and shut off the muffle after the last TIME END displayed and the control beeps three times 4 Press the 4 key foliowed by the ENTER key will cause the conte 9 to con tinuously repeat the cycle that has been started HIGH LIMIT CUTOFF 5 Pressing the 5 key followed by the ENTER key will cause the High Limit Cutoff temperature to be displayed 1100 is the faci bry preset value To select a different temperature enter the new using the digit keys followed by the ENTER key CAUTION Previously pro grammed values for TEMP s must be lower than High Limit utoff The furnace will now shut down and display Err3 if the tempera ture goes above the programmed High Limit Cutoff The e or is cleared by turning off the furnace Attempting to program a tempe lature higher than the High Limit Cutoff will cause the control to beep anti display the maximum temperature 6 14 SYSTEM RESET CAUTION 7 Press the 7 key fo
15. IME TEMP LED s will alternately come on If a DELAY START has been selected its LED will light first and when the delay ts complete the rest of the cycle LED s will light A flashing RATE LED indicates that the control is unable to maintain the pro grammed rate of change in temperature The flashing is only an indication for the operator the furnace will continue the cycle uniterrupted This condition can be caused by programming the furnace with high programmed RATE large loads or low power line voltages Refer to the heating and cooling curves in the SPECIFICATIONS section 5 for more information A power outage or turning off the power when the furnace is in the idle or off mode does not cause loss of the programs The furnace will resume a delay start cycle if a power interruption occurs during its operation A power outage when the furnace Is heating will result in the resumption of the cycle when power is reapplied if the muffle temperature has dropped less than 50 C 90 F If the muffle temperature has dropped more than 50 C 90 F the fur nace turns off If power is interrupted or the power switch is turned off when the furnace is operating at less than 100 C the furnace will turn on when power is reapplied HOLDING A TEMPERATURE The furnace can be stopped or held in the middle of a cycle indefinitedly by pressing the HOLD RESUME key The muffle temperature when the key is pressed will be maintained with the associate
16. Ney Industrial Park Bloomfield CT 06002 203 242 2281 6288 7937 FAX 203 242 5688 Built and Repaired at The J M Ney Company 13553 Calimesa Boulevard Yucaipa CA 92399 714 795 2461 FAX 714 795 5268 1990 The J M Ney Company Printed in U S A
17. OUPLE REMOVAL 1 Turn off the power to the furnace and remove the line cord from the allrecep tacle outlet Allow the furnace to cool to room temperature before tarting service 2 Remove Control Panel by fotlowing the instructions above 3 Disconnect thermocouple red and yellow wires from the left hand side of the computer power pc board Disconnect the blue or blue white muffle wires from computer power pc board and triac 4 Remove the exhaust port by removing the 3 retaining screws 5 Remove Front Panel from enclosure by removing 7 screws from top and sides 6 The Front Panel with the muffle attached pulls out of the front of the enclosure 7 The thermocouple can now be removed from the back of the muffle by pulling it out 8 Route the thermocouple through the bushing in the rear of the heatshield and behind the door switch bracket 9 Reverse steps 1 6 for reinstallation Note The screws holding the front panel to the cabinet must be installed prior to installing the control panel 6 525 MUFFLE REMOVAL 1 Turn off the power to the furnace and remove the line cord from the wail recep tacle outlet Allow the furnace to cool to room temperature before starting service 2 Remove Control Panel by following the instructions above 3 Remove the exhaust port by removing the three retaining screws 4 Disconnect the blue or blue white muffle leads from the triac and the power board 5 Remove the thermocouple by pul
18. OWER SWITCH TRIAC pr ACCESSORIES DESCRIPTION ORDER NUMBER Tongs Stainless Steel 10 25cm 9390014 Tongs Stainless Steel 12 30cm 9390015 Tongs Plated Steel 14 36cm 9491010B 9390017 Tray Hard Ceramic 3 75 4 8 5 10cm Tray Hard Ceramic 8 0 8 0 20cm 20cm 9353027 Shelf Honeycomb ceramic 1 75 4 5cm in height 9492211 3 0 7 6cm in height 9492210 Muffle Hardening Agent 6 525 only 9491006 Temperature Peliets Bottle of 25 705C 1300F 815C 1500F 9490911 94909124 Exhaust port bali plug 2 each Small 6 525 6 1604 Large 6 1350A 9491093A 9492456 SU LIMITED WARRANTY and LIMITATION OF LIABILITY 1 WARRANTY Except with respect to those components parts and uses which are hereinafter described The J M Ney Company warrants this furnace to be free from defects in material and workmanship for a period of one year from the date of sale The J M Ney Company s liability under this warranty is limited solely to repairing or at Ney s option replacing those products included within the warranty which are returned to Ney within the applicable warranty period with shipping charges pre paid and which are determined by The J M Ney Company to be defective This warranty shall not apply to any product which has been subject to misuse negli gence or accident or misapplied or mod
19. at line voltage of 100 Volts 120 Volts 220 Volts 240 Volts Fan set to maximum and damper open MECHANICAL Furnace Width 39cm 15 5in 74cm 29in 41cm 16in Depth 37cm 14 5in 56cm 22in 33cm 13in Height 42cm 16 5in 53cm 21in 42 16 5 Muffle Inside Width 23cm 9in 30cm 12in 23cm 9in Depth 23cm 9in 32cm 12 Sin 11 5cm 4 5in Height 17cm 6 5in 23cm 9in 10cm 4in Furnace Weight 16Kg 35 155 7 160 Ibs 20Kg 44 lbs shipping Weight 21Kg 46 Ibs 95Kg 210 Ibs 27Kg 60 lbs Maximum Muffle Load 6 8 9 15 16 13 6 30 lbs 6 8Kg 15 Ibs eI a a NN a HD EST DD A TInt na rE re mr rrr OC A A lj T1 Te A IM CD T AE cs X u 2 s5 DLP OPERATIONAL 100 C to 1100 C 60 212 F to 2012 F at 14 Temperature Control Range and Resolution 1000 C max with full air exchange rate on 6 160A and 1350A T 5 C F in contro raj from 100 C to 1100 5 2 Temperature Control to 2012 F Amplitude at Setpoint Less than 3 C 5 5 F Settable Heat RATE Range 0 C O F to CFM in 0 1 0 292 increments Note See following graphs for actual expected heat rate performance 49 C 72 F MIN is not possible at the maximum temperatures air exchange or with
20. ately 5 air changes a minute in the muffle Pressing the ENTER key stores the setting fan symbol will appear in the far left character of the displays The two bars the display will rotate at a speed relative to that programmed If 1 is 6 12 nm d4c2 5 DMU OMOZPIO programmed they will rotate slow 9 is programmed they will r rotate e fast During cycle operation this symbol will appear when ever the fan is pro grammed to be on Compressed air or inert gas can also be ported into the furnace muffle via the rear female 1 8 NPT fitting This fitting is located behind the fan damper Lower the damper for access The gas will be preheated by the bottom heating plate and injected into the front of the furnace The graph below gives an ap proximate relationship between changes per minute and gas pressure COMPRESSED GAS CHANGES GRAPH Ho TT NL PN 5 POR HAND NL 3 10 20 30 40 50 60 70 80 90 100 110 PRESSURE PSI Note Maximum Pressure Allowable is 120 PSI CON FIGURATION SETUP The furnace has other features or operations that are only accessible when power is applied power up These features are programmed by pressing the Eh TER key during the 3 seconds after power up when the furnace displays the mod l number SELECT will appear on the display to indicate configuration setup The following selections are available for programming EN
21. ave power Test with another load ie lamp or A radio 2 2 0 Does furnace beep when power is turned on If yes go to 2 8 0 If no go to 2 9 0 2 3 0 Do any of the LED s on the control power board light Look to rear back vents of furnace If yes check pc board to pc board connections 2 9 0 Please note the answers to the following questions before cafling the service telephone number listed on page 8 1 What is model number and serial number of furnace List on data plate on back of furnace 1 Did furnace ever operate For how long 3 0 0 No Heat Display and LED s operate 3 1 0 Does the display show ERR 2 See Section 5 3 0 below 3 2 0 Does the neon light on the control power board light when th switch is turned on If not check muffle continuity with ohr so check wiring and terminals between muffle triac and co pe board 3 3 0 Does the neon light flash off and on when the start key is pressed Does LED 051 upper lefthand corner of control power pc board flash oppo site the neon light on to off 1f not go to point 2 9 0 abov power meter trol power 4 0 0 Furnace operates but not correcily 4 1 0 Does RATE LED flash slowly when program is operating The RATE parameter is programmed faster than furnace heat or cool Unit will continue to operate but with a slower rate than prodrammed See Heating Curves in Section 5 4 2 0 Control lost all preprogrammed parameters when turned off Program
22. d HOLD LED STAGE LED and parameter LED on Pressing the key a second time releases the control and it resumes the cycle that is had been operating The program parameters can be reprogrammed when the control is put in the ROLD mode NUS ie A A O ae AS END CYCLE The default End Of Cycle maintains the last programmed temperajure dis plays HOLD and beeping every six minutes Other End Of Cyclef operations available Include maintaining the Jast programmed temperature wit out beep ing turning off the muffle at the end of the cycle while displaying END and continuously repeating the cycle The end of cycle default setting dan be changed by following the directions outlined later in this section under CON FIGURATION SETUP PROGRAMMING THE FURNACE The furnace control parameters can only be changed during idle mb not running a cycle or when put on hold during a cycle with the HOLD RESUME key out of range value is entered the control beeps and displays the maximum or minimum acceptable value The previous stored is retained DELAY START Pressing the DELAY START key displays the current programmed Yalue and flashes the associated LED When the LED is flashing the DELAY START value can be reprogrammed by keying in a new value followed by the ENTER key if the value already stored for the delay start is acceptable then eithq r the ENTER key or the TEMP CYCLE
23. d can be programmed Displays the currently programmed time for the selected program and stage Also glves the operator access to pro gram the desired time value When the corresponding LED is flashing that TIME is being reviewed and can be pro grammed Pressing the HOLD RESUME key when a cycle is operating holds the current temperature indefinitely The HOLD RESUME LED will light along with the LED for the portion of the cycle operating when the key was pressed Pressing the key a second t me will resume the cycle from the hold point When a cycle is held with the HOLD RESUME key the pro gram parameters can be changed on any stage of the se lected program Resuming the cycle causes the control to use the newly programmed parameters Resets the display to the current muffle temperature if para meters are being reviewed or programmed Displays the cycle time remaining in a TIME segment during operation 6 5 10 START STOP Starts the furnace The e cycle will operate as prog rammed Stops the cycle if the furnace is operating Restarting a cycle that has been stopped with the START ST DP key will restart from the beginning 11 Digit or Numeric Keys Used to enter temperatures times and hgat rates 12 ENTER 13 Parameter LED s When entering a value any incorrect entry can changed by reentering the correct value The incorrect value will dis appear off the left side of the display Con
24. d top brick must be put back in place Fiber rope used between back brick and rear edges of plates must jb reinstalled to prevent air from flowing into the chamber before preheating 6 13504 THERMOCOUPLE REMOVAL 1 Turn off the power to the furnace and remove the line cord from th wall recep tacle outlet Allow the furnace to cool to room temperature beforejstarting service 2 Remove the furnace back by removing the back panel screws 3 Remove the control module assembly See the Control Panel Sectid Disconnect only the thermocouple and thermocouple strain relief 4 Pass the thermocouple Jeads through the back of the control module housing 5 Remove thermocouple from the back of the muffle 6 To replace the thermocouple reverse the above procedure 1 NOTE nno rr The furnace and its internal components and assembiies are delicate and need to be packed properly for return shipment Pack all parts or assemblies in a bag then foam and seal them in suitable boxes Use original packaging when it is available FURNACE 6 525 VOLTAGE DESCRIPTION 100V 120V 220V 240V Muffie 29491042 9491040 9491041 R94919041B Thermocouple H9491747 Triac Power Switch Control Power PC Board Assembly Display PC Board Assembly Membrane Switch and Switch Plate Battery Lithium Panasonic Part Number BR2032 Radio Shack Number CR2032 EXPLODED VIEW 6 525 ENCLOSURE
25. ds are replaceable along with the membrane switch panel wit its mount ing plate The control be examined at this point along with battery replace ment and temperature calibration 5 If the control panel needs to be completely removed the wiring connections should all be noted labeled or verified with the schematic included in this manual 6 Reverse the steps above for reinstallation making sure that all electrical tions are tight 6 160 MUFFLE REMOVAL 1 Turn off the power to the furnace and remove the line cord from the wall recep tacle outlet Allow the furnace to cool to room temperature before gtarting service 2 Remove the Control Panel by following the instructions above for Removal 3 Disconnect the blue or blue white muffle leads from the triac and the power board 4 Remove the eight Phillips screws from the back panel 5 Open the door and remove the 3 screws along the bottom front of the muffle 6 Remove the thermocouple from the back of the furnace 7 Remove the muffle lead wires from the muffle terminals 8 Remove the exhaust port by removing the three retaining screws 9 Slide the muffle out the back of the furnace enclosure 10 To reinstall slide the muffle into the grooves in the rail and reverselsteps 1 7 Panel 6 160A THERMOCOUPLE REMOVAL TYPE 1 Turn off the power to the furnace and remove the line cord from the wall recep tacle out
26. eat rate or temperature increase rate Pressing the RATE key displays the currrent value for the program and stage selected The corre sponding RATE LED aiso flashes While the RATE LED is flashing a new RATE can be entered on the keyboard If an incorrect digit key is pressed while entering a parameter the correct pa rameter should be reentered The incorrect digit will shift off the display to the left Once the correct value is displayed save it by pressing the ENTER key if the ENTER key is not pressed the original value will be retained and the new value will be lost After the ENTER key is pressed the display returns to the current temperature Entering a 0 for any RATE 2 through 6 causes the cycle to end after the previ ous stage Example RATE 4 0 Program ends after STAGE 3 Program ming RATE 1 to O causes the program to start with STAGE 2 TEMPERATURES The TEMP key sets the muffle temperature Pressing the TEMP key displays the current value for the program and stage selected The corresponding TEMP LED also flashes While the TEM eto is flashing a new temperature can be entered on the keyboard If an incorrect digit key is pressed while entering a parameter the correct parameter should be reentered The incorrect digit will shift off the display to the left Once the correct value is displayed save it by pressing the ENTER key If the ENTER key is not pressed the original value will be retained and the
27. er the switch panel and cause damage Clean the furnace cabinet with any household non abrasive cleaner and soft cloth CALIBRATION Under normal use the furnace will not require calibration Situations where cali bration may be required include thermocoupie damage and replacement con trol power pc board assembly replacement An electronic temperature meter if available should be used to calibrate the furnace If one is not available then the boards and thermocouples should be used as supplied They have been precalibrated at the factory and will be more accurate than other methods of calibration an electronic temperature meter is used then its thermocouple sensor should be placed in the center of the muffle half way between the top and bottom Program the furnace to heat to 960 C at a rate of 20 C min and start the con trol After the furnace reaches 960 C wait 30 minutes for the muffle tempera ture to stabilize Record the temperature measured by the electronic tempera ture meter as the difference between 960 and its reading For example if the meter reads 980 then the difference is 20 If the meter reads 950 then the difference is 10 Once a measurement has been recorded turn off the furnace and unplug its power cord Allow the furnace to cool to room temperature Remove the con tro panel by following the directions under Control Panel Removal in section 8 The following directions apply once the contr
28. firms the Numeric Key entries and stores them in the controls memory LED s in the graph next to the switches are used to indicate control status 14 PROGRAM SELECT 1 4 Selects PROGRAM to be reviewed programmed or 15 STAGE 1 6 16 AUX 1 run by the control A new program can be selegted when ever the control is not running the current program Selects the STAGE segment of the selected program to be reviewed or programmed The stages of the cugrently se lected program can be reviewed at any time The corre sponding LED lights with each key and goes In seven seconds if a parameter key RATE TEMP TIM 3 AUX is not pressed Stage parameters can be reprogrammed only when the control is not running the current program or when the current program has been put on HOLD Ali the STAGE LED s that are programmed lightiwhen the furnace is started They go out in sequence asjeach STAGE is completed Normally open electrical contact output that caj be pro grammed to turned on and off as the furnace ru ins the preprogrammed cycle The AUX 1 output can pro grammed to be on or off independently for each segment of a cycle The IEC socket on the back of the fur lace provides a 5 amp max fused contact closure when turned on See the auxiliary output section that follows 6 6 17 AUX 2 NOTE NOT APPLICABI LE TO 6 6 525 The AUX 2 key controls the air exchange fan located on the back of the furnace The AUX 2 or a
29. he following tools are required for disassembly reassembly work described in this section Small blade screwdriver Medium Phillips screwdriver Needle nose pliers Regular pliers 6 525 SERVICE 6 525 CONTROL PANEL REMOVAL Access to pe boards trlac power switch door switch thermocouple And muffle wiring connections 1 Turn off the power to the furnace and remove the line cord from the tacle outlet Allow the furnace to cool to room temperature before service 2 Remove 9 screws from around the top sides and bottom of the con ol panel Hanging the front of the furnace off of the counter by 2 inches 50nf m will aid In removing the bottom screws 3 The control panel can now be removed by pulling It out the front of ti e furnace while raising the panel up slightly The contro panel will slide out pproxi mately 6 inches 150mm 4 With the control panel pulled out various connections can be accesged The pc boards are replaceable along with the membrane switch panel witt its mount ing plate with the drawer out The contro can be examined at this point along with battery replacement and temperature calibration 5 If the control panel is to be completely removed the wiring connectigns should all be noted labeled or verified with the schematic Included in thislmanual 6 Reverse the steps above for reinstallation making sure that all electr al connec tions are tight all recep starting 6 525 THERMOC
30. he urnace insulation The MSDS documents and warning labels are for your training prograr to Inform your employees of the hazards associated with the use of these product At the time of publication of this manual The J M Ney Company is acti ly studying and performing test as to comply with the State of California law regulrirfg that the public be informed of products containing materials which in some circumstances are carcinogenic in nature At the conclusion of this analysis additional inf rmation will be provided in new product Operator Manuals Should you desire a co 3 of the find ings write The J M Ney Company Yucaipa CA or call 714 795 2461 nd ask for Customer Service RECEIVING IN F UNPACKING Carefully remove the furnace from the shipping carton Save the carton and packing materials The carton serves as the best container for transporting the furnace The shipping carton contains the following One furnace Ceramic floor trays 1 each 8 20cm SQ 6 525 6 1350A 2 each 4 10cm SQ 6 160A Exhaust port 6 525 top mount packed outside furnace during shipment 6 160 6 1350A top mounted Two exhaust port ball plugs One operator service manual One Electrical Plug for Auxilliary Output _ One bottle of fiber harding agent 6 525 only LOSS OR DAMAGE If there is any visible damage do not attempt to operate the furnace Note any exter nal evidence of los
31. ified or repaired by unauthorized per sons or improperly installed 2 WARRANTY EXCLUSIONS The warranty described in Paragraph 1 does not Include normal wear of Ney s product or its components The muffle a component of Ney furnaces has a warranty period from the date of sale as outlined in the table below FURNACE MUFFLE LENGTH OF WARRANTY 6 160A 6 Months 6 525 60 Days 6 1350A 6 Months 3 INSPECTION Buyer shall inspect the product upon receipt The buyer shall notify The J M Ney Company in writing of any claims of defects in material and workmanship within thirty days after the buyer discovers or should have discovered the facts upon which such a claim is based Failure of the buyer to give written notice of such a claim within this time period shall be deemed to be a waiver of such claim 4 DISCLAIMER The provisions here in stated The J M Ney Company s sole obli gation and exclude all other remedies or warranties expressed or implied including those related to MERCHANTABILITY and FITNESS FOR A PARTICULAR PURPOSE 5 LIMITATION OF LIABILITY Under no circumstances shall The J M Ney Com pany be liable to the buyer for any incidental consequential or special damages losses or expenses 6 LIMITATION OF ACTIONS The buyer must initiate any action with respect to claims under the warranty described in the first paragraph within one year after the cause of action has accrued Corporate Offices The J M Ney Company
32. key is pres bed They are individually turned off as each function is completed Any one the four furnace programs can be started in this way Programs can be chained together run in groups by pressing and holding the first program key in the chain While this key is held down press fhe additional programs to be chained to the first program The LED for each pr gram that is selected will light Two three or four programs can be chained li i their num ber sequence For example 1 2 3 4 1 2 3 4 1 3 4 2 4 Pressing the START STOP key starts the first program in the chain The other programs follow the first sequence STARTING THE FURNACE WITH A DELAY START A value for the DELAY START must be programmed first The default value is preprogrammed to zero Press the DELAY START key followed by the digit keys of the desire amount of delay in hours The DELAY START LED will flash and the programmed value will be displayed Pressing the ENTER key will store this value and turn off the DELAY START LED Pressing the DELAY START key again will activate the function flash the LED and display the delay value in hours Pressing the START STOP key will start the delay followed by the selected program The DELAY START LED will be on during the delay FURNACE OPERATION During cycle operation all the indicating LED s Program and Stage for a cycle will initially light and go out as that portion of the cycle is completed The RATE and T
33. let Allaw the furnace to cool to room temperature before dtarting service 2 Remove the Control Panel by following the instructions above for C ntrol Panel Removal 3 Follow steps 4 6 of the muffle replacement procedure 4 Disconnect thermocouple red and yellow wires from the left hand sige of the computer power board and remove thermocouple 5 Reverse steps 1 4 to reinstall x nal 27 Lebe md MS ds ft UI ODEI nmi O ee TI ME obra 42 0 A ee Mc 6 1 1350A SERVICE 6 1350A CONTROL PANEL REMOVAL Access to pc boards triac power switch door switch also thermocouple and muffle wiring connections 1 Turn off the power to the furnace and remove the line cord from the wall recep tacie outiet Allow the furnace to cool to room temperature before starting service 2 Remove the rear electrical panel 3 screws in lower left of furnace back looking from the rear and lay it to the side The retaining screw for the control module is located above and inside the furnace 3 Push on this screw as it is removed The control panel will slide out the front The control panel can be pulled out approximately 6 inches before any wires need to be disconnected 4 Refer to the schematic wiring diagram page 8 5 before removing any wires Calibration can be done in this position and most of the other possible service requirements such as PC board replacement triac replacement and
34. ling it out of the muffle Follow the instructions above if thermocouple to be replaced 6 The can now be removed by releasing the two springs that hold it in posi tion USE CAUTION WHEN RELEASING OR INSTALLING THE SPRINGS Us ing pliers release spring on end farthest from you This will prevent it from flying at you if your grip should slip 7 When installing the muffle make sure that the muffle is pressed tightly against the front panel the muffle wires must be fed through the two bushings in the front ofthe heatshield 8 Reverse steps 1 6 for reinstallation Gloves and protective eyewear should be worn when instailing the springs 6 160A SERVICE 6 160A CONTROL PANEL REMOVAL Access to po boards triac power switch door switch thermocouple and muffle wiring connections 1 Turn off the power to the furnace and remove the line cord from the wall recep tacle outlet Allow the furnace to cool to room temperature before starting service 2 Remove 9 screws from around the top and bottom of the control panel Hanging the front of the furnace over a counter by 2 inches 50mm will aid in removing FREI pent DO UT Sates 3 The control panel can now be removed by pulling it out of the front df the furnace while raising the panel up slightly The control panel will slide out Rpproxi mately 6 inches 150mm 4 With the control panel pulled out various connections can be 266659860 The boar
35. llowed by the ENTER key will cause the control to reset ail the parameters and settings in the control Rese will be displayed This is for diagnostics and system checking Refer to Configuration Setup in the maintenance section 7 for further directions To end the configuration setup routine press the 9 key followed by the ENTER key The control will go into normal operation displaying the current muffle temperature rn NEJ a a all r canet LE 1 A A A O t 00 0 at DU VL helm e tar Sr eve ied E LO T ue a ae TET D SS TT TELL ON FLS CNC tet Prats O CE e EST a HI oth Eee pra AT ane vn A a a 1 meee SITUATION You wish to do a six stage temperature profile The following heating rates tempera tures and holding times are desired RATE 45 F min TEMP 500 F TIME 3 Hour RATE 10 F min TEMP 760 F TIME 5 Hour RATE 5 F min TEMP 1200 F TIME 1 7 Hours RATE 10 F min TEMP 1760 F TIME 3 Hours RATE 5 F min TEMP 1510 F TIME 1 Hours RATE 10 F min TEMP 1000 F TIME 30 Hours a ASSUMPTIONS 1 Furnace is turned on 2 The muffie is cool 3 The muffle temperature is being displayed in degrers Fahrenheit Press C F key if cu
36. lr exchange fan can be programmed to be on at a particular level or off independ ently for each stage of a cycie or program The speed of the fan 0 for OFF and 9 for MAX which is related to the number of air exchanges can also be programmed NOTE High air exchange rates will reduce the maximum possible heat rates and temperatures Door Switch not shown Internal switch deactivated by door opening which causes the control to disconnect the from both sides of the power line Thermocouple Type K thermocouple located in the rear of the muffle to measure chamber temperature for the control Auxillary Output Rear connection for AUX 1 described previously z a Iento e DDD ete ipa aie tenn ie Tet so eT TED San ats atte OU a Deas O BE MMSE US ae 0000000 l O Ci a cChons amp s eT LM E v zu nett E meris fao mUM e SM ia ELI LU 001 Luv OTD CAEL Do Cg Bee tT l is A u A tn A a toi NO ja jar EN 000 780 A CA Serum 6 LO U u OPERATING THE FURNACE POWER ON VY Turning on the power switch activates the control The control perf prms a self test for approximately three seconds and displays the model number ie 525 160A or 1350A At the end of the self test the actual muffle tempe
37. mpiFused 100 H RECEPTACLE ENCLOSURE GROUND 07 220 240 PLUG N J RECEPTACLE CONNECTIONS CONTROL EARTH TE GROUND DOOR A SWITCH 277 Fit2 CALIBRATION ADJUSTMENT YELLOW White Black RED THERMOCOUPLE COMPUTER POWER PC BOARD L ds DISPLAY PC BOARD MEMBRANE SWITCH 8 4 6 160A and 6 1350 SCHEMATIC HEATING ELEMENTS DOOR SWITCH OM 1 THERMOCOUPLE HOA MUFFLE CONNECTIONS 13504 SHOWN YELLOW RED MEMBRANE SWITCH CALIBRATION ADJUSTMENT COMPUTER POWER PC BOARD CONTROL EARTH GROUND DISPLAY PC BOARD HO ENCLOSURE GROUND SA Black AUX 1 SOCKET Black S Amp Fused White 79 To Red Fan POWER FAN SUPPLY PCB SWITCH O ta LT a VN OA ian IESE ott On ut 7 0 1 5 a 5 5 5 4 STO lies mee Cb CU Tann AEL NETA MN AR n L D APOTE NOT O 1 70 DISASSEMBLY INSTRUCTIONS READ THE CAUTIONS ON PAGES 1 1 AND 1 2 BEFORE PROCEEDING DISCONNECT THE FURNACE LINE CORD FROM THE WALL RECEPTAC fie furnace Refer to the schematics and the exploded view drawings for the appropriate furnace during servicing Respiratory eye and hand protection should be worn during the following proce dures T
38. ms Chainable Into 24 Stages Total gt Programmable Auxiliary Output 5 Amp Max Normally Open Switched Contact gt Long Life Battery Lithium Backup Of Program Parameters gt Power Interruption Cycle Continuation Power Outage Return gt Digital PID Proportional integral Derivative Temperature Control gt Delay Start Of Operation Timer gt High Temperature Range To 1100 C 2012 F gt Hold Feature For Cycle Interruption Or Infinite Hold Capability gt Negative Rate Ramp Temperature Control gt 0 1 Degree Per Minute Rate Ramp Resolution gt Programmable High Limit Cutoff gt LO Battery Indicator gt Various Diagnostic Indications gt Type K Thermocouple 6 52 gt Large Low Thermal Mass Fiber Muffle Fast Heat and Cool Rates 6 160 gt Integral Fan for Forced Air Exchange gt Compressed Air Exchange Fitting 1 8 NPT Female gt Vertical Lift Door gt Firebrick Lined Muffles 6 13 gt Integral Fan for Forced Air Exchange gt Compressed Air Exchange Fitting 1 8 NPT Female gt Largest Firebrick Lined Muffle LU nant annt Benue Ly O RUN ne tet canons aint M AMA ELECTRICAL 6525 61350 6 160A Power requirements in watts 4000 220V 1800 at nominal line voltage 4780 240V Watts to maintain 1000C 1100 500 1600 Nominal current 50 60Hz in Amps
39. new value will be lost After the ENTER key is pressed the display returns to the current muffle temperature TIMES The TIME key sets the length of the hold time at the programmed temperature Pressing the TIME key displays the current value for the program and stage selected The corresponding TIME LED also flashes While the TIME LED is flashing a new time can be entered for the selected STAGE on the keyboard f an incorrect digit key is pressed while entering a parameter the correct parameter should be reentered The incorrect digit will shift off the display to the left Once the correct value is displayed save it by pressing the ENTER key If the ENTER key is not pressed the original value Suny will be retained and then new value will be lost After the ENTER kd the display returns to the current muffle temperature y is pressed Setting the last TIME to 0 causes the control to end the cycle and Shut off The muffle temperature is not held The last TIME can be TIME 6 or the TIME im meadiately before a RATE set equal to zero AUXILIARY OUTPUT 1 The AUX 1 output is a normally open electrical contact accessible o the user n the rear of the furnace close to the power cord A adaptor plug is Bupplied in the accessory kit to make the connections The socket for AUX 1 5 fused at 5 amps with the fuses mounted in the socket The AUX 1 contacts can be independently closed ON or opened
40. ol panel is opened The trimmer potentiometer labeled R12 SPAN ADJ see page 8 4 on the computer power printed circuit board assembly horizontally mounted pob will be adjusted to correct the calibration If the muffle temperature measures higher positive difference in example above than the furnace indicates turn WQME VOU tet Vues 2 Tate nr lo 00 the trimmer potentiometer la labeled F 812 gt SPAN ADJ clockwise e to reduce the display temperature The potentiometer should be turned one komplete turn for every 10 C of difference If the temperature measures lower negative difference adjust the potentiometer counterclockwise CCW using the same ratio BATTERY REPLACEMENT If the program contents are lost when the furnace power is turned and off then the battery is dead In addition if the Low Batt indicator flaghes the battery should be replaced The battery in question is a small Lithium coin type battery 2032 Refer to the CONTROL PANEL REMOVAL section 8 for instructions 1 on your furnace Once the control panel has been pulled out of the front o ithe furnace 30cm to 40cm 6 inches the old battery can be removed The battery is lo cated near the front center of the computer power pc board Rem e the tape then using a small screw driver remove the old battery Replace itiwith
41. pendable service Preparation For Return Shipment 1 The furnace muffle interior should be emptied of ali trays and work pieces 2 The exhaust tube on 525 units should be removed and stored for use upon the return of the furnace 3 The original packing materials should be used for return shipment if they are not available new materiais can be purchased for a nominal fee 4 Equipment damaged in shipment as the result of improper packing may be paid for by the carrier The J M Ney Company will not be responsible for equipment damaged in return shipment due to improper packing Ship the furnace shipping costs prepaid to The J Ney Company RMA 13553 Calimesa Boulevard Yucaipa CA 92399 2398 714 795 2461 FAX 714 795 5268 T NOM 200 0000 5 4 an Pora T EDAT a 2gcc MANN 4 00 aam uu at em S tt NMT O S T V muere see m Sans tam o SARE non ING and ERROR CODES See 5 0 0 Below for the ERR codes Review the following list of questions and suggestions before calling thelservice number listed on the previous page Some of the answers may prove hefpful in help ing us solve the problem 1 0 0 Shipping damage SEE SECTION 2 RECEIVING INFORMATION 2 0 0 No operation Furnace Dead Display does not lightup LED s do hot come and muffle does not heat 2 1 0 Does the power receptacie h
42. rature is dis played If an operating cycle is stopped with the START STOP key pressing the key a second time will restart the cycle from the beginning If the ib atan elevated temperature the control will use the programmed RATE 1 for the cool ing or heating to TEMP 1 If the model number is not displayed or the display sequences throhgh all the model numbers listed on the front cover see BATTERY REPLACEMENT and CONFIGURATION SETUP in Maintenance Section 7 The furnace s operation can be changed in several ways by changihg the de fault settings These are the preselected parameters the factory entered when the unit was tested For more information about these see CONFIGURATION SETUP later in this section under programming REVIEWING THE PROGRAM The current stored programs can be reviewed by selecting a progr stage and parameter keys to display the values The first step is to press a PRO GRAM key followed by a particular stage key for that program Pre ssing the TEMP RATE TIME or AUX keys dispiays the current value for tha stage and program The displayed parameter is replaced with the current muffle tempera ture by pressing the TEMP CYCLE TIME key STARTING THE FURNACE WITHOUT A DELAY START The current program can be started by pressing the START STOP ey The display continues to display the muffle temperature as the muffle E 3815 up The LED s in the programmed cycle are turned on when the
43. rding Agent has been included with your furna le shipment The Fiber Harding Agent is a binding solution with the viscosity of water It will harden the surface which was damaged Directions for using this material are listed below 1 Unplug the furnace and allow to cool 2 Apply liquid hardening agent generously to the damaged area with a small brush or swab 3 Plug in the furnace and heat to 250C 500F for approximately two hours or until the agent is dry or solid Allow the furnace to run longer if the mate is not dry 4 After the agent is solidified the furnace is ready for normal use SERVICE This section is provided as assistance to qualified service personnel If you are quali fied to service the furnace please read the entire manual before you attempt any servicing IF YOU ARE NOT QUALIFIED TO SERVICE THE FURNACE PLEASE READ THE PARAGRAPH BELOW AND FOLLOW THE DIRECTIONS SPECIFIED If the unit requires service review pages 8 2 8 3 before contacting the service de partment at your dealer or The J Ney Company Yucaipa CA Describe the par ticular problem and give the model and serial numbers of the furnace This informa tion is located on the data plate attached to back of the furnace An RMA Return Material Authorization number will be assigned to your unit as a control during the repair period The RMA number must appear on the shipping label so we can give you fast and de
44. rrent displaygiis in C 4 The load is inside the muffle on a ceramic tray 5 Program will be stored in PROGRAM 1 Press PROGRAM 1 key if PROGRAM 1 LED is not on PROGRAMMING STEPS STEP PRESS KEY ACTION 1 RATE Press key until the RATE 1 LED flashas 4 5 0 45 0 F min ENTER RATE 1 15 now programmed TEMP Press key until the TEMP 1 LED flashas 5 0 0 500 F ENTER TEMP 1 is now programmed TIME Press key until the TIME 1 LED flasheg 3 0 3 Hour 9 ENTER TIME 1 is now programmed STAGE 1 5 NOW PROGRAMMED 10 RATE Press key until the RATE 2 LED flashes 11 1 0 0 10 0 F min 12 ENTER RATE 2 is now programmed 13 TEMP Press key until the TEMP 2 LED flashas 14 7 6 0 760 F 15 ENTER TEMP 2 is now programmed 16 TIME Press key until the TIME 2 LED flashes 5 0 5 Hour 18 ENTER TIME 2 is now programmed STAGE 2 IS NOW PROGRAMMED 19 RATE Press key until the RATE 3 LED flasheb 20 5 0 5 0 F min 21 ENTER RATE 3 is now programmed e OT 6 6 1 2 0 0 24 ENTER 25 TIME 26 1 7 27 ENTER STAGE 3 5 NOW PROGRAMMED 28 RATE 29 1 0 0 30 ENTER 31 TEMP 32 1 7 6 0 33 ENTER 34 TIME 35 3 0 36 ENTER STAGE 4 15 NOW PROGRAMMED 37 RATE 38 5 39 ENTER 40 TEMP 41 1 5 1 0 42 ENTER 43 TIME 44 1 45 ENTER STAGE 5 iS NOW PROGRAMMED 46 RATE 47 1 0 0 48 ENTER 49 TEMP 50 1 0 0 0 51 52
45. s or damage on the freight way bill or express receipt and have it signed by the carrier s agent Failure to adequately describe such external evidence of loss or damage may result in the carrier s refusal to honor your damage claim The form required to file such a claim will be supplied by the carrier Concealed loss or damage means loss or damage which does not become apparent until the merchandise has been unpacked and inspected Should either occur make a written request for inspection by the carrier s agent within 15 days of the delivery date Then file a claim with the carrier since the damage is the carrier s responsibility 6 525 MUFFLE The 6 525 muffle heating chamber is constructed in one piece It is considered nor mal for cracks to appear on the surface along edges and in the corners This will not degrade or limit the performance or life of the muffle Remove all packing materials from inside and around the furnace Select a benchtop location within five feet 1 5 meters of the power receptacle The furnace should be on a Jevel surface at least 6 inches 16 cm away from wails other equipment and heat sensitive materials Do not mount under shelves or other structures that will restrict the flow of air The furnace should be located under an exhaust hood if mate rial or chemical reactions will be taking place inside the furnace The power receptacle should have the following overcurrent protection as follows
46. the furnace In addition wear respira tory protection when cleaning or servicing the muffle chamber MATERIAL SAFETY DATA SHEETS On March 25 1983 the Occupational Safety and Health better krov OSHA put the Hazard Communication Standard 29CFR 1910 1200 better known ap the Right to Know into effect This regulation became effective on November 25 1985 for manufacturg 7 and dis tributors of products that OSHA has determined to be hazardous Vitrdous Alumi nosiliciate Cristobalite mineral dusts in concentrations over 1 fiber centil meter are included in the OSHA tables as air contaminates The J M Ney Company manufactures and selis products that use inst ating refrac tories These refractories contain Vitreous Aluminosiliciate fibers eramic fibers will form crystalline silica Cristobalite after operating at temper tures above 1600 degrees F To comply with the OSHA regulations Material SafetylData Sheets MSDS have been developed and are available to you upon request his phase of the regulation took effect in 1986 The information contained in the MSDS documents take into account the Intended Use of all products It may not necessarily address all processes or procedures in your particular application We highly recommend that you determine the health in every pertinent operation including but not limited to install tion mainte nance cutting sawing drilling or filing t
47. trou bleshooting 5 To replace the control panel assembly reverse the disassembly procedure 6 1350A MUFFLE PLATE REMOVAL Each of the four ceramic plates have heating element wires within the plate Each plate can be replaced individually if a failure occurs 1 Turn off the power to the furnace and remove the line cord from the wall recep tacie outlet Allow the furnace to cool to room temperature before starting service 2 Hemove the furnace back by removing the back panel screws 3 Remove the thermocouple from the muffle and push it back into the control section 4 Disconnect the power leads connecting the muffle to the control section Discon nect all of the individual muffle plate connections from the terminal block 5 Remove the 6 screws which hold the muffle back to the muffle then remove the aluminum back 6 Remove the exhaust port tube by removing the 3 retaining screws 7 Remove the rear fiber brick from the back of muffle It will slide out the back while the leads are fed through it TAKE CARE NOT TO DAMAGE THE BRICK Note Each plate supports the others The sides or top plates will fall unless ade quate support is provided 8 Slide the top plate out the back while supporting the others Continue with the sides and then the bottom plate 9 The muffle can now be reassembled using the new part 10 To reassemble reverse the procedure and use the following precautions Fiber rope used between top plate an
48. utes TEST CONDITIONS No Load in Muffle No Power Applied To 6 160A and 6 19 50 with Internal an Set O for OFF and 9 for MAX FURNACE DESCRIPTION AND OPERATION 6 525 EXHAUST PORT At writin Fi ER FUL watt Dno lU ues hse n 1 Thy pile Pane S ai wer era Mi Mri L IAE Frost Sd 3 ini hd DAE ET soda len Tabarka ra Pange van ARTE Juve rana ETT Gn ME a T TET d m TET S Die sp Ve qp ura ER Wa ub db ai k b Soke ad poe DE Tana js aeir 244 mra Ban re Are s gt ett Pi JE Hr ha zje ar de n ib nur U ea ee w Li i To at by Atatay AM quini Sidecar aara TIA s Fu Deb r sos Z r run o Sel ord dake e ied des kr ee k dag x
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