THERMOLYNE MINI-MELT FURNACE

Transcription

1 THERMOLYNE MINI-MELT FURNACE OPERATION MANUAL AND PARTS LIST Series 366 Record serial number here BARNSTEAD/THERMOLYNE CORPORATION MODEL NUMBERS F25810 & F25815 READ ALL S, CAUTIONS, AND INSTRUCTIONS CAREFULLY BEFORE OPERATING THIS THERMOLYNE FURNACE. January 1990 LT366X2

2 IMPORTANT INFORMATION This manual contains important operating and safety information. The user must carefully read and understand the contents of this manual prior to the use of this equipment. TABLE OF CONTENTS SAFETY INFORMATION... 1 SIGNAL WORDS... 1 S... 2 INTRODUCTION... 2 INSTALLATION... 3 OPERATION... 4 REPLACEMENT PARTS LIST... 7 MAINTENANCE AND SERVICING... 7 ORDERING PROCEDURES... 9 WARRANTY INFORMATION... 9 SAFETY INFORMATION Your Thermolyne furnace has been designed with function, reliability and safety in mind. It is the user s responsibility to insure conformance with required electrical codes. For safe operation, please observe the following: SIGNAL WORDS "DANGER" "" "CAUTION" "NOTES" notes apply when there are hazards which result in severe personal injury or death. notes apply when there is a possibility of personal injury. notes apply when there is a possibility of damage to the equipment. alert the user of the manual to pertinent facts and conditions. 1 Barnstead/Thermolyne

3 S THIS FURNACE CONTAINS REFRACTORY CERAMIC INSULATION WHICH CAN PRODUCE RESPIRABLE FIBERS AND DUST WHEN HANDLED. THESE FIBERS CAN CAUSE IRRITATION AND CAN AGGRAVATE PRE- EXISTING RESPIRATORY DISEASE. THE INTERNATIONAL AGENCY FOR RESEARCH ON CANCER (IARC) HAS CLASSIFIED REFRACTORY CERAMIC FIBER AS POSSIBLY CARCINOGENIC. AFTER SERVICE REFRACTORY CERAMIC FIBER DUSTS MAY CONTAIN CRYSTALLINE SILICA, WHICH MAY CAUSE LUNG DAMAGE (SILICOSIS) AND WHICH HAS BEEN CLASSIFIED BY IARC AS A PROBABLE CARCINOGEN. CONSULT THE OWNER S MANUAL FOR THIS EQUIPMENT BEFORE YOU MAKE ANY REPAIRS TO OR REPLACE ANY PARTS, INCLUDING REPAIRS TO OR REPLACEMENTS OF ELECTRICAL COMPONENTS OR INSULATING MATERIALS. THE OWNER S MANUAL CONTAINS INFORMATION AND S RELATING TO THE HAZARDS ASSOCIATED WITH THE REPAIR AND MAINTENANCE OF THIS EQUIPMENT. REFER SERVICING TO QUALIFIED PERSONNEL. TO AVOID ELECTRICAL SHOCK, THIS FURNACE MUST: 1) ALWAYS USE A PROPERLY GROUNDED ELECTRICAL OUTLET OF CORRECT VOLTAGE AND CURRENT HANDLING CAPACITY. 2) ALWAYS BE DISCONNECTED FROM THE POWER SUPPLY PRIOR TO MAINTENANCE AND SERVICING. TO AVOID BURNS, THIS FURNACE MUST: 1) NOT BE TOUCHED ON THE EXTERIOR OR INTERIOR FURNACE SURFACES DURING USE OR FOR A PERIOD OF TIME AFTER USE. TO AVOID PERSONAL INJURY: 1) DO NOT USE IN THE PRESENCE OF FLAMMABLE OR COMBUSTIBLE CHEMICALS. FIRE OR EXPLOSION MAY RESULT; THIS DEVICE CONTAINS COMPONENTS WHICH MAY IGNITE SUCH MATERIALS. 2) DO NOT OPERATE OR CLEAN FURNACE WITHOUT PROPER EYE PROTECTION. INTRODUCTION The Thermolyne MINI-MELT Furnace is designed for convenient electric melting of metals. It is an ideal metal melting unit for casting as well as for alloying metals providing melting temperatures up to 2000 F. The furnace, supplied with a special graphite crucible, features embedded elements in a molded ceramic fiber insulation. Chamber dimensions are 1-7/8" in diameter by 5-1/4" depth. The graphite crucible has a melting capacity of 30 troy ounces gold, 25 troy ounces silver, 1-1/2 lbs. brass, and 8 ounces aluminum. 2

4 NOTE: It is recommended that the graphite crucible be examined after each use. Should the crucible show excess wear and/or cracks on the surface, it should be discarded and replaced with a new graphite crucible. The operating temperatures of the Thermolyne "MINI-MELT" Furnace, which range from room temperature to 2000 F, are indicated on the built-in pyrometer. The Power-Control Switch allows the furnace to reach and maintain any desired temperature within the specified operating range. The pilot light indicates when the furnace is operating. CAUTION: THE "MINI-MELT" FURNACE HEATING CHAMBER BECOMES HOT WHEN OPERATING. ALWAYS USE THE HANDLE. INSTALLATION Install the Thermolyne MINI-MELT furnace by plugging it into an outlet of proper voltage. The MINI-MELT is available in 120 volt and 240 volt models. Look on the nameplate for the correct power rating. The furnace is shipped with a three wire and three prong plug to conform to modern electrical practice. Where two wire service is in use, an inexpensive grounding adaptor may be secured from local suppliers and should be used. GENERAL OPERATION OF FURNACE OBSERVE THESE S BEFORE OPERATING YOUR FURNACE: DO NOT USE IN THE PRESENCE OF FLAMMABLE OR COMBUSTIBLE MATERIALS. FIRE OR EXPLOSION MAY RESULT; THIS DEVICE CONTAINS COMPONENTS WHICH MAY IGNITE SUCH MATERIALS. TO AVOID EYE DAMAGE, DO NOT OPERATE OR CLEAN FURNACE WITHOUT WEARING PROPER EYE PROTECTION. TO AVOID FIRE, DO NOT PLACE COMBUSTIBLE MATERIALS WHERE EXPOSED TO HEAT FROM OPEN CHAMBER ENDS. DO NOT TOUCH ON THE EXTERIOR OR INTERIOR FURNACE SURFACES DURING USE OR FOR A PERIOD OF TIME AFTER USE. 3 Barnstead/Thermolyne

5 OPERATION POWER-CONTROL SWITCH: The power is turned "ON" and "OFF" by turning the Power-Control Switch in the Thermolyne "MINI-MELT" Furnace which is a manually operated Percentage Time Input Controller. This switch applies power to the furnace at a pre-determined time interval corresponding to the selected setting. Because of the safety switch, power to the elements is removed when the lid is opened. CAUTION: When removing crucible always turn power OFF. DO NOT USE IN THE PRESENCE OF FLAMMABLE OR COMBUSTIBLE CHEMICALS. FIRE OR EXPLOSION MAY RESULT. THIS DEVICE CONTAINS COMPONENTS WHICH MAY IGNITE SUCH MATERIALS. The dial marks on the Switch indicate the percent of time that power enters the heating elements (e.g. at a setting of 3, power is applied 30% of the total ON-OFF cycle time). Higher numerical control settings result in a higher chamber temperature. The furnace chamber may be heated up at a rapid rate or at a controlled slower rate. For rapid heating, set the Power-Control Switch on "Hl" or in the RED ZONE. It is suggested that the furnace be allowed to stabilize in the 1500 to 1600 F temperature range for a few minutes, before increasing temperatures to achieve melt. This is accomplished by turning the switch back to a setting of 4 for two to three minutes and then returning to a higher setting for final metal melting. For controlled slower heating, set the Power-Control Switch at a desired Percent Power Input (e.g. 4 for 40% time input). Once operating temperature has been reached, as indicated by the Pyrometer, adjust the Switch to the corresponding Power-Control Switch Setting (see Thermolyne "MINI-MELT" Reference Chart for approximate settings). Experience in the melting operation, using the Percent Time Input Controller, will allow you to determine exact control settings for subsequent furnace use. The Thermolyne "MINI-MELT" Reference Chart gives the approximate chamber temperature and Heat-Up Time required at the various Power-Control Switch Settings. The Power-Control Switch can be positioned at any selected setting and the indicated Approximate Chamber Temperature will be reached and maintained. Because the values given in the Reference Chart are approximate, Power-Control Switch Settings for given temperatures may differ somewhat from unit to unit or from that shown in the Chart. THERMOLYNE "MINI-MELT" REFERENCE CHART Power Control Switch Setting Chamber Temperature Approximate F ( C) Heat-Up Time Power-Control Set on "HI" LO min. 8 min. 13 min. 16 min. 22 min. 26 min. 27 min. 4

6 It should be noted, when the power control switch is set on HI or in the RED ZONE, the furnace is receiving power input 100% of the time. This means the power is on continuously and the chamber temperature will continue to increase. If unattended, the chamber temperature may overheat the furnace causing serious damage to the heating elements and thermocouple. REFER SERVICING TO QUALIFIED PERSONNEL. GRAPHITE CRUCIBLE: The graphite crucible has a melting capacity of 30 troy ounces gold, 25 troy ounces silver, 1-1/2 lbs. brass and 8 ounces aluminum. Because the crucible is made of graphite, it serves to deoxidize the metal during the melting process. A carbon stirring rod is supplied for stirring the molten metal to assure a complete metal melt has been achieved when alloying or before casting. NOTE: It is recommended that the graphite crucible be examined after each use. Should the crucible show excess wear and/or cracks on the surface, it should be discarded and replaced with a new graphite crucible. PILOT LIGHT: The Pilot Light, when lit, indicates electrical power input to the heating elements of the furnace. The "ON" time will increase as the Power-Control Switch is turned to a higher number setting. When placed on the "Hl" setting, the Pilot Light remains "ON" 100% of the time. PYROMETER: The Pyrometer indicates chamber temperature; it performs no control functions. The Pyrometer has been calibrated and tested at the factory. Tampering with the adjusting screw, located beneath the cap in the base of the "MINI-MELT", will change the accuracy of the instrument. With the chamber at room temperature, the needle should register 72 F. Over a period of time, the styrene cover may pick up a static electric charge which will affect Pyrometer accuracy. It is good practice to wipe the cover periodically with a damp cloth. Using a non-abrasive detergent will usually give a residual anti-static effect. NOTE: CAUTION: Care should be taken not to damage either the heating element, insulating materials or instrumentation. When operating this furnace, IT IS IMPERATIVE TO MONITOR THE PYROMETER CLOSELY TO PREVENT OVERHEATING, PARTICULARLY WHEN THE CONTROL IS SET ON "Hl" OR IN THE RED ZONE. Disconnect from power supply if temperature exceeds 2000 F. Heating elements and crucibles must be considered expendable and replacement can be expected. The life of heating elements is affected by overheating and/or contamination. Since use conditions vary, the manufacturer cannot be responsible for damage to these parts. For maximum crucible life keep the lid in the closed position as much as possible. DISCONNECT FROM POWER SUPPLY BEFORE SERVICING. 5 Barnstead/Thermolyne

7 REPLACEMENT PARTS LIST FOR THERMOLYNE MINI-MELT FURNACE SERIES 366 PART NUMBER EL257X3B EL257X4B TC257X1A ME257X1A CNX60 CNX61 PH257X1 CR163X1 CR163X2 PLX48 PLX49 CV257X1B PT257X1 BR257X1 AY258X2 AY258X1 DESCRIPTION Repl. Heating Element 120 Volts Repl. Heating Element 240 Volts Thermocouple C/A Pyrometer Control Unit 120 Volts Control Unit 240 Volts Hearth Plate Cord and Plug 120 Volts Cord and Plug 240 Volts Pilot Light 120 Volts Pilot Light 240 Volts Lid, insulated Bottom Chamber Plate Thermocouple Protection Bushing Crucible Stirring Rod As with all manufactured products, some parts of your furnace may break down after considerable use. Always use genuine factory parts to replace a worn out part, and replace all unserviceable parts as soon as possible. A list of the parts most often replaced is included in these instructions. Always order parts by part number, and supply the model number, series number and serial number of the furnace it will be used to repair. Parts may be ordered from the dealer from whom you bought your furnace or from the factory. 6 Barnstead/Thermolyne

8 MAINTENANCE AND SERVICING S THIS FURNACE CONTAINS REFRACTORY CERAMIC INSULATION WHICH CAN PRODUCE RESPIRABLE FIBERS AND DUST WHEN HANDLED. THESE FIBERS CAN CAUSE IRRITATION AND CAN AGGRAVATE PRE- EXISTING RESPIRATORY DISEASE. THE INTERNATIONAL AGENCY FOR RESEARCH ON CANCER (IARC) HAS CLASSIFIED REFRACTORY CERAMIC FIBER AS POSSIBLY CARCINOGENIC. AFTER SERVICE REFRACTORY CERAMIC FIBER DUSTS MAY CONTAIN CRYSTALLINE SILICA, WHICH MAY CAUSE LUNG DAMAGE (SILICOSIS) AND WHICH HAS BEEN CLASSIFIED BY IARC AS A PROBABLE CARCINOGEN. The refractory ceramic materials are located in the door, the hearth collar bricks, and in the chamber of the furnace. Tests performed by the manufacturer indicate that there is no significant risk of exposure to dust or respirable refractory ceramic fiber resulting from operation of the equipment under normal conditions. However, there may be a risk of exposure to respirable refractory ceramic dust or fiber when repairing or maintaining the insulating materials, or when otherwise disturbing the materials in a manner which causes release of dust or fibers therefrom. Through the use of proper handling procedures you can work safely with these insulating materials and minimize any exposure. Accordingly, before you repair or replace any insulating materials, or perform any other servicing on this product which could disturb or cause exposure to dust from insulating materials, you should consult the appropriate Material Safety Data Sheets (MSDS s) for such products with respect to proper handling and appropriate protective equipment. For additional MSDS s, or additional information concerning the handling of refractory ceramic products, please contact the Customer Service Department of Barnstead/Thermolyne Corporation. TO AVOID ELECTRICAL SHOCK, THIS FURNACE MUST: 1) ALWAYS USE A PROPERLY GROUNDED ELECTRICAL OUTLET OF CORRECT VOLTAGE AND CURRENT HANDLING CAPACITY. 2) ALWAYS BE DISCONNECTED FROM THE POWER SUPPLY PRIOR TO MAINTENANCE AND SERVICING. TO AVOID BURNS, THIS FURNACE MUST: 1) NOT BE TOUCHED ON THE EXTERIOR OR INTERIOR FURNACE SURFACES DURING USE OR FOR A PERIOD OF TIME AFTER USE. TO AVOID PERSONAL INJURY: 1) DO NOT USE IN THE PRESENCE OF FLAMMABLE OR COMBUSTIBLE CHEMICALS. FIRE OR EXPLOSION MAY RESULT; THIS DEVICE CONTAINS COMPONENTS WHICH MAY IGNITE SUCH MATERIALS. 2) DO NOT OPERATE OR CLEAN FURNACE WITHOUT PROPER EYE PROTECTION. 7 Barnstead/Thermolyne

9 THERMOLYNE MINI-MELT FURNACE Series 366 Instructions for replacing the heating element: 1. Disconnect unit from power supply. 2. Invert furnace and remove bottom cover (A) by removing 5 screws and feet (B). 3. Remove 2 screws (C) from terminal block and lift thermocouple out (D). (Save these parts to be reused). 4. Disconnect both element leads from control (E). 5. Place furnace upright and remove 2 screws (F) from element base plate (G). 6. Lift element (H) straight up. (You may need to twist slightly and rock to unseat from the base plate). 7. Remove 2 screws (J) from hinge plate and element (H). (Keep these parts to be reused on new element). 8. Remove 2 screws (K) and carefully remove top plate (L) and hearth collar (M). (Keep these parts also, to be reused on new element). 9. Reassemble hinge plate and screws (J) to element, then carefully set new heating element into place aligning element leads and insulators to pass through and seat in the holes in the element base cover (G). 10. Reverse steps 1 through 8 to reassemble. 8

10 Tools required: 6 phillips screwdriver, 5 standard screwdriver and needle nosed pliers. 8

11 ORDERING PROCEDURES Please refer to the Specification Plate for the complete model number, serial number and for series number when requesting service, replacement parts or in any correspondence concerning this THERMOLYNE unit. All parts listed herein may be ordered from the BARNSTEAD/THERMOLYNE dealer from whom you purchased this unit or can be obtained promptly from the factory. When service or replacement parts are needed we ask that you check first with your dealer, if he cannot handle your request, then contact our Customer Service Department - (319) or (800) Prior to returning any materials to Barnstead/Thermolyne Corp., please contact our Customer Service Department for a Return Goods Authorization number (RGA). Material returned without a RGA number will be refused. ONE YEAR LIMITED WARRANTY Barnstead/Thermolyne Corporation warrants this product to be free from defects in material and workmanship for a period of one year from date of purchase. This warranty applies only to defects in original parts or components, and does not apply to claims or alleged product failures resulting from unauthorized repairs, misuse, accidents or lack of proper maintenance, failure to follow Barnstead/Thermolyne's instructions for use or from ordinary wear and tear. Warranty service may be obtained by returning any defective product to an authorized Barnstead/Thermolyne dealer or to Barnstead/Thermolyne. Heating elements, because of their susceptibility to overheating and contamination, must be returned to our factory and if, upon inspection, it is concluded that failure is not due to excessive high temperature or contamination, warranty replacement will be provided. Barnstead/Thermolyne's sole obligation under this warranty shall be to repair or replace any products which it delivers and are found to be defective. Special Two Year Warranty on Control Module There are no other warranties, expressed or implied, made in connection with the sale of this product. Barnstead/Thermolyne expressly disclaims any implied warranty of merchantability or fitness for specific use. 9 Barnstead/Thermolyne

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