Test Oven

Series 3600 and 3700

Contents

Preface    4Unpacking    4Warranty    4After-SaleSupport    4

Section1:Introduction    51.1GeneralDescription    51.2Specifications    61.3EnvironmentalConditions    61.4Controls    7

Section2:Safety    72.1ForOwners,Operators,andMaintenance Personnel    7

Section3:UnpackingandInstallation    103.1Unpacking    103.2PositioningandConnecting    103.3OvenBake-out    113.4OvenMountingtoaTestMachine    123.5SolenoidValveInstallation    12

Section4:Operation    14Section5:Maintenance    16

5.1PreventiveMaintenance    165.2CorrectiveMaintenance    16

AppendixA:Warranty    19

RevisedJuly2015

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PrefaceUnpackingRetainallcartonsandpackingmaterialsuntiltheunitisoperatedandfoundtobeingoodcondition.Ifdamagehasoccurredduringshipping,notifyAppliedTestSystems(ATS)andthecarrierimmediately.Ifitisnecessarytofileadamageclaim,retainthepackingmaterialsforinspectionbythecarrier.

WarrantyAllnewATSsystemsareshippedwithawarranty.Unitshaveawarrantyagainstdefectivepartsandworkmanshipforonefullyearfromdateofshipment.PleaseseeAppendixA ofthismanualforcompletedetailsonthewarranty.

After-Sale SupportIfthereareanyquestionsconcerningtheoperationoftheunit,contacttheATSServiceDepartmentat+1-724-283-1212.Beforecalling,pleaseobtaintheserialnumberfromtheunit’sdatatag.Asampledatatagisshownbelowandcanbecompletedwiththeunit’sinformationforeasyreference.PleasebepreparedtogiveacompletedescriptionoftheproblemtoATSServiceEngineers.

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Section1:Introduction1.1 General DescriptionTheAppliedTestSystems(ATS)Series3600and3700TestOvensareavailableinavarietyofsizesandtemperatureranges.Theovensareconstructedwithastainlesssteelshell.Thestainlesssteellinerisstandardforthe3700Seriesandisanoptionalitemonthe3600Series.Arecirculatingblower/plenumsystemprovidesuniformtemperatureperformanceforcriticaltestingrequirementsandheavy-dutyusage.

Thisinformationisrelatedtothefunction,setup,safeoperation,andmaintenanceoftheOvenanditsrelatedcomponents.

Thismanualisintendedforanyonewhowillbesettingupand/oroperatingtheTestOven.

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1.2 SpecificationsMaximumOvenTemperatureRating

Oven Series

Dimensions

Internal

External

Ports

Viewports

OvenPowerRequirements

Watts Amps VAC Hz

ThermocoupleType

1.3 Environmental Conditions• Temperatureof15°Cto35°C

• Relativehumiditynotmorethan75%

• Airpressureof75kPato106kPa

• Nohard-frost,dew,percolatingwaterrain,solar irradiation,etc.

• InstallationcategoryII

• Pollutiondegree2

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1.4 ControlsTheATS3600and3700SeriesTestOvensarecontrolledbyatemperaturecontroller.Refertothemanufacturer’sliteratureforoperatingprocedures.

Section2:SafetyAllATSequipmentisdesignedtobeoperatedwiththehighestlevelofsafety.ThismanualandATSendeavortoeducatetheoperatoraboutsafetyissuessurroundingcertainpartsofthemachinerybyusingequipmentlabeling.

2.1 For Owners, Operators, and Maintenance Personnel

Readandunderstandallinstructionsandsafetyprecautionslistedinthismanualbeforeinstallingoroperatingtheunit.Ifthereareanyquestionsregardingoperationoftheunitortheinstructionsinthismanual,contacttheATSServiceDepartmentat+1-724-283-1212.

Inadditiontothesafetywarningslistedontheequipment,warningsarepostedthroughoutthismanual.Readandfollowtheseimportantinstructions.Failuretoobservetheseinstructionscanresultinpermanentdamagetotheunit,significantpropertydamage,personalinjury,ordeath.

Thoroughlyunderstandthesafetyfeaturesandoperationoftheequipment.Thismanualwillprovideoperatorswithsafetyconcernsandgeneralprocedures.Befamiliarwithcorrectoperatingproceduresandusegoodjudgment.Alsorefertotheappropriatemanualsforsystemcomponentsafety.

Usecautionwhenworkingwithelementsatelevatedtemperatures.Preventburnsbywearingprotectiveclothing,andfollowsafety,operation,andmaintenanceproceduresdescribedintheappropriateinstructionmanuals.

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Avoidradiatingheat.Itemswithalargemassretainheatforalongtime.Firstdegreeburnsmayoccurfromheatradiationaswellasfromdirectcontactwithahotsurface.

Obeyallnationalandlocalelectriccoderequirements.Ovensandcontrolsystemsmustbegroundedandwiredaccordi ngtonationalandlocalelectricalcoderequirements.

Handletheovencarefully.Avoiddroppingandjarringtheoven.Damagetoelementsandinsulationmayresult.

Avoiddamagetocables.Donotletthepowercablestouchtheheatedfurnaceshell.

Donotexceedmaximumoperatingtemperature.Operatetheovenandaccessorieswithintheappropriatetemperaturerange.Refertotheappropriatemanuals.

Thisistheelectricalhazardsymbol.ItindicatesthatthereareDANGEROUSHIGHVOLTAGESPRESENTinsidetheenclosureofthisproduct.TOREDUCETHERISKOFFIREORELECTRICSHOCK,donotattempttoopentheenclosureorgainaccesstoareaswhereyouarenotinstructedtodoso.

REFERSERVICINGTOQUALIFIEDSERVICEPERSONNELONLY.

Thisistheusercautionsymbol.Itindicatesaconditionwhereinjurytotheoperatorcouldoccurifoperationalproceduresarenotfollowed.

TOREDUCETHERISKOFDAMAGEORINJURY,followallstepsorproceduresasinstructed.Refertoaccompanyingdocuments.

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VENTILATION–slotsandopeningsinthecabinetareprovidedforventilationandtoensurereliableoperationoftheproduct.Toprotecttheunitfromoverheating,thoseopeningsmustnotbeblockedorcovered.

Thisproductshouldnotbeplacedinabuilt-ininstallation,suchasawallcutout,unlessproperventilationisprovidedorhottemperatureswillresult.

Refertomanual-Beforetuningthetemperaturecontroller,besuretoreadandunderstandthetuninginstructionsinthecontrollermanual. Followallinstructionscarefully.

CLEANING–Ifitshouldbecomenecessarytocleanthisequipment,disconnecttheunitfromitspowersourcefirst.

Donotuseliquidcleaners,aerosols,abrasivepads,scouringpowders,orsolventssuchasbenzineoralcohol.Useasoftclothlightlymoistenedwithamilddetergentsolution.

Ensurethecleanedsurfaceisfullydrybeforereconnectingpower.

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Section3:UnpackingandInstallation3.1 UnpackingCarefullyunpacktheequipmentandinspectitfordamageduringshipment.Retainallcartonsandpackagingmaterialsuntiltheunitisoperatedandfoundtobeingoodcondition.Ifdamagehasoccurredduringshipping,notifythecarrierandATSimmediately.Ifitisnecessarytofileadamageclaim,retainthepackingmaterialsforinspectionbythecarrier.

3.2 Positioning and Connecting1.Iftheovenisequippedwithmountingbrackets,installthematthistime.Refertothemountingbracketinstallation drawingatthebackofthismanualifavailable.

2.Placetheunitonasturdyworksurface.Removeanypackagematerialsfromtheunit.Adjusttheovenpositiontoalignwiththeloadtrainandotherapplicableaccessories.

WARNING:Ifthisdeviceweighsinexcessof35lbs(16kg),atwo-manliftisrequired.

CAUTION:Iftheovenisusedonaworkbench,allsupportingandcontactingsurfacesmustbenonflammable.Donotallowflammablematerialstocontacttheshell.

3.Connectthethermocoupletothecontrolsystem.Usethethermocoupletyperequiredforthecontrolsystem.Refertotheappropriatemanufacturer’sliterature.

NOTE:Thermocoupleextensioncablesandconnectorsmustbecompatiblewiththethermocoupletypebeingused.

4.Connectthecontrolcabletotheterminalsontheovenas marked.Refertotheovenwiringdiagramenclosedinthis manualforterminalidentification.

5.Ifequipped,mountthecoolingsolenoidvalvetotheinjectorassemblyontheoven.Usesuitableflexiblelineortubingtoconnectthesupplytanktothesolenoidvalve.refertoSection3.5forproceduralsteps.Besuretoinsulatethetubingas required.

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6.SupplyCordType:FlexiblecordagethatmeetsIEC60227orIEC60245.Alternativelymaybe<HAR>markedorapprovedforuseinthecountryinwhichtheequipmentisinstalledandsuitableforthevoltageandapplication.

Rating 250VAC,25Aminimum

ConductorSize 2.5mm2(12AWG)

MaximumLength 4.5m(15ft)

NumberofConductorsTwoconductor(L,N)plusGround

Connector(Male)Approvedforuseinthecountryinwhichtheequipmentisinstalledandsuitableforthevoltageandapplication.

CAUTION:Theovenandthecontrolsystemmustbegroundedaccordingtocoderequirements.

3.3 Oven Bake-outThefollowingbake-outproceduremustbeperformedonnewovens,thoseovensthathavenewinsulation,andovensthathavebeeninstorageforalongperiodoftimeinanunheatedstoragearea.Ovenswithnewly-replacedheatingelementsdonotrequireabake-out.

NOTE:Internallightshouldberemovedduringovenbake-out.Removethelightandreplaceitwiththeinsulationplugprovided.

NOTE:Iftheovenisusedwitharetort,performthebake-outprocedurewiththeretort.Besuretoventtheretortduringtheprocedure.

WARNING:Bake-outwillproduceodorsandsmoke.Itshouldbeperformedinawell-ventilatedarea.

1.Heattheovento400°F(205°C),andopentheendcapsordoorslightlytoventilate.Lettheovensoakatthis temperatureforapproximatelytwo(2)tofour(4)hoursuntilalltracesofwatervaporandgasesaregone.Ifthisisahightemperaturemodel,soaktimeisfour(4)toeight(8)hours.

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2.Increasetheoventemperatureto800°F(425°C)ortheratedoventemperature,whicheverislower.Bakeuntilsmokeandodorareeliminated.

NOTE:Use1000°F(537°C)forhightemperaturemodels.

3.Increasethetemperaturetotheexpectedoperating temperature,ifitishigherthan800°F(425°C).

NOTE:Use1000°F(537°C)asthebaselineforhightemperaturemodels.

4.Aftertheoperatingtemperatureisreached,shutoffthe power.Withtheodororendcapsclosed,allowtheoventocool8-10hoursorovernightbeforeopening.

3.4 Oven Mounting to a Test MachineManyATSovensaredesignedtomountonanATStestmachine.Usethemountingbracketsandrefertothemountingbracketdrawing(ifprovided)inthebackofthismanual.Alsorefertoapplicablemanualsforinstallationandoperationproceduresforeachofthetestingaccessories.

3.5 Solenoid Valve InstallationManyATSovensaredesignedforcryogeniccooling.Beforeoperating,installthesolenoidvalveusingthefollowingprocedure.

NOTE:Thecustomermustsupplythefollowing:CO₂orLN₂tankwithareliefvalve,flexiblelinewitha2500minimumairpressure,anda¼NPTelbow.

1.AttachasiphontypeCO₂orLN₂tankwithareliefvalvetoaflexibleline(2500minimumairpressure).

NOTE:CO₂tanksmustbetheinverted,bottomsiphontype.

NOTE:Donotuseregulatorsbetweenthetankandthechamber.

NOTE:Avoidusingmanifolds.Changesinthecrosssectionoftheliquidpathcanresultinthefluidsolidifying.

2.Attachtheotherendoftheflexiblelinetothefittingonthesolenoidvalve.

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3.Connectthesolenoidcordtothematingconnectionthat comesfromthebackoftheoven.

4.Attacha¼NPTelbowtothesolenoidvalveaccordingtothediagram.

5.IfanLN₂solenoidvalveisused,skiptostep6.IfaCO₂ solenoidvalveisused,attachtheelbowtotheCO₂fitting.

6.Inserttheelbow(oftheCO₂fitting)intotheinjectorassembly.

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Section4:OperationInstallthespecimenandrelatedcomponents,suchas1. theloadtrainandtestingaccessories.Allowsufficientclearancewithspecimenandloadtrain;thiswillpreventdamagetotheovenifthespecimenfails. NOTE:Keeptheloadtraincomponentsassmallaspossibleinordertominimizeheattransfer.

Turnonthetemperaturecontrollerandadjustittoroom2. temperature.Checkthebloweroperationandairflowinsidetheoven.Theblowershouldoperatecontinuouslywhenthetemperaturecontrolleristurnedon. NOTE:Refertothemanufacturer’sliteraturefortemperaturecontrolleroperation.

Closetheovendoorandsetthedesiredtemperature3. setpointonthetemperaturecontroller. NOTE:Internallampshaveamaximumoperatingtemperatureof600°(315°C)unlessstatedotherwise.Tooperatetheovenabovethistemperature,removethelampandreplaceitwiththeinsulationplugprovided. CAUTION:Preventinjuryfromescapingheat.Keephandsandfacefromtheovendooropening. NOTE:Ifapplicable,donotstartcryogeniccoolingwhentheoventemperatureisabove300°F(148°C).

Uponcompletionofthetest,returnthecontrollersetpoint4. toroomtemperatureandopenthedoorslightlytoventtheoven.

Aftertheovenhasreturnedtoroomtemperature,turnoff5. thetemperaturecontrollerandthemainpower. CAUTION:Failuretodisconnectthepowermayresultinpersonalinjuryordeath.

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Section5:Maintenance

WARNING:Whenperformingmaintenanceandservicing,disconnectpowerfirst.Failuretodosocouldresultinseriousinjuryordeathfromelectricalshock.

WARNING:REFERSERVICINGTOQUALIFIEDSERVICEPERSONNELONLY.

5.1 Preventive MaintenanceIftheblowermotorisequippedwithoilcups,lubricatewith5dropsofSAE20non-detergentoilat6-monthintervals.

Checktheblowermotorextensionshaftatmonthlyintervalsorbetweenteststomakecertaintheassemblyissecure.Heatingandcoolingcyclescauseexpansionandcontractionoftheassemblythatmayloosenthesetscrewsand/ormountingscrews.

5.2 Corrective Maintenance5.2.1 Blower Replacement1.Disconnectpowertotheovenandremovetheplenumcover.

2.Loosenthesetscrewsandremovethemachinescrewholdingtheblowerontheshaft.Removetheblowerwheel.Ifreplacingthemotororshaftadapter,removethemotorfromtherearoftheoven.Loosenthesetscrewsholdingtheshafttothemotorandremovetheshaft.

NOTE:Beforereassemblingtheblowerassembly,useananti-seizecompoundtocoatthematingsurfacesoftheblowershaft,theadapter,theblowerwheelhub,andthesetscrews.

3.Mounttheblowermotorontoitsmoutningbracket.

4.Securethebracketinavise.

5.Installtheshaftadapterontothemotorshaft.

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6.Spintocheckshaftconcentricitywithanindicator-adjust with4setscrewsuntiladapterisconcentricwithin±0.001.”

7.Installassemblyontooven.

8.Installblowerwheelontoshaft(blowerwheelsarepre- balanced).

9.Tightenthesetscrews.

10.Installthemachinescrew.

11.Installtheplenumcover.

5.2.2 Thermocouple Replacement1.Disconnectthethermocoupleconnectoratthesideofthe ovenandremovethethermocouplefromtheoven.

2.Removetheoldthermocouplefromtheconnectorand replaceitwiththenewdevice.

3.Routethereplacementunitintothechamberfollowingtheoriginalroutingandreconnect.

NOTE:Ifthetemperaturereadingdropsastheoventemperatureincreases,thepolarityofthethermocoupleisreversed.Correctthepolarityproblembystoppingtheheatingprocessandreversingthethermocouple.Continuetheheatingprocessifthetemperaturereadingrisesastheoventemperaturerises.

5.2.3 Heating Element ReplacementATSovensareequippedwitheithercartridgeorfinstripelements.Bothelementtypesmaybereplacedinthefield.

1.Disconnectpowertotheovenbeforereplacingtheheatingelements.

CAUTION:Failuretodisconnectthepowermayresultinpersonalinjuryordeath.

2.Refertothewiringdiagraminthebackofthismanual.Followtheinstructionsbelow,dependingontheoven’swiringtype.

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3.CartridgeElements:Removetwoscrewsfromtheaffectedelement.

a.UseaDMV(DigitalVoltMeter)tocheckresistanceof eachheatingelement.Notethatresistanceshouldbelow becauseinfiniteresistancecorrespondstoanopen ordefectiveelement.

b.Removethedefectiveelement’swiresfromwirebundle.

c.Theseelementsareaccessedthroughthesideofthe ovenandareheldinplacebytwoscrews.

d.Removeandreplacetheheatingelements.

e.Trimandconnectwirestotheterminalblock,anduse thewiretiestodressupthewireharness.Allowaspace betweenthewireharnesswiresandovenshell.

4.FinStripElements:Accesstheseelementsbyremovingtheplenumcover.

a.Disconnectthewiresattheelement.

b.Unboltthedefectiveheatingelementandreplaceit withthenewone.

c.Replacethenutsandbolts.

d.Connectthewiringandcheckforshortstoelectrical ground.

e.Afterelectricalshortshavebeencheckedforand/or fixed,replacetheplenumcover.

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AppendixA:Warranty

WarrantyStatementYourAppliedTestSystemsproducthasbeenmanufacturedandinspectedbyexperiencedcraftsmen.AppliedTestSystemswarrants,fortheoriginalpurchaser,eachproducttobefreefromdefectsinmaterialandworkmanshipforaperiodofthirteen(13)monthsfromdateofshipmentortwelve(12)monthsfromdateofinstallationwhichevercomesfirst.Thiswarrantydoesnotapplytofailurescausedbynormalusage,misuse,orrepairorservicebyunauthorizedpersonnel,nordoesitcoverlimitedlifeelectricalcomponentswhichdeterioratewithagesuchastubes,lamps,fuses,andheaters.ThewarrantydoesnotextendtoproductsnotmanufacturedorassembledbyAppliedTestSystems.

Thiswarrantyisexpresslylimitedtotherepair,replacement,oradjustmentoftheproductatAppliedTestSystems’option.TheproductmustbereturnedtotheAppliedTestSystemsfactoryoranauthorizedrepaircenter.AppliedTestSystemsshallnotbeliableforanylabor,transportation,orinstallationcoststhatmayariseinconnectionwiththeproductorreturn.

Toobtainwarrantyservice:

1.AppliedTestSystemsmustbepromptlynotifiedinwritingof thedefect.

2.Uponreceiptofwrittenauthorization,saiddefective equipmentisreturnedasdirected,withtransportation chargesprepaidbythebuyerand–

3.AppliedTestSystemsexaminationofsuchequipmentdiscloses toitssatisfactionthatthedefectexistsandwasnotcaused bynegligence,misuse,improperinstallation,accident,or unauthorizedrepairoralteration.

Thiswarrantyisinlieuofallotherwarranties,expressedorimplied,includingtheimpliedwarrantyofmerchantabilityorfitnessforparticularpurpose.InnoeventshallAppliedTestSystemsbeliablefordirect,indirect,special,incidental,collateralorconsequentialdamages.

TheaforementionedprovisionsdonotextendtheoriginalwarrantyperiodofanyarticlethathasbeeneitherrepairedorreplacedbyAppliedTestSystems.

AppliedTestSystemsreservestherighttochangepublishedspecifications.

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