Model 105 Tunnel Oven Operating Manual Datasheet

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connectivity

Operating manual

MODEL 105 TUNNEL OVEN (TE 1-1198896-5

RAYCHEM 955018-000)

Customer Manual No. 412-94301

Customer Manual PN: 9-744015-9

Language: en (original)

- -TE APPLICAYION - room/s mmrlvlry

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

The Model 105 Tunnel Oven is manufactured for TE Connectivity

 All of the information in this manual, including illustrations, is believed to be reliable. Users,

however, should independently evaluate the suitability of each product for their application.

 TE makes no warranties as to the accuracy or completeness of the information and

disclaims any liability regarding its use.

 TE's only obligations are those in the Standard Terms and Conditions of Sale for this

product and in no case will TE be liable for any incidental, indirect or consequential

damages arising from the sale, resale, use or misuse of the product.

 TE Specifications are subject to change without notice. In addition TE reserves the right to

make changes in materials or processing, without notification to the Buyer, which do not

affect compliance with any applicable specification.

-.'TE mun/wry APPLICATION TOOL/N6 a\

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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Table of contents

1 DESCRIPTION .......................................................................................................... 3

1.1 General ................................................................................................................................................... 3

1.2 Introduction ............................................................................................................................................. 4

1.3 Left-Right Conventions ........................................................................................................................... 5

1.4 Safety Features/Self Diagnostic Circuitry ............................................................................................... 5

1.5 Components and Controls ...................................................................................................................... 9

1.6 Control Enclosure Layout ..................................................................................................................... 11

1.7 Specifications ....................................................................................................................................... 13

2 PREVENTING EQUIPMENT DAMAGE ................................................................... 14

3 SETUP ..................................................................................................................... 15

3.1 Unpacking, Transport, Handling and Storage ...................................................................................... 15

3.2 Top Assembly Adjustment .................................................................................................................... 15

3.3 Removing Shipping Support. ................................................................................................................ 17

3.4 Inspection (Power Off) .......................................................................................................................... 17

3.5 Electrical Connections .......................................................................................................................... 17

3.6 Inspection (Power On) .......................................................................................................................... 18

4 Operation ................................................................................................................. 19

4.1 Power On and Warm-up ....................................................................................................................... 20

4.2 Loading and Unloading ........................................................................................................................ 20

4.3 Power OFF and Cool-Down ................................................................................................................. 20

5 MAINTENANCE ....................................................................................................... 21

5.1 Daily Maintenance ................................................................................................................................ 21

5.2 Semi-Annual Maintenance ................................................................................................................... 22

5.2.1 Clean the inside of the Tunnel Oven. ................................................................................................... 22

5.2.2 Change temperature setpoint to 0°C. ................................................................................................... 22

5.2.3 General condition check. ...................................................................................................................... 22

5.2.4 Check the Conveyor Belt for tension. ................................................................................................... 22

5.2.5 Inspect the motor brushes. ................................................................................................................... 22

5.2.6 Lubricate Drive Chain. .......................................................................................................................... 22

5.3 Maintenance Procedures ..................................................................................................................... 22

5.3.1 Belt Tension Adjustment ...................................................................................................................... 22

5.3.2 Upper Heater Element Replacement ................................................................................................... 24

5.3.3 Lower Heater Element Replacement ................................................................................................... 24

6 TROUBLESHOOTING ............................................................................................. 25

6.1 Troubleshooting Guide ......................................................................................................................... 25

6.1.1 Troubleshooting Guide (continued) ...................................................................................................... 26

-.'TE mun/wry APPLICATION TOOL/N6 a\

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5 RAYCHEM 955018-000)

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6.2 Heater Element Test ............................................................................................................................ 26

6.3 Thermocouple Check ........................................................................................................................... 27

6.4 Cool Down circuit test. .......................................................................................................................... 27

6.5 Solid State Relay/Temperature Controller Test ................................................................................... 28

6.6 Over Temperature Switch Test ............................................................................................................ 28

6.7 Drive Circuit Test .................................................................................................................................. 29

6.7.1 Motor Controller .................................................................................................................................... 29

6.7.2 Motor Resistance.................................................................................................................................. 29

6.7.3 Motor Brush Inspection ........................................................................................................................ 29

7 CALIBRATION AND ADJUSTMENTS ..................................................................... 30

7.1 Motor Controller / Speed Calibration .................................................................................................... 30

7.2 Temperature Controller ........................................................................................................................ 31

7.2.1 Changing Temperature Set Point ......................................................................................................... 31

7.2.2 Parameter Settings and Temperature Controller Operation ................................................................ 31

8 SPARE PARTS LIST ............................................................................................... 36

9 ELECTRICAL SCHEMATIC .................................................................................... 37

10 Customer Support .................................................................................................... 39

- .' TE mmrlvlry

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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1 DESCRIPTION

1.1 General

The Model 105 Tunnel Oven is a low maintenance, high production heater that provides a

controlled processing system, suitable for processing a variety of products, including heat-

shrinkable tubing and thermal curing of various products. The unit is designed as a modular unit

consisting of the upper heater chamber and base, modular wire mesh belt conveyor with lower

heater element, and a remote electrical enclosure. The standard unit, P/N 12000012 is provided

with a 39” long conveyor. The wire mesh belt conveyor is designed to permit custom conveyor

lengths in excess of 39” for specific customer application requirements. A four foot detachable

umbilical cable connects the processor unit to the control enclosure.

The Model 105 Tunnel Oven is a table top unit. Overall dimensions of the unit is approximately

27" W x 39" L x 16 ½" H. The two key process parameters of conveyor speed, and heater element

temperature are controlled using closed loop electronic modules. Speed settings range from 0 to

5 feet/minute, and temperature settings range from ambient to 700°C, however settings below

0.5 feet per minute and above 600°C are not recommended. The Tunnel Oven is designed to

run continuously at the recommended settings. The Model 105 Tunnel Oven has two upper

housing height positions. The upper pivot position provides 4 inch nominal oven clearance for

large part production. The lower position provides 2.25 inch nominal oven clearance for smaller

parts.

An auxiliary E-Stop enclosure is provided on a flying lead, suitable for customer positioning when

two operators are required for production processing.

The Model 105 Tunnel Oven also contains many self diagnostic and safety features to protect the

operator, machine and product. These include alarms, indicator lights and cool down circuitry,

when the OFF ("O") push button is pressed, the Tunnel Oven goes into a 20 minute Cool Down

mode that allows the conveyor and fans to run without the heater elements. This prevents

components in the machine from being repeatedly exposed to high temperatures when powered

down.

These indicator lights and alarms include:

“Cool Down” - Power has been turned off and the machine is in cool down mode.

“Process Ready” - The oven temperature is in the preset temperature range for processing

product.

“Over Temp” – the internal chamber temp exceeds the rating of a thermal switch.

“Heater Fault”-- one of the heating elements fails.

It is the user’s responsibility to independently verify all process parameters and settings

immediately after equipment is installed. The user must also maintain and adjust the

equipment, monitor the process, and inspect the installed product to ensure that process

requirements are met on an ongoing basis.

- -TE Appu:,4mw - rum/mo mmI/Wry A C A A m a\

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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1.2 Introduction

Caution

This symbol (black print on yellow background) indicates that there is something that could

damage the machine or cause bodily harm if not handled properly. Refer to the manual for further

instructions.

Read Manual

This symbol directs the operator to read the manual in order to under stand the operation of the

machine.

Hot Surface

This symbol (black print on yellow background) indicates that a given surface becomes hot during

normal operation of the machine. Care must be to avoid direct skin contact with this surface.

High Voltage

This symbol (black print on yellow background) indicates that high voltage is present in the vicinity.

Only trained technicians should be working in such an area. Normal procedures for working in

such an area dictate that the machine be powered down, and the power be removed by

unplugging the main power cord from the facility’s power supply outlet. In circumstances where

this is not possible, the technician must exercise extreme care to avoid contact between body

parts, conductive tools, and electrical conductors.

Wear Protective Clothing

This symbol directs the operator to wear protective clothing when operating the machine. Most

specifically cotton gloves and long sleeve cotton shirts which protect the operator from hot

surfaces which may be encountered.

um ‘ "

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Use Protective Eye Wear

This symbol directs the operator to use protective eye wear when operating the machine.

Keep Hands Out of This Area of the Machine

This symbol directs the operator to keep their hands out of this area while operating the machine.

1.3 Left-Right Conventions

In this document, left and right are always defined with respect to the operator when standing in

a normal working position. That is, standing in front of and facing the Tunnel Oven.

1.4 Safety Features/Self Diagnostic Circuitry

Cool Down Circuit

To prevent equipment damage, a timer circuit allows the fans and belt to continue running after

the OFF ("O") button is pressed. This circuit will shut off power to the heater elements while

allowing the conveyor and fans to run for a period of 20 minutes, at which time all power will shut

off automatically. The Cool down Indicator illuminates when the Tunnel Oven is operating in this

mode.

Front of Control Enclosure

Heater Fault Circuit

The Heater Fault Circuit constantly monitors the current flowing to the two heater elements during

normal operation. In the event of a heater element failure (open circuit) the heater fault circuit

senses a difference in current between the two elements, and sounds an audible alarm. The

Heater Fault Indicator is also illuminated. If this condition occurs, the operator should press the

OFF ("O") button and allow the unit to begin cooling. The operator must not run product

through the Tunnel Oven while this indicator is on. After the Tunnel Oven has cooled down,

an ohmmeter can be used to probe the end of the heater element plug and determine which

heater element has failed. Once the problem has been corrected, normal operation may begin

again.

- -TE APPLICATION - TOOL/NC mm” Do not use the Emerqencv Stop Button for normal shut down as it will defeat the cool down circuit. al

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Over Temperature Indicator

In the event of the heater element temperature becomes excessive, a light on the front of the

Control Enclosure will illuminate. The machine will automatically enter Cool Down mode. See over

Temperature Switch Below for more information.

Emergency Stop Enclosure

The Emergency Stop Enclosure is located on the front left hand side of the Tunnel Oven. Aside

from the Emergency Stop Button, the enclosure contains a second Cool down Indicator a second

Heater Fault Indicator as well and a Process Ready Indicator. If so desired by the user, an

additional Emergency Stop station may be added to the unit. This can be done by purchasing an

Auxiliary Emergency Stop Enclosure from TE. Simply remove the rear jumper plug from the

factory installed Emergency Stop Enclosure, and plug the Auxiliary Emergency Stop Enclosure

flying lead into the connector on the rear of the factory installed enclosure. The Auxiliary

Emergency Stop Enclosure may be mounted where deemed necessary by the user.

Emergency Stop Enclosure

Processor Ready Indicator

When the heater element temperature falls within the allowable processing temperature limits, a

light on the Emergency Stop Enclosure will illuminate. The operator must not run product

through the Tunnel Oven unless this indicator is on. The factory setting for this indicator is

±20°C of the temperature set point. This value is set in the Band Alarm 2 location in the

Temperature Controller.

Emergency Stop Button

There is an Emergency Stop button located on the upper heating chamber. Pressing this button

will kill all power to the Tunnel Oven.

Note: Do not use the Emergency Stop Button for normal shut down as it will defeat the cool down

circuit.

€15 APPLICAYIGN TOOL/NE Do not use the Circuit Breaker for normal shut down as it deieats the cool down circuit. mu muuwwv a\

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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Circuit Breaker

All mains circuitry is protected from electrical overload by the Main Circuit Breaker (1CB) located

on the rear of the Control Enclosure. It may be left on indefinitely and should be turned OFF only

after the Tunnel Oven has completed its Cool Down mode.

Note: Do not use the Circuit Breaker for normal shut down as it defeats the cool down circuit.

Fuses

There are two (2) fuses protecting the Tunnel Oven control circuitry. These fuses are labeled 1

Fuse (1FU), and 2 Fuse (2FU) and are located on the rear of the Control Enclosure. Fuse 1FU

protects the control transformer (1XFMR) and fuse 2FU protects all 120V control circuits including

fans and control devices. These fuses are 5x20mm IEC low breaking time delay fuses. 1FU is a

1.6A fuse (Littelfuse #21801.6, Bussman #GDC-1.6A or equivalent) while 2FU is a 1A fuse

(Littelfuse #218001, Bussman #GDC-1A or equivalent).

Rear of Control Enclosure

mum: Always use the Top Lock Pin to secure the hinqed conveyor top when i1 is not in the horizontal position. Failure to do so can result in serious personal injury and/or damage to the unit. al

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5 RAYCHEM 955018-000)

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Top Lock Pin

The Top Lock Pin is used to lock the top of the Tunnel Oven in a full open (vertical) or partially

open (30° from vertical) position for heater element change or other maintenance. To use the Top

Lock Pin, open the Tunnel Oven Top with one hand by grasping the handle on the right side of

the unit and hold it at the desired position. This will expose the Top Lock Pin in its holder. Retrieve

the Top Lock Pin from its holder. (The pin is tethered to the Tunnel Oven by a chain.) While still

supporting the top with one hand, fully insert the Top Lock Pin into the hole or channel in the Pivot

Stand, making sure that the pin also passes through the hole in the Pivot Block. When fully

inserted the top will be locked in position. Work on the Tunnel Oven can then proceed safely.

When work is complete, support the top with one hand and remove the pin with the other, and

reverse the process described above to place the Tunnel Oven into its normal operating state.

When returning the pin to its holder, make sure the chain is hanging in the cavity between the

holder mounting angle and the electrical control enclosure.

Top Lock Pin – Engaged Top Lock Pin - Stored

Note: Always use the Top Lock Pin to secure the hinged conveyor top when it is not in the

horizontal position. Failure to do so can result in serious personal injury and/or damage to the

unit.

Before operating the unit, the top must be returned to its horizontal position. To do this, support

the Tunnel Oven Top with one hand by grasping the handle. Remove the Top Lock Pin from the

Pivot Stand with the other hand and return it to its holder. Gently lower the top until it engages the

Top Rest Pins.

- .' TE WWII-y

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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1.5 Components and Controls

Front of Control Enclosure

ON ("I") Push Button

This button is used to turn the machine on at the beginning a shift, or to restore power to the

heater elements during the Cool Down mode. It is located on the front of the Control Enclosure.

OFF ("O") Push Button

This button is used to turn off the Tunnel Oven. Pressing this button puts the Tunnel Oven in the

cool down mode, shutting off power to the heater elements and illuminating the Cool down

Indicator. This button is also used to clear the Heater Fault Circuitry, turning off the indicator light

and silencing the Audible Alarm once it has been activated. After the OFF ("O") button is pressed,

the conveyor and fans to continue to operate for 20 minutes, allowing the Tunnel Oven cool to a

safe temperature. At the end of this Cool Down period, the conveyor and fans will shut OFF

automatically. The OFF ("O") push button is located on the front of the Control Enclosure.

"On" Indicator

This Tunnel Oven "On" indicator is located between the ON ("I") and OFF ("O") push buttons.

When illuminated, it indicates that the Tunnel Oven is in normal operating mode with power

applied to the heater elements. If it is not illuminated, the Tunnel Oven is completely shut down,

or in Cool Down mode, which means there is no power applied to the heater elements.

Temperature Controller

The temperature controller uses type K thermocouple (integral to the Upper Heater Element) to

close the temperature loop. The heater element temperature set point may be adjusted from 0 to

600°C for different types and sizes of assemblies and tubing. UP and Down arrows on the face

of the controller adjust the temperature set point. The Temperature Controller is located on the

front of the Control Enclosure.

Oven Top Assembly

The Oven Top Assembly can be set to two (2) different positions. The upper position provides a

4 inch vertical opening for taller parts. The lower position provides a 2 ¼ inch vertical opening.

The lower setting is recommended if the height of parts to be run through the machine do not

exceed 2 ¼ inches.

Top Cover/Air Vents

There are air vents located on the oven Top Cover of the Tunnel Oven. When reinstalling this

cover make sure the vent openings face away from the top lift handle. (Venting toward the left

side of the Tunnel Oven). Failure to do so may cause over heating of critical electrical components

in the top of the Tunnel Oven.

- - TE APPLICAYIGN - TOOL/N5 mm Drive chain may cause personal iniurv or uroduct damaoe if finqers clothinq or product enters into drive chain/sprocket area. Never operate machine without chain quard and left rear belt guard in place. ai

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5 RAYCHEM 955018-000)

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Front and Rear Heat Shields

Heat Shields are located on the front and rear of the oven Top Cover. These covers are to be

adjusted to the lowest possible position that still provides clearance for parts to enter the oven

chamber. This will ensure optimum efficiency and consistent performance.

Oven Top Assembly

Heater Elements

Two (2) infra-red heater elements, one upper and one lower are used in the Tunnel Oven. Each

elements is rated 1500 Watts at 240 Volts, and may be used at nominal mains voltages ranging

from 208 to 240 Volt 50/60 Hz AC. The upper heater element contains an integral “K” type

thermocouple.

Over Temperature Switch

An Over Temperature Switch Located on top of the upper Heater Element Enclosure protects the

machine from Over Temperature conditions resulting from faulty control components or shorted

thermocouple wiring. When an excessive temperature is sensed, the switch trips, the Over

Temperature Indicator on the front of the Control Enclosure will illuminate. The machine will

automatically enter Cool Down mode.

Drive Chain

The drive chain is located between the motor and the rear conveyor shaft. It should be lubricated

with a commercially available chain lubricant every six months.

Note: Drive chain may cause personal injury or product damage if fingers, clothing, or product

enters into drive chain/sprocket area. Never operate machine without chain guard and left rear

belt guard in place.

Air Vents

Top Cover

Heat Shield

Clamping Knob

Front Heat

Shield

Over

Temperature

Switch

- -TE APPLICAT/ON - TOOL/N6 mm httg://www.wirebelt.com Conveyor belt may cause personal injury or product damage if fingers clothing or product gets entangled in belt slots or pinched between moving and stationary components. Exercise caution when operating the machine. Never operate machine without all belt guards in place. There are seven (7) belt guards on the machine. They are the front side center side and rear side guards (both left and right sides) and the front belt guard. al

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Conveyor Shaft Bearings

The rear conveyor shaft is mounted into permanently lubricated bearing units. The front roller

rides on permanently lubricated roller bearings as well. The front roller can be loosened and

moved using a 13 mm open end wrench to adjust conveyor belt tension if required (see section

5.3.1). Spacer clips on the front roller bearing assemblies must be removed before the wrench

can be inserted on the clamping bolt. Always replace spacer clips after tightening clamping bolts.

No lubrication of the bearing units is required over the life of the Tunnel Oven.

Conveyor Belt

The conveyor belt is made out of stainless steel and needs no lubrication during its service life.

If required, the belt may be taken apart by cutting the splice link that holds it together. Animated

instructions on installing and removing splice clips can be found on the Internet at URL

http://www.wirebelt.com. This is a low tension belt and should not be over tightened. Generally

the belt needs to be only tight enough to present slipping on the drive belt cogs. Replacement

belts and splice clips may be purchased from TE.

Note: Conveyor belt may cause personal injury or product damage if fingers, clothing, or product

gets entangled in belt slots or pinched between moving and stationary components. Exercise

caution when operating the machine. Never operate machine without all belt guards in place.

There are seven (7) belt guards on the machine. They are the front side, center side, and rear

side guards (both left and right sides), and the front belt guard.

1.6 Control Enclosure Layout

The Control Enclosure (shown at right) houses the bulk of the electrical and electronic

components. All items are identified by schematic designation. The below table defines the each

of the mentioned items.

.‘TE mmrlv’fy 1CB Circuit Breaker, 2 Pole, 15A, 250VAC, 50/60 Hz, UL, CSA, VDE Approved 2PB Contact Block, 22.5mm IEC, 3 Across, NC 3PB Contact Block, 22.5mm IEC, 3 Across, NO Button, 1NO Contact on "I" Button, 1NC Contact on "0" Button 1FLT Line Filler, 120/250 VAC, 20A, 50/60 HZ Approved Approved CRM Relay Sockel, 4PDT, 10A, 220VAC, Surface or DIN Rail Mount Approved CRF,ZCR Relay Sockel, DPDT, 10A, 220VAC, Surface or DIN Rail Mount Approved 1TMR Timer, Delay on Break, 20 Minute Delay Time, 1 A, 120 VAC 50/60 Hz 0.5 Sec. Cycle Time 1POT Digilal Polenliomeler, 3 Digit, 5K, 2 Watl, 0.1% 1R Resistor, Metal Oxide Film, 2 Walt, 5%,47K Cover 1TS Terminal Slrip, 12 Position, Type G 5/12 1TS Terminal Slrip, 6 Position, Type G 5/6 SCR Electrical Subassembiy, R10 Relay Socket, 2 Pole CRM,CRF,2,ECR Relay Mounting Track, DIN Style, 3 Fl. Extruded Aluminum Section 2XFMR Current Transformer, 600 Turns, 600 VAC Working Class, 50/60 Hz Approved 1FU Fuse, IEC 5x20mm, Low Breaking, Time Delay, 250V, 1.6A 2FU Fuse, IEC 5x20mm, Low Breaking, Time Delay, 250V, 1A 0.250 Tabs Tabs 1TVS Transient Voltage Surge Suppressor (MOV), 130VAC, 20mm Disk 2TVS Transient Voltage Surge Suppressor (MOV), 275VAC, 20mm Disk ai

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Electrical Enclosure Components

Designator

Description

1CB

Circuit Breaker, 2 Pole, 15A, 250VAC, 50/60 Hz, UL, CSA, VDE Approved

2PB

Contact Block, 22.5mm IEC, 3 Across, NC

3PB

Contact Block, 22.5mm IEC, 3 Across, NO

2,3PB,1LT

Dual Push Button w/ 125 VAC Pilot Light, Red "O" Button, Green "I"

Button,

1NO Contact on "I" Button, 1NC Contact on "O" Button

1FLT

Line Filter, 120/250 VAC, 20A, 50/60 Hz

1XFMR

Transformer, 130 VA - 115/230 V Input, 115/230 V Output, 50/60 Hz, VDE

Approved

CRM

Relay, 4PDT, 10A, 220VAC Contacts, 120 VAC 50/60Hz Coil, VDE

Approved

CRM

Relay Socket, 4PDT, 10A, 220VAC, Surface or DIN Rail Mount

CRF,2CR

Relay, DPDT, 10A, 220VAC Contacts, 120 VAC 50/60Hz Coil, VDE

Approved

CRF,2CR

Relay Socket, DPDT, 10A, 220VAC, Surface or DIN Rail Mount

1CR

Relay, DPST, 25A, 220VAC Contacts, 110 VAC 50/60Hz Coil, VDE

Approved

1TMR

Timer, Delay on Break, 20 Minute Delay Time, 1 A, 120 VAC 50/60 Hz

1TEMPCON

Dynapar Temperature Controller, 1/16 DIN, Type K Input, 4 VDC Output,

0.5 Sec. Cycle Time

1POT

Digital Potentiometer, 3 Digit, 5K, 2 Watt, 0.1%

Resistor, Metal Oxide Film, 2 Watt, 5%,47K

1SSR

Solid State Relay, 24-330VAC, 40A Output, 4-20VDC Input, w/ Safety

Cover

1TS

Terminal Strip, 12 Position, Type G 5/12

1TS

Terminal Strip, 6 Position, Type G 5/6

3CR

Electrical Subassembly, R10 Relay Socket, 2 Pole

3CR

Relay, Super Sensitive, SPDT, 2A, 155VAC Contacts, 5 VDC Coil

CRM,CRF,2,3CR

Relay Mounting Track, DIN Style, 3 Ft. Extruded Aluminum Section

2XFMR

Current Transformer, 600 Turns, 600 VAC Working Class, 50/60 Hz

1,2FU

Fuse Holder, IEC 5x20mm Fuses, 10A, 250VAC, 16A, 120VAC, VDE

Approved

1FU

Fuse, IEC 5x20mm, Low Breaking, Time Delay, 250V, 1.6A

2FU

Fuse, IEC 5x20mm, Low Breaking, Time Delay, 250V, 1A

5LT

Ind. Light, 125 VAC Neon, Amber, 0.5" Round Snap-in Panel Mount,

0.250 Tabs

6LT, 7LT

Ind. Light, 125 VAC Neon, Red, 0.5" Round Snap-in Panel Mount, 0.250

Tabs

1TVS

Transient Voltage Surge Suppressor (MOV), 130VAC, 20mm Disk

2TVS

Transient Voltage Surge Suppressor (MOV), 275VAC, 20mm Disk

-.'TE mmmrry phase elements 1500 Watts, 240V 999 pot setting) 114cm (45") x 135cm (53") x 64cm (25") high at

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1.7 Specifications

Input power

208-240VAC 15A 3500 Watts, 50/60Hz single

phase

Heating

- Stamped foil IR

elements

20.3cm (8.00") wide x 38.7cm (15.25") long -

1500 Watts, 240V

Vertical Oven

Upper Position

10cm ((3.9")

Clearance

Lower Position

5.6cm (2.2")

Effective Heat Zone - Horizontal

35.5cm (14")

Fuses

1FU

5x20 mm IEC, 1.6A Time Delay Low Breaking

2FU

5x20 mm IEC, 1A Time Delay Low Breaking

Temperature Control

Dynapar Temp. Control w/ Type K T/C interface

Operating Temperature

Ambient to 700°C maximum

Sound Level

Less than 70dB(A)

Conveyor Speed

15.2 to 152.4 cm/min (0.5 to 5.0 ft/min) (100 to

999 pot setting)

Potentiometer

Setting

Speed (cm/min)

Speed (ft/min)

100

15.2

0.5

200

30.5

1.0

300

45.7

1.5

400

61.0

2.0

500

76.2

2.5

600

91.4

3.0

700

106.7

3.5

800

121.9

4.0

900

137.2

4.5

999

152.4

5.0

Conveyor Dimensions

76cm (30") W x 99cm (39") L x 42cm (16 ½") H

Conveyor Weight

91 Kg (200 lb)

Electrical Enclosure Dimensions

22cm (8 ½") W x 46cm (19") L x 17cm (6 ½") H

Electrical Enclosure Weight

8 Kg (17 lb)

Shipping Case

114cm (45”) x 135cm (53”) x 64cm (25”) high

.' TE Mmrlv’fy Such malfunctions are the only reasons to press the ErStop while the belts and lans are still running. DO NOT use this as the normal shut down procedure as it will defeat the cool down circuit. al

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2 PREVENTING EQUIPMENT DAMAGE

1. To prevent over heating of conveyor belt, do not set the speed potentiometer to less than

100.

2. For normal shutdown, press the OFF ("O") button. When the machine cool down cycle

completes (20 minutes), the conveyor and fans stop running, and the cool down lights turn

OFF the circuit breaker and unplug the machine. Do not attempt to bypass the circuit breaker.

3. For normal maintenance and repair, after the first cool down cycle, restart the machine by

pressing the ON ("I") and immediately press the OFF ("O") button again. When the second

cool down cycle completes, turn off the circuit breaker and unplug the machine. Do not

attempt to bypass the circuit breaker.

4. Do not set the temperature above 600°C. Operating the Tunnel Oven above 600°C will

shorten the life of the Heater Elements.

5. Do not cover the fan vents. Covering the vents by setting objects on or next to them may

cause uneven heating, or over heating of components.

6. An exposed thermocouple wire due to abrasion of the insulation will cause an over

temperature condition which can destroy components of the Tunnel Oven and cause

inconsistent processing of assemblies. When replacing the covers, ensure that no wires get

pinched between the cover and the frame.

7. Excessive conveyor belt tension can cause premature belt wear. Tension the belts as called

out in section 5.3.1 of this manual.

8. Emergency Stop: In the case of a product catching fire, excessive smoke, sparks, grinding

noises, or any other signs of malfunction, press the Emergency Stop button. Then (with

gloved hands) raise the Tunnel Oven Top Assembly with one hand, and manually remove

any assemblies which may be in the heating chamber to prevent fire damage. Contact

Maintenance Personnel to investigate the cause of the problem before restarting the machine.

Note: Such malfunctions are the only reasons to press the E-Stop while the belts and fans

are still running. DO NOT use this as the normal shut down procedure as it will defeat the

cool down circuit.

9. Use only as advised: This machine was designed for use with TE approved products only.

.' TE Will/NI Ii you plan to use the M105 Tunnel Oven in the 4" nominal position the below steps may be skipped. Alwavs perform this operation with the control box power cord unpluqqed irom the facililv's power outlet and the umbilical cord unoluqqed from the machine. Hole If you are iust unpacking the unit the Shipping Support is already installed. al

MODEL 105 TUNNEL OVEN (TE 1-1198896-

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3 SETUP

3.1 Unpacking, Transport, Handling and Storage

1. The Model 105 has a mass of 99 Kg. When unpacking, transporting, handling or moving the

unit to storage, it is recommended that no less than two persons or a lift truck be used for the

process. When storing the unit it should be placed in a suitable crate 114cm x 135cm x 64cm

tall, and stored indoors away from any harmful effects of weather or other hazards.

2. 2. Remove the processor from its shipping container and check for damage. Inspect the

shipping container and processor for any evidence of damage during shipment. If you believe

there has been damage, contact the shipping agent immediately.

3. Set the processor on a flat, level surface. Choose a work area with enough room around the

processor for loading and unloading wire harnesses. Also allow room for routine maintenance

and repair.

4. Provide adequate ventilation. Allow enough clearance above and around the processor so

that the fans can circulate cooling air without obstruction. Do not place anything on the upper

chamber or cover the fan louvers.

5. Remove packing material from between the heaters. Packing material has been placed

between the heating elements to prevent vibration damage during shipment. Discard this

material.

3.2 Top Assembly Adjustment

The M105 tunnel oven has two upper housing height positions. The unit is shipped with the top

engaged in the upper (4 inch nominal oven clearance) position. A second lower position (2.25

inch nominal oven clearance) is designed into the unit. If your parts are 2 inches or less in height,

it is recommended that the Oven Top Assembly be placed in the lower position. To make this

change, follow the steps detailed below.

Note: If you plan to use the M105 Tunnel Oven in the 4" nominal position, the below steps may

be skipped. Always perform this operation with the control box power cord unplugged from the

facility’s power outlet, and the umbilical cord unplugged from the machine.

Left Heat Shield

1. Remove Oven Top Cover. Remove the Top Cover by turning the four (4) quarter turn

fasteners counter-clockwise and lifting the cover vertically from the machine.

2. Install the Shipping Support.

Note: If you are just unpacking the unit, the Shipping Support is already installed.

Remove the two (2) M8 button head screws with flat washers from the right side belt guard. Install

the Shipping Support using the two (2) M8 button head screws with flat washers and placing them

through the bottom two (2) holes of the support.

Top

Mounting

Hole

Bottom

Mounting

Hole

£15 APPLICAYION TOOL/NS a\

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5 RAYCHEM 955018-000)

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3. Remove the Left and Right Side Heat Shields. These are removed by loosening two (2)

M5 socket head cap screws.

Left Side of Tunnel Oven

4. Remove the Upper Cover from between the Pivot Shaft Stands on the left side of the

unit. This is upper most cover that is fastened to the stationary Pivot Shaft Stands (not

fastened to the moveable top of the unit) and resembles an upside down "T". The Upper

Cover is removed by loosening two (2) M5 button head screws.

5. Remove the Spacer Plate between the Pivot Shaft Stands. This is the 1.75" high plate

located beneath the right side top cover you just removed. The Spacer Plate is removed by

loosening two (2) M5 button head screws. Place the Spacer Plate in a safe location as it will

be required when the upper Oven Top Assembly setting used.

6. Remove the Top Stop Angle. The Top Stop angle is located on the inside of the Pivot Shaft

Stands and contains the Top Lock Pin, tether chain and mounting clip. Its purpose is to hold

the Oven Top Assembly in a horizontal position when the Shipping Support is removed. The

Top Stop angle is removed by loosening four (4) M5 socket head screws.

7. Reinstall the Top Stop Angle. Move the Top Stop angle down to the lower set of mounting

holes a reinstall it using the screw you just removed.

8. Remove the Pivot Shaft. Loosen and remove the two (2) M6 socket head set screws using

a 3 mm hex wrench. Supporting the Oven Top Assembly, slide the pivot shaft out of the Pivot

Stands and bushing blocks.

9. Reinstall the Pivot Shaft. Move the Oven Top Assembly down to the lower Pivot Shaft holes

and slide the pivot shaft back into the bushing blocks and of the Pivot Stands. Make sure the

Pivot Shaft is centered and the flats are aligned with the set screw holes. Replace and tighten

the two (2) M6 socket head set screws.

10. Ensure electrical wiring is neatly routed. The wiring that powers the Oven Top Assembly

must be positioned so that the Top Cover and fasteners will not pinch or damage the wire

bundle in either the fully opened or fully closed position.

11. Replace covers and shields. This includes the Left and Right Side Heat Shields, Left Side

Upper Cover, and the Oven Top Cover. The Left and Right Side Heat Shields must be

attached using the bottom two (2) holes when Oven Top Assembly is in the lower position.

Spacer Plate

Upper Cover

Top Stop

Angle

'-'J.IE APPLICATION TOOL/N6 a\

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5 RAYCHEM 955018-000)

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3.3 Removing Shipping Support.

Removing Shipping Support. Before using the M105 Tunnel Oven, the Shipping Support may be

removed. Loosen and remove two (2) M8 button head screws with flat washers to remove

Shipping Support. Replace the two (2) screws / flat washers to keep right side belt guard secure

to the side rails of the conveyor. It is recommended that the Shipping Support and shipping

container be stored in a safe place for possible later use should the unit need to be shipped to

another location. The shipping support is also used for changing the Oven Top Assembly

adjustment. Shipping Support must be reinstalled before shipping the unit or serious

damage may occur.

Tunnel Oven with Shipping Support Installed

3.4 Inspection (Power Off)

At the completion of the unpacking sequence, follow these steps to inspect the Tunnel Oven

before making any electrical connections. If you believe there is damage that may have been

caused during shipping, contact the shipping agent immediately.

1. Inspect the Heater Elements for damage. Visually check the Heater Elements for evidence

of cracking or chipping of the glass face during shipment. The heater screws should be snugly

fastened to heater trays.

2. Ensure that the covers are in place and secure. There are four (4) quarter-turn fasteners

that secure the top cover. All other covers and guards are secured with M4 or M5 screws.

3.5 Electrical Connections

Electrical Connections Should Be Carried Out By a Qualified Electrician

1. Attach an appropriately rated power plug to the end of the power cord. A 250V, 15A or

greater plug is recommended. This plug serves as the disconnecting means for the machine

during service operations. The power cord insulation colors are defined below.

Brown = L1

Blue = L2

Green/Yellow = PE Ground (Protective Earth)

2. Connect the umbilical cord plug (PL1) from electrical enclosure to mating receptacle

on conveyor (PL1).

Shipping

Support

.‘TE mmumy Usan the Emerqency Stop or circuit breaker as the normal shut down procedure defeats the automatic cccl down circuit and will cause heat damage to the Tunnel Oven. /_ ¥ al

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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3. If an auxiliary E-stop was ordered/provided with the M105. Remove the PL2 jumper

plug from the rear of the fix mounted E-stop and connect PL2 from the flying lead of

the Auxiliary E-stop to the mating receptacle (PL2).

4. Connect installed Mains plug to an appropriate 230VAC supply receptacle. A 15A or

larger service is required.

Note: This unit is designed for industrial use only. As such, it is to be connected to an

industrial power system. This unit is not intended to be connected to a public power system.

3.6 Inspection (Power On)

When the Power Off inspection, and the electrical connections sequence have been completed,

follow these steps to complete the inspection and set up of the Tunnel Oven.

1. Switch the Circuit Breaker On.

2. Ensure the Emergency Stop is not depressed. A ¼ counter-clock wise turn will release the

E-Stop.

3. Press the ON ("I") button. With the temperature set above ambient and the conveyor speed

control set above 100, the heaters, conveyor, and fans will begin to function.

4. Set the temperature controller to 600°C, and the speed control potentiometer to 999

(maximum).

5. Change the digital-speed control from maximum (999) to minimum (100) to verify that

the belt speed increases and decreases smoothly, with no jerky motion or excessive noises.

6. Wait approximately 5 minutes for the temperature to reach its setpoint. When this

occurs, the Processor Ready Indicator will go on.

7. The lower display on the temperature controller face indicates the temperature set

point, the upper display indicates the actual Heater Element temperature. Both displays

should read within 2°C of the same temperature during normal operation.

8. Press the OFF ("O") button. The conveyor and fans will continue to run for 20 minutes. At

that point the Heater Elements will have cooled to a safe temperature and the conveyor and

fans will turn off and all displays will power off.

Note: Using the Emergency Stop or circuit breaker as the normal shut down procedure

defeats the automatic cool down circuit and will cause heat damage to the Tunnel Oven.

Temperature Controller

Actual

Temperature

Setpoint

-.'TE zonnKIMry APPLICAYION TOOL/NS and unnel he re a\

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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4 Operation

After the Tunnel Oven has been set up and inspected as described on the preceding pages, read

the following warnings carefully and proceed with the steps in sections 4.1 to 4.3 for normal

operation.

WARNING!

 Only trained qualified personnel are to operate this machine. To minimize

the risks of burns, electrical shock, or other injuries, all safety precautions

must be observed.

 Because this piece of equipment is first and foremost an oven, it contains

hot components and surfaces which can cause burns. The conveyor belt

and workpieces exiting the oven will be hot. Protective clothing and

equipment such as cotton gloves, long sleeved cotton workshirt and

protective eye wear are required for safe operation.

 Opening the electrical panel while the machine is powered may cause

electrical shock. Always press the OFF ("O") button (if machine is hot, allow

it to cool down), turn OFF the circuit breaker, and unplug the Tunnel Oven

prior to any electrical maintenance or repair.

 If hands, hair, clothing, or any other foreign objects are caught by the Tunnel

Oven’s moving parts, you could be injured and the equipment could be

damaged. Operate the Tunnel Oven with all guards and covers in place.

 If you open the top of the Tunnel Oven and do not use the Top Lock Pin,

the top may fall and cause injury to the operator and damage the Tunnel

Oven. Always use the top lock pin, and ensure it is fully seated its hole on

the Pivot Block when opening the top. (Top cover must first be removed to

use the Top Lock Pin. See "Top Lock Pin" in section 1.4)

 Emergency Stop - In the case of a product catching fire, excessive smoke,

sparks, grinding noises, or any other signs of malfunction, press the

Emergency Stop button. Then (with gloved hands) raise the Tunnel Oven

Top Assembly with one hand, and manually remove any assemblies which

may be in the heating chamber to prevent fire damage. Contact

Maintenance Personnel to investigate the cause of the problem before

restarting the machine.

Note: Such malfunctions are the only reasons to press the E-Stop while the

Tunnel Oven is still running.

 Do not use the circuit breaker or Emergency Stop as your normal shut down

procedure as it will defeat the cool down circuit and will cause heat damage

to the Tunnel Oven.

 To keep the Tunnel Oven in optimum working condition, please follow all of

the maintenance procedures described in Section 5.1 and 5.2.

 This machine is designed for use on industrial power systems. Do not

connect it to a public power system.

 This machine was designed for use with TE approved products only. Always

use TE recommended process settings.

- .' TE mmrlvlry

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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4.1 Power On and Warm-up

1. Verify that the machine is plugged in to the proper power source, that the circuit

breaker is ON, and the E-Stop is not depressed and the speed control is set to 100 or

greater.

2. Press the ON ("I") Button

3. Set the temperature controller to the correct set point temperature for your application.

Remember, Temperature above 600°C will greatly reduce Heater Element life.

4. Set the belt speed to the proper setting for your application. Always set the belt speed

at or above 100. A setting of less than 100 will cause belt over heating. Refer to the chart in

the Specifications section 1.6 to translate dial setting to actual belt speed.

5. Take note of indicator lights while machine is warming up. The control power light located

between the ON ("I") and OFF ("O") buttons on the control enclosure will be illuminated. The

Temperature Controller will display Heater Element temperature and setpoint temperature.

No other indicators will be illuminated.

6. Allow the Tunnel Oven to warm up for about 10 minutes. It takes about 5 minutes for

Heater Elements to reach the set point, allow an additional 5 minutes of soak time and

processing can begin.

4.2 Loading and Unloading

At the completion of the Power On and Warm-up sequence, follow these steps to process

workpieces.

1. Prepare the workpiece.

2. Place workpiece onto conveyor belt making sure the portion to be heated is aligned

with the heat zone.

3. Allow workpiece to travel through the oven.

4. Remove the workpiece from the conveyor belt after it has cleared the cooling fans in

the rear of the conveyor, or simply allow the workpiece to fall into a collection tray

positioned at the end of the conveyor.

4.3 Power OFF and Cool-Down

1. At the end of the work shift, press the OFF ("O") button. The conveyor and the fans will

continue to run for 20 minutes, until a safe temperature has been reached, at which time they

will shut off automatically.

2. Take note of indicator lights while machine is cooling down. The control power light

located between the ON ("I") and OFF ("O") buttons on the control enclosure will be

illuminated. The Temperature Controller will display Heater Element temperature and setpoint

temperature. The Cool Down indicator light located on the Emergency Stop Enclosure will

also be illuminated.

Note: DO NOT use the Circuit Breaker or E-stop for the normal shutdown procedure. This

defeats the automatic cool down cycle and will cause heat damage the Tunnel Oven.

- - ' E APPLICAYION - TOOL/NS mmrlvlry on Do not use solvents for cleanino. Solvents are unnecessarv and may damaue some components 01 the Tunnel Oven. a\

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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5 MAINTENANCE

The Model 105 Tunnel Oven is a very low maintenance machine, however, given a few minutes

each week will ensure reliability and the long life of the Tunnel Oven. The following are guidelines

for daily, weekly, and monthly maintenance procedures that will keep the Model 105 Tunnel Oven

in optimum working condition. Don't wait until the Tunnel Oven has problems to give it some

attention.

WARNING!

 These procedures should be performed only by trained qualified personnel.

To minimize the risks of burns, electrical shock, or other injuries, all safety

precautions must be observed.

 Always perform maintenance operations on a cool machine. If the machine

is already hot, place the machine in cool down mode by pressing the OFF

("O") button. The conveyor and the fans will continue to run for 20 minutes.

At this point, the Heater Elements will likely remain too hot to allow work on

the machine. To avoid any burns or injury, initiate a second cool down cycle

by pressing the ON ("I") button, and the immediately pressing the OFF ("O")

button, wait for the cool down to complete. The machine should now be cool

enough to begin maintenance. (See item 3 in section 2.0 "Preventing

Equipment Damage")

Note: Do not use solvents for cleaning. Solvents are unnecessary and may damage some

components of the Tunnel Oven.

5.1 Daily Maintenance

Before the daily production begins, while the Tunnel Oven is cool, take a few minutes to perform

the following steps.

1. Inspect and clean any dirt from the surfaces of the Tunnel Oven. Use a damp cloth to

clean any stainless steel or painted surfaces. Black oxide steel surfaces should be cleaned

with a dry cloth. A household spray cleaner such as Formula 409 or Windex may be used on

stainless steel or painted surfaces to remove dirt that a damp cloth will not remove. Likewise

dirt on black oxide steel surfaces that cannot be removed with a dry cloth can be removed

using a cloth dampened with WD-40 or a lightweight oil.

2. Inspect and the Heater Elements. Look for any accumulation of debris or film on the Heater

Elements. If necessary, clean the black glass surface of the Heater Elements using a damp

cloth. Windex may also be used for this purpose.

3. Verify that the temperature controller is not set above 600°C. Operating the Model 105

Tunnel Oven at a set point above 600°C will shorten the life of the Heater Elements.

4. General condition check. As the Tunnel Oven warms up for normal operation, check the

general condition of the Tunnel Oven. Ensure that all the fans are working properly, and listen

for any abnormal noises. The conveyor should be run smoothly without a jerky motion. Check

to see that all guards and covers are securely in place. Make any repairs or adjustments

necessary to return the unit to proper working order.

-.'TE mun/wry APPLICATION TOOL/N6 a\

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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5.2 Semi-Annual Maintenance

Take time every six months before daily production begins to perform the following procedures.

5.2.1 Clean the inside of the Tunnel Oven.

With the Tunnel Oven still cool at the beginning of the day, turn off the circuit breaker and unplug

the unit. Remove all guards and covers. This includes the Rear Belt Guards, Front Belt Guards,

Side Belt Guards, Top Cover. Using an air hose or cloth, clean any dirt, dust, tubing, or anything

which has been trapped inside the Tunnel Oven.

5.2.2 Change temperature setpoint to 0°C.

With the Tunnel Oven still cool, plug the Tunnel Oven into its power source and turn on the circuit

breaker on. Press the ON ("I") button, then immediately press the OFF ("O") button to put the

Tunnel Oven in cool down mode. Change temperature setpoint to 0°C. This will prevent the

Tunnel Oven from heating up in the subsequent steps of the procedure.

5.2.3 General condition check.

As the conveyor runs, check the general condition of the unit and listen for abnormal noises.

Ensure that all the fans are working properly. Make any repairs or adjustments necessary to return

the unit to proper working order.

5.2.4 Check the Conveyor Belt for tension.

Belt tension can be determined by observing the length of belt in contact with the lower glide rails.

If there is no contact on this glide rails, the belt is overly taught. If there is more than eighteen (18)

inches of contact, the belt is too loose.

5.2.5 Inspect the motor brushes.

Remove the brushes from the motor brush receptacles. If they are not at least ¼ inch long,

replace them.

5.2.6 Lubricate Drive Chain.

Use a commercially available roller chain lubricant on the steel drive chain.

5.3 Maintenance Procedures

Always perform maintenance procedures on a cool machine.

5.3.1 Belt Tension Adjustment

If the belt is too loose, a number of links will need to be removed to restore the tension to proper

operating condition. Before starting, assess the number of links to be removed by squeezing a

number of links together until the belt reaches the desired tension level (see 5.2.4). The distance

you manually shrink the belt by this process should help you determine the number of links to

remove. Every 0.3 inches the belt is squeezed represents 1 link to be removed.

mum: Belt Guard ":1- Belt Guard hng://www.wirebelt.cum 3‘

MODEL 105 TUNNEL OVEN (TE 1-1198896-

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Belt Tensioning Steps:

1. Run the conveyor in Cool down Mode by pressing the ON ("I") button, and the immediately

pressing the OFF ("O") button. Watch the belt and find the previous splice link. Stop the

conveyor belt when the splice link is in a convenient working position in the front portion of

the conveyor. In this case the conveyor is stopped by pressing the E-Stop button. (Previous

splices are normally identified by spice clips or slight deformation of the link in the belt. If you

can not find the splice link, pick any link that is convenient).

2. Turn off circuit breaker and unplug the power cord from the facility’s power outlet. Separate

the umbilical cord from the unit for ease of working on the machine.

3. Remove four (4) screws from panel that houses the umbilical cord connector. This panel must

be loose to allow for the subsequent removal of left center belt guard.

4. Remove front belt guard, and all side belt guards. This includes the front, center, and rear left

side belt guards and the front, center, and rear right side belt guards.

5. Remove spacer clips on front roller bearings.

6. Note the position of the front roller for later repositioning. Use a 13mm open end wrench to

turn the bearing hex bolts until they are loose enough to allow the roller to slide.

7. Loosen the four (4) screws that secure the front guide rail/fan tray assembly to the conveyor

sides. Make sure the screws are sufficiently loose to allow the front guide rails to be lifted

above the front roller.

8. Lift the front guide rail plate from the conveyor side extrusions, and slide front roller under the

front guide rails. This will allow sufficient ‘slack’ room for resplicing the belt.

9. Use a diagonal cutters to cut the previous splice link into pieces which can easily be removed

from the belt.

10. Remove the number of links required for adequate belt tension (as determined in the prelude

to this procedure).

11. Resplice the belt using two (2) three position splice clips or one of the seven position links

just removed. More information on the spicing procedure and animated instructions on

installing splices can be found on the internet at URL http://www.wirebelt.com.

12. Slide the front roller forward until it clears the guide rails, then reposition the front and rear

guide rail plates back into their original position making sure the ‘T’ nuts slide back into their

slots on the conveyor side extrusions.

13. Reposition the front roller to its initial position and tighten into place. (Generally, this position

is so that its foremost surface of the roller is flush with the foremost vertical surface of the

conveyor side extrusions.)

14. Retighten front and rear guide rail plates.

15. Replace remaining components in reverse sequence to which they were removed.

Conveyor Belt

Left Front Side

Belt Guard

Right Front Side

Belt Guard

Front Belt Guard

.‘TE Mmrlv’fy Aiwavs secure Tunnel Oven TOD with in the uDr‘iaht Dositiun with the Top Lock Pin. Failure to do so can resuit in serious personai ‘iniury and/or damage to the unit. ai

MODEL 105 TUNNEL OVEN (TE 1-1198896-

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5.3.2 Upper Heater Element Replacement

1. Turn off circuit breaker and unplug the power cord from the facility’s power outlet.

2. Remove upper right side heat shield mount to expose Upper Heater Element power and

thermocouple connectors.

3. Raise top of the tunnel oven to full vertical position and lock it into position with the Top Lock

Pin.

Note: Always secure Tunnel Oven Top with in the upright position with the Top Lock Pin.

Failure to do so can result in serious personal injury and/or damage to the unit.

4. Remove the two (2) screws securing the Upper Left Heat Shield Mount (the heat shield

nearest the lift handle) in place. This will expose the Upper Heater Element connectors.

5. Unplug the Upper Heater Element power and thermocouple connectors.

6. Remove one of the button head cap screws securing the Upper Heater Element in place.

7. Use one hand to hold the Upper Heater Element while removing the second the button head

cap screw.

8. Gently remove the Upper Heater Element from position while sliding cables out of the access

slot provided.

9. Replace components in reverse sequence to which they were removed.

5.3.3 Lower Heater Element Replacement

1. Turn off circuit breaker and unplug the power cord from the facility’s power outlet. Separate

the umbilical cord from the unit for ease of working on the machine.

2. Remove four (4) screws from panel that houses the umbilical cord connector. This panel must

be loose to allow for the subsequent removal of left center belt guard.

3. The Lower Heater Element connector is housed under the left side belt guard. To provide

access it will be necessary to remove the front belt guard, and left side belt guards. This

includes the front, center, and rear left side belt guards.

4. Unplug Lower Heater Element by rotating the collar on the plug.

5. Remove the two button head cap screws securing the Lower Heater Element in place. This

is done by placing a 3mm hex key though the conveyor belt and into the head of the screw.

6. Lift the right side of the belt from the guide rails and retrieve the screws.

7. Lift the right side of the belt from the guide rails and slide out the Heater Element.

8. Slide in the new Heater Element.

9. Replace components in reverse sequence to which they were removed.

'TE mmm’fy Tunnel Oven's power to be Main Power source not connected. Connect power. Stop. Circuit breaker is off. Turn on breaker. activated. Over Temperature Switch is faulty. Replace switch. Circuit breaker is defective. Replace circuit breaker. pressed. ("0") button. Fuse 1FU or 2 FU blown. Replace fuse. Cool Down timer is defective. Replace as necessary. CRM is delective. Replace CRM. Control is transformer delective. Replace 1XFMR. Heater Elements failed. Replace Heater Elements. Element. Element is faulty. Element. Solid state relay is defective. Replace tSSR. Temperature controller detective Replace controller. Master Control Relay Defective Replace CRM. programmed correctly. Upper Heater Element. programmed incorrectly. Tunnel Oven. al

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

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6 TROUBLESHOOTING

WARNING!

 Some troubleshooting procedures require the Tunnel Oven’s power to be

ON. To minimize the risk of burns, electrical shock, or other injuries, these

procedures should be performed only by a qualified Maintenance Person,

and all safety precautions must be observed.

 Wear protective gloves to prevent possible burns or electrical shock.

 The Heater Elements remain hot after the conveyor and fans stop moving.

To avoid any burns or injury during maintenance, initiate a second cool

down cycle and wait for it to complete, before beginning. (See item 3 in

section 2.0 "Preventing Equipment Damage")

6.1 Troubleshooting Guide

PROBLEM

POSSIBLE CAUSE

CORRECTIVE ACTION

No power in the

Tunnel Oven.

Main Power source not connected.

Connect power.

Emergency Stop is depressed.

Turn and release Emergency

Stop.

Circuit breaker is off.

Turn on breaker.

Over Temperature Switch is

activated.

Wait for switch to cool down.

Over Temperature Switch is faulty.

Replace switch.

Circuit breaker is defective.

Replace circuit breaker.

ON ("I") button has not been

pressed.

Press the ON ("I") button.

ON ("I") button is defective.

Replace the ON ("I")/OFF

("O") button.

Fuse 1FU or 2 FU blown.

Replace fuse.

Cool Down timer is defective.

Replace as necessary.

CRM is defective.

Replace CRM.

Control is transformer defective.

Replace 1XFMR.

Heater Elements will

not reach set point.

Heater Elements failed.

Replace Heater Elements.

Thermocouple lead wire is faulty

between controller and Heater

Element.

Repair as necessary.

Thermocouple in Upper Heater

Element is faulty.

Replace Upper Heater

Element.

Solid state relay is defective.

Replace 1SSR.

Temperature controller defective

Replace controller.

Master Control Relay Defective

Replace CRM.

Temperature controller not

programmed correctly.

Reset controller parameters.

Temperature control

varies.

Thermocouple lead wire is faulty.

Repair the thermocouple wire

as necessary or replace the

Upper Heater Element.

Temperature controller is

programmed incorrectly.

Reset internal parameters.

There is excessive air movement

around the Tunnel Oven.

Check for external fans or air

conditioning which may be

blowing excessive air at the

Tunnel Oven.

'TE mmm’fy Solid state relay is defective. Replace tSSR. tCR is defective. Replace tCR. CRM is detective. Replace CRM. loo low. necessary. programmed incorrectly. Temperature controller is defective. Replace the controller. connections. Solid state relay is defective. Replace tSSR. Fan is detective. Replace the defective fan. Thermocouple lead is shorted. Repair shon. Temperature controller is defective. Replace controller. Cool down timer is detective. Replace tTMR. connections. A fan is defective. Replace the defective fan. connections. laulty. connections. Fan is detective. Replace fan. Main Power source not connected. Connect power. sprockets. tighten set screws. motor. Check motor plug. required. Speed dial set to less than 100. Increase speed setting. Motor controller is defective. Replace motor controller. as necessary. Motor controller is defective. Replace controller. Digital speed control is defective. Replace as necessary. are faulty. required. al

MODEL 105 TUNNEL OVEN (TE 1-1198896-

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6.1.1 Troubleshooting Guide (continued)

PROBLEM

POSSIBLE CAUSE

CORRECTIVE ACTION

No Heat in the

Tunnel Oven.

Solid state relay is defective.

Replace 1SSR.

1CR is defective.

Replace 1CR.

CRM is defective.

Replace CRM.

Temperature controller set point set

too low.

Increase set point as

necessary.

Temperature controller is

programmed incorrectly.

Reset parameters.

Temperature controller is defective.

Replace the controller.

Electrical connections are faulty.

Ensure the integrity of

connections.

Heater Elements go

"Over Temperature".

Solid state relay is defective.

Replace 1SSR.

Fan is defective.

Replace the defective fan.

Thermocouple lead is shorted.

Repair short.

Temperature controller is defective.

Replace controller.

Automatic cool down

isn't functioning.

Cool down timer is defective.

Replace 1TMR.

Electrical connections are faulty.

Ensure the integrity of

connections.

Fans do not operate.

A fan is defective.

Replace the defective fan.

Fan wiring is faulty.

Check wiring and

connections.

Electrical connections to the fan are

faulty.

Ensure the integrity of

connections.

Fan is defective.

Replace fan.

Conveyor does not

move.

Main Power source not connected.

Connect power.

Set screws and keys loose on drive

sprockets.

Replace/reposition keys,

tighten set screws.

Electrical connections to the motor

are faulty or motor is unplugged.

Check all connections from

the motor controller to the

motor. Check motor plug.

Motor is defective.

Inspect the motor brushes.

Replace brushes or motor as

required.

Speed dial set to less than 100.

Increase speed setting.

Motor controller is defective.

Replace motor controller.

Speed potentiometer is defective.

Ensure that the speed varies

through the entire range of

the potentiometer. Replace

as necessary.

No variable speed

control.

Motor controller is defective.

Replace controller.

Digital speed control is defective.

Replace as necessary.

Electrical connections between

potentiometer and motor controller

are faulty.

Ensure the integrity of

connections. Repair as

required.

6.2 Heater Element Test

If a heater element has failed, the Heater Fault LED on the front control panel will light. The

following procedure is to determine which heater element has failed.

1. If Tunnel Oven is not already cool, allow the machine to cool down. (Follow instructions in

item 3 in section 2.0 "Preventing Equipment Damage"). When the machine is cool, turn off

circuit breaker, and unplug the power cord.

.' TE .; Mmrlv’fy The Upper Heater Etement and thermccuuple are a sinqle unit. It the wire or insutation cannot be repaired the UDDer Heater Etement must be reDIaced. at

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2. Disconnect the umbilical cord from the machine.

3. Measure the element resistance. The Upper Heater Element resistance can be measured

between pins 1 and 7 of the panel mount umbilical cord receptacle (1PL). The Lower Heater

Element resistance is measured between pins 9 and 8 of the same receptacle. The resistance

of the Heater Element may range from 34 to 45Ω.

6.3 Thermocouple Check

Note: The Upper Heater Element and thermocouple are a single unit. If the wire or insulation

cannot be repaired, the Upper Heater Element must be replaced.

1. When the machine is cool, turn off the circuit breaker, and unplug the power cord.

2. Remove the top sheet metal cover.

3. Lift the top of the Tunnel Oven and lock it in place with the Top Lock Pin.

4. Disconnect the thermocouple plug and measure the resistance across the pins on the end

connected to the Upper Heater Element Thermocouple (male side of connector). If the

resistance is less than 2Ω, the fault likely lies between the female side of the connector and

the temperature controller. If the resistance is greater than 2Ω, but less than infinity (∞ Ω),

replace the Upper Heater Element. If the resistance is infinity (∞ Ω), the wire is broken. Trace

the circuit though the length of the wire. If a break is found, it can be repaired, otherwise, the

break is likely inside the Upper Heater Element and the element must be replaced. Continue

with the following procedure.

5. Unplug the temperature controller from its housing. This is done by firmly grasping the sides

of the front control panel and applying a strong forward force in conjunction with a slight side

to side rocking force. The front ¼" of the control panel and all active electrical components

will separate from the control housing. All terminals of the control housing will then be open

circuit.

6. Open the control enclosure cover to provide access to rear of the Temperature Controller.

7. Attach Ohmmeter to thermocouple lead wires. With the thermocouple connector still

separated, remove female receptacle from the mount and then remove the cable clamp/cover

from the female receptacle. Attach Ohmmeter leads to the two thermocouple sockets which

are now exposed. Place a jumper across terminal 4 and 5 on the rear of the Temperature

Controller. The resistance should be less than 2Ω. If the resistance is greater than this value,

the wire is broken. Remove the jumper. The resistance should read infinity (∞ Ω). If the

resistance is less than infinity (∞ Ω), the wire is shorted. Continue with the following

procedure. Repair or replace either the wire or the Upper Heater Element as appropriate.

6.4 Cool Down circuit test.

When the OFF ("O") button is pressed, it actuates an electronic timer (1TMR) located in the control

enclosure. The following test must be performed with the power on and the control enclosure

open.

Caution! Only a qualified electrician should perform this test, as power to the Tunnel Oven

is required. Electrical insulating gloves should be worn and all electrical safety

precautions followed when performing this procedure.

1. Measure the timer input power. While the Tunnel Oven is on and operating normally,

measure the voltage between terminal #2 and #3 on 1TMR (wires #4 and #2). The voltage

should read approximately 120 VAC.

2. Measure the timer output power. While the Tunnel Oven is on and operating normally,

measure the voltage between terminal #1 and #3 on 1TMR (wires #7 and #2). The voltage

should read approximately 120 VAC.

.‘TE Mmrlv’fy The ﬁrst part of this test is performed whlle the temperature controller is demandlnq full Dower to the Heater Elements. The second part of the test is performed with the temDerature controller is demandlnq no power to the Heater Elements. al

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3. Measure the timer "initiate" signal. While the Tunnel Oven is on and operating normally,

measure the voltage between terminal #6 and #3 on 1TMR (wires #9 and #2). The voltage

should read approximately 120 VAC. Press the OFF ("O") button, the voltage should drop

below 100 VAC. (The actual reading will vary depending on the type of meter used.)

6.5 Solid State Relay/Temperature Controller Test

The temperature controller uses a time proportioning 12 VDC signal to control the solid-state

relay.

Caution! Only a qualified electrician should perform this test, as power to the Tunnel Oven

is required. Electrical insulating gloves should be worn and all electrical safety

precautions followed when performing this procedure.

Note: The first part of this test is performed while the temperature controller is demanding full

power to the Heater Elements. The second part of the test is performed with the temperature

controller is demanding no power to the Heater Elements.

1. With the temperature controller set to its normal operating setpoint (≈ 600°C), allow the

Tunnel Oven to cool by pressing the OFF ("O") button and waiting for the 20 minute

cool down cycle to complete.

2. Open the control enclosure cover and remove the transparent cover on the solid state

relay. It snaps on and off.

3. Press the ON ("I") button to power up the Heater Elements.

4. Plug in the unit, turn ON circuit breaker and press the ON switch.

5. Measure the input voltage on the solid state relay. When full power is being demanded,

the voltage across terminals #3 and #4 on 1SSR (wires #20 and #21) should be approximately

12 VDC. If no voltage is present, check the output of the temperature controller and the

electrical connections between the temperature controller and the solid state relay.

6. Measure the output voltage. With 10 to 12 VDC across the input terminals of 1SSR, the

output across terminals #1 and #2 (wires #2L1 and #4L1) should be approximately 0 VAC. If

the voltage present is significant (>15VAC), the solid state relay is exhibiting an open circuit

condition and should be replaced.

7. Lower the set point of the temperature controller to 0°C. This will result in the temperature

controller demanding no power from the Heater Elements.

8. Measure the input voltage on the solid state relay. The voltage across terminals #3 and

#4 (wires #20 and #21). The voltage should be approximately 0 VDC.

9. Measure the output voltage. The voltage across terminals #1 and #2 (wires #2L1 and #4L1)

should be the line voltage (208 to 240 VAC). If there is no voltage present, check the voltage

on the output of relay 1CR (wires #5L1 and #3L2). If no voltage appears across either 1SSR

or 1CR, the solid state relay is shorted and must be replaced. If the line voltage shows up

across the terminals of 1CR, 1CR must be replaced.

6.6 Over Temperature Switch Test

If the Over Temperature Switch has failed, the unit will not start when the ON ("I") button is

pressed. If the ON ("I") button is held in the depressed position, and the red “Over Temp” indicator

located on the control enclosure glows, in all likelihood, the Over Temperature Switch has either

tripped or is defective. To positively resolve the issue, perform the following steps.

.' TE Mmrlv’fy When reinstalling the brushes ensure that they are seated in the same orientation as when they were removed. ai

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1. If Tunnel Oven is not already cool, allow the machine to cool down. Since the machine will

not run, you will simply have to wait for the cooling to occur without the aid of the fans. When

the machine is cool, turn off circuit breaker, and unplug the power cord.

2. Disconnect the umbilical cord from the machine.

3. Measure the Over Temperature Switch resistance. The Over Temperature Switch resistance

can be measured between pins 15 and 19 of the panel mount umbilical cord receptacle (1PL).

The resistance of the Over Temperature Switch must be under 2Ω.

6.7 Drive Circuit Test

The drive circuit consists of the motor, motor controller, and speed potentiometer.

Caution! Only a qualified electrician should perform this test, as power to the Tunnel Oven

is required. Electrical insulating gloves should be worn and all electrical safety

precautions followed when performing this procedure.

6.7.1 Motor Controller

1. Open the Motor Controller Enclosure cover to gain access to the motor controller.

2. Press the ON ("I") button to start normal operation of the Tunnel Oven.

3. Measure the input AC voltage across terminals L1 and L2, wires #10A & #2A. The

voltage measured should be approximately 120 VAC. If it is not 120 VAC, check control power

fuses (1&2FU). If control power is good, i.e. power is evident on temperature controller, wiring

to the motor controller is defective.

4. Adjust the speed pot to maximum speed (999).

5. Measure the DC output voltage. With the speed set at maximum, the voltage measured

across terminals A- and A+ (wires #11 & #12), should be approximately 65-130 VDC. If there

is incoming voltage but no output voltage, the motor controller is probably defective.

6.7.2 Motor Resistance

1. Turn off circuit breaker and disconnect the power from the Tunnel Oven.

2. Remove Motor Controller Enclosure cover.

3. Remove Motor Controller guard and disconnect motor leads from A+ and A- terminals.

4. Measure armature resistance. Using an ohmmeter measure the resistance between motor

leads. This resistance should be between 70 and 100Ω. If the resistance is higher or lower,

replace the motor.

6.7.3 Motor Brush Inspection

1. Remove the motor from the Tunnel Oven.

2. Unscrew the brush receptacles located on either side of the motor casing and remove the

brushes. They should be at least ¼ " in length. Replace as necessary.

Note: When reinstalling the brushes, ensure that they are seated in the same orientation as

when they were removed.

- - I'E APPLICAYION - TOOL/NE mum Only the MIN and MAX trimpols are used ior calibration purposes. The IR and CL trimpots are set at the factor and should not be ad'usted. Adjusting the MAX lrimpot affects the MIN setting and vise versa. ai

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7 CALIBRATION AND ADJUSTMENTS

7.1 Motor Controller / Speed Calibration

The motor controller must be calibrated every time one of the following occurs:

 Motor is changed.

 Motor Controller is changed.

 Speed Potentiometer is changed.

Note: Only the MIN and MAX trimpots are used for calibration purposes. The IR, and CL trimpots

are set at the factory and should not be adjusted.

Motor Controller

It is recommended that this operation is performed on a totally cooled machine with a 20°C

temperature setpoint and all top heat shields raised or removed. To determine conveyor speed

you will need to measure the time required for the conveyer to travel a given distance. To

accomplish this, place three pieces of masking tape on the right side aluminum belt guard that

abuts the side of the conveyor belt. Place one piece near the front of the conveyor. This will be

the 0” datum. Place a second piece 6” from the 0” datum, and a third piece 24” from the 0” datum.

Mark the tape with a line so that you will have exactly 6” and 24” data from which to measure.

1. Measure the conveyor speed at the 999 speed setting. The target is 5.0 feet per minute

(2 feet in 24 seconds). If it the speed is not within limits, adjust the MAX. trimpot slightly in

the clockwise direction to increase the speed, or counterclockwise direction to reduce the

speed.

Note: Adjusting the MAX trimpot affects the MIN setting and vise versa.

2. Place a marker on the front of the conveyor belt. Using a stopwatch, begin timing when

the marker passes the 0” datum. Stop timing when the marker passes the 24” datum. The

time should read 24 ±1.2 seconds. If it is more, the conveyor is running too slow. If it is less,

the conveyor is running too fast.

3. Measure the belt speed at the 200 speed setting. The target speed is 1.0 feet per minute

(0.5 feet in 30 seconds). If it the speed is not within limits, adjust the MAX. Trimpot slightly in

the clockwise direction to increase the speed, or counterclockwise direction to reduce the

speed.

Min Pot

Max Pot

.' TE Mmrlv’fy If you are havinq trouble naviqatincl the below described menus and cannot Get out of one of the many controller modes do not panic. The temperature controller will return to the Control Mode ii there is no key entry activity for 2er minutes. al

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4. Place a marker on the front of the conveyor belt. Using a stopwatch, begin timing when

the marker passes the 0” datum. Stop timing when the marker passes the 6” datum. The time

should read 30 ±1.5 seconds. If it is more, the conveyor is running too slow. If it is less, the

conveyor is running too fast.

5. Repeat the above steps until the maximum and minimum speed targets are reached.

The process may take a few adjustments to meet both requirements.

7.2 Temperature Controller

The internal parameters of the temperature controller are preset at the factory. The only reason

these parameters (other than temperature set point) should be changed is when calibrating the

Model 105. It is a good idea, however, to periodically check to ensure that no one has tampered

with the settings. See Section 7.2.2 for internal program parameters.

Temperature Calibration

1. Run the UHI-250 Temperature Probe through the centre of the machine at a belt setting of

200 and a set temperature of 600°C (1112°F). * The target probe temperature (calibrated) is

125°C +/- 5°C (257°F +/- 9°F at a belt setting of 200. If the average of the recorded probe

temperatures is not within the limits, offset the temperature controller, as follows, to obtain

proper calibration.

2. Run the UHI-250 Temperature Probe through the center of the machine a minimum of 3 times.

Note the maximum temperature reading and calculate the average.

3. Enter into the “SETUP MODE” and scroll down to Temperature Offset (OFFS). Offset the

controller 2 degrees for every degree differential from the target temperature of 125°C

(257°F).

4. Repeat steps 2 and 3 until the target temperature has been reached.

7.2.1 Changing Temperature Set Point

The number in the bottom display is the set point and upper number is the actual heater

element temperature.

1. To change the temperature set point, press the "" or "" keys. The "" key

decreases the value and the "" key increases it. The set point is displayed in °C.

2. In case of thermocouple failure, an error message “OPEN” will appear in the upper

display.

7.2.2 Parameter Settings and Temperature Controller Operation

The internal parameters of the temperature controller are preset at the factory; however, it is a

good idea to periodically check to ensure that no one has tampered with them.

Note: If you are having trouble navigating the below described menus and cannot get out of one

of the many controller modes, do not panic. The temperature controller will return to the Control

Mode if there is no key entry activity for 2-½ minutes.

The Partlow temperature controller has five operating modes. The unit powers up in the

Operator mode by default.

Operator Mode

The following table shows the parameters accessible from Operator Mode (OPtr). These

parameters can be reached by pressing the  (Scroll) button.

- - I E APPLICATION - TOOL/N6 tonnecllvlfy e Selpoint 2 = Alarm 2 active, 1 = Alarm 1 active (Visible only it an alarm is active) O erator Auto-Tu ni Product Information Con uration Set U Normal instrumenlo lion Invoke Pre-Tune or Self-Tune Partlow oductinlormation Con ure device Tailor settin a\

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Any value displayed in the Lower Display window that is not a read only parameter can be

changed by pressing the  or  button.

Mode Selection

To select a mode, press and hold the  button then depress the  button. Once in the select

mode, use the  or  button to locate the desired mode then press  to proceed within that

mode.

The table below shows the five modes employed by the Partlow controller.

To exit from any mode, press and hold the  button then depress the  button. Select the new

mode using the  or  button, and enter the desired mode by pressing the  button.

Always return to the Operator (OPtr) mode to return to normal operation.

Configuration Mode

To select the Configuration Mode (ConF), press and hold the  button then depress the  button.

Once in the select mode, use the  or  button to locate the Configuration Mode then press 

to proceed with the configuration. Use the  or  button to change the value in the Upper Display

until it matches the value shown in the table below, then press the “AUTO/MANUAL” button to

Action

Upper Display

Lower

Display

Description

Factory Setting

Actual Temperature

Temperatur

e Setpoint

Normal instrument operation

600



Active Alarms

ALSt

2 = Alarm 2 active, 1 = Alarm 1

active (Visible only if an alarm is

active)

N/A (read only)

Action

Mode

Upper

Display

Lower

Display

Description



Operator

OPtr

SLct

Normal instrument operation



Auto-Tuning

Atun

SLct

Invoke Pre-Tune or Self-Tune



Product Information

inFo

SLct

Partlow product information



Configuration

ConF

SLct

Configure device



Set Up

SEtP

SLct

Tailor settings

.‘TE: mmmky Conﬁguration Lock Code 0 Input Type YC inPt Type K thermocouple 0 Upper Range for Scaling (°C) 0 Lower Range for Scaling (°C) 0 Control Type SnGL 0th Single control (heat only) 0 Action 0 Alarm 1 Type dE ALA1 Alarm 1 = Deviation 0 Deviation Alarm = 30 °C 0 Alarm 1 Hysteresis = 1 °C 0 Alarm 2 Type bAnd ALA2 Alarm 2 = Band Alarm 0 Band Alarm = 20 “C 0 Alarm 2 Hysteresis = 1 °C 0 Loop Alarm diSA LAEn Loop Alarm disabled 0 Alarm Inhibit nonE Inhi No Inhibits 0 Output 1 Usage Pri USE1 Use Output 1 for primary control 0 Output 2 Usage A2_r USEZ Use Output 2 lor Alarm 2, Reverse 0 Output 3 Usage A1_d USES Use Output 3 for Alarm 1, Direct 0 Display Strategy 2 diSP Use second display strategy 0 al

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If you do not press the “AUTO/MANUAL” button after changing the parameter in the Upper

Display, the setting will revert to the previous value.

To exit from Configuration Mode, press and hold the  button then depress the  button. Select

the new mode using the  or  button, and enter the desired mode by pressing the  button.

Always return to the Operator (OPtr) mode to return to normal operation.

Setup Mode

To select the Setup Mode (SEtP), press and hold the  button then depress the  button. Once

in the select mode, use the  or  button to locate the Setup Mode then press  to proceed

with the setup.

Use the  or  button to change the value in the Upper Display until it matches the value shown

in the table below, then press the  button to register the value in the Upper Display window.

There is no need to press the “AUTO/MANUAL” button to register the value when operating in

the Setup Mode. Note that display values in the chart below that show a question mark (?) are

read only or values that are determined by the user. They vary depending on user settings or the

state of the machine.

Action

Parameter

Upper

Display

Lower

Display

Description

 

Input Type

inPt

Type K thermocouple

 

Range Upper Limit

760

ruL

Upper Range for Scaling (C)

 

Range Lower Limit

rLL

Lower Range for Scaling (C)

 

Control Type

SnGL

Ctyp

Single control (heat only)

 

Primary Output

Action

rEV

Ctrl

Reverse acting (for heating)

 

Alarm 1 Type

ALA1

Alarm 1 = Deviation

 

Alarm 1 Value

dAL1

Deviation Alarm = 30 C

 

Alarm 1 Hysteresis

Ahy1

Alarm 1 Hysteresis = 1 C

 

Alarm 2 Type

bAnd

ALA2

Alarm 2 = Band Alarm

 

Alarm 2 Value

bAL2

Band Alarm = 20 C

 

Alarm 2 Hysteresis

AHy2

Alarm 2 Hysteresis = 1 C

 

Loop Alarm

diSA

LAEn

Loop Alarm disabled

 

Alarm Inhibit

nonE

Inhi

No Inhibits

 

Output 1 Usage

Pri

USE1

Use Output 1 for primary control

 

Output 2 Usage

A2_r

USE2

Use Output 2 for Alarm 2, Reverse

 

Output 3 Usage

A1_d

USE3

Use Output 3 for Alarm 1, Direct

 

Display Strategy

diSP

Use second display strategy

 

Configuration Lock

Code

CLoc

Configuration Menu unlocked

:TE tannerrlv’fy O Constant input lilter 0 Actual value determined by factory or field calibration 0 Primary Power 7 PPW Power output (Read only) 0 Primary Proportional Proportional Band setting Band (Actual setting may vary slightly) 0 (Actual setting may vary slightly) 0 Derivative time setting (Actual setting may vary slightly) 0 Bias (Manual reset) 62 biAS Bias setting is 62 O Setpoint Upper Limit is 700 °C 0 Setpoint Lower Limit is 0 °C 0 Primary Output Control Output = 100% Power Limit (Not limited) 0 0.5 seconds 0 Deviation Alarm = 30 °C 0 Alarm 1 Hysteresis Value : 1 ”C 0 Band Alarm = 20 “C 0 Alarm 2 Hysteresis Value : 1 ”C 0 Auto PrerTune diSA APt Auto PreiTune capability is disabled 0 Selection 0 Setpoint Ramping EnAb SPr Setpoint Ramping capability is disabled 0 Value 0 Setpoint 600°C (lactory setting — actual setpoint determined by application requirements) 0 Setup Lock Code 0 SLoc Setup Menu unlocked al

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To exit from Setup Mode, press and hold the  button then depress the  button. Select the new

mode using the  or  button, and enter the desired mode by pressing the  button.

Always return to the Operator (OPtr) mode to return to normal operation.

Automatic Tuning Mode

Variations in system dynamics may occur due to normally occurring differences in the thermal

characteristics of heater elements originating from different manufacturing lots, different materials

or changes brought about by improved heater element design. Therefore, if you find that the

factory-installed parameters yield unsatisfactory performance, you may wish to perform a Pre-

Tuning operation when replacing heater elements. To perform a Pre-Tuning operation you must

enter the Automatic Tuning Mode.

Before performing the Pre-Tuning operation it is important to first allow the system to reach the

setpoint operating temperature, then press the O (off) button and allow the actual temperature to

fall at least 100°C below the setpoint temperature.

Press the I (on) button and immediately enable Pre-Tuning by following the steps below. Note

that the table below details the parameters located in the Automatic Tuning Mode menu.

Action

Parameter

Upper

Display

Lower

Display

Description

 

Input Filter Time

Constant

0.5

FiLt

Time constant of 0.5 second used for

input filter

 

Temperature Offset

OFFS

Actual value determined by factory or field

calibration

 

Primary Power

PPW

Power output (Read only)

 

Primary Proportional

Band

3.0

Pb_P

Proportional Band setting

(Actual setting may vary slightly)

 

Automatic Reset

.12

ArSt

Integrator time setting

(Actual setting may vary slightly)

 

Rate

.03

rAtE

Derivative time setting

(Actual setting may vary slightly)

 

Bias (Manual reset)

biAS

Bias setting is 62

 

Setpoint Upper Limit

700

SPuL

Setpoint Upper Limit is 700 C

 

Setpoint Lower Limit

SPLL

Setpoint Lower Limit is 0 C

 

Primary Output

Power Limit

100

OPuL

Control Output = 100%

(Not limited)

 

Output 1 Cycle Time

0.5

Ct1

Control output cycle time is

0.5 seconds

 

Deviation Alarm 1

dAL1

Deviation Alarm = 30 C

 

Alarm 1 Hysteresis

AHy1

Alarm 1 Hysteresis Value = 1 C

 

Band Alarm 2

bAL2

Band Alarm = 20 C

 

Alarm 2 Hysteresis

AHy2

Alarm 2 Hysteresis Value = 1 C

 

Auto Pre-Tune

diSA

APt

Auto Pre-Tune capability is disabled

 

Auto/Manual Control

Selection

diSA

PoEn

Auto/manual control selection is disabled

 

Setpoint Ramping

EnAb

SPr

Setpoint Ramping capability is disabled

 

Setpoint Ramp Rate

Value

Setpoint Ramp Rate Not Applicable

 

Setpoint

600

Setpoint 600C (factory setting – actual

setpoint determined by application

requirements)

 

Setup Lock Code

SLoc

Setup Menu unlocked

- -TE APPLICATION - TOOL/NC tonmrfvify Lower Upper Display Display 0 PrerTune OFF Ptun PrerTune capability is disabled 0 SelfiTune OFF Stun SelfrTune capability is disabled 0 Tune Lock 0 tLoc Automatic Tuning Menu unlocked Input Type Uni In 1 Input 1 is a universal type input Option 1 Module Output 1 module = + 10 to 12 VDC for Type driving a solid state relay Type Option 3 Module Type Type Firmware Type 7 FW Value displayed is firmware type O O O O O O O O O O O O Firmware Issue 7 I88 Value displayed is firmware issue Product Revision Level Date of Manufacture 7 dOM Manufacturing date code (mmyy) Serial Number 1 7 8m First four digits of serial number Serial Number 2 7 Sn2 Middle four digits of serial number Serial Number 2 7 Sn2 Last four digits of serial number al

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

Page 35 - 39

Operating manual

412-94301

Enter select mode by pressing and holding the  button then depressing the  button. Use the

 or  button to locate the Automatic Tuning Mode (Atun) then press  button to proceed with

the operation.

Use the  button to select the Pre-Tune (Ptun) parameter then depress the  button to turn on

the Pre-Tuning operation. You are now performing a Pre-Tuning operation.

Do not change the value of the Self-Tune (Stun) parameter or the Tune Lock (tLoc)

parameter when in the Automatic Tuning Mode menu.

Watch the display windows. The Lower Display should read Ptun, and the Upper Display should

read On. When the value in the Upper Display changes from On to OFF, the Pre-Tuning operation

has successfully completed. Exit the Automatic Tuning Mode by pressing and holding the 

button then depress the  button. Select the new mode using the  or  button, and enter the

desired mode by pressing the  button.

The entire process should take one or two minutes depending on the actual heater element

temperature when the Pre-Tune process is invoked.

Always return to the Operator (OPtr) mode to return to normal operation.

Product Information Mode

To select the Product Information Mode (inFo), press and hold the  button then depress the 

button. Once in the select mode, use the  or  button to locate the Product Information Mode

then press  to proceed with the interrogation.

All information in the Product Information Mode menu is read only. As such, the  and  and

“AUTO/MANUAL” buttons serve no purpose when operating within this menu. Note that display

values in the chart below that show a question mark (?) are read only values that vary from unit

to unit.

Action

Parameter

Upper

Display

Lower

Display

Description

 

Pre-Tune

OFF

Ptun

Pre-Tune capability is disabled

 

Self-Tune

OFF

Stun

Self-Tune capability is disabled

 

Tune Lock

tLoc

Automatic Tuning Menu unlocked

Action

Parameter

Upper

Display

Lower

Display

Description

 

Input Type

Uni

In_1

Input 1 is a universal type input

 

Option 1 Module

Type

SSr

oPn1

Output 1 module = + 10 to 12 VDC for

driving a solid state relay

 

Option 2 Module

Type

rLy

oPn2

Output 2 module = relay contact

 

Option 3 Module

Type

rLy

oPn3

Output 2 module = relay contact

 

Auxiliary Module

Type

nonE

oPnA

No auxiliary module used

 

Firmware Type

Value displayed is firmware type

 

Firmware Issue

ISS

Value displayed is firmware issue

 

Product Revision

Level

PrL

Value displayed is product revision level

 

Date of Manufacture

dOM

Manufacturing date code (mmyy)

 

Serial Number 1

Sn1

First four digits of serial number

 

Serial Number 2

Sn2

Middle four digits of serial number

 

Serial Number 2

Sn2

Last four digits of serial number

-.'TE:- :Mnerllv’fy 5090827000 Replacement Wirebelt D330097000 Three Position Splice Clip Set SCR Motor Controller Assy, 120V, Model KBMM w/ 0.25 Ohm Resistor, Assembled T/C 0283807000 Lower Heater Element, IR, 15.25"x 8.0", 1500 W, 240 VAC 8460027000 1TEMPCON Dynapar Temperature Controller, Programmed 8746067000 Replacement Motor Brush Set . Model 105 Tunnel Oven Approved Relay, DPST, 25A, 220VAC Contacts, 110 VAC 50/60Hz Coil, VDE Approved 4986667000 30R Relay, Super Sensitive, SPDT, 2A, 115VAC Contacts, 5 VDC Coil Relay, DPDT, 10A, 220VAC Contacts, 120 VAC 50/60HZ Coil, VDE Approved 0506847000 4FAN Fan, Ball Bearing, 88/106 CFM, 120VAC 50/60 HZ, 4.69 X 4.69 X 1.5" 2437227000 173FAN Fan, Ball Bearing, 31 CFM, 120VAC, 3.62 X 3.62 X 0.98", with 12" leads 2419007000 Gearmotor, 1/12 HP, 130VDC, 0.7A 2111857000 4,6,7,10LT Ind. Light, 125 VAC Neon, Red, 0.5" Rnd Snap In Panel Mnt, 0.250 Tabs Tabs Ind. Light, 125 VAC Neon, Clear, 0.5" Rnd Snap In Panel Mnt, 0.250 Tabs Approved Switch, Temperature, NC, Open @ 225° F +/. 5°, Close @ 205° F +/7 5°, Horizontal Tabs 8585157000 2FU Fuse, IEC 5x20mm, Low Breaking, Time Delay, 250V, 1A Contact TE 1FU Fuse, IEC 5X20mm, Low Breaking, Time Delay, 250V, 1.6A 5143577000 1POT Digital Potentiometer, 3 Digit, 5K, 2 Watt, 0.1% 8127857000 1TMR Timer, Delay on Break, 20 Minute Delay Time, 1 A, 120 VAC 50/60 Hz Cover al

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

Page 36 - 39

Operating manual

412-94301

8 SPARE PARTS LIST

Part Number

Item

Description

509082-000

Replacement Wirebelt

D33009-000

Three Position Splice Clip Set

575938-000

1MTRCON

SCR Motor Controller Assy, 120V, Model KBMM w/ 0.25 Ohm Resistor,

Assembled

C35538-000

Upper Heater Element, IR, 15.25"x 8.0", 1500 W, 240 VAC, w/ Type K

T/C

028380-000

Lower Heater Element, IR, 15.25"x 8.0", 1500 W, 240 VAC

846002-000

1TEMPCON

Dynapar Temperature Controller, Programmed

874606-000

Replacement Motor Brush Set - Model 105 Tunnel Oven

832785-000

CRM

Relay, 4PDT, 10A, 220VAC Contacts, 120 VAC 50/60Hz Coil, VDE

Approved

882465-000

1CR

Relay, DPST, 25A, 220VAC Contacts, 110 VAC 50/60Hz Coil, VDE

Approved

498666-000

3CR

Relay, Super Sensitive, SPDT, 2A, 115VAC Contacts, 5 VDC Coil

353155-000

2CR,CRF

Relay, DPDT, 10A, 220VAC Contacts, 120 VAC 50/60Hz Coil, VDE

Approved

050684-000

4FAN

Fan, Ball Bearing, 88/106 CFM, 120VAC 50/60 Hz, 4.69 x 4.69 x 1.5"

243722-000

1-3FAN

Fan, Ball Bearing, 31 CFM, 120VAC, 3.62 x 3.62 x 0.98", with 12" leads

241900-000

Gearmotor, 1/12 HP, 130VDC, 0.7A

211185-000

4,6,7,10LT

Ind. Light, 125 VAC Neon, Red, 0.5" Rnd Snap In Panel Mnt, 0.250 Tabs

875571-000

2,5,8LT

Ind. Light, 125 VAC Neon, Amber, 0.5" Rnd Snap In Panel Mnt, 0.250

Tabs

684893-000

3,9LT

Ind. Light, 125 VAC Neon, Clear, 0.5" Rnd Snap In Panel Mnt, 0.250

Tabs

D13099-000

1CB

Circuit Breaker, 2 Pole, 15A, 250VAC, 50/60 Hz, UL, CSA, VDE

Approved

999764-000

1TSW

Switch, Temperature, NC, Open @ 225° F +/- 5°, Close @ 205° F +/- 5°,

Horizontal Tabs

858515-000

2FU

Fuse, IEC 5x20mm, Low Breaking, Time Delay, 250V, 1A

Contact TE

1FU

Fuse, IEC 5x20mm, Low Breaking, Time Delay, 250V, 1.6A

514357-000

1POT

Digital Potentiometer, 3 Digit, 5K, 2 Watt, 0.1%

812785-000

1TMR

Timer, Delay on Break, 20 Minute Delay Time, 1 A, 120 VAC 50/60 Hz

641271-000

1SSR

Solid State Relay, 24-330VAC, 50A Output, 4-20VDC Input, w/ Safety

Cover

- - TE AWL/01mm - TOOL/N6 mm m zumwwsn/sn n r—Aﬁ Wit * H” at 2 \L 552' Nun: :wwnuw: m n M w was uwmxs: mm: 2 w: w LMUUDR mum mm “3:: n; M cunnutmk: :nwmm mmunn m Emmy m m uncun my: PIN wa Awawim: 1 ALL umuwm :Ecuwnnv EnNm/cruks m is m u: u: mm m m m can»: muss mums: Nmtn 4 m amt/MED :En‘mmiv :nmmrmw: (z [Wm/[n m m m uk mm mu VNJYE m mm was uwzwvlii NM}: 3 ALL szcnvz [mm (mm/ml) mecmRS m: u M 5w W m smug uv mm: mm: uwtwvlsz NnYED 5 arm mu m mum: 3pm smz, ma, am, saw mm 04thva 57W ' a mum mun wow u;

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

Page 37 - 39

Operating manual

412-94301

9 ELECTRICAL SCHEMATIC

Mmrlv’fy —‘ Elk E"E\\ E‘ :leP E‘JULDNWE (whtw) 'c ma - . , \ ? pm (m m» / A \ / A \ \ ‘ /_y\ , / / /\ /\ :;LT THE LAT _ ,

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

Page 38 - 39

Operating manual

412-94301

Mmrlv’fy Fie‘dSeNiceEMEA@1e.com hug://tuu|ing.te.com/euroge www.te.cum/suggortrcemer a\

MODEL 105 TUNNEL OVEN (TE 1-1198896-

5 RAYCHEM 955018-000)

Page 39 - 39

Operating manual

412-94301

10 Customer Support

EMEA Service Hotline

Please contact us for all service enquiries or technical support:

Monday - Thursday 08:00 - 16:00

Friday 08:00 - 14:00

Tel. +49 (0) 6151 607 -1518

www FieldServiceEMEA@te.com

______________________________________________

TE Connectivity Germany GmbH

c/o Schenck Technologie- und Industriepark GmbH

Landwehrstr. 55/Gebäude 83

D-64293 Darmstadt

Germany

Additional information and contacts can also been found on the WEB.

Visit us at : http://tooling.te.com/europe

Our EMEA Service Hotline supervises and provides the following services:

 Customer service technicians for:

– Commissioning

– Preventive maintenance

– Repair

– Certification of hand crimping tools

– Activities based on service contracts

 Customer training for:

– Operation, maintenance and repair of TE processing equipment

– TE connection technology including crimping techniques, IDC termination, etc.

 Support in identifying spare parts requirements

 Provision of technical documentation for TE processing equipment

To help us help you as quickly as possible with any questions you may have regarding TE

processing equipment, please have the following data available when contacting us:

 Machine description

 TE part number

 Serial number

 Commissioning date/year of manufacture

To avoid unnecessary delays

 for spare parts orders in general and questions regarding prices and delivery times, please

contact your local TE sales specialist or distributor, direct.

 for all technical enquiries relating to TE connectors, please contact our Product Information

Centre at www.te.com/support-center

Please note that our EMEA Service Hotline staff speak German and English.

TE Connectivity Germany GmbH

a TE Connectivity Ltd. Company

Ampèrestr. 12–14

64625 Bensheim / Germany

Tel. +49-6251-133-0

Fax +49-6251-133-1600

www.te.com

TE Connectivity Germany GmbH certified

acc. ISO 14001 and ISO/TS 16949:2002

AMP, Raychem, TE Connectivity and TE connectivity (logo) are trademarks.

Other products, logos and company names mentioned herein may be trademarks of their respective

owners.

412-94301 / 22-05-06

Model 105 Tunnel Oven Operating Manual Datasheet

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