Installation, Operation & Maintenance Instructions

INDUSTRIAL CURING OVENS

This manual is for the guidance of operator for CURING Ovens and should be read before the oven is connected to the electricity supply. CONTENTS Section Pages

1.0 Symbols & Warnings 2 2.0 Installation 3 3.0 Operation 4 4.0 Maintenance 7 5.0 Repairs & Replacements 8 NOTE: This manual is provided with the temperature controller manual. Please read the Temperature controller manual before operating the Oven.

Manufactured By: XIAMEN NEWBEST AUTOMATION Co., LTD

SUPPLIED By: CRISTAL TECHNOLOGY CORPORATION PTE LTD

Page 2 of 9

1.0 SYMBOLS & WARNINGS 1.1 Switches and Lights Supply Light: when the oven is connected to the electrical supply the 3 phase lights on the door mounted control panel will be illuminated. 1.2 Warning Symbols DANGER ! of electrical shock— read any warning printed by this symbol. DANGER ! — hot surface. Read any warning printed by this symbol. WARNING: all surfaces of an oven may be hot. DANGER — read any warning printed by this symbol.

Page 3 of 9

2.0 INSTALLATION 2.1 Unpacking & Handling Lift the unit from the four roof mounted lifting lugs provided. The oven door should not be used to support the equipment when moving it. Use mechanical equipment (cranes & hoist) to carry the oven where possible. Remove any packing material from the inner chamber before use. 2.2 Siting & Setting Up Place the oven on a clean and level surface. Ensure that there is free space around the oven. Ensure that any vents in the oven are not obscured. Ensure that the oven is placed in such a way that it can be quickly switched off or disconnected from the electrical supply - see below. 2.3 Electrical Connections Connection by a qualified electrician is recommended. All ovens covered by this manual are ordered for use on a three phase supply (i.e. 380 VAC) with a neutral supply. Single phase, Live to Neutral non-reversible supply and other form of power supply models may be ordered for during the order processing. Check the Oven rating label before connection. The supply voltage should agree with the voltage on the label, and the supply capacity should be sufficient for the amperage indicated on the mains circuit breaker. The incoming power supply is rated for 60A, located at the Manual Line MCC power board. The mains supply should be rated to the next size equal to or higher than the amperage on the panel breaker. The rated MCCB capacity in the Oven control panel is 40A. The Oven power supply cable must be a permanent connection to an isolator switch located in the oven control panel. It should be connected to the internal terminals of the Oven control panel with proper cable glanding The Oven panel has mains breaker switch located in the MCC manual Line distribution board for power isolation purpose. The Power supply MUST incorporate an earth (ground) connection to the Oven panel body.

Page 4 of 9

3.0 OPERATION NOTE: The instructions for operating the temperature controller are given in a separate manual. 3.1 Operating Cycle The Oven control system is standalone mounted on the side of the Oven housing. The Oven control system is fitted with a Blower AUTO/MAN selector and push buttons for START/STOP operation and indication for Blower RUN/STOP/TRIP lights. The light is illuminated whenever the oven is connected to the supply. The Oven has 3 banks of 5.0 kW finned air heaters heating air within the insulted enclosure. The heated air is being re-circulated by a steel blower. The blower fan motor is rated at 1.5kW. To operate the Oven, first the Blower must be switched ON. This is realized by selecting the Blower mode to AUTO and the operator pushes the blower START button on the control panel. The Blower circulation fan operates when the Blower is switched on. After the Blower is in operation, the Heaters must be selected to AUTO mode, from a selector switch just below the temperature controller. When the heating AUTO mode is selected, the heater power supply will be enabled and the temperature controller will drive the air temperature inside the Oven to the target set point. The temperature controller is mounted on the control panel door. The controller will provided the start /stop signal to power the finned heaters to heat the air to the desired temperature. The temperature controller is YUDIAN AI-518 series, with PID Control scheme. The temperature controller has a feature to provide a control voltage (5 - 13VDC) to a Solid State Relay (SSR) that will provide bursts of power to the heater banks to increase the air temperature. The power supply will be turned on in full power during the initial heating stage. As the air temperature increases steadily towards the set point, the controller will steadily lower the output power to the heater bank to ensure the set temperature is arrived in the oven uniformly. The power output is varied by varying the voltage signal from the temperature controller to the SSR which will pulse the power output to the finned heaters after the SSR. The temperature controller display is always turned on. The Oven door limit switch is installed such that the control power supply to the panel is switched off when the door oven door is opened at any time. When the door is opened all display on the Oven control panel will be switched off. The temperature controller will display the Actual temp (in RED) and the set temperature. (in Green LED) The Oven is built to reach up to 2500C air temperature within its insulated enclosure.

Page 5 of 9

Whenever the STOP pushbutton switch of the Blower is activated, the power to the Blower and Heating elements will be disengaged. During the temperature ramp up stage, it is not advisable to switch off the Blower as the high temperature inside the Oven may cause accelerated materials failure. During operation, it is advisable not to open the Oven door if the temperature inside had exceeded 150deg C. 3.2 STEP by STEP operating procedures: - 1) Connect the Oven to the electrical supply. 2)` Push the Start Switch for the Blower and select the AOM switch for Heater to AUTO Mode. The Heaters power supply will now start and stop in accordance to the output relay signal of the Temp Controller. 3) When the power to the panel is switched to ON, the temperature controller will lit up. To adjust the temperature controller – press on the up key ▲ or the down key ▼ on the controller key pad to change the set temp reading. Stop when the desired temp setting is displayed on the controller display. Release the setting key and the temperature setting is now ready for use. For details of temp controller usage, refer top the controller manual – YUDIAN AI-518 model temperature controller. 4) The oven begins immediately to power up the heating element and heat the air inside the Oven to the controller set point or program. 5) To switch OFF the Oven heater element turn the Heater selector switch to OFF or Manual mode, position. 6) If the Oven Heater selector is locally switched to manual, the temperature controller is Bypassed and heating and blower remained in active operation. (Note: Blower must be in operation at all times) DO NOT switch off the Blower if the temperature is above 150°C - damage could be caused to the fan and motor. Allow the air temperature to fall for some time, before switching off the Oven air recirculation blower. 7) For high temperature operation settings (above 2000C) it is recommended not to retrieve objects from within the heated oven enclosure, until the Oven temperature had cooled to below 1500C. In view of possible hot surfaces from the internals of the oven housing, extreme care must be taken not to allow any part of the body to be in contact with the hot surfaces. Operator should have the necessary PPE for high temperature operation in use, e.g. leather gloves, aprons, face shield etc.

Page 6 of 9

JS48S-S（DH48S-S）

3.2 PROCESS TIMING When the target temperature is reached in the Oven, a settable analogue timer is available to maintain the product in the Oven at the target temperature for a preset period of time. When the temperature in the Oven has reached set point, a green flashing light mounted above the Oven control panel will indicate the status. The operator can then proceed to set the time required for soaking the product at the target temperature and press the START process timer button on the control panel. Once the START time button is pressed, the digital display time on the timer will lit up and the display will start counting. When the timer is running, a green light will be illuminated. When the preset process time has expired, a red light is illuminated and at the same time, a RED flashing light is also display in the warning light mounted above the control panel. The flashing light indicate to the operator the batch time is completed. When the timing had ceased, the control system also shut off the power to the heaters. As long as a red reset button on the control panel is not pressed, the heater will not power up again. The operator must remove the product in the oven after the curing cycle before pressing the REST button on the panel. Once RESET, the Oven heater will restart, (provided the Blower is still in operation) and the cycle expired time flashing light will be switched off. NOTE: The Green flashing light indicates the temperature in the Oven had attained the set point temperature. During the cooling stage, when the temperature falls below the target temperature, the green color flashing light will automatically switched off. Time setting: The timer (picture shown above) has six columns of click switches. The 2 right-hand side switches are for setting 1/10 of the defined time. The mid column click switches is for defining the desired range in (secs, min or hours) The 2 left-hand side switches are for setting 0-99 digits of the desired time. The upper row of click switches are for increasing count, and the lower row click switches are for decreasing count.

3.3 Explosive Vapors The standard curing Oven models are not suitable for drying or heat treatment applications where vapors are released which are combustible or which can form explosive mixtures with air. For such applications consult the manufacturer especially for the purpose.

Page 7 of 9

4.0 MAINTENANCE 4.1 General Maintenance No routine maintenance is required other than the occasional replacement of consumable items. The oven outer surface may be cleaned with a damp cloth. Do not allow water to enter the interior of the case. Do not clean with organic solvents. The Blower shaft requires some greasing at regular intervals. Recommended greasing interval is on a yearly basis. Recommended grease type: Molykote 44 light/Lithium soap/Silicone, viscosity: 70mm2/s The blower fan motor is sealed for life; no lubrication is required. The Oven door hinges may require occasional light greasing. The recommended grease type is EP1 or EP2 light lithium grade grease for general industrial application. 4.2 Calibration After prolonged use the controller and/or thermocouple could require recalibration. This would be important for processes, which require accurate temperature readings. A quick check using an independent thermocouple and temperature indicator should be made from time to time to determine whether full calibration is required. For a quick check of the temperature shown by the control thermocouple and Oven controller, a portable temperature indicator and probe thermocouple may be used. Depending on the controller, the controller manual may contain calibration instructions. 4.3 After Sales Service The Oven is manufactured by a Local company. For repairs, calibration and preventive maintenance of the furnace and oven products, please contact the relevant personnel listed in the contact section of the manual. In all correspondence please quote the type and voltage given on the rating label of the Oven. Manufacturer contact: -

Xiamen New Best Automation Co., Ltd 厦门欣必佳机电设备有限公司 15E,NO.1 WUHAN BUILDING ,NO.261 JIAHE ROAD,XIAMEN ,FUJIAN,CHINA

Tel：86-592-5360107 Fax：86-592-5146283 Mr. YeFujiang 4.4 Recommended Spares The recommended spares required are the air heating elements in the ovens. Contact the manufacturer for placing spares order for the Oven.

Page 8 of 9

5.0 REPAIRS & REPLACEMENTS 5.1 Safety Warning – Disconnection from Power supply Always ensure that the oven is disconnected from the supply before repair work is carried out.

BALL BEARING GREASING INTERVALS CHART

SYNC. RPM

RANGE

MOTOR

FRAME SIZE

STANDARD

DUTY

SEVERE DUTY VERY SEVERE

DUTY

3000

1500-750

143T-256T

143T-256T

8 Months

30 Months

4 Months

12 Months

1 Month

4 Months

Bearing Size

6205/6206

6207/6208/6305

6306

6308/6309

Periodic Grease amount

3 g

5g

10 g

20 g

3000

1500-750

284T-365T

284T-365T

8 Months

24 Months

4 Months

12 Months

1 Month

14 Months

Bearing Size

6211

6309

6310/6312

6314

Periodic Grease amount

10 g

20 g

30 g

50 g

3000 1500-750

143T-256T 143T-256T

8 Months 18 Months

4 Months 8 Months

1 Month 3 Months

Bearing Size

6216

6313/NU317

NU318/NU320

6317/6318

6320/6322/6324

NU322/NU324

NU328/NU2228

Periodic Grease amount

20 g

30 g

50 g

80 g

80 g

80 g

100 g

Notes: 1. When re-lubricating roller bearings divide the monthly service time by two.

2. See below for definitions of Service Conditions

3. Grease (g) quantity when using a typical low pressure hand grease gun equals

(4 stroke of hand pump = 5 grams)

SERVICE CONDITIONS: DEFINITION

STANDARD DUTY Eight hours per day; Light to normal loading; Clean condition, free from dust.

SEVERE DUTY 24 hours per day; Light to normal shock loading, vibration; Exposure to dirt

or dusty conditions.

VERY SEVERE

DUTY

24 hours per day; High ambient; Normal to high shock loading, vibration;

Dusty conditions; Confined mounting conditions.

Page 9 of 9

5.2 Safety Warning – Oven Refractory Lining/Insulation This oven contains Rockwool Fiberglass in its thermal insulation. These materials may be in the form of fiber blanket or felt, mineral wool slabs or loose filled fiber. Normal use of the oven does not result in any significant level of airborne dust from these materials, but much higher levels may be encountered during maintenance repair of the oven. Whilst there is no evidence of any long term health hazards, we strongly recommend that safety precautions are taken whenever such materials are handled.

NOTICE: Exposure to dust from fibers that has been used at high temperatures may cause respiratory disease. When handling fiber always use an approved mask, eye protection, gloves, and long sleeved clothing. Avoid breaking up the waste material. Dispose of waste fiber in sealed containers. After handling rinse exposed skin water before washing gently with soap (not detergent). Wash work clothing separately. Before commencing any major repairs we recommend references to the OSHA permissible fiber emission level. Disconnect the oven from the electrical supply!! 5.3 The panel is mounted on the right hand side of the oven housing. Note that the panel remains connected by wiring. Do not disconnect any wiring without making a careful note of all the connections. 5.4 Temperature Controller Replacement These controllers are fitted on the door of the control panel, which can be removed by unscrewing from the inside of the door panel. Refer to a qualified electrician in the event a temperature controller has to be removed for some purpose. E.g. recalibration.

APPENDICES:

ATTACHED DOCUMENTS:-

A) TEMPERATURE CONTROLLER CATALOGUE B) ANALOGUE TIMER CATALOGUE C) OVEN CONTROL PANEL CIRCUIT DRAWING D) MFG’s OVEN LAYOUT DRAWING

AI-518 Digital Industrial Process Temperature Controller Ideal for accurate controls of temperature, pressure, flow, level, humidity etc

Main features:

l High performance at a low price l High measurement accuracy: 0.25%FS ± 0.1°C l PID, auto tuning, ON/OFF l Universal programmable input l Universal input power- 85-264VAC, or 11-26VAC/VDC l Highly versatile Output, multiple modules available l Wide variety of alarm mode selectable l CE, RoHS, ISO9001 approved

Specification:

Control mode On-off control mode AI PID Control with Auto Tuning(AT)

Measurement accuracy

0.25%FS ± 0.1°C

Resolution 0.01°C

Response time ≤0.3s ( when digital filter parameter dL=0)

Input

Thermocouple: K, S, R, T, E, J, N,WRe3~WRe25,WRe5~WRe26 etc

Resistance temperature detector: Pt100, Cu50

Linear voltage:0~5V,1~5V,0~1V,0~100Mv, 0~20mV, 0~500Mv etc

Linear Current:0~10Ma,0~20mA,4~20mA

Input range

Thermocouple: K(-100~1300°C), S(0~1700°C), R(0~1700°C), T(-200~+390°C), E(0~1000°C), J(0~1200°C),B(600~1800°C), N(0~1300°C)

Resistance temperature detector:Pt100(-200~+800°C) , Cu50(-50~+150°C)

Output (modularized)

Relay output (NO+NC): 250VAC/2A or 30VDC/1A

TRIAC Switch Output

TRIAC zero Crossing trigger output

SSR Voltage output: 12VDC/30mA (used to drive SSR)

Linear current output: 0~20mA, 4~20mA (The output voltage of X module ≥10.5V; and that of X3 module ≥10.5V.)

General specifications

Voltage: support AC85-265V,50/60Hz or DC24V.

Power consumption: ≤3W

Electromagnetic compatibility (EMC) : ±4KV/5KHz according to IEC61000-4-4; 4KV according to IEC61000-4-5.

Operating Ambient : temperature -10~60°C; humidity ≤90%RH

AI-518 Digital Industrial temperature controller -

AI-518 Digital Industrial temperature controller -

8/31/2011

Appendix: Temperature controller set values:- Oven temperature controller model: YUDIAN 518T Temperature controller parameter settings:- 1) HIAL: 249oC Note: This temp setting must be changed if the SV on the temperature controller main page is modified. The HIAL is the warning temp that the oven has reached the desired working temp and at this temp, it will activate a flashing green light above the control panel.

2) dHAL 0 3) dLAL 0 4) dF 1.0 5) Ctrl 3 4) π5 9.0 5) P 520 6) t 68 7) Ct 1 8) diL 0 9) diH 0 10) SC 0.0 11) Sn 0 (K-type thermocouple input) 12) OPL 0 13) OPH 0 14) ALP 19 15) Loc 808 16) run 0 ** Blue color values indicate current applicable settings.

-formulation time relay

JS48S（DH48S）

JS48S-S（DH48S-S）

Application

SAWANASH48S(DH48S)introduce aboard technology,supply advanced great-scale special IC and

LED,according to aboard technology standard ,can replace H5CN of OMRON company and same products, the priduct have beautiful outlook, Wide delaying range,used in controlling element of auto control system.

Technical parameter

■ Power:85～110% rated voltage

■ AC：110V. 220V. 380V

■ DC：12V. 24V

■ Delaying control precision:≤0.03% ± 0.05%

■ Contact capacity:AC220 5A DC30V 5A(resistance)

■ Mechanical life:≥107time

■ Electrical life:≥105time

■ Ambient temperature:-10℃～+50℃

■ Consumption power:≤5W

■ Altitude:<2000m

Delaying range(provide with button-switch on the panel)

Switch position h m s Delaying range 1m～99h99m 1s～99m99s 0.01s～99.99s

Working program pictur

Outline dimension

Page 1 of 1

温州斯万纳电子技术有限公司