Rev 1/2/15 FORCED-AIR LABORATORY OVENS MODELS: TFO-1, TFO-3, TFO-5, TFO-10, TFO-28 INSTALLATION and OPERATION MANUAL 4861672
CONTACT US TOLL FREE (888) 835-9250 FAX (503) 648-1798 EMAIL info@cascadetek.com ADDRESS 5245-A NE Elam Young Parkway Hillsboro, Oregon USA 97124 WEBSITE 2
TABLE OF CONTENTS TABLE OF CONTENTS 3
SECTION 1: INSTALLATION CONGRATULATIONS! Congratulations on selecting a Cascade TEK forced-air oven. We have put together this manual to make sure you get the most from your oven. Our Lawyers Say: This is a general-purpose oven for professional, industrial or educational use. It is suitable for a working environment where no flammable, volatile or combustible materials are being heated. This oven is not intended for hazardous or household use. Your satisfaction and safety require a complete understanding of this unit. Read the instructions thoroughly and be sure all operators are given adequate training before attempting to put the unit in service. This equipment must be used only for its intended application; ANY ALTERATIONS OR MODIFICATIONS WILL VOID YOUR WARRANTY. Your City Inspector Says: Local city, county or other ordinances may govern the use of your forced-air oven. If you have any questions about local installation requirements, please contact the appropriate local agency. Our Design Engineers Say: Your oven is intended for use indoors, at temperatures between 25 C and 40 C, at no greater than 80% Relative Humidity. Extreme external temperatures or humidity levels can affect the oven s ability to control temperature. This oven is not designed to handle combustible gasses and is not an explosion proof unit. Do not place explosive, combustible, or flammable materials into the chamber. 4
SECTION 1: INSTALLATION A. SET UP A.1 IMMEDIATELY INSPECT THE CRATE & OVEN FOR FREIGHT DAMAGE: The carrier has responsibility for safe delivery and is liable for loss or damage. Describe on the freight bill any damage found, and enter your claim on the form supplied by the carrier. Photos are always helpful in making sure your freight claim is handled expeditiously. A.2 Return Shipment: Save the shipping crate until you are sure all is well. If for any reason you must return the unit, first contact Cascade TEK for authorization. Supply nameplate data, including model number and serial number. A.3 Accessories: Verify that all of the equipment indicated on the packing slip is included with the unit. Carefully check all packaging before discarding. The oven is equipped with shelves. In some models, shelves are wrapped to the side of the oven to prevent interior damage. See Section 4.0: Parts List. A.4 Location, Location, Location: Consider conditions that may affect the oven s ability to accurately control temperatures. such as extreme heat from radiators, stoves, other ovens, autoclaves, etc. Avoid direct sun, fast-moving air currents, heating/cooling ducts, and high traffic areas. IMPORTANT: On benchtop models (TFO-1, TFO-3, TFO-5) fresh air is drawn in from the slats/louvers around the base of the oven. Give the oven room to breathe. Leveling feet help with this as well. To ensure proper air circulation around the unit, allow a minimum of 30 cm between the oven and any walls or partitions, and install leveling feet. A.5 Easy Tiger! Ovens are heavy and should only be lifted from their bottom surfaces. Doors, handles and knobs are not adequate for lifting or stabilization. Shelves should be removed and doors need to be positively locked closed during transfer to prevent shifting and damage. 5
SECTION 1: INSTALLATION A.6 Remove Pallet. The oven is secured to its pallet with 4 washer/bolts. Remove with a 1/2 wrench. NOTE: You are about to install leveling feet in those same 4 holes on the bottom of the oven. A.7 Install Leveling Feet: Each oven comes with 4 leveling feet. These need to be installed in the 4 threaded inserts on the bottom of the oven. Aside from leveling the oven, leveling feet help keep the controls and exterior cool. A.8 Cleaning: The oven interior was cleaned at the factory, but not sterilized. Clean with a disinfectant that is appropriate for your application. Remove any protective vinyl film on the shelf surface. 6
SECTION 1: INSTALLATION A.9 Adjustable Shelves with Clips: 1. Place shelves in the chamber at the desired location with the included shelf clips. 2. Be mindful of the temp probe when installing the shelves. Temp Probe 3. Position the shelves not to block the small holes on the oven s interior side wall. 7
SECTION 1: INSTALLATION B. FACILITIES Standard TFO ovens require the following facility connections: B.1 Electrical Power of the TFO Ovens: Oven Model Voltage Cycle Amperage TFO-1 120V 50/60 Hz 15 Amps TFO-3 120V 50/60 Hz 15 Amps TFO-5 208V-220V 50/60 Hz 13 Amps TFO-10 208V-220V 50/60 Hz 26 Amps TFO-28 208V-220V 50/60 Hz 50 Amps NOTE: Consult the oven data plate for the voltage, cycle, and amperage requirements before making power connection. B.2 Your Electrician Should Know: A separate circuit for the oven is strongly recommended to prevent possible loss of product due to overloading or failure of other equipment on a shared circuit. Electrical supply circuit must conform to all national and local electrical codes. VOLTAGE SHOULD NOT VARY MORE THAN 10% FROM THE DATA PLATE RATING. B.3 OPTIONAL - GN2 Purge Option: This fitting will allow for connection to nitrogen for the GN2 purge option. 80 PSI inlet connection. See Section 5.0: GN2 Purge if your oven is equipped with the purge option. 8
SECTION 2: LET S GO! A. HOW FORCED-AIR OVENS WORK Theory: In a Forced-Air Oven (electric convection), a fan circulates hot air rapidly through the oven s interior. This rapid, forced circulation insures temperatures throughout the oven are uniform and heat is transferred more evenly. By blowing hot air past the product, it prevents cooler air from building up near product surfaces you are trying to dry. Since products in a convection oven are always in contact with hot air, products pick up heat faster and dry faster. Fresh Air Intake: The louvers/slats on the side and back of the TFO oven draw in fresh air, pass it across heaters to a fan blower directing the air up and across the shelves. On the TFO-10 and TFO- 28, the fresh air intake is on the top of the ovens. Allow adequate space for the oven to draw in fresh air. Horizontal Airflow Pattern: The heated air is directed across the oven shelves in a HORIZONTAL pattern. The smaller holes on the side of the oven push hot air across and through the larger holes on the opposite side. The oven is a mix of heated, recirculated air. TIP: Position the shelves not to block the smaller holes. Exhaust Port (Top): The oven exhausts through the top. This exhaust port can be left open or closed. To speed drying in highmoisture requirements, considering keeping the exhaust vent 100% open to allow the oven to expel the damp hot air and replace with fresh dry hot air. Access Port (Rear): This adjustable access port allows insertion of cables and feedthroughs. Top Exhaust Port (Adjustable) Adjustable Access Port - Cables, Feedthroughs, etc. (Back Center Wall) Horizontal Air Flow Pattern (Across Shelves) Fresh Air Intake (Sides and Rear) 9
SECTION 2: LET S GO! CELCIUS/FARENHEIT CONVERSION TABLE Cascade TEK ovens are typically configured in degrees Celsius. C is displayed in red on the upper right of the Watlow Controller. TIP: Ovens want to heat. They are not able to control well at lower temperatures. C F 20 68 22 71.6 24 75.2 26 78.8 28 82.4 30 86 32 89.6 34 93.2 36 96.8 38 100.4 40 104 42 107.6 44 111.2 46 114.8 48 118.4 50 122 52 225.6 54 129.2 56 132.8 58 136.4 60 140 62 143.6 64 147.2 66 150.8 68 154.4 70 158 72 161.6 74 165.2 76 168.8 78 172.4 80 176 82 179.6 84 183.2 86 186.8 88 190.4 C F 90 194 92 197.6 94 201.2 96 204.8 98 208.4 100 212 105 221 110 230 115 239 120 248 125 257 140 284 145 293 150 302 155 311 160 320 165 329 170 338 175 347 180 356 185 365 190 374 195 383 200 392 210 410 220 428 230 446 340 464 250 482 260 500 270 518 280 536 290 554 300 572 - Max Temp. with Standard Gasket - Max Temp. TFO-10 & TFO-28 - Max Temp. TFO-1, TFO-3, TFO-5 WATCH: Changing your Watlow EZ- ZONE from C to F 10
SECTION 2: LET S GO! B. CONTROL PANEL OVERVIEW / SYMBOLS POWER SWITCH - It must be in the I or on position to operate. TEMP CONTROLLER - Displays temperature, set-point, and profile status. BUILT-IN HIGH LIMIT CONTROL - Shuts down heaters if oven temp exceeds main temp controller set-point. This will need to be set first thing. Up Temp TEMPERATURE & HIGH LIMIT CONTROL ON WATLOW EZ-ZONE C EZ1 EZ2 OFF Down Temp GREEN VALUE - the temperature you want to get to. VALUE - the current temperature. WATCH THE TUTORIAL (Internet connection required) Cascade TEK s Forced Air Oven Controller 11
SECTION 2: LET S GO! GRAPHIC SYMBOLS Your oven may contain a variety of graphic symbols which should help in identifying the use and function of the available user adjustable components. ATTENTION! Consult your manual for further description. Indicates AC Power Indicates Degrees Celsius (Seen on Temperature Controllers) Indicates Over Temperature Safety (High Limit Controller) Indicates Earth Ground Indicates Potential Shock Hazard behind partition RECYCLE THIS UNIT! Do the right thing for the planet and your children. Do not dispose of in land-fill. Indicates Temperature Indicates Warning: Hot Surface 12
SECTION 2: LET S GO! C. QUICK START GUIDE (SET-POINT TEMPERATURE) STEP 1 STEP 2 Put stuff in, close door. Turn oven on. Green power switch and controller lights up. STEP 3 Set High Limit Temperature on Controller. It is important to make sure the overtemp protection is set properly. It will shut down power to the heaters if the oven runs away or heats beyond your desired temperature. When you first get the oven, the overtemp is configured from the factory at the highest possible setting: 270 C for the benchtop ovens and 305 C for the TFO-10 and TFO-28. We recommend setting the overtemp about 5 C higher than the temperature you want to run the oven to. For example, if you are heating your product to 200 C, set the overtemp to 205 C. 1. Press the Green Advance Key until Limit High, set-point 1 (LhS1) appears on the screen. 2. Press the UP/DOWN arrows unit the desired overtemp temperature is reached in the red digital display. 3. Press the Green Advance Key to activate the overtemp protection. Desired High Limit Temp Limit High, set-point 1 WATLOW EZ-ZONE C EZ1 EZ2 4 Hi-temp alarm (Lih1) Green Advance Key 13
SECTION 2: LET S GO! WATCH: Getting Started with your Cascade TEK Oven Controller WATCH: Set OverTemp Control - Cascade TEK s TFO Ovens STEP 4 Single Temperature Set-Point Operation 1. Use UP/DOWN arrows to select desired set-point temperature. Red = the current temp inside the oven, Green = the temperature you desire. 2. Red 2 light is on to show power to the heaters. Current Temperature Set-Point Temperature WATLOW EZ-ZONE C EZ1 Up Temperature EZ2 Down Temperature Heating STEP 5 Oven heats to set-point temperature. 14
SECTION 2: LET S GO! STEP 6 Using Exhaust Vent: The slide damper vent on the top of the oven controls ventilation. The oven does not need additional venting. However, powerful fumes or heat output may lead you to attach a vent hose and exhaust the fumes/heat elsewhere. When attaching a vent hose: 1. Put a dip in the hose. Do not vent straight up. Moisture can condense and run back into the oven. 2. Keep exhaust fans far away to prevent heat loss from oven. 3. A standard dryer hose and clamp will work fine. STEP 7 When finished, turn off main power, or press the DOWN arrow on Temp Controller to lower temperature below ambient. STEP 8 Open door and remove samples. CAUTION: They may be hot. 15
SECTION 2: LET S GO! D. CONTROLLER PROGRAMMING PROGRAM CONTROLLER WITH SOFTWARE Watlow s Configurator Software is an optional tool you can use to program your controller. The software presents pages and menus as they are in the controller s display, RUI and manuals: On-screen parameter help & copy parameter settings Save and download configuration files on the computer with all the information required to set up a controller Preserves settings for archiving, recovery or to simplify setting up another controller Enables files to be e-mailed or made available to users on a network or via the internet to aid them with set up You will need: Cascade TEK s USB to RS-485 Cable Connection - available for purchase. EZ-ZONE Configurator software (included). Located on the disk: Controller Support Tools Directory: EZ-ZONE Configuration Software > Software > EZ ZONE > EZ-ZONE Configurator Oven RS-485 Comm Port USB / 485 Converter Cable Watlow Configurator Software 16
SECTION 2: LET S GO! PROGRAM RAMP AND SOAK TEMP PROFILE STEP 1 Flip the POWER Switch to the ON position. Controller will illuminate. STEP 2 Set High Limit Temperature on Controller. It is important to make sure the overtemp protection is set properly. It will shut down power to the heaters if the oven runs away or heats beyond your desired temperature. When you first get the oven, the overtemp is configured from the factory at the highest possible setting: 270 C for the benchtop ovens and 305 C for the TFO-10 and TFO-28. We recommend setting the overtemp about 5 C higher than the temperature you want to run the oven to. For example, if you are heating your product to 200 C, set the overtemp to 205 C. 2. Press the Green Advance Key until Limit High, set-point 1 (LhS1) appears on the screen. 3. Press the UP/DOWN arrows unit the desired overtemp temperature is reached in the red digital display. 4. Press the Green Advance Key to activate the overtemp protection. 5. Press the reset button to activate High Limit Control. Desired High Limit Temp Limit High, set-point 1 WATLOW EZ-ZONE C EZ1 EZ2 4 Hi-temp alarm (Lih1) Green Advance Key WATCH: How to set Ramp and Soak Profiles 17
SECTION 2: LET S GO! STEP 3 Trust me. Watch this first: WATCH: Programming a Simple Ramp and Soak Temperature Profile Simple Profile: Single Set-Point and Time (Example: 150 C for 1 hour) 1. Green Advance Key hold for 3 seconds 2. See Profile 1 appear on display 3. Press Green Advance Key to Step 1 4. Press Green Advance Key to Step Type StyP Step 1 Use UP and DOWN arrows until Ti (Time Step appears). This step tells the controller to achieve 150 C as quickly as possible. (Or how quickly to ramp to temp.) 1. Ti (Time Step) 2. Press Green Advance Key until you see tsp1 3. Press UP/DOWN arrows until 150 4. Press Green Advance Key 5. Hour = 0 hour (0 Hours) (Enter number of Hours) 6. Press Green Advance Key 7. Min = 0 Min (0 Minutes) (Enter number of Minutes) 8. Press Green Advance Key 9. SEC =0 SEC (0 Seconds) (Enter number of Seconds) 10. Press Green Advance Key 11. Ent 1 = OFF 12. Press Green Advance Key 13. Ent 2 = OFF 14. Press Green Advance Key 15. Press Infinity Key which takes you to back to P1 16. Use UP arrow to select 2 (Step 2 in Profile 1) 18
SECTION 2: LET S GO! STEP 3 CONT. Step 2 - Wait for Process Step 1. Press Green Advance Key until you see StyP (Step Type) 2. Press UP/DOWN arrows until WPr (Wait For Process). This means we are waiting for the oven to get close to the set-point temp (145 C) before we actually start the process time. 3. Press Green Advance Key 4. WPi (Wait For Process 1) 5. Press UP/DOWN arrows to select 1 6. Press Green Advance Key 7. Press UP/DOWN arrow to about 5 C lower than your process temperature (145 C if you want 150 C) 8. Press Green Advance Key 9. Ent 1 = OFF 10. Press Green Advance Key 11. Ent 2 = OFF 12. Press Green Advance Key 13. Press Infinity Key which takes you to back to P1 14. Use the UP/DOWN arrows to select Step 3. Step 3 - Soak Step (Step 3 in Profile 1) 1. Press Green Advance Key. To see Step Type (StyP) 2. Use UP/DOWN arrows until soah (Soak Step) appears. This step tells the controller how long to remain at 150 C 3. Press Green Advance Key 4. Hour = 1 hour (1 Hours) (Specify time) 5. Press Green Advance Key 6. Min = 0 Min (0 Minutes) (Specify time) 7. Press Green Advance Key 8. EC = 0 SEC (0 Seconds) (Specify time) 9. Press Green Advance Key 10. Ent 1 = OFF 11. Press Green Advance Key 12. Ent 2 = OFF 13. Press Green Advance Key 14. Press Infinity Key which takes you to back to P1 15. Use UP arrow to select 4 (Step 4 in Profile 1) 19
SECTION 2: LET S GO! STEP 3 CONT. Step 4 - (End of process, reduce temperature oven does not actively cool) 1. Press Green Advance Key until you see Step Type (StyP) 2. Press UP/DOWN arrows until Ti (Time Step) 3. Press Green Advance Key 4. Press UP/DOWN arrows until 150 5. Change 150 to 0 6. Press Green Advance Key 7. Hour = 0 hour (0 Hours) 8. Press Green Advance Key 9. Min = 0 Min (0 Minutes) 10. Press Green Advance Key 11. SEC = 0 SEC (0 Seconds) 12. Press Green Advance Key 13. Ent 1 = OFF 14. Press Green Advance Key 15. Ent 2 = OFF 16. Press Green Advance Key 17. Press Infinity Key, which takes you to back to P1 18. Use UP arrow to select 5 (Step 5 in Profile 1) Step 5 - End Step (Step 5 in Profile 1) 1. Press Green Advance Key until you see StyP (Step Type) 2. Press UP/DOWN arrows until End (End Process). 3. Press Green Advance Key 4. Press UP/DOWN arrows until HoLd (Hold Step). This will hold the oven temperature at the last set-point. (The temp that was called out in Step 4.) 5. Press Green Advance Key 6. Ent 1 = OFF 7. Press Green Advance Key 8. Ent 2 = OFF 9. Press Green Advance Key 10. Press Infinity Key, which takes you to back to P1. 11. Press Infinity Key for 2 seconds to go back to home screen. 20
SECTION 2: LET S GO! STEP 4 Start the Profile 1. Press EZ-1 button a. 3 things should happen right away i. The red ramp symbol will light up ii. The green application display should read 150 iii. The red 2 light will come on showing the oven is calling for heat. The oven should begin heating. Current Temperature Set-Point Temperature WATLOW EZ-ZONE C EZ1 Press EZ1 Button to Start EZ2 Press EZ2 Button to Stop Heating Ramping 21
SECTION 3: PROPER CARE AND FEEDING A. MAINTENANCE WARNING: Always disconnect the unit from the electrical service when cleaning and assure all volatile or flammable cleaners are evaporated and dry before reattaching the unit to the power supply. A.1 Gasket Inspection: The door gasket is considered a highwear item. Heat and pressure will take its toll. If you notice loss of door seal, tearing or wear, the gasket should be replaced. Contact Cascade TEK for replacement gaskets. Please see Section 4.0: Parts List. A.2 Interior Cleaning Improves Performance: Remove shelves. Be careful not to disturb the sensor located in the back. Any undue pressure may cause breakage and replacement will be necessary. Disinfect with a solution that is suitable for your application. Any oily residue or moisture in the chamber should be removed after each operation to ensure maximum performance. Using a lint free cloth, wipe down the oven. DO NOT use chlorine-based bleaches or abrasives as this may damage stainless steel surfaces. DO NOT use spray cleaners that might leak through openings and get on electrical parts. 22
SECTION 3: PROPER CARE AND FEEDING B. PRECAUTIONS AND FAQS PRECAUTIONS B.1 THIS IS NOT AN EXPLOSION PROOF OVEN. Do not place or use explosive, combustible, or flammable materials in or around the oven. This oven is not suitable for use in Class I, II, or III locations as defined by the National Electrical Code NFPA 70, U.S.A. B.2 Disconnect from electrical power source before attempting to make any repairs, cleaning or component replacements. This is just plain common sense. 23
SECTION 3: PROPER CARE AND FEEDING INSTALLATION FAQS Will my TFO-5 run on 208V? Yes, the TFO-5 will run on 208V. However, with the lower wattage you may notice slower heat up times and maximum high temperature may be limited. Where / how does the oven exhaust? TFO ovens exhaust via the top mounted port. It is fully adjustable in the opened and closed positions. It is okay to run the oven with the exhaust port fully closed, however, having it open may improve dry times. Using Exhaust Vent: The slide damper vent on the top of the oven controls ventilation. The oven does not need additional venting. However, powerful fumes or heat output may lead you to attach a vent hose and exhaust the fumes/heat elsewhere. When attaching a vent hose: 1. Put a dip in the hose. Do not vent straight up. Moisture can condense and run back into the oven. 2. Keep exhaust fans far away to prevent heat loss from oven. 3. A standard dryer hose and clamp will work fine. See Section 5.0 options regarding the power exhaust feature on the TFO-10 and TFO-28. What are the BTU s of the oven? There are formulas for calculating BTUs; based on the wattage of the oven. However, the actual BTU s for your particular situation would have to be determined by your specific use. Here are the MAXIMUM BTU conversions by model. Oven Model Watts BTU Per Hour TFO-1 1,600 5,461 TFO-3 1,600 5,461 TFO-5 2,000 6,827 TFO-10 5,300 18,091 TFO-28 10,300 35,430 24
SECTION 3: PROPER CARE AND FEEDING PROCESS FAQS My oven has the dry air purge option. What is the PSI for the inlet? 80 PSI. See Section 5.0: GN2 purge. Can I put my product on the oven floor? Yes. How much weight will the shelves hold? The shelves are made of 304 stainless steel, we estimate about 50 to 75 lbs. max. How full can the oven be? Less is more. Over crowding the oven will inhibit air flow and cause inconsistent, longer drying time. 25
SECTION 3: PROPER CARE AND FEEDING CONTROL FAQS Where is the oven s controller manual on the Watlow disc? Temperature Controller Manual (Watlow EZ) This manual can be found on the Watlow Controller Support Tools disc included with the oven. User Manuals > EZ-ZONE User Manuals > PM Integrated (Temp Controller) How do I change my controller from Celsius to Fahrenheit? 1. Press and hold both UP and DOWN arrows 6 seconds. 2. Display says A1 SEt. 3. Use arrows to go to glbl (Global) on upper display. 4. Press green Recycle Key once to display C or F. 5. Use arrows to go to change to C or F. 6. Press Infinity Key twice to exit to main screen. See video instructions here. My display reads Er11 or Er12. What does it mean? 1. Loose thermocouple. Thermocouple wires have come loose on the back of the controller. Jumper a wire across the TC input to see if error clears. Check thermocouple connection inside oven. How do I find the serial number of my Watlow EZ Controller? This info may be necessary for warranty support from Watlow: 1. Hold down the Infinity and Green Recycle Keys simultaneously (will take about 8 seconds). 2. Display says CUSt and FCty. 3. Press DOWN arrow once to go to diag on upper display. 4. Press Green Recycle Key once to display Pn (Part Number). 5. Part number will scroll across display, it should look similar this PM9R1CJ-ACFJCAA. 6. Press green Recycle Key again to see Sn (Serial Number). 7. Press green Recycle Key again to see date (Date of Manufacture). 8. Press Infinity Key twice to exit to main screen - 26
SECTION 3: PROPER CARE AND FEEDING CONTROL FAQS What do the Watlow profile terms mean? Terms ti Ent1 Ent 2 SoAh JL WPr End Description Time Step: Select temperature, time to temperature and toggle outputs. Event 1: Activates an option on the oven. (Power exhaust or GN2 Purge.) Event 2: Activates an option on the oven. SOAK: Holds temperature for set time period. Can also set events in this step. Jump Loop: Jumps to previous step (JS) for number of counts (JC) Wait For Process. Waits for temperature to reach set-point before next step continues. End Step. Choose user to return to set-point before profile. Watch our video: Cascade TEK Tutorial on Watlow EZ-ZONE. How do I get the EZ-ZONE out of OFF mode? 1. Hold down UP and DOWN arrows together. 2. Display says A1 and oper. 3. Use UP/DOWN arrow to go to LooP on upper display. 4. Press green Recycle Key to display 1 LooP. 5. Press green Recycle Key again and use UP/DOWN keys to ensure display reads Auto. 6. Press Infinity Key 3 times to exit to main screen. 7. Arrows should allow you to manually change temperature. What do the red lighted numbers on the EZ- ZONE Controller mean? Numbers Description 1 Retransmit. The controller is retransmitting a signal to a chart recorder or datalogging device. 2 The controller is calling for heat. 3 Outputs in use. Typically Ent1 or Ent2. 4 The overtemp is alarming. 27
SECTION 3: PROPER CARE AND FEEDING TEMPERATURE FAQS Why isn t my oven heating? If the red 2 light is lit on the controller, the controller is calling for heat. If no heat is being generated, a relay may have failed, so the heaters are not being energized. 1. Is the red 2 light lit on your controller? a. If yes, the oven is calling for heat. A relay may have failed, or heaters have shorted. 2. Is your overtemp limit alarming? a. If the EZ Limit Controller is alarming or set too low, it will prevent the oven from heating. The 4 will be illuminated on the EZ-ZONE Controller if the overtemp is alarming. It will need to be reset. 3. Is your overtemp set too low? a. See Section 2, Step 3 (Quick Start Guide) to set overtemp. 4. Has the door been opened? Or has there been a power outage? a. It takes time for the oven to regain heat and stabilize. Look for the solid or flashing red 2 to make sure the oven is heating. 28
SECTION 3: PROPER CARE AND FEEDING MECHANICAL FAQS My oven door won t close properly. Often in shipping the door hinges can become misaligned. Adjust the door hinges, and make sure the door is squared to the rest of the unit. My oven is noisy. The fan motor is wearing out. If it does not move at all, it has seized and needs to be replaced. Oven will not turn on. Check wall power source. Check fuse or circuit breaker. Why is my oven smoking the first time I turn it on? Residual oils from manufacturing are probably burning off. Did you remember to remove the protective plastic coating on the shelves prior to installation? 29
SECTION 4: PARTS LIST PARTS LIST PART NO. DESCRIPTION TFO-1 FORCED-AIR OVEN 9570763 ELEMENT ESSY. 9600570 BLOWER MOTOR ASSY. 2600535 BLOWER WHEEL 6 X 2 4880549 BLOWER MOTOR 3450722 DOOR GASKET 10 FT. 5120689 SHELF 2700512 ADJUSTABLE FEET 3300513 FUSE 16A TFO-3 FORCED-AIR OVEN 9570970 ELEMENT ASSY. 9600571 BLOWER MOTOR ASSY. 2600535 BLOWER WHEEL 6 X 2 4880549 BLOWER MOTOR 3450722 DOOR GASKET 10 FT. 4120690 SHELF 2700512 ADJUSTABLE FEET 3300513 FUSE 16A TFO-5 FORCED-AIR OVEN 9570665 ELEMENT ASSY. 2350564 HEATING ELEMENT 9600572 BLOWER MOTOR ASSY. 2600535 BLOWER WHEEL 6 X 2 4880549 BLOWER MOTOR 3450722 DOOR GASKET 12 FT. 5120691 SHELF 2700512 ADJUSTABLE FEET 3300516 FUSE T10A NOTE: Part Numbers are subject to change. Please confirm description and model number with your order. 30
SECTION 4: PARTS LIST PART NO. DESCRIPTION TFO-10 FORCED-AIR OVEN 9570679 ELEMENT ASSY. 9600646 MOTOR ASSY. 2600535 MOTOR WHEEL 6 X 2 4880548 MOTOR 3450699 DOOR GASKET 11.5 FT 995-00007 SHELF 2700500 ADJUSTABLE FEET TFO-28 FORCED-AIR OVEN 9570666 ELEMENT ASSY. (TFO-28) 9570767 ELEMENT ASSY. (TFO-28-3) 9600550 MOTOR ASSY. 2600535 MOTOR WHEEL 6 X 2 4880548 MOTOR 3450699 DOOR GASKET 17 FT 995-00005 SHELF 2700500 ADJUSTABLE FEET ALL FORCED-AIR OVEN PARTS 7030533 SOLID STATE RELAY 9650503 SOLID STATE RELAY ASSY. 6600519 TC PROBE CLOSED END 4650553 TC PROBE CLOSED END 7850570 GREEN I/O SWITCH 4450506 SOFT TOUCH KNOB 1250511 SHELF CLIPS - SMALL 8000542 TERMINAL BLOCK 9660505 WATLOW PM CONTROLLER 1250512 SHELF CLIPS - LARGE NOTE: Part Numbers are subject to change. Please confirm description and model number with your order. 31
SECTION 5: OPTIONAL FEATURES GN2 PURGE The GN2 purge creates an inert atmosphere (non-corrosive, noncondensing, non-oxidizing) within the oven s interior. Generally, the purge cycle should force a volume of gas equal to 5 to 10 times the volume of the oven. The purge will displace 0 2 and other impurities. The atmosphere within the oven is a mixture of room air and the purging gas until the purge cycle is completed. For this reason, the purge cycle should be finished before heat is applied to the chamber. Failure to properly complete a purge cycle may result in oxidation. A slight positive pressure should be maintained while running up to the set point temperature and throughout the heating portion of operation. GN2 atmosphere should be maintained until the work load is below the temperature at which oxidation will occur. Oxidation is generally detectable by a discoloration seen in the product. 125 C is considered the highest / safe temperature. Most materials can be removed from the oven at this temperature without discoloration. 32
SECTION 5: OPTIONAL FEATURES OPERATION OF GN2 PURGE Facilitating the GN2 Purge 1. Connect a source of GN2 to the ¼ female pipe thread provided at the back top of the oven. 2. Supply should be rated at 80 PSI. Using the GN2 Purge in Manual mode 1. Ensure intake and exhaust damper on top of the oven are closed. 2. Turn knob on front panel to ON. GN2 will begin to flow into the oven. 3. Adjust flow to desired rate on the flow meter. 4. Turn the knob to AUTO to stop the flow of GN2. OFF Flow Meter Using the GN2 Purge in Auto mode Programming the controller with the time and steps you want GN2 to flow during your drying process is required. For assistance in programming your controller to run GN2 Purge in Auto Mode, See Section 2.0 D: Program a Ramp and Soak Profile. 1. Create a drying profile, identifying which steps and time you want the GN2 to stop and start. 2. Ent1 (Event 1) = ON will start the flow of GN2. 3. Ent2( Event 2) = OFF will stop the flow of GN2. 4. Ensure the intake and exhaust dampers are closed. 5. Turn the knob on the front panel to AUTO. 6. On the Watlow EZ-ZONE control, start your preprogrammed drying/purge profile. 33
SECTION 5: OPTIONAL FEATURES POWER EXHAUST - TFO-10 & TFO-28 MODELS The power exhaust provides rapid evacuation (return to ambient) of the oven. The power exhaust mounts to the top of the exhaust vent on the top of the oven. The power exhaust plugs into the switched 220V outlet on the back top of the oven. It is not intended to enhance air exchanges or ventilation. Hot Exhaust Exhaust Vent (Open) TIP: If you are running the oven above 80 C and NOT using the power exhaust, CLOSE the oven s top exhaust vent. This will help prevent heat deterioration of the power exhaust motor. 34
SECTION 5: OPTIONAL FEATURES INSTALLATION OF POWER EXHAUST Installing the Power Exhaust The Power Exhaust is packaged separately and shipped inside the oven. 1. Install the oven per manufacturer s instructions prior to installing power exhaust. 2. Unwrap the Exhaust assembly. 3. Remove the eight screws from the top of the oven around the Exhaust Port 4. Place over the exhaust vent on top of the oven. 5. Align the screw holes. 6. Attach the power exhaust with the eight screws. 7. Plug the power exhaust into the accessory outlet on the oven. OPERATION OF POWER EXHAUST TIP: If you are running the oven above 80 C and NOT using the power exhaust, CLOSE the oven s top exhaust vent. This will help prevent heat deterioration of the power exhaust motor. Using the Power Exhaust: 1. Open the exhaust damper on top of the oven. 2. Open the intake damper. 3. Turn knob on front panel to ON 4. The power exhaust will evacuate the oven. 5. Monitor the temperature on the main controller. 6. When the oven has cooled sufficiently, turn the knob to OFF. 7. The power exhaust will turn off. 8. Close the exhaust damper. 35
SECTION 5: OPTIONAL FEATURES CHART RECORDER - DATA LOGGING Track Oven Temperature with a 24 hour or 7 day chart recorder. An easy visual to insure your process is staying on track, maintaining temperature. A record of each process. Multi-channel, digital datalogger also available to measure oven control temp and the temperature of individual parts inside the oven. Refer to the Datalogger Manual. 36
SECTION 5: OPTIONAL FEATURES USB TO RS-485 CABLE CONNECTION This plug and play cable is available for purchase from Cascade TEK. Call us, we will send you one. It allows you to use Watlow s Configurator Software for your oven. IQ / OQ: QUALIFICATION MANUALS Complete IQ / OQ manual customized to your oven and tracked by serial number. Ask for details. ON-SITE QUALIFICATION SERVICES Factory-Authorized performance of IQ / OQ available upon request. Please inquire for pricing and availability. 37
SECTION 6: FORCED-AIR OVEN SPECIFICATIONS TFO-1: 1.6 Cubic Foot Forced-Air Oven CAPACITY 1.6 cubic feet (45 cubic litres) INTERIOR DIMENSIONS (WxDxH) 13 x 14.63 x 14.75 (33.02 x 37.16 x 37.47) EXTERIOR DIMENSIONS (WxDxH) 22.5 x 21 x 32 (57.15 x 53.34 x 81.28) TEMPERATURE RANGE Ambient +15 C to 300 C TEMPERATURE UNIFORMITY +/-3 C at 150 C TEMPERATURE TIME TO 150 C TEMPERATURE RECOVERY TIME AIR FLOW CONTROLS POWER HEATER WATTAGE STANDARD DOOR GASKET SHELVES ACCESS PORT WEIGHT WARRANTY 10 minutes 2 minutes (after door open 30 seconds) 120 feet per minute Watlow EZ programmable control with ramp & soak capabilities. Built-in, independent overtemperature controller. DB25 pin RS-485 serial comm port. 120V / 1Ph / 50/60 Hz / 15 Amp 1500 Watts Silicone 235 C Max (300 C Teflon available) 2 Adjustable, 304 Stainless Steel 2.75 Rear 127 lbs. (195 lbs. shipping) 1 Year 38
SECTION 6: FORCED-AIR OVEN SPECIFICATIONS TFO-3: 3.2 Cubic Foot Forced-Air Oven CAPACITY 3.2 cubic feet (90.6 cubic litres) INTERIOR DIMENSIONS (WxDxH) 18 x 19 x 16.5 (45.72 x 48.26 x 41.91) EXTERIOR DIMENSIONS (WxDxH) 28 x 26 x 35.25 (71.12 x 66.04 x 81.92) TEMPERATURE RANGE Ambient +15 C to 300 C TEMPERATURE UNIFORMITY +/-3 C at 150 C TEMPERATURE TIME TO 150 C TEMPERATURE RECOVERY TIME AIR FLOW CONTROLS POWER HEATER WATTAGE STANDARD DOOR GASKET SHELVES ACCESS PORT WEIGHT WARRANTY 15 minutes 3 minutes (after door open 30 seconds) 120 feet per minute Watlow EZ programmable control with ramp & soak capabilities. Built-in, independent overtemperature controller. DB25 pin RS-485 serial comm port. 120V / 1Ph / 50/60 Hz / 15 Amp 1600 Watts Silicone 235 C Max (300 C Teflon available) 2 Adjustable, 304 Stainless Steel 2.75 Rear 171 lbs. (220 lbs. shipping) 1 Year 39
SECTION 6: FORCED-AIR OVEN SPECIFICATIONS TFO-5: 4.9 Cubic Foot Forced-Air Oven CAPACITY 4.9 cubic feet (138.75 cubic litres) INTERIOR DIMENSIONS (WxDxH) 23 x 20 x 18.5 (58.42 x 50.8 x 46.99) EXTERIOR DIMENSIONS (WxDxH) 33" x 27" x 37.25" (83.82 x 68.58 x 94.62) TEMPERATURE RANGE Ambient +15 C to 300 C TEMPERATURE UNIFORMITY +/-3 C at 150 C TEMPERATURE TIME TO 150 C TEMPERATURE RECOVERY TIME AIR FLOW CONTROLS POWER HEATER WATTAGE STANDARD DOOR GASKET SHELVES ACCESS PORT WEIGHT WARRANTY 20 minutes 6 minutes (after door open 30 seconds) 145 feet per minute Watlow EZ programmable control with ramp & soak capabilities. Built-in, independent overtemperature controller. DB25 pin RS-485 serial comm port. 208-230V / 1Ph / 50/60Hz / 9 Amps 2000 Watts Silicone 235 C Max (300 C Teflon available) 2 Adjustable, 304 Stainless Steel 2.75 Rear 210 lbs. (295 lbs. shipping) 1 Year 40
SECTION 6: FORCED-AIR OVEN SPECIFICATIONS TFO-10: 10.4 Cubic Foot Forced-Air Oven CAPACITY 10.4 cubic feet (294.5 cubic litres) INTERIOR DIMENSIONS (WxDxH) 30 x 20 x 30 (76.2 x 50.8 x 76.2) EXTERIOR DIMENSIONS (WxDxH) 44 x 29.75 x 77.5 (111.76 x 75.57 x 196.85) TEMPERATURE RANGE Ambient +15 C to 260 C TEMPERATURE UNIFORMITY +/-3 C at 150 C TEMPERATURE TIME TO 150 C TEMPERATURE RECOVERY TIME AIR FLOW CONTROLS POWER HEATER WATTAGE SHELVES ACCESS PORT WEIGHT WARRANTY 10 minutes 2 minutes (after door open 30 seconds) 200 feet per minute Watlow EZ programmable control with ramp & soak capabilities. Built-in, independent overtemperature controller. DB25 pin RS-485 serial comm port. 208-230V / 1Ph / 50/60Hz / 26 Amps 5300 Watts 3 Adjustable, 304 Stainless Steel, Storage cabinet base 2.75 Rear 382 lbs. (540 lbs. shipping) 1 Year 41
SECTION 6: FORCED-AIR OVEN SPECIFICATIONS TFO-28: 28 Cubic Foot Forced-Air Oven CAPACITY 28.0 cubic feet (793 cubic litres) INTERIOR DIMENSIONS (WxDxH) 31.62 x 25 x 61 (80.31 x 63.5 x 154.94) EXTERIOR DIMENSIONS (WxDxH) 42.5 x 34.75 x 86.25 (107.9 x 88.3 x 218.4) TEMPERATURE RANGE Ambient +15 C to 260 C TEMPERATURE UNIFORMITY +/-3 C at 150 C TEMPERATURE TIME TO 150 C TEMPERATURE RECOVERY TIME AIR FLOW CONTROLS POWER HEATER WATTAGE SHELVES ACCESS PORT WEIGHT WARRANTY 10 minutes 2 minutes (after door open 30 seconds) 200 feet per minute Watlow EZ programmable control with ramp & soak capabilities. Built-in, independent overtemperature controller. DB25 pin RS-485 serial comm port. 208-230V / 1Ph / 50/60Hz / 50 Amps 10300 Watts 6 Adjustable, 304 Stainless Steel 2.75 Rear 455 lbs. (600 lbs. shipping) 1 Year 42
SECTION 7: SCHEMATICS TFO-1 120V FORCED-AIR OVEN POWER CORD FUSE GREEN LIGHTED SWITCH FAN MOTOER BLACK FAN BLUE F1 L3 98 G1 K3 99 H1 J3 CF W2 L4 CD Y2 K4 CE T1 S1 T2 S2 WATLOW CONTROL 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 R1 R2 SUB D CONNECTOR 1 0 2 ½ OF RELAY 3 4 2 1 SOLID STATE RELAY DUAL TYPE J THERMOCOUPLE RELAY COIL FOR RELAY 6 ½ OF RELAY 4 1200 W 8 43
SECTION 7: SCHEMATICS TFO-1 220V FORCED-AIR OVEN FUSED INLET EMI FILTER GREEN LIGHTED SWITCH FAN MOTOER FAN BLACK BLUE F1 L3 98 G1 K3 99 H1 J3 CF W2 L4 CD Y2 K4 CE T1 S1 T2 S2 WATLOW CONTROL 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 R1 R2 SUB D CONNECTOR 1 0 2 ½ OF RELAY 3 4 2 1 SOLID STATE RELAY DUAL TYPE J THERMOCOUPLE RELAY COIL FOR RELAY 6 ½ OF RELAY 4 1200 W 8 44
SECTION 7: SCHEMATICS TFO-1-2E FORCED-AIR OVEN FUSED INLET EMI FILTER GREEN LIGHTED SWITCH FAN MOTOER FAN BLACK BLUE F1 L3 98 G1 K3 99 H1 J3 CF W2 L4 CD Y2 K4 CE T1 S1 T2 S2 WATLOW CONTROL 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 R1 R2 SUB D CONNECTOR 1 0 2 ½ OF RELAY 3 4 2 1 SOLID STATE RELAY DUAL TYPE J THERMOCOUPLE RELAY COIL FOR RELAY 6 ½ OF RELAY 4 1200 W 8 45
SECTION 7: SCHEMATICS TFO-3 FORCED-AIR OVEN POWER CORD FUSE GREEN LIGHTED SWITCH FAN MOTOER BLACK FAN BLUE F1 L3 98 G1 K3 99 H1 J3 CF W2 L4 CD Y2 K4 CE T1 S1 T2 S2 WATLOW CONTROL 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 R1 R2 SUB D CONNECTOR 1 0 2 ½ OF RELAY 3 4 2 1 SOLID STATE RELAY DUAL TYPE J THERMOCOUPLE RELAY COIL FOR RELAY 6 ½ OF RELAY 4 1500 W 8 46
SECTION 7: SCHEMATICS TFO-5 220V FORCED-AIR OVEN POWER CORD FUSE FUSE GREEN LIGHTED SWITCH FAN MOTOER FAN BLACK BLUE F1 L3 98 G1 K3 99 H1 J3 CF W2 L4 CD Y2 K4 CE T1 S1 T2 S2 WATLOW CONTROL 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 R1 R2 SUB D CONNECTOR 1 0 2 ½ OF RELAY 3 4 2 1 SOLID STATE RELAY DUAL TYPE J THERMOCOUPLE RELAY COIL FOR RELAY 6 ½ OF RELAY 4 2000 W 8 47
SECTION 7: SCHEMATICS TFO-10 FORCED-AIR OVEN GR/Y 10G BLACK 10G GR/Y 10G BLACK 10G TB GREEN LIGHTED SWITCH 7850570 BLACK BLUE TB EMI FILTER 2800531 FAN MOTORS 4880548 FAN FAN BLACK BLUE 3 4 COOLING FAN 48850551 5 C1 BLACK 10G BLACK 10G 6 CONTACTOR 7030525 CHART RECORDER LEADS C2 RELAY 7030528 5 6 3 4 1650581 1650581 F1 G1 L3 K3 98 99 OUTLET 6100526 H1 J3 CF W2 Y2 L4 K4 WATLOW CONTROL 9660505 CD CE T1 T2 S1 R1 S2 R2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 SUB D CONNECTOR 1650576 C2 COIL 7 8 SOLID STATE RELAY 7030533 2 1 3 4 DUAL TYPE J THERMOCOUPLE 6600533 C1 COIL 2 1 QUENCHARC 7830507 5200 W BLACK 10G 48
SECTION 7: SCHEMATICS TFO-28 FORCED-AIR OVEN GR/Y 6G BLACK 6G GR/Y 6G BLACK 6G GREEN LIGHTED SWITCH 7850570 BLACK 6G BLACK 6G EMI FILTER 2800530 BLACK 10G BLACK 10G TB BLACK FAN MOTORS 4880548 BLACK FAN FAN BLUE BLUE TB L1 L3 L1 L3 T1 C1 T3 T1 CONTACTORS C1,C2 7030534 T3 C2 COOLING FAN 4880551 CHART RECORDER LEADS C3 RELAY 7030528 5 6 3 4 BLACK 10G BLACK 10G BLACK 10G BLACK 10G 1650581 1650581 F1 G1 L3 K3 98 99 OUTLET 6100526 H1 J3 CF W2 Y2 L4 K4 WATLOW CONTROL 9660505 CD CE 2 1 2 1 3 4 SOLID STATE RELAYS 7030533 3 4 BLACK 10G T1 S1 R1 T2 S2 R2 DUAL TYPE J THERMOCOUPLE 6600533 5200 W C3 COIL 7 8 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 SUB D CONNECTOR 1650576 C2 COIL C1 COIL 1 2 1 QUENCHARCS 7830507 BLACK 10G 5200 W 49
SECTION 7: SCHEMATICS TFO-28-3 FORCED-AIR OVEN BLACK 6G BLACK 6G BLACK 6G GREEN LIGHTED SWITCH L1 L2 L3 FAN MOTORS BLACK FAN BLUE FAN T1 T2 T3 BLACK 10G BLACK 10G BLACK 10G CONTACTOR C1 F1 L3 BLACK BLUE CHART RECORDER LEADS 98 RELAY C3 5 6 3 4 OUTLET G1 K3 99 H1 J3 CF W2 Y2 L4 K4 WATLOW CONTROL 1750888 CD CE T1 T2 S1 R1 S2 R2 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 SUB D CONNECTOR 2 1 3 4 SSR RELAY 1 SOLID STATE RELAYS DUAL TYPE J THERMOCOUPLE C3 COIL 7 8 C1 COIL 2 1 3 4 SSR RELAY 2 BLACK 10G BLACK 10G 11.7Ώ 11.7Ώ 11.7Ώ BLACK 10G 50
SECTION 8: WARRANTY Manufacturer warrants for the original user of this product in the U.S.A. only that this product will be free from defects in material and workmanship for a period of one year from the date of delivery to the original user - the Warranty Period. During the Warranty Period, the Manufacturer, at its election and expense, will repair or replace the product or parts that are proven to Manufacturer s satisfaction to be defective, or at Manufacturer s option, refund the price or credit (against the price of future purchases of the product) the price of any products that are proven to Manufacturer s satisfaction to be defective. This warranty does not include any labor charges if outside of the U.S.A. This warranty does not cover any damage due to accident, misuse, negligence, or abnormal use. Use of Manufacturer s product in a system that includes components not manufactured by Manufacturer is not covered by this warranty. This warranty is void in the event that repairs are made by anyone other than Manufacturer without prior authorization from Manufacturer. Any alteration or removal of the serial number on Manufacturer s products will void this warranty. Under no circumstances will Manufacturer be liable for indirect, incidental, consequential, or special damages. The terms of this warranty are governed by the laws of the state of Oregon without regards to the principles of conflicts of laws thereof. If any provision of this limited warranty is held to be unenforceable by any court of competent jurisdiction, the remainder of this limited warranty will remain in full force and effect. This warranty is in lieu of and excludes all other warranties or obligations, either express or implied. Manufacturer expressly disclaims all implied warranties, including without limitation, the warranties of merchantability and fitness for a particular purpose. 51