hoff Street, Bldg D
Orange, California 92868 USA
714.935.0302 fax 714.935.9809
www.furnacepros.com
service@furnacepros.com

The information in this document is subject to change without notice. The statements, configurations, technical data and
recommendations in this document are believed to be accurate and reliable, but are presented without express or implied
warranty. The only warranty for FurnacePros or Lochaber Cornwall, Inc. products and services are set forth in the express
warranty statements accompanying such products and services. Nothing herein should be construed as constituting an
additional warranty. THERE ARE NO OTHER WARRANTIES, EXPRESS, STATUTORY OR IMPLIED, INCLUDING THOSE
OF MERCHANTABILITY AND OF FITNESS FOR PARTICULAR PURPOSE, NOR ANY AFFIRMATION OF FACT NOR
REPRESENTATION WHICH EXTENDS BEYOND THE DESCRIPTION OF THE FACE HEREOF.
Users must take full responsibility for their application of any products, recommendations, processes or procedures mentioned
in this document. Lochaber Cornwall shall not be liable for technical or editorial errors or omissions contained herein. The
information in this document is proprietary to Lochaber Cornwall, Inc.

©2008 Lochaber Cornwall, Inc.
All Rights Reserved.
No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical without
express written permission from the publisher.



Training Guide and Supplemental Reference
Page
i


Contents

Chapter 1
1

1

Introduction 1

1.1
Introduction ............................................................................................. 1
1.2
Format..................................................................................................... 2
1.3
Where to Get Help................................................................................... 3
Chapter 2
5

2

Safety 5

2.1
General Precautions................................................................................ 5
2.2
EMO Buttons........................................................................................... 6
2.3
H
2
Operation Safety Overview (Option ) .............................................. 8
Chapter 3
9

3

Furnace Overview
9

3.1
Terminology ............................................................................................ 9
3.2
General Furnace Layout........................................................................ 14
3.3
Thermal Process ................................................................................... 15
3.4
Furnace Options Listing ........................................................................ 17
Chapter 4
25

4

Thermal Processing
25

4.1
Heating Concepts.................................................................................. 25
4.2
Furnace Construction ............................................................................ 25
4.3
Heating Chamber Design ...................................................................... 27
4.4
Heating Lamps ...................................................................................... 28
4.5
Controlled Atmosphere (Option )........................................................ 29
4.6
Cooling Section (Option ) ................................................................... 30
4.7
Heating Chamber Options..................................................................... 33
Chapter 5
39

5

Software 39

5.1
Windows Interface................................................................................. 39
5.2
Startup Screen ...................................................................................... 40
5.3
Security Screen .................................................................................... 41
5.4
Available Functions by Access Level .................................................... 44
5.5
Operator Level Interface........................................................................ 45 Contents

Page

ii


Reference
Manual
5.6
Alarms....................................................................................................52
5.7
Other Options ........................................................................................53
Chapter 6
57

6

Controller 57

6.1
Conceptual Overview.............................................................................57
6.2
Terminology ...........................................................................................57
6.3
Data Flow...............................................................................................58
6.4
Ethernet Location...................................................................................58
6.5
PLC Components ..................................................................................59
Chapter 7
63

7

Maintenance 63

7.1
Maintenance Screen Overview ..............................................................63
7.2
User Defined Maintenance Items...........................................................64
7.3
Furnace Calibration ...............................................................................65
7.4
Typical Wiring ........................................................................................72
7.5
Mechanical System Maintenance ..........................................................78
Chapter 8
85

8

Troubleshooting 85

Chapter 9
87

9

Process Engineering
87

9.1
Infrared Heating .....................................................................................87
9.2
Temperature Profiling ............................................................................90
9.3
Creating a Recipe ..................................................................................98
9.4
Gas Flow..............................................................................................104
9.5
Creating an Optimum Process Environment........................................106
9.6
Balancing Gas Flow.............................................................................108
9.7
Hydrogen Operation (Option ) .........................................................110
9.8
Check for an Escaping Environment....................................................117
9.9
Plenum Gas Flow ................................................................................117
9.10 Gas Flow Screen .................................................................................118
9.11 Mass Flow Controller (Option ) .........................................................119
9.12 PC Anywhere.......................................................................................120
Glossary 121

Training Guide and Supplemental Reference
Page
iii


Tables and Figures


Figure 2-1: Panel Switches Showing Normal Operation Position
7
Figure 2-2: Panel Switch Installed (Override Mode Position)
7

Figure 3-1: Furnace Nomenclature
9
Figure 3-2: Control Panel
10
Figure 3-3: Safety Enclosure
10
Figure 3-4: Lower Electrical Panel
11
Figure 3-5: SCR Panel and Fuses
11
Figure 3-6: Element Monitor Installation
12
Figure 3-7: Conveyor Belt Motor
13
Figure 3-8: Furnace Layout
14
Figure 3-9: Temperature Profile Example
15
Figure 3-10: Photoelectric Product Sensor
17
Figure 3-11: Brush Belt Cleaning System
18
Figure 3-12: Circuit Breaker Option
18
Figure 3-13: Lexan Shields
19
Figure 3-14: Standard Light Tower Option
20
Figure 3-15: Conveyor Belt Shown with Quartz Rollers
21
Figure 3-16: Thermocouple Wheel Assembly - 3 T/Cs
22
Figure 3-17: Ultrasonic Cleaner and Dryer installation
23
Figure 3-18: Uninterruptable Power Supply
24


Figure 4-19: Heating Chamber Construction. End view
27
Figure 4-20: Flow Meters
29
Figure 4-21: Water Cooled Controlled Atmosphere Cooling Module
31
Figure 4-22: Controlled Atmosphere Air Cooled Module
32
Figure 4-23: Pre-filter/Regulator Shown
33
Figure 4-24: Typical Air Purification Tanks
34 Tables and Figures

Page

iv


Reference
Manual
Figure 4-25: Edge Heaters
35
Figure 4-26: Cross Section of Furnace showing Edge Heaters
35
Figure 4-27: Plenum Box
36
Figure 4-28: Oxygen Analyzer
37
Figure 4-29: Oxygen Analyzer
37
Figure 4-30: Moisture Analyzer
38

Figure 5-1: FurnacePros Furnace Windows Start Bar
39
Figure 5-2: FurnacePros Furnace Software Startup screen
40
Figure 5-3: Security screen
41
Figure 5-4: Log-On Log-Off group
42
Figure 5-5: Exit button
42
Figure 5-6: Exit button
42
Figure 5-7: User List
42
Figure 5-8: Manage User Accounts
43
Figure 5-9: New User ID pop-up window
43
Figure 5-10: New User Password pop-up
43
Figure 5-11: New User Security Access Level assignment window
43
Figure 5-12: Process Screen
45
Figure 5-13: Recipe Screen (Operator Level Access)
47
Figure 5-14: MS Windows Browsing Pop-up
48
Figure 5-15: Recipe Storage and Retrieval
49
Figure 5-16: Logging Screen
51
Figure 5-17: Alarm Monitor Pop-up Window
52
Figure 5-18: Thermocouple Interface
53
Figure 5-19: Process Screen Highlighting Lane Button,
54
Figure 5-20: Recipe Screen Highlighting Product Length input field box
55
Figure 5-21: Send Value window
55
Figure 5-22: Product Tracking Window
56


Tables and Figures

Training Guide and Supplemental Reference


Page
v


Figure 6-1: Controller Overview
57
Figure 6-2: Control Data Flow
58
Figure 6-3: PLC Controller Ethernet Interface
58
Figure 6-4 Typical Channel Assignments - Windows Environment
61


Figure 7-1 Maintenance Screen
63
Figure 7-2 User Selectable Maintenance Description
64
Fig