INSTALLATION, OPERATION and

SERVICE MANUAL

MODELS: 6-525
6-160A
6-1350A

6- 9363014 9014
 TABLE OF CONTENTS

SECTION DESCRIPTION PAGE NUMBER

1 Safety Precaution and MSDS 1-1

II Receiving Information 2-1

lil Installation 3-1

IV Features 4-1

V Specifications 5-1
Heating Curves 5-3
Cooling Curves 5-4

VI Furnace Description and Operation 6-1

Control Panel Description 6-3
Operating the Furnace 6-6
Programming the Furnace 6-8
Example 6-16

VII Maintenance 7-1

VIII Service 8-1

Troubleshooting Charts and
Error Codes 8-2
Schematics 8-4
Disassembly Instructions 8-6

IX Replacement Parts 9-1

6-525 Parts 9-1
Exploded View 6-525 9-2
6-1350A Parts 9-3
Exploded View 6-1350A 9-4
6-160A Parts 9-6
Exploded View 6-160A 9-7

X Accessories 10-1

Warranty Inside Back Cover

SAFETY PRECAUTIONS and MSDS

Please read and follow the safety precautions listed below. These are intended for
your safety and the safe operation of the equipment.

CAUTION

* NEVER OPERATE THE FURNACE WITH COMBUSTIBLE MATERIALS ABOVE, ON

TOP OF, OR IN CLOSE PROXIMITY TO THE FURNACE.

* DO NOT USE TONGS OR OTHER TOOLS TO OPERATE THE CONTROLS.

* KEEP THE DOOR IN THE CLOSED POSITION WHILE NOT IN USE.

* DO NOT USE SOLVENTS OR LIQUID CLEANERS ON THE CONTROL PANEL.

* DO NOT PLACE HOT ITEMS REMOVED FROM THE FURNACE ON TOP OR IN

FRONT OF THE FURNACE.

* DO NOT ATTEMPT TO SERVICE THE FURNACE UNTIL YOU HAVE READ AND UN-
DERSTOOD THE SERVICE INSTRUCTIONS INCLUDED IN THIS MANUAL.

* ALWAYS TURN OFF THE POWER AND REMOVE THE LINE CORD FROM THE WALL
OUTLET BEFORE SERVICING THE FURNACE.

* ALWAYS VERIFY THAT THE FURNACE CONTROL IS DISPLAYING "door" BEFORE

ATTEMPTING TO LOAD, UNLOAD, REACH INTO THE FURNACE CHAMBER WITH
ANY TOOLS OR INSTRUMENTS.

* USE ONLY INERT GASES WITH THE AIR EXCHANGE FEATURE.

WARNING

> This furnace is not designed for use in hazardous (Class I, II, or III) locations as
defined by the National Electric Code.

> For personal safety, this furnace must be grounded.

The furnace power cord is equipped with a three prong (grounding) plug for use with
wall receptacles to minimize the possibility of electric shock hazard from the furnace.
The wall receptacles and circuit should be checked by a qualified electrician to make
sure the receptacle is properly grounded.

1-1
Two prong wall receptacles must be replaced with three prong wall receitacles to
ensure proper operation and safety. Two to three prong adaptors are nqft considered
reliable, safe methods of electrical connection.

> This furnace must be connected to a properly sized power circuit with the correct
overcurrent protection for safe and reliable operation.
> As a routine working precaution, always wear safety glasses and protective
gloves when operating, loading and unloading the furnace. In addition wear respira-
tory protection when cleaning or servicing the muffle chamber.

MATERIAL SAFETY DATA SHEETS

On March 25, 1983 the Occupational Safety and Health Administration (OSHA) put
the Hazard Communication Standard 29CFR 1910.1200 (better known as the "Right
to Know") into effect.
This regulation became effective on November 25, 1985 for manufactures and dis-
tributors of products that OSHA has determined to be hazardous. Vitreous Alumi-
nosiliciate Cristobalite mineral dusts (in concentrations over 1 fiber per] cubic centi-
meter) are included in the OSHA tables as air contaminates.
The J. M. Ney Company manufactures and sells products that use insulating refrac-
tories. These refractories contain Vitreous Aluminosiliciate fibers. The ceramic
fibers will form crystalline silica (Cristobalite) after operating at temperatures above
1600 degrees F. To comply with the OSHA regulations, Material Safety]! Data Sheets
(MSDS) have been developed and are available to you upon request "flhis phase of
the regulation took effect in 1986.
The information contained in the MSDS documents take into account t i e "Intended
Use" of all products. It may not necessarily address all processes or procedures in
your particular application. We highly recommend that you determine the health
hazard in every pertinent operation including, but not limited to, installation, mainte-
nance, cutting, sawing, drilling or filing the furnace insulation.
The MSDS documents and warning labels are for your training prograr to inform
your employees of the hazards associated with the use of these product

At the time of publication of this manual, The J. M. Ney Company is actively studying
and performing test as to comply with the State of California law requiring that the
public be informed of products containing materials which in some circumstances are
carcinogenic in nature. At the conclusion of this analysis, additional information will
be provided in new product Operator Manuals. Should you desire a copy of the find-
ings, write The J. M. Ney Company, Yucaipa, CA, or call (714) 795-2461 Jnd ask for
Customer Service.

1-2
RECEIVING INFORMATION

UNPACKING
Carefully remove the furnace from the shipping carton. Save the carton and packing
materials. The carton serves as the best container for transporting the furnace.

The shipping carton contains the following:

- One furnace

- Ceramic floor trays (1 each 8"(20cm)SQ - 6-525, 6-1350A)

(2 each 4"(10cm)SQ - 6-160A)
- Exhaust port (6-525 top mount packed outside furnace during shipment)
(6-160A, 6-1350Atop mounted)

- Two exhaust port ball plugs

- One operator/service manual

- One Electrical Plug for Auxilliary Output

- One bottle of fiber-harding agent (6-525 only)

LOSS OR DAMAGE
If there is any visible damage, do not attempt to operate the furnace. Note any exter-
nal evidence of loss or damage on the freight way bill or express receipt and have it
signed by the carrier's agent. Failure to adequately describe such external evidence
of loss or damage may result in the carrier's refusal to honor your damage claim. The
form required to file such a claim will be supplied by the carrier.
Concealed loss or damage means loss or damage which does not become apparent
until the merchandise has been unpacked and inspected. Should either occur, make
a written request for inspection by the carrier's agent within 15 days of the delivery
date. Then file a claim with the carrier since the damage is the carrier's responsibility.

6-525 MUFFLE
The 6-525 muffle (heating chamber) is constructed in one piece. It is considered nor-
mal for cracks to appear on the surface, along edges and in the corners. This will not
degrade or limit the performance or life of the muffle.

2-1
INSTALLATION

Remove all packing materials from inside and around the furnace. Select a benchtop
location within five feet (1.5 meters) of the power receptacle. The furnace should be
on a level surface at least 6 inches (16 cm) away from walls, other equipment, and
heat sensitive materials. Do not mount under shelves or other structures that will
restrict the flow of air. The furnace should be located under an exhaust hood if mate-
rial or chemical reactions will be taking place inside the furnace.

The power receptacle should have the following overcurrent protection as follows:
6-525 15 Amp fuse or circuit breaker
(100V units require 20 Amp)
6-160A, 6-1350 ...20 Amp fuse or circuit breaker with receptacle for
furnace only.

Firing trays are supplied with the furnace. Please place these in the muffle before the
first firing. These will prevent molten materials from flowing into the muffle.

6-160A and 6-1350A ONLY: The air exchange feature on these furnaces is accessible
from the rear of the furnace. If the integral fan is not to be used the rear damper
panel must be lowered. The compressed air fitting (1/8" female NPT) is then acces-
sible behind the damper panel.

If the top exhaust port is to be plugged, then it is recommended that the rear damper
panel be lowered. This will minimize the escape of hot air from around the door and
resulting discolored paint.

6-525 ONLY: The exhaust port along with mounting screws are packed in the top
packing insert. Locate the port and install it on top of the furnace.

3-1
FEATURES
GENERAL
> Six Stages (Segments) Of Temperature Control
> Four User Definable Stored Programs (Chainable Into 24 Stages Total)

> Programmable Auxiliary Output (5 Amp Max. Normally Open Switched

Contact)
> Long Life Battery (Lithium) Backup Of Program Parameters

> Power Interruption Cycle Continuation (Power Outage Return)

> Digital PID (Proportional, Integral, Derivative) Temperature Control

> Delay Start Of Operation Timer

> High Temperature Range To 1100°C (2012°F)

> Hold Feature For Cycle Interruption Or Infinite Hold Capability

> Negative Rate (Ramp) Temperature Control

> 0.1 Degree Per Minute Rate (Ramp) Resolution

> Programmable High Limit Cutoff

> "LO" Battery Indicator

> Various Diagnostic Indications.
> Type K Thermocouple

6-52$
> Large Low Thermal Mass Fiber Muffle - Fast Heat and Cool Rates

6-16*>A
> Integral Fan for Forced Air Exchange

> Compressed Air Exchange Fitting (1/8" NPT Female)

> Vertical Lift Door

> Firebrick Lined Muffles

6-13i
> Integral Fan for Forced Air Exchange

> Compressed Air Exchange Fitting (1/8" NPT Female)

> Largest Firebrick Lined Muffle

4-1
SPECIFICATIONS
ELECTRICAL:
6-525 6-1350A 6-160A

Power requirements in watts 1500 4000 @220V 1800

at nominal line voltage: 4780 @240V

Watts to maintain 1000C: 1100 3500* 1600*

Nominal current 50/60Hz in

Amps at line voltage of
100 Volts: 15.0 NA 18
120 Volts: 12.5 NA 15
220 Volts: 6.8 18.2 8.2
240 Volts: 6.3 19.9 7.5

Fan set to maximum and damper open

MECHANICAL:

6-525 6-1350A 6-160A

Furnace: Width: 39cm(15.5in) 74cm (29in) 41cm(16in)

Depth: 37cm(14.5in) 56cm (22in) 33cm(13in)
Height: 42cm(16.5in) 53cm (21 in) 42cm(16.5in)

Muffle (Inside): Width: 23cm (9in) 30cm(12in) 23cm (9in)

Depth: 23cm (9in) 32cm(12.5in) 11.5cm(4.5in)
Height: 17cm(6.5in) 23cm (9in) 10cm(4in)

Furnace Weight: 16Kg(35lbs) 73Kg(160lbs) 20Kg(44 lbs)

Shipping Weight: 21Kg(46lbs) 95Kg(210lbs) 27Kg(60 lbs)

Maximum Muffle Load: 6.8Kg(15lbs) 13.6Kg(30lbs) 6.8Kg(15lbs)

5-1
OPERATIONAL:

Temperature Control Range and 100°Cto1100°C at1°C I

Resolution: (212°Fto2012°F at1T)
(1000°C max with full air exchange
rate on 6-160A and 1350A)

Temperature Control Accuracy: +/- 5°C (9°F) in control ratige

from 100°C to 1100°C (732°F
to2012°F).

Amplitude at Setpoint. Less than +/- 3°C (5.5°F)|

Settable Heat RATE Range: 0°C(0°F) to 40°C(72°F)/Ml|l

in 0.1 °C (0.2°F) increments

Note: See following graphs for actual expected heat rate performance. 40°C(72°F)/
MIN is not possible at the maximum temperatures, air exchange, or withfnaximum
loads.

Programmable Parameter Ranges and Presets:

Parameter Increment Minimum Maximum

DELAY START 1 Hour 0 Hour 99 Hours

RATE 0.1 deg/min 0°C/min 40°C/min

(0°F/min) (72°F/min

TIME 0.1 Hour 0.0 Hour 499.9 Hour

TEMP 1 deg 100°C 1100°C

(212°F) (2012°F)j

Programmable 1 deg 500°C 1100°C

High Limit Cutoff (932°F) (2012°F)

End Of Cycle Operation: Factory Preset:

(1) Hold last temperature and bef p every 6
minutes.
Options:
(2) Hold last temperature no beef
(3) Turn off after last TIME (muffIf off)
(4) Repeat cycle continuously

5-2
 HEATING CURVES:

1100

1000

800..
T 6-1350A
E FAN OFF
M
P 6-1350A
E FAN HIGH
600
R
A 6-160A
T FAN HIGH
U
R
E
400..

200--

10 20 30 40 50 60 70 80 90 100 110
TIME (Minutes)
TEST CONDITIONS: Nominal Line Voltage; No Load In Muffle; Full Power Applied To Muffle; 6-160A
and 6-1350A with Internal Fan Set To 0 for OFF and 9 for MAX.

5-3
 COOLING CURVES:

1100

1000__

800 _.

T
E
M
P
E 600
R
A
T FAN OFF
U 6-160A
R FAN HIGH .6-525
E 400

200--

0 0 10 20 30 40 50 60 70 80 90
TIME (Minutes)
TEST CONDITIONS: No Load In Muffle; No Power Applied To Muffle; 6-160A and 6-1 >0A with Internal
r
an Set To 0 for OFF and 9 for MAX.

5-4
FURNACE DESCRIPTION AND OPERATION:
6
"525: EXHAUST
'PORT

POWER
CORD

AUX1
OUTPUT
MUFFLE
THERMOCOUPLI

DOOR POWER
INSULA- CONTROL
SWITCH
TION PANEL

6-1
6-160A:

6-2
£:-:':£:::":::£::::::i&:&^

6-1350A:

6-3
CONTROL PANEL DESCRIPTION:

2.

IE*TAT C
/F
2 3
PROGRAM
1 0 BATT
SELECT 5 6
1 C3 C3 C3 L13
en
STAGE STAG£ SiPtib STAGE Sl«at: SiAafc
TIME,
2 nn 1 2 3 A 5 6
AUX1
8 9
HOLD
3 CD START RESU
START ENTER
4 RATE TEMP TIME
STOP
1.

NOTE: 1350A KEY LOCATIONS ARE SLIGHTLY DIFFERENT BUT PERFORM THE SAME OPERATIONS.

1. POWER SWITCH Turns main power on and off to furnace. Does rfot start
furnace operation.

2. DIGITAL DISPLAY Displays operating and programmed temperatures, times

"LO BATT1 and status conditions. The right most decimal point in the
display is used to indicate a low battery conditU

3. °C/°F Changes temperature display from degrees Cellius to de-

grees Fahrenheit. This key is only active when the current
muffle temperature is being displayed. It is locked when
displaying programmed parameters.

4. DELAY START Turns the furnace on at a later time and runs the preselected
cycle. Also gives operator access to program ti e amount of
delay time desired. Pressing the DELAY START key causes
the DELAY START LED to flash and the current' alue to be
displayed. A new value can be programmed or he START/
STOP key can be pressed to start a cycle after a delay.

5. RATE Displays the currently programmed RATE for th j selected

program and stage. Gives the operator access b program
the desired value.

6-4
 RATE refers to the desired temperature increase or de-
crease in tenths of a degree per minute (xx.x°/min). The
decrease in temperature or cooling is limited by the natural
cooling RATE of the furnace and its load. The control can
force it to be slower but not faster. See the heating and
cooling curves in Section 5.

Programming a TEMP lower than the previous TEMP will

cause a negative RATE. Similarly, starting the furnace with
the muffle temperature higher than the first TEMP 1 will
cause the control to cool at RATE 1 to TEMP 1.

Programming a RATE to zero prevents that stage and the

following stages from running. For example if RATE 4 is set
to zero only stages 1, 2 and 3 will operate and the program
will end after stage 3.

6. TEMP Displays the currently programmed temperature for the

selected program and stage. Also gives the operator ac-
cess to program the desired temperature value. When the
corresponding LED is flashing, that TEMP is being reviewed
and can be programmed.

7. TIME Displays the currently programmed time for the selected

program and stage. Also gives the operator access to pro-
gram the desired time value. When the corresponding LED
is flashing, that TIME is being reviewed and can be pro-
grammed.

8. HOLD / RESUME Pressing the HOLD/RESUME key, when a cycle is operating,

holds the current temperature indefinitely. The HOLD/
RESUME LED will light along with the LED for the portion of
the cycle operating when the key was pressed. Pressing the
key a second time will resume the cycle from the hold point.

When a cycle is held with the HOLD/RESUME key the pro-

gram parameters can be changed on any stage of the se-
lected program. Resuming the cycle causes the control to
use the newly programmed parameters.

9. TEMP / CYCLE TIME Resets the display to the current muffle temperature if para-
meters are being reviewed or programmed. Displays the
cycle time remaining in a TIME segment during operation.

6-5
10. START/STOP Starts the furnace. The cycle will operate as prdhrammed.
Stops the cycle if the furnace is operating. Restarting a
cycle that has been stopped with the START/STjpP key will
restart it from the beginning.

11. Digit or Numeric Keys Used to enter temperatures, times, and heat rates.
When entering a value, any incorrect entry can me changed
by reentering the correct value. The incorrect v|lue will dis-
appear off the left side of the display.

12. ENTER Confirms the Numeric Key entries and stores th|m in the
control's memory.

13. Parameter LED's LED's in the graph next to the switches are use|( to indicate
control status.
14. PROGRAM SELECT 1-4 Selects PROGRAM to be reviewed, programmed, or
run by the control. A new program can be seleited when-
ever the control is not running the current progfam.

15. STAGE 1-6 Selects the STAGE (segment) of the selected p gram to be
reviewed or programmed. The stages of the c rently se-
lected program can be reviewed at any time. T! e corre-
sponding LED lights with each key and goes o in seven
seconds if a parameter key (RATE, TEMP, TIM AUX) is not
pressed. Stage parameters can be reprogram led only
when the control is not running the current pro ram or when
the current program has been put on "HOLD".

All the STAGE LED's that are programmed light when the
furnace is started. They go out in sequence asfeach STAGE
is completed.

16. AUX1 Normally open electrical contact output that call be pro-
grammed to turned on and off as the furnace runs the
preprogrammed cycle. The AUX 1 output can i e pro-
grammed to be on or off independently for eacp segment of
a cycle. The IEC socket on the back of the furnace provides
a 5 amp max fused contact closure when turnei on.

See the auxiliary output section that follows.

6-6
17. AUX 2 NOTE: NOT APPLICABLE TO 6-525
The AUX 2 key controls the air exchange fan located on the
back of the furnace. The AUX 2 or air exchange fan can be
programmed to be on at a particular level or off independ-
ently for each stage of a cycle or program. The speed of the
fan (0 for OFF and 9 for MAX) which is related to the number
of air exchanges can also be programmed.

NOTE: High air exchange rates will reduce the maximum

possible heat rates and temperatures.
Door Switch (not shown)
Internal switch deactivated by door opening which causes
the control to disconnect the muffle from both sides of the
power line.
Thermocouple
Type K thermocouple located in the rear of the muffle to
measure chamber temperature for the control.

Auxiliary Output
Rear connection for AUX 1 described previously.

6-7
OPERATING THE FURNACE:

POWER ON:
Turning on the power switch activates the control. The control perf|rms a self-
test for approximately three seconds and displays the model numblr (ie. 525,
160A, or 1350A). At the end of the self-test the actual muffle tempei|jture is dis-
n played.

If an operating cycle is stopped with the START/STOP key, pressing the key a
second time will restart the cycle from the beginning. If the muffle is at an
elevated temperature, the control will use the programmed RATE 1||or the cool-
ing or heating to TEMP 1.

If the model number is not displayed or the display sequences throjigh all the
model numbers listed on the front cover; see BATTERY REPLACEMENT and
CONFIGURATION SETUP in Maintenance Section 7.

The furnace's operation can be changed in several ways by changing the "de-
fault settings". These are the preselected parameters the factory entered when
the unit was tested. For more information about these see CONFIGURATION
SETUP later in this section under programming.

REVIEWING THE PROGRAM:

The current stored programs can be reviewed by selecting a progrlm, stage,
and parameter keys to display the values. The first step is to press a PRO-
GRAM key followed by a particular stage key for that program. Pressing the
TEMP, RATE, TIME, or AUX keys displays the current value for thai stage and
program. The displayed parameter is replaced with the current muffle tempera-
ture by pressing the TEMP / CYCLE TIME key.

STARTING THE FURNACE WITHOUT A DELAY START:

The current program can be started by pressing the START/STOP cey. The
display continues to display the muffle temperature as the muffle sats up. The
LED's in the programmed cycle are turned on when the key is pre; sed. They
are individually turned off as each function is completed. Any on< of the four
furnace programs can be started in this way.

Programs can be chained together (run in groups) by pressing an holding the

first program key in the chain. While this key is held down, press e additional
programs to be chained to the first program. The LED for each pr< gram that is
selected will light. Two, three, or four programs can be chained ii their num-
ber sequence. (For example 1-2-3-4,1-2, 3-4,1-3-4, 2-4). Pressin| the START/
STOP key starts the first program in the chain. The other prograi follow the
first in sequence.

6-8
STARTING THE FURNACE WITH A DELAY START:
A value for the DELAY START must be programmed first (The default value is
preprogrammed to zero). Press the DELAY START key followed by the digit
keys of the desire amount of delay in hours. The DELAY START LED will flash
and the programmed value will be displayed. Pressing the ENTER key will
store this value and turn off the DELAY START LED. Pressing the DELAY
START key again will activate the function, flash the LED, and display the delay
value in hours. Pressing the START/STOP key will start the delay followed by
the selected program. The DELAY START LED will be on during the delay.

FURNACE OPERATION:
During cycle operation all the indicating LED's (Program and Stage) for a cycle
will initially light and go out as that portion of the cycle is completed. The
RATE and TIME - TEMP LED's will alternately come on. If a DELAY START has
been selected, its LED will light first and when the delay is complete the rest of
the cycle LED's will light.

A flashing RATE LED indicates that the control is unable to maintain the pro-
grammed rate of change in temperature. The flashing is only an indication for
the operator; the furnace will continue the cycle uniterrupted. This condition
can be caused by programming the furnace with high programmed RATE,
large loads, or low power line voltages. Refer to the heating and cooling
curves in the SPECIFICATIONS section 5 for more information.

A power outage or turning off the power when the furnace is in the idle or off
mode does not cause a loss of the programs. The furnace will resume a delay
start cycle if a power interruption occurs during its operation. A power outage
when the furnace is heating will result in the resumption of the cycle when
power is reapplied, if the muffle temperature has dropped less than 50°C
(90°F). If the muffle temperature has dropped more than 50°C (90°F) the fur-
nace turns off. If power is interrupted or the power switch is turned off when
the furnace is operating at less than 100°C, the furnace will turn on when
power is reapplied.

HOLDING A TEMPERATURE:
The furnace can be stopped or held in the middle of a cycle indefinitedly by
pressing the HOLD/RESUME key. The muffle temperature, when the key is
pressed, will be maintained with the associated HOLD LED, STAGE LED, and
parameter LED on. Pressing the key a second time releases the control and it
resumes the cycle that is had been operating. The program parameters can be
reprogrammed when the control is put in the HOLD mode.

6-9
END OF CYCLE:
The default "End Of Cycle" maintains the last programmed temperature, dis-
plays "HOLD" and beeping every six minutes. Other "End Of Cycle! operations
available include maintaining the last programmed temperature without beep-
ing, turning off the muffle at the end of the cycle while displaying VEND", and
continuously repeating the cycle. The end of cycle default setting dan be
changed by following the directions outlined later in this section urfper CON-
FIGURATION SETUP.

PROGRAMMING THE FURNACE

The furnace control parameters can only be changed during idle mbde (not
running a cycle) or when put on hold during a cycle with the H O L D I R E S U M E
key. If an out of range value is entered the control beeps and displays the
maximum or minimum acceptable value. The previous stored value is retained.

DELAY START:
Pressing the DELAY START key displays the current programmed ialue and
flashes the associated LED. When the LED is flashing, the DELAY iTART value
can be reprogrammed by keying in a new value followed by the El ERkey. If
the value already stored for the delay start is acceptable, then eithi If the ENTER
key or the TEMP / CYCLE TIME key can be pressed to save the vaii e. If an
incorrect digit key is pressed while entering a parameter, the correl ;t parameter
should be reentered. The incorrect digit will shift off the display to| he left. An
alternate method to clear an incorrect entry is to press the DELAY TART key a
second time.

PROGRAMS:
Any one of the four programs can be selected for operation or programming
independently. Pressing a PROGRAM key activates that program and the
associated LED lights.

Programs can be chained together (run in groups) by pressing a n i holding the

first program key in the chain. While this key is held down, press f i e additional
programs to be chained to the first program. The LED for each program that is
selected will light. The group selected in the chained is not stored in memory
and must be assigned each time it is requested. Each individual program is
stored and can be operated independently.

STAGES:
Once a program has been selected the individual stage RATE'S, TiMP's,
TIME'S, and AUX's can be programmed. A STAGE key has to be pressed before
the various parameters can be programmed. After the key is pressed the
STAGE LED will remain on for 7 seconds if no other keys are pressed. If one of

6-10
 the parameter keys is pressed, it will remain on until the ENTER or TIME/TEMP
key is pressed. If the LED goes out, the STAGE key must be pressed again.

RATES:
The RATE key sets heat rate or temperature increase rate. Pressing the RATE
key displays the currrent value for the program and stage selected. The corre-
sponding RATE LED also flashes.

While the RATE LED is flashing, a new RATE can be entered on the keyboard.
If an incorrect digit key is pressed while entering a parameter, the correct pa-
rameter should be reentered. The incorrect digit will shift off the display to the
left. Once the correct value is displayed, save it by pressing the ENTER key. If
the ENTER key is not pressed, the original value will be retained and the new
value will be lost. After the ENTER key is pressed, the display returns to the
current muffle temperature.

Entering a 0 for any RATE (2 through 6) causes the cycle to end after the previ-
ous stage. (Example: RATE 4 = 0; Program ends after STAGE 3). Program-
ming RATE 1 to 0 causes the program to start with STAGE 2.

TEMPERATURES:
The TEMP key sets the muffle temperature. Pressing the TEMP key displays
the current value for the program and stage selected. The corresponding
TEMP LED also flashes.

While the TEMPa4^ED is flashing, a new temperature can be entered on the

keyboard. If an incorrect digit key is pressed while entering a parameter, the
correct parameter should be reentered. The incorrect digit will shift off the
display to the left. Once the correct value is displayed, save it by pressing the
ENTER key. If the ENTER key is not pressed, the original value will be retained
and the new value will be lost. After the ENTER key is pressed, the display
returns to the current muffle temperature.

TIMES:
The TIME key sets the length of the hold time at the programmed temperature.
Pressing the TIME key displays the current value for the program and stage
selected. The corresponding TIME LED also flashes.

While the TIME LED is flashing a new time can be entered for the selected
STAGE on the keyboard. If an incorrect digit key is pressed while entering a
parameter, the correct parameter should be reentered. The incorrect digit will
shift off the display to the left. Once the correct value is displayed, save it by
pressing the ENTER key. If the ENTER key is not pressed, the original value

6-11
 will be retained and the new value will be lost. After the ENTER k / is pressed,
the display returns to the current muffle temperature.

Setting the last TIME to 0 causes the control to end the cycle and hut off. The
muffle temperature is not held. The last TIME can be TIME 6 or th TIME im-
meadiately before a RATE set equal to zero.

AUXILIARY OUTPUT # 1 :
The AUX 1 output is a normally open electrical contact accessible 0 the user in
the rear of the furnace close to the power cord. A adaptor plug is upplied in
the accessory kit to make the connections. The socket for AUX 1 1 fused at 5
amps with the fuses mounted in the socket.

The AUX 1 contacts can be independently closed (ON) or opened OFF) for
each STAGE of each PROGRAM. The AUX 1 is programmed to be ON (contacts
closed) by selecting a STAGE key of a program followed by the A X 1 key.
"AUX1 ON *" will be displayed if it was previously programmed to te off. Press-
ing the AUX 1 key a second time turns it off. "AUX1 OFF" is displa ed. "*"is
displayed in the far right character of the display when AUX 1 is o and the
cycle is running.

AUXILIARY OUTPUT #2:

The AUX 2 output (NOT APPLICABLE TO 6-525) controls the air e change fan
feature. The air exchange fan is located on the back of the furnac A vertical
damper is provided to block fan air from entering the furnace whe moved into
the down position. Putting the damper in this position also provid s access to
the compressed air fitting. When the damper is in the up position the fan will
force pre-heated air into the furnace. If the exhaust port is plugge when the
fan is operating, the exhaust gas will escape around the door and discolor the
paint.

The air exchange fan can be programmed to be OFF or ON at a paViicular

speed for each stage. The fan is programmed to be ON by pressii g a STAGE
key of a program followed by the AUX 2 key. With "SELECT 0" bei g displayed
a digit key (1-9) can be pressed to set that speed. 1 is the slowes and 9 is the
fastest. Entering a 0 turns the fan to the lowest speed (the fan is e ways on at a
slow speed to prevent its possible overheating). A setting of 9 produces ap-
proximately 5 air changes a minute in the muffle. Pressing the "Eh TER" key
stores the setting.

A fan symbol"-1 -" will appear in the far left character of the display, The two
bars in the display will rotate at a speed relative to that programmed. If 1 is

6-12
 programmed they will rotate slow. If 9 is programmed they will rotate fast.
During cycle operation this symbol will appear when ever the fan is pro-
grammed to be on.

Compressed air or inert gas can also be ported into the furnace muffle via the
rear female 1/8"NPT fitting. This fitting is located behind the fan damper.
Lower the damper for access. The gas will be preheated by the bottom heating
plate and injected into the front of the furnace. The graph below gives an ap-
proximate relationship between changes per minute and gas pressure.

COMPRESSED GAS CHANGES GRAPH:

^

C •7
1
H
A
N c /
0
G
E /
'e-ieoA
5
S

P 4 /
E /
R I5-1350A
0 /
M
I /
£.
N
U
1
T
E
0
0
1
10 20 30 40 50 60
I 70 80 90 100 110
PRESSURE (PSI)
Note: Maximum Pressure Allowable is 120 PSI

6-13
CONFIGURATION SETUP:

The furnace has other features or operations that are only accessible whfen power is
applied (power up). These features are programmed by pressing the ENTER key
during the 3 seconds after power up when the furnace displays the modjl number.
"SELECT" will appear on the display to indicate configuration setup.

The following selections are available for programming.

END OF CYCLE:
(1) Pressing the 1 key followed by the ENTER key will cause the cintrol to
continuous hold the last TEMP and beep every 6 minutes. 1HOLD
TEMP" is displayed. (This is the factory preset.)

(2) Pressing the 2 key followed by the ENTER key will cause the cintrol to
continuous hold the last TEMP without beeping. "HOLD TEMP" is dis-
played.
(3) Pressing the 3 key followed by the ENTER key will cause the c ntrol to end
the cycle and shut off the muffle after the last TIME. "END" 5 displayed
and the control beeps three times.

(4) Press the 4 key followed by the ENTER key will cause the cont||ol to con-
tinuously repeat the cycle that has been started.

HIGH LIMIT CUTOFF:

(5) Pressing the 5 key followed by the ENTER key will cause the lurrent High
Limit Cutoff temperature to be displayed (1100C is the factory preset
value). To select a different temperature enter the new value using the
digit keys followed by the ENTER key. CAUTION: Previously pro-
grammed values for TEMP's must be lower than High Limitfputoff.

The furnace will now shut down and display "Err3" if the nibffle tempera-
ture goes above the programmed High Limit Cutoff. The eiror is cleared
by turning off the furnace. Attempting to program a temperature higher
than the High Limit Cutoff will cause the control to beep anp display the
maximum temperature.

6-14
SYSTEM RESET: CAUTION!!!
(7) Press the 7 key followed by the ENTER key will cause the control to reset all
the parameters and settings in the control. "Reset" will be displayed.
This is for diagnostics and system checking.

Refer to Configuration Setup in the maintenance section 7 for further

directions.

To end the configuration setup routine press the 9 key followed by the ENTER
key. The control will go into normal operation displaying the current muffle
temperature.

6-15
EXAMPLE

SITUATION:
You wish to do a six stage temperature profile. The following heating ra. . !S, tempera-
tures and holding times are desired.
1. RATE=45°F/min TEMP=500°F TIME=.3 Hour
2. RATE=10°F/min TEMP=760°F TIME=.5Hour
3. RATE=5°F/min TEMP=1200°F TIME=1.7 Hours
4. RATE=10°F/min TEMP=1760°F TIME=3 Hours
5. RATE=-.5°F/min TEMP=1510°F TIME=.1 Hours
6. RATE=-10°F/min TEMP=1000°F TIME=30 Hours

ASSUMPTIONS: 1. Furnace is turned on.

2. The muffle is cool.
3. The muffle temperature is being displayed in degr !S
Fahrenheit. Press °C/°F key, if current display is in °C.
4. The load is inside the muffle on a ceramic tray.
5. Program will be stored in PROGRAM 1. Press PR SRAM 1 key,
if PROGRAM 1 LED is not on.
PROGRAMMING STEPS:
STEP PRESS KEY ACTION •
1. RATE Press key until the RATE 1 LED flashe
2. 4-5-0 45.0 °F/min
3. ENTER RATE 1 is now programmed.
4. TEMP Press key until the TEMP 1 LED flashc s.
5. 5-0-0 500°F
6. ENTER TEMP 1 is now programmed
7. TIME Press key until the TIME 1 LED flashe
8. 3 0.3 Hour
9. ENTER TIME 1 is now programmed.
•AGE1 IS NOW PROGRAM ED.
10. RATE Press key until the RATE 2 LED flashi
11. 1 -0-0 10.0°F/min
12. ENTER RATE 2 is now programmed.
13. TEMP Press key until the TEMP 2 LED flashc
14. 7-6-0 760°F
15. ENTER TEMP 2 is now programmed
16. TIME Press key until the TIME 2 LED flashe
17. 5 0.5 Hour
18. ENTER TIME 2 is now programmed.
AGE 2 is NOW PROGRAF; ED.
19. RATE Press key until the RATE 3 LED flashes
20. 5-0 5.0 °F/min .
21. ENTER RATE 3 is now programmed.

6-16
 22. TEMP Press key until the TEMP 3 LED flashes.
23. 1-2-0-0 1200°F
24. ENTER TEMP 3 is now programmed
25. TIME Press key until the TIME 3 LED flashes.
26. 1-7 1.7 Hours
27. ENTER TIME 3 is now programmed.
STAGE 3 IS NOW PROGRAMMED.
28. RATE Press key until the RATE 4 LED flashes.
29. 1-0-0 10.0°F/min
30. ENTER RATE 4 is now programmed.
31. TEMP Press key until the TEMP 4 LED flashes.
32. 1-7-6-0 1760°F
33. ENTER TEMP 4 is now programmed
34. TIME Press key until the TIME 4 LED flashes.
35. 3-0 3.0 Hours
36. ENTER TIME 4 is now programmed.
STAGE 4 IS NOW PROGRAMMED.
37. RATE Press key until the RATE 4 LED flashes.
38. 5 0.5 °F/min
39. ENTER RATE 5 is now programmed.
40. TEMP Press key until the TEMP 4 LED flashes.
41. 1-5-1-0 1510°F '
42. ENTER TEMP 5 is now programmed
43. TIME Press key until the TIME 4 LED flashes.
44. 1 0.1 Hour
45. ENTER TIME 5 is now programmed.
STAGE 5 IS NOW PROGRAMMED.
46. RATE Press key until the RATE 6 LED flashes.
47. 1-0-0 10.0°F/min
48. ENTER RATE 6 is now programmed.
49. TEMP Press key until the TEMP 6 LED flashes.
50. 1-0-0-0 1000°F
51. ENTER TEMP 6 is now programmed
52. TIME Press key until the TIME 6 LED flashes.
53. 3-0-0 30.0 Hours
54. ENTER TIME 6 is now programmed.
STAGE 6 IS NOW PROGRAMMED.

After TIME 6 the control will continue to hold the last temperature (TEMP 6) until
turned off while beeping every 6 minutes.

6-17
MAINTENANCE

CLEANING:
Vacuum (rather than blow) any muffle dust found in and around the furnace.
This will minimize the airborne dust.

SEE SECTION 1: SAFETY PRECAUTIONS and MSDS

Clean the control panel with a soft dry cloth. Do not use water, liquids or spray
cleaners on the panel or on the cloth. These cleaners can enter the switch
panel and cause damage.

Clean the furnace cabinet with any household non-abrasive cleaner and a soft
cloth.

CALIBRATION:
Under normal use the furnace will not require calibration. Situations where cali-
bration may be required include thermocouple damage and replacement, con-
trol/power pc board assembly replacement.

An electronic temperature meter, if available, should be used to calibrate the

furnace. If one is not available, then the boards and thermocouples should be
used as supplied. They have been precalibrated at the factory and will be more
accurate than other methods of calibration.

If an electronic temperature meter is used then its thermocouple sensor should

be placed in the center of the muffle half way between the top and bottom.
Program the furnace to heat to 960°C at a rate of 20°C /min and start the con-
trol. After the furnace reaches 960°C, wait 30 minutes for the muffle tempera-
ture to stabilize. Record the temperature measured by the electronic tempera-
ture meter as the difference between 960 and its reading. For example if the
meter reads 980 then the difference is +20°C. If the meter reads 950 then the
difference is -10°C.

Once a measurement has been recorded, turn off the furnace and unplug its
power cord. Allow the furnace to cool to room temperature. Remove the con-
trol panel by following the directions under "Control Panel Removal" in section
8. The following directions apply once the control panel is opened.

The trimmer/potentiometer labeled R12 "SPAN ADJ" (see page 8-4) on the
computer/power printed circuit board assembly (horizontally mounted pcb) will
be adjusted to correct the calibration. If the muffle temperature measures
higher (positive difference in example above) than the furnace indicates, turn

7-1
 the trimmer/potentiometer labeled R12 "SPAN ADJ" clockwise (CV|) to reduce
the display temperature. The potentiometer should be turned one lomplete
turn for every 10°C of difference. If the temperature measures lowlr (negative
difference) adjust the potentiometer counterclockwise (CCW) usin| the same
ratio.

BATTERY REPLACEMENT:
If the program contents are lost when the furnace power is turned | n and off,
then the battery is dead. In addition, if the "Low Batt" indicator flashes the
battery should be replaced. The battery in question is a small Lithfim coin type
battery (#2032).

Refer to the CONTROL PANEL REMOVAL section 8 for instructions" on your

furnace. Once the control panel has been pulled out of the front ofthe furnace
30cm to 40cm (6 inches), the old battery can be removed. The battery is lo-
cated near the front center of the computer/power pc board. Remove the tape,
then using a small screw driver, remove the old battery. Replace itjwith a new-
battery with the positive "+" side to the top. (The battery bracket siould be
opened only a small amount so that it is not deformed. Replace the control
panel and reapply power. The battery replacement will cause the control to
lose complete memory. NOTE: THE POWER MUST BE APPLIED SfORTLY
AFTER BATTERY REPLACEMENT OR THE BATTERY WILL BE DE/1D WITHIN
SEVERAL HOURS. Go to configuration setup below.

CONFIGURATION SETUP:
When powered up for the first time after battery replacement, the control will
display a series of furnace model numbers (ie 525,160A, 1350A). fress the EN-
TER key when the correct model number of the furnace being worlled on ap-
pears. A pattern similar to "SELECT" will appear to indicate configuration
setup. Pressing the 9 key followed by the ENTER key will place the control in
the normal operating mode. See the CONFIGURATION SETUP in t | e program-
ming section 6 for details on possible operating mode changes.

MUFFLE REPAIR:
The 6-525 furnace muffle is constructed of a lightweight fiber insulltion. Exer-
cise caution to prevent punctures or tears in the muffle when loading and un-
loading the furnace. Punctures exposing the heating elements embedded in
the insulation may significantly shorten muffle life. The accessory peramic tray
provided with the furnace should be used to protect the muffle floe

Damage to the fiber insulation in the muffle or the door can be replired. A
bottle of "Fiber Harding Agent" has been included with your furnace shipment.

7-2
The "Fiber Harding Agent" is a binding solution with the viscosity of water. It
will harden the surface which was damaged. Directions for using this material
are listed below:

1. Unplug the furnace and allow to cool

2. Apply liquid hardening agent generously to the damaged area with a small
brush or swab.
3. Plug in the furnace and heat to 250C(500F) for approximately two hours or
until the agent is dry or solid. Allow the furnace to run longer if the mate-
rial is not dry.
4. After the agent is solidified the furnace is ready for normal use.

7-3
SERVICE
This section is provided as assistance to qualified service personnel. If you are quali-
fied to service the furnace, please read the entire manual before you attempt any
servicing.

IF YOU ARE NOT QUALIFIED TO SERVICE THE FURNACE, PLEASE READ THE
PARAGRAPH BELOW, AND FOLLOW THE DIRECTIONS SPECIFIED.

If the unit requires service, review pages 8-2 and 8-3 before contacting the service de-
partment at your dealer or The J. M. Ney Company, Yucaipa, CA. Describe the par-
ticular problem and give the model and serial numbers of the furnace. This informa-
tion is located on the data plate attached to back of the furnace. An RMA (Return
Material Authorization) number will be assigned to your unit as a control during the
repair period. The RMA number must appear on the shipping label so we can give
you fast and dependable service.

Preparation For Return Shipment:

1 - The furnace muffle interior should be emptied of all trays and work pieces.
2 - The exhaust tube on 525 units should be removed and stored for use upon the
return of the furnace.
3 - The original packing materials should be used for return shipment. If they are not
available, new materials can be purchased for a nominal fee.
4 - Equipment damaged in shipment as the result of improper packing may not be
paid for by the carrier. The J. M. Ney Company will not be responsible for
equipment damaged in return shipment due to improper packing.

Ship the furnace shipping costs prepaid to:

The J. M. Ney Company

RMA#
13553 Calimesa Boulevard
Yucaipa, CA 92399-2398

(714)795-2461
FAX: (714) 795-5268

8-1
TROUBLESHOOTING and ERROR CODES:
(See 5.0.0 Below for the "ERR" codes)

Review the following list of questions and suggestions before calling thefeervice
number listed on the previous page. Some of the answers may prove hefpful in help-
ing us solve the problem.

1.0.0 Shipping damage: SEE SECTION 2 RECEIVING INFORMATION

2.0.0 No operation - Furnace Dead - Display does not lightup , LED's do fiot come on,
and muffle does not heat.
2.1.0 Does the power receptacle have power? Test with another lo d (ie lamp or
radio.)
2.2.0 Does furnace beep when power is turned on? If yes, go to 2 ,0. If no, go
to 2.9.0.
2.3.0 Do any of the LED's on the control/power board light? Look fito rear back
vents of furnace. If yes, check pc board to pc board connections,
2.9.0 Please note the answers to the following questions before ca ing the
service telephone number listed on page 8-1.
What is model number and serial number of furnace? (List data plate
on back of furnace.)
Did furnace ever operate? For how long?

3.0.0 No Heat - Display and LED's operate.

3.1.0 Does the display show "ERR 2"? See Section 5.3.0 below.
3.2.0 Does the neon light on the control/power board light when th power
switch is turned on? If not, check muffle continuity with ohnf meter. If
so, check wiring and terminals between muffle, triac, and co trol/power
pc board.
3.3.0 Does the neon light flash off and on when the start key is pre sed? Does
LED DS1 (upper lefthand corner of control/power pc board) ash oppo-
site the neon light (on to off)? If not, go to point 2.9.0 abovef

4.0.0 Furnace operates, but not correctly:

4.1.0 Does RATE LED flash slowly when program is operating?
The RATE parameter is programmed faster than furnace carl] heat or cool,
Unit will continue to operate but with a slower rate than prog] amrned.
See Heating Curves in Section 5.
4.2.0 Control lost all preprogrammed parameters when turned off. Program-
ming not saved when power is turned off. Did "LO BATT" iri icator
flash? Battery dead or not seated properly. See 5.1.0 belov|

8-2
 4.3.0 Cabinet around the door is discoloring. ("A" models only) Remove ex-
haust port ball plug if air exchange fan or compressed air fitting is being
used.

5.0.0 Abnormal Display Signals and Operation:

5.1.0 Lower Right Decimal Point Flashes In Display: "LO BATT" Battery is low
or dead, replace with a number 2032 Lithum coin type. See
MAINTENANCE SECTION 7 and SERVICE PARTS SECTION 9.

5.2.0 ERR 1 is displayed: The muffle temperature is above 1100C (2012F) or

overtemperature. Possible problems include: shorted output triac,
shorted optotriac (U7) on control/power pc board, wiring shorted,
thermocouple pushed back out of muffle, thermocouple shorted outside
of muffle.

5.3.0. ERR 2 is displayed: The control thermocouple is open or disconnected.

Possible problems include: themocouple disconnected at control/power
pc board, themocouple weld inside muffle open or damaged.

5.4.0. ERR 3 is displayed: The control is attempting to go above the Program-

mable High Limit Cutoff. Review the section on programming the Cutoff
in the programming section 6.

5.5.0 "DOOR" remains on display when door is closed. Check door switch con-
tinuity. Check door switch actuator tab by listening for switch click as
door closes.

8-3
6-525 SCHEMATIC:
AUX1 RECEPTACLE
5 Amn Fused

220 / 240V
RECEPTACLE

CONTROL
EARTH
GROUND

DOOR
SWITCH

THERMOCOUPLE
COMPUTER/POWER
PC BOARD

f \ r -\

MEMBRANE
SWITCH
\. J

8-4
6-160A and 6-1350A SCHEMATIC:
HEATING ELEMENTS

DOOR
SWITCH

THERMOCOUPLE

MUFFLE
CONNECTIONS
1350A SHOWN

R12
CALIBRATION
ADJUSTMENT ' 220/240V
RECEPTACI
COMPUTER/POWER
?C BOARD

CONTROL
EARTH
GROUND

ENCLOSURE
GROUND

AUX 1 SOCKET
(5 Amp Fused)
White

POWER
SWITCH Red

8-5
DISASSEMBLY INSTRUCTIONS:

READ THE CAUTIONS ON PAGES 1-1 AND 1-2 BEFORE PROCEEDING!

DISCONNECT THE FURNACE LINE CORD FROM THE WALL RECEPTACLE/OUTLET.

Refer to the schematics and the exploded view drawings for the appropri tte furnace
during servicing.

Respiratory, eye, and hand protection should be worn during the followin|j proce-
dures.

The following tools are required for disassembly/reassembly work descr ed in this
section.
* Small blade screwdriver * Medium Phillips screwdriv
* Needle nose pliers * Regular pliers

6-525 SERVICE:
6-525 CONTROL PANEL REMOVAL:
(Access to pc boards, triac, power switch, door switch, thermocouple nd muffle
wiring connections)
1. Turn off the power to the furnace and remove the line cord from the \ia\\ recep-
tacle/outlet. Allow the furnace to cool to room temperature before tailing
service.
2. Remove 9 screws from around the top, sides, and bottom of the con rol panel.
Hanging the front of the furnace off of the counter by 2 inches (50n m) will aid
in removing the bottom screws.
3. The control panel can now be removed by pulling it out the front of t le furnace
while raising the panel up slightly. The control panel will slide out pproxi-
mately 6 inches (150mm).
4. With the control panel pulled out, various connections can be access ed. The pc
boards are replaceable along with the membrane switch panel with its mount-
ing plate with the drawer out. The control can be examined at this >oint along
with battery replacement and temperature calibration.
5. If the control panel is to be completely removed, the wiring connecti ns should
all be noted, labeled, or verified with the schematic included in this manual.
6. Reverse the steps above for reinstallation making sure that all electr cal connec-
tions are tight.

6-525 THERMOCOUPLE REMOVAL:

1. Turn off the power to the furnace and remove the line cord from the all recep-
tacle/outlet. Allow the furnace to cool to room temperature before • tarting
service.

8-6
 2. Remove Control Panel by following the instructions above.
3. Disconnect thermocouple red and yellow wires from the left-hand side of the
computer/power pc board. Disconnect the blue or blue/white muffle wires from
computer/power pc board and triac.
4. Remove the exhaust port by removing the 3 retaining screws.
5. Remove Front Panel from enclosure by removing 7 screws from top and sides.
6. The Front Panel with the muffle attached pulls out of the front of the enclosure.
7. The thermocouple can now be removed from the back of the muffle by pulling it
out.
8. Route the thermocouple through the bushing in the rear of the heatshield and
behind the door switch bracket.
9. Reverse steps 1-6 for reinstallation.( Note: The screws holding the front panel to
the cabinet must be installed prior to installing the control panel.

6-525 MUFFLE REMOVAL:

1. Turn off the power to the furnace and remove the line cord from the wall recep-
tacle/outlet. Allow the furnace to cool to room temperature before starting
service.
2. Remove Control Panel by following the instructions above.
3. Remove the exhaust port by removing the three retaining screws.
4. Disconnect the blue or blue/white muffle leads from the triac and the power
board.
5. Remove the thermocouple by pulling it out of the muffle. Follow the instructions
above if thermocouple to be replaced.
6. The muffle can now be removed by releasing the two springs that hold it in posi-
tion. USE CAUTION WHEN RELEASING OR INSTALLING THE SPRINGS! Us-
ing pliers, release spring on end farthest from you. This will prevent it from
flying at you if your grip should slip.
7. When installing the muffle, make sure that the muffle is pressed tightly against
the front panel, the muffle wires must be fed through the two bushings in the
front of the heatshield.
8. Reverse steps 1-6 for reinstallation. Gloves and protective eyewear should be
worn when installing the springs.

6-160A SERVICE:
6-160A CONTROL PANEL REMOVAL:
(Access to pc boards, triac, power switch, door switch, thermocouple and
muffle wiring connections)
1. Turn off the power to the furnace and remove the line cord from the wall recep-
tacle/outlet. Allow the furnace to cool to room temperature before starting
service.
2. Remove 9 screws from around the top and bottom of the control panel. Hanging
the front of the furnace over a counter by 2 inches (50mm) will aid in removing

8-7
 the bottom screws.
3. The control panel can now be removed by pulling it out of the front the furnace
while raising the panel up slightly. The control panel will slide out pproxi-
mately 6 inches (150mm).
4. With the control panel pulled out, various connections can be acces ted. The RC
boards are replaceable along with the membrane switch panel wit [its mount-
Ing plate. The control can be examined at this point along with ba jry replace-
ment and temperature calibration.
5. If the control panel needs to be completely removed, the wiring con lections
should all be noted, labeled, or verified with the schematic include in this
manual.
6. Reverse the steps above for reinstallation making sure that all elect leal connec-
tions are tight.

6-160A MUFFLE REMOVAL:

1. Turn off the power to the furnace and remove the line cord from the llvall recep-
tacle/outlet. Allow the furnace to cool to room temperature before smarting
service.
2. Remove the Control Panel by following the instructions above for Control Panel
Removal.
3. Disconnect the blue or blue/white muffle leads from the triac and the* power
board.
4. Remove the eight Phillips screws from the back panel.
5. Open the door and remove the 3 screws along the bottom front of thfe muffle.
6. Remove the thermocouple from the back of the furnace.
7. Remove the muffle lead wires from the muffle terminals.
8. Remove the exhaust port by removing the three retaining screws.
9. Slide the muffle out the back of the furnace enclosure.
10. To reinstall, slide the muffle into the grooves in the rail and reverse steps 1 -7.

6-160A THERMOCOUPLE REMOVAL (TYPE K):

1. Turn off the power to the furnace and remove the line cord from the Svall recep-
tacle/outlet. Allow the furnace to cool to room temperature before |tarting
service.
2. Remove the Control Panel by following the instructions above for Control Panel
Removal.
3. Follow steps 4+6 of the muffle replacement procedure.
4. Disconnect thermocouple red and yellow wires from the left-hand si le of the
computer/power board and remove thermocouple.
5. Reverse steps 1-4 to reinstall.

8-8
6-1350A SERVICE:
6-1350A CONTROL PANEL REMOVAL
(Access to pc boards, triac, power switch, door switch, also thermocouple and
muffle wiring connections)
1. Turn off the power to the furnace and remove the line cord from the wall recep-
tacle/outlet. Allow the furnace to cool to room temperature before starting
service.
2. Remove the rear electrical panel (3 screws in lower left of furnace back, looking
from the rear.) and lay it to the side. The retaining screw for the control module
is located above and inside the furnace.
3. Push on this screw as it is removed. The control panel will slide out the front. The
control panel can be pulled out approximately 6 inches before any wires need
to be disconnected.
4. Refer to the schematic/wiring diagram (page 8-5) before removing any wires.
Calibration can be done in this position and most of the other possible service
requirements such as PC board replacement, triac replacement, and trou-
bleshooting.
5. To replace the control panel assembly, reverse the disassembly procedure.

6-1350A MUFFLE PLATE REMOVAL:

Each of the four ceramic plates have heating element wires within the plate. Each
plate can be replaced individually if a failure occurs.

1. Turn off the power to the furnace and remove the line cord from the wall recep-
tacle/outlet. Allow the furnace to cool to room temperature before starting
service.
2. Remove the furnace back by removing the back panel screws.
3. Remove the thermocouple from the muffle and push it back into the control
section.
4. Disconnect the power leads connecting the muffle to the control section. Discon-
nect all of the individual muffle plate connections from the terminal block.
5. Remove the 6 screws which hold the muffle back to the muffle, then remove the
aluminum back.
6. Remove the exhaust port tube by removing the 3 retaining screws.
7. Remove the rear fiber brick from the back of muffle. It will slide out the back
while the leads are fed through it. TAKE CARE NOT TO DAMAGE THE BRICK.
Note: Each plate supports the others. The sides or top plates will fall unless ade-
quate support is provided.
8. Slide the top plate out the back while supporting the others. Continue with the
sides and then the bottom plate.
9. The muffle can now be reassembled using the new part.
10. To reassemble, reverse the procedure and use the following precautions:
- Fiber rope used between top plate and top brick must be put back in place.

8-9
 Fiber rope used between back brick and rear edges of plates must bp reinstalled
to prevent air from flowing into the chamber before preheating.

6-1350A THERMOCOUPLE REMOVAL:

1. Turn off the power to the furnace and remove the line cord from the! wall recep-
tacle/outlet. Allow the furnace to cool to room temperature before starting
service.
2. Remove the furnace back by removing the back panel screws.
3. Remove the control module assembly. (See the Control Panel Sectibn) NOTE:
Disconnect only the thermocouple and thermocouple strain relief.
4. Pass the thermocouple leads through the back of the control modu je housing.
5. Remove thermocouple from the back of the muffle.
6. To replace the thermocouple, reverse the above procedure.

8-10
REPAIR PARTS
The furnace and its internal components and assemblies are delicate and need to be
packed properly for return shipment. Pack all parts or assemblies in a bag then foam
and seal them in suitable boxes. Use original packaging when it is available.

FURNACE 6-525

VOLTAGE
DESCRIPTION 100V 120V 220V 240V

Muffle R9491042 R9491040 R9491041C R94919041B

Thermocouple .—R9491747

Triac -—R9303015
Power Switch R9306021

Door Switch R9492666-—

Control/Power PC Board
Assembly —R9492572 R9492573

Display PC Board
Assembly . R9492703

Membrane Switch and R9492636

Switch Plate

Battery, Lithium
Panasonic Part Number Obtain Locally
BR2032
Radio Shack Number
CR2032

Fuse, 1 Amp, 250V, Obtain Locally

5mm x 20mm

9-1
EXPLODED VIEW 6-525

MUFFLE
SPRING

DOOR + FRONT
PANEL

CONTROL
PANEL DIS1LAY
PC BOARD
SWlfTCH PLATE
MEMBRANE
SWITCH
CONTROL/
POWER
PC BOARD
POWER
SWITCH

9-2
FURNACE 6-1350A
The furnace and its internal components and assemblies are delicate and need to be
packed properly for return shipment. Pack all parts or assemblies in a bag then foam
and seal them in suitable boxes. Use original packaging when it is available.

VOLTAGE
DESCRIPTION 220V - 240V

Top + Bottom Heating Plate R9492684

Side Heating Plate R9492683

Triac R9303015
Power Switch R9306021

Door Switch R9492666

Thermocouple R9491747

Control/Power PC Board
Assembly R9492573

Display PC Board R9492707

Assembly

Membrane Switch and R9492659

Switch Plate

Air Exchange Fan, 12 VDC R9492455

Fan Supply PCB Assy R9492710

Battery, Lithium Obtain Locally

Panasonic Part Number
BR2032
Radio Shack Number
Cr2032

Fuse, 1 Amp, 250V, Obtain Locally

5mm x20mm

9-3
EXPLODED VIEW 6-1350A:

,CK PANEL

FAN, DUCT,
DAMPER ASSY

EAR ELECTRICAL
ANEL AND LINE CORD

CONTROL
PANEL

CONTROL/
POWER
PC BOARD
\DISPLAY
POWER .MEMBRANE PC BOARD
SWITCH SWITCH

9-4
EXPLODED VIEW 6-1350A MUFFLE:

Rear Muffle Panel

Terminal
Block

Top Heating Plate

Bottom Heating Plate

9-5
FURNACE 6-160A

The furnace and its internal components and assemblies are delicate an i need to be
packed properly for return shipment. Pack all parts or assemblies a in I ag then foam
and seal them in suitable boxes. Use original packaging when it is avail ible.

VOLTAGE
DESCRIPTION 100V 120V 220V 240V

Muffle 6-160A R94???? R94???? R94????? R94????

Thermocouple R9491747
Triac R9303015-—

Power Switch R9306021

Door Switch R9492666

Control/Power PC Board
Assembly —R9492570 R9492J 71 —
#
Display PC Board
Assembly R9492702

Membrane Switch and R9492???

Switch Plate

Air Exchange Fan R9492???

Fan Supply PCB Assy R9492???

Battery, Lithium Obtain Locally

Panasonic Part Number
BR2032
Radio Shack Number
CR2032

Fuse, 1Amp, 250V Obtain Locally

5mm x 20mm

9-6
EXPLODED VIEW 6-160A:

BACK PANEL

DAMPER
THERMOCOUPLE
ASSEMBLY

DOOR + FRONT
PANEL

DISPLAY
PC BOARD
CONTROL
PANEL SWITCH PLATE

MEMBRANE
SWITCH

CONTROL/
POWER
PC BOARD
POWER
SWITCH TRIAC

9-7
ACCESSORIES

DESCRIPTION ORDER NUMBER

Tongs - Stainless Steel 10" (25cm) 9390014

Tongs - Stainless Steel 12" (30cm) 9390015
Tongs - Plated Steel 14" (36cm) 9491010B

Tray - Hard Ceramic (3.75" * 4") 9390017

(9.5cm * 10cm)
Tray - Hard Ceramic (8.0" * 8.0") 9353027
(20cm * 20cm)

Shelf - Honeycomb ceramic

1.75" (4.5cm) in height 9492211
3.0" (7.6cm) in height 9492210

Muffle Hardening Agent (6-525 only) 9491006

Temperature Pellets - Bottle of 25

705C (1300F) 9490911
815C(1500F) 9490912A

Exhaust port ball plug - 2 each

Small (6-525, 6-160A) 9491093A
Large (6-1350A) 9492456

10-1
 LIMITED WARRANTY and LIMITATION OF LIABILITY

1. WARRANTY: Except with respect to those components parts and uses which are
hereinafter described, The J.M. Ney Company warrants this furnace to be free from
defects in material and workmanship for a period of one year from the date of sale.
The J.M. Ney Company's liability under this warranty is limited solely to repairing or,
at Ney's option, replacing those products included within the warranty which are
returned to Ney within the applicable warranty period (with shipping charges pre-
paid), and which are determined by The J.M. Ney Company to be defective. This
warranty shall not apply to any product which has been subject to misuse; negli-
gence; or accident; or misapplied; or modified; or repaired by unauthorized per-
sons; or improperly installed.

2. WARRANTY EXCLUSIONS: The warranty described in Paragraph 1 does not

include normal wear of Ney's product or its components. The muffle, a component
of Ney furnaces, has a warranty period from the date of sale as outlined in the table
below.

FURNACE MUFFLE LENGTH OF WARRANTY

6-160A 6 Months
6-525 60 Days
6-1350A ' 6 Months

3. INSPECTION: Buyer shall inspect the product upon receipt. The buyer shall
notify The J.M. Ney Company in writing of any claims of defects in material and
workmanship within thirty days after the buyer discovers or should have discovered
the facts upon which such a claim is based. Failure of the buyer to give written
notice of such a claim within this time period shall be deemed to be a waiver of such
claim.

4. DISCLAIMER: The provisions here-in stated The J.M. Ney Company's sole obli-
gation and exclude all other remedies or warranties, expressed or implied, including
those related to MERCHANTABILITY and FITNESS FOR A PARTICULAR PURPOSE.

5. LIMITATION OF LIABILITY: Under no circumstances shall The J.M. Ney Com-

pany be liable to the buyer for any incidental, consequential or special damages,
losses or expenses.

6. LIMITATION OF ACTIONS: The buyer must initiate any action with respect to
claims under the warranty described in the first paragraph within one year after the
cause of action has accrued.
Corporate Offices:

The J.M. Ney Company

Ney Industrial Park
Bloomfield, CT 06002
203-242-2281
Tlx 6288-7937
FAX 203-242-5688

Built and Repaired at:

The J.M. Ney Company

13553 Calimesa Boulevard
Yucaipa, CA 92399
714-795-2461
FAX 714-795-5268

@1990 The J.M. Ney Company

Printed in U.S.A.