Related Manuals for VERDER CARBOLITE GERO HTF 18/4
Summary of Contents for VERDER CARBOLITE GERO HTF 18/4
- Page 1 Installation, Operation and Maintenance Instructions 1800°C Chamber Furnace - HTF Model: 4 Litres 3508 Controller HTF 18/4 + 3508 Controller MEN-HTF1804-001_3508 02-08-2019...
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Page 2: Table Of Contents
Contents This manual is for guidance on the use of the Carbolite Gero product specified on the front cover. This manual should be read thoroughly before unpacking and using the furnace or oven. The model details and serial number are shown on the back of this manual. - Page 3 3.8.7 To pause (hold) a program 3.8.8 To stop and reset a program 3.8.9 To run a different program (P10 and P25) 3.8.10 Program Status 3.8.11 Program Hold with Holdback 3.8.12 Power Failure Recovery 3.8.13 Alarms 3.8.14 Program Example 1 3.8.15 Program Example 2 Controller Options...
- Page 4 Navigation Diagram 6.0 Operation Operating Cycle Operator Safety Loading The Furnace Opening the Door Insulation Cracking Atmospheres & Corrosive Materials Pesting Explosive Materials Notes on Temperature Control 6.10 Thermocouple Warnings 6.11 Thermal Cutouts 6.12 General Operating Advice 7.0 Maintenance General Maintenance Maintenance Schedule 7.2.1 Cleaning...
- Page 5 8.11 Fuse Replacement 9.0 Fault Analysis Furnace Does Not Heat Up Product Overheats 10.0 Wiring Diagrams 10.1 Single Phase 208 V, 220-240 V 11.0 Fuses and Power Settings 11.1 Fuses 11.2 Power Settings 12.0 Specifications 12.1 Environment...
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Page 6: Symbols And Warnings
1.0 Symbols and Warnings 1.0 Symbols and Warnings Switches and Lights Instrument switch: when the instrument switch is operated the temperature control circuit is energised. Heat light: the adjacent light glows or flashes to indicate that power is being supplied to the elements. Warning Symbols DANGER –... - Page 7 1.0 Symbols and Warnings Caution – Double Pole/Neutral Fusing...
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Page 8: Installation
2.0 Installation 2.0 Installation Unpacking and Handling When unpacking or moving the product always lift it by its base. Do not use the door or any other protruding parts. The product contains a transformer and is heavy: use two or more people to carry the product. -
Page 9: Fitting The Heating Elements
2.0 Installation If the product is to be used in a process which could liberate hazardous gases, then it should be installed together with a suitable fume extraction system. Ensure that the product is placed in such a way that it can be quickly switched off or disconnected from the electrical supply. -
Page 10: Electrical Connections
2.0 Installation Separators/ Block Chimney Unit The installation of these elements is described in section 0.1. Electrical Connections Connection by a qualified electrician is recommended. These models are designed only for single phase electrical supplies, or for two live phases and neutral of a 3-phase supply. The product must be connected only to the type and voltage of supply for which it was ordered. -
Page 11: Power Supply Notes
2.0 Installation 2-phase L1 Black to phase 1 Black to phase 2 Light Blue to neutral Green/ Yellow to earth (ground) Power Supply Notes Each model is manufactured for one of the following voltage ranges: 208 V 220 to 240 V 380 to 415 V (not HTF 17/5 or HTF 18/4) It is not possible to modify and use a furnace manufactured for the 380-415 range on either of the other two voltage ranges listed above: there are too many component... -
Page 12: 3508 Controller
3.0 3508 Controller 3.0 3508 Controller PID control This controller uses PID (Proportional Integral Derivative) temperature control. This type of control uses a complex mathematical control system to adjust the heating power and achieve the desired temperature. 3508P1 The 3508P1 is a digital temperature controller which uses PID algorithm to give excellent temperature control when properly set. -
Page 13: Basic Operation
3.0 3508 Controller Basic Operation Alarm Indicator Power Output Indicator Not Used Runs, Holds, Resets the current program Page Scroll Down Power Output Percentage Program Setpoint Temperature (PSP) when a program is running Setpoint Temperature (SP) when basic controlling Measurement Temperature... -
Page 14: Controller Layout
3.0 3508 Controller Measurement Units 3.5.1 Controller Layout 3.5.2 Keys A/ Man Disabled Runs, Holds or Resets the current program. Hold down for 3 RUN/ HOLD seconds to Reset. Scrolls through the page headings. Hold down for 3 seconds to Page Key access further levels, pass codes are required. -
Page 15: Resetting The Programmer
3.0 3508 Controller This will cause the product to heat as quickly as possible which may not be appropriate where the product contains sensitive ceramic components. For products with ceramic components, e.g. a tube furnaces fitted with a long ceramic work tube, use the ramp rate feature set with a low heating rate such as 5°C per minute (300°C per hour), to prevent damage. -
Page 16: Setting Up Controller
3.0 3508 Controller To Enter Level 2: 1. Press and hold page for 3 seconds. The display will show “Access Goto Level 1” 2. Press up to select level 2. After a short pause the display will show “Access Pass code”. 3. -
Page 17: Units
3.0 3508 Controller 3.7.3 Units Press page until "Units" is displayed. Press up or down to select: Celsius Fahrenheit Kelvin 3.7.4 Language The text on the 3508 Controller can be shown in different languages, this can only be set at the factory and therefore must be specified at the time of placing an order. Programming 3.8.1 Programming Notes Programs can be created in Level 1 or Level 2 of the 3508 Controller. -
Page 18: Holdback
3.0 3508 Controller To alter parameters or segments of an operating program, this program must be held or reset. Press RUN/ HOLD to pause the program, or press RUN/ HOLD for 2 seconds to reset. 3.8.2 Holdback Holdback can be used to prevent the program from operating ahead of the actual heating or cooling. -
Page 19: Program Cycling
3.0 3508 Controller 3. 'Dev Hi’ Wait until the measured temperature exceeds a fixed* threshold by an amount ‘WaitVal’ set for that segment. 4. ‘Dev Lo’ Wait until the measured temperature drops below a fixed* threshold by an amount ‘WaitVal’ set for that segment. * The fixed threshold used by deviation parameters is set in the configuration level of the programmer and if required should be requested when purchasing a product from Carbolite Gero. -
Page 20: Running A Program
3.0 3508 Controller Holdback Type Press scroll until the display shows 'Holdback Type'. If required, press up or down to select 'Off', 'Low', 'High' or 'Band'. Target Setpoint (Visible only for Rate, Time and Step segments) Press scroll until the display shows 'Target SP'. Press up or down to set a value. -
Page 21: To Pause (Hold) A Program
3.0 3508 Controller 3.8.7 To pause (hold) a program Press RUN/HOLD Press page until 'Program Status Reset' appears Press scroll until the cursor moves to 'Reset' Press up or down to select 'Hold' RUN/HLD will be displayed 3.8.8 To stop and reset a program Press and hold RUN/HOLD Press page until 'Program Status Reset' appears... -
Page 22: Program Hold With Holdback
3.0 3508 Controller Current program number (P10 and P25 only) Current segment number Time remaining for that segment Further presses of the scroll key while a program is operating will reveal additional information: Status. This can be changed to 'Hold', 'Reset' or 'Run' by pressing up or down Program Setpoint (PSP) Current Segment Type. -
Page 23: Alarms
3.0 3508 Controller 3.8.13 Alarms Alarms are used to alert the operator when a pre-set level has been exceeded or a function error has occurred such as a sensor break. They are indicated by a flashing red ALM (Alarm) indicator. The alarm may also switch an output – usually a relay to allow external devices to operate when an alarm occurs. - Page 24 3.0 3508 Controller 11. Press scroll until 'Segment Type' is displayed. Press up or down to select 'End' 12. Press scroll until 'End Type' is displayed. Press up or down to select 'Reset' 13. Press page and scroll together to return to the home display. To run the program either press RUN/HOLD or: 14.
- Page 25 3.0 3508 Controller Time Display Examples 10:05:3 Min/Sec/10th Sec 21:10:05 Hour/Min/Sec 196:10 Hour/Min Segment Type 'Rate' Type 'Dwell' Type 'Step' Type 'Dwell' Type 'Time' Type 'End' Target 400°C Duration 30 min Target 600° Duration 30 min Target 200° End Type 'Reset' Rate 5.0°/Min Time 120 min 3.8.15 Program Example 2...
- Page 26 3.0 3508 Controller 5. Press scroll until 'Cycles' is displayed. Default ‘1’ 6. Press scroll until 'Segment 1' is displayed 7. Press scroll until 'Segment Type' is displayed. Press up or down to select ‘Time’ 8. Press scroll until 'Holdback Type' is displayed. Default ‘Off’ 9.
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Page 27: Controller Options
3.0 3508 Controller Segment Type 'Time' Type 'Rate' Type 'Step' Type 'Dwell' Type 'Call' Type 'End' Target 600°C Target 400°C Target 200°C Duration 30 min Call prog 3 End Type 'Dwell' Duration 30min Rate 2°C/min H back type 'High' Call cycles 2n * Segment 4 'Holdback Value' 5°C ** P10 and P25 only *** Program 3 Example... -
Page 28: Digital Communications - Rs232
3.0 3508 Controller 3.9.1 Digital Communications - RS232 If the RS232 option is supplied, the furnace is fitted with one sub-miniature D-socket connected to the controller comms module. RS232 is suitable for direct connection to a personal computer (PC) using a “straight through” cable as follows (the linked pins at the computer end are recommended but may not be necessary). -
Page 29: Remote Input And Output (Analogue Communications)
3.0 3508 Controller Temperature Controller Fuse (2A) Supply Load Normally open relay contacts Relay Output 240V 2A The purpose of the 2 amp fuse is to break the circuit to prevent overloading on the circuit due to high voltage. The instrument configuration and parameters available to the operator depend on the customer requirements. -
Page 30: Temperature Controller Replacement
3.0 3508 Controller is set to on, then the relay closes during the segment and a small 1 appears in the top left of the screen. If more than one program segment output is fitted, then there are extra boxes depending on how many event outputs there are. -
Page 31: Operator Level 1 - No Program Running
3.0 3508 Controller 3.11.1 Operator Level 1 - No Program Running Home Display Controller identity when using more than one controller Read Only Black = Progress Page Key White = Return Scroll Key Visible Parameters depend on the Segment Type... -
Page 32: Operator Level 1 - Program Running
3.0 3508 Controller 3.11.2 Operator Level 1 - Program Running Home Display Controller identity when using more than one controller Read Only Black = Progress Page Key White = Return Scroll Key See previous diagram: Operator Level 1- No Program Running... -
Page 33: Supervisor Level
3.0 3508 Controller 3.11.3 Supervisor Level 2 To enter Level 2 Scroll Key Level 2 Locked before Pass Code entered Level 1 Home Display Unlocked Level 2 Home Display Black = Progress See previous diagram: Page Key Operator Level 1- No Program Running Hold Page Key for 3 seconds If configured Arrow Key... -
Page 34: 3508 Dual Loop Cascade Control (If Fitted)
4.0 3508 Dual Loop Cascade 4.0 3508 Dual Loop Cascade Control (if fitted) Principle of Cascade Control When cascade control is fitted, the Load Loop 3508 senses the temperature of the workload, and the Element Loop 3508 senses the element temperature. Depending on the oven or furnace model, the Load Thermocouple may be in a fixed position, or may be movable. - Page 35 4.0 3508 Dual Loop Cascade Home Display View Load Loop View Element Loop View The Element Loop should never be adjusted. Note that the elements usually run at a higher temperature than the load.
- Page 36 4.0 3508 Dual Loop Cascade Because the details of the customer’s cascade application (in particular the nature of the load) are generally not known, the feed forward parameter (FF Trim) is made easily accessible in level 2 (Refer to instrument operating instructions). Its default setting is 2%.
- Page 37 4.0 3508 Dual Loop Cascade Power Limit View...
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Page 38: Bypassing Cascade Control
4.0 3508 Dual Loop Cascade Bypassing Cascade Control This applies where the Control Thermocouple is a removal probe (e.g. in a tube furnace), or where for other reasons it may be required to operate the furnace or oven directly from the Element Loop. To operate without Cascade Control the load thermocouple has to remain connected at all time;... -
Page 39: 2132 Over-Temperature Controller Description (If Fitted)
5.0 2132 Over-Temperature 5.0 2132 Over-Temperature Controller Description (if fitted) Description Alarm Light Page Scroll D Down Display This over-temperature controller is fitted and supplied ready to use by Carbolite Gero. It is a digital instrument with a latching alarm, requiring no additional panel controls. The controller features easy setting of over-temperature setpoint and reading of current temperature by the over-temperature sensor. -
Page 40: Operation
5.0 2132 Over-Temperature 5.2.2 Operation When switched on, the controller lights up, goes through a short test routine and then displays the measured temperature or the over-temperature setpoint. The page key allows access to parameter lists within the controller. A single press of the page key displays the temperature units, normally set to °C;... -
Page 41: Audible Alarm
5.0 2132 Over-Temperature Audible Alarm If an audible alarm is supplied for use with the over-temperature controller, it is normally configured to sound on over-temperature condition and to stop sounding when the alarm is acknowledged as given in section 5.2. Note: the alarm may sound during controller start-up. -
Page 42: Operation
6.0 Operation 6.0 Operation Operating Cycle The product is fitted with an instrument switch. The switch cuts off power to the controllers and contactor. Connect the product to the electrical supply. The cooling fans will operate. Turn on the instrument switch to activate the temperature controllers. The controllers illuminate and go through a short test cycle. -
Page 43: Loading The Furnace
6.0 Operation When the product is opened during operation there is considerable radiated heat. Do not keep any flammable objects near the product, nor objects which could be damaged by radiated heat. Loading The Furnace When heating large objects, in particular poor conductors, avoid shielding the thermocouple from the heating elements. -
Page 44: Pesting
6.0 Operation may be used with nitrogen, argon or helium atmospheres to 1600 °C. Reducing atmospheres are not recommended. Sulphur dioxide is not harmful in low concentrations. However chlorine and fluorine attacks oxidised elements and should be avoided. A harmful gas is produced and collects in poorly ventilated spaces. The furnace is not recommended for burning off carbonaceous materials. -
Page 45: Thermocouple Warnings
6.0 Operation The programmer is used in conjunction with a phase angle thyristor power controller, which incorporates a current limit potentiometer pre-set by Carbolite Gero, but which will require adjustment in the event of change of supply voltage. The elements are connected in series across the low voltage output of a transformer housed in the furnace case. -
Page 46: General Operating Advice
6.0 Operation 6.12 General Operating Advice Heating element life is shortened by overheating. Do not leave the product at high temperature when it is not required. The maximum temperature is shown on the product rating label and in section 12.0 towards the back of this manual. -
Page 47: Maintenance
7.0 Maintenance 7.0 Maintenance General Maintenance Preventive rather than reactive maintenance is recommended. The type and frequency depends on the product use; the following are recommended. Maintenance Schedule CUSTOMER QUALIFIED PERSONNEL DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically qualified personnel should attempt these maintenance procedures. - Page 48 7.0 Maintenance Thorough inspection and report incor- Operational Check porating a test of all functions Performance Element Circuit Electrical measurement Measure the current drawn on each phase / Power Consumption circuit Hearth Visual check for fit and damage Cooling Fans (if fitted) Check whether the cooling fans are working...
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Page 49: Cleaning
7.0 Maintenance 7.2.1 Cleaning Soot deposits may form inside the furnace, depending on the process. At appropriate intervals remove these by heating as indicated in the General Operation Notes. The product's outer surface may be cleaned with a damp cloth. Do not allow water to enter the interior of the case or chamber. -
Page 50: Element Glaze
7.0 Maintenance 7.2.4 Element Glaze Depending on the use, heating elements may lose their glaze and gain a rough appearance. They should be checked from time to time. If the glaze has disappeared, it may be restored by heating the furnace up to 1500 °C, without load, for approximately 2 hours. -
Page 51: Power Adjustment (Thyristor)
7.0 Maintenance Power Adjustment (Thyristor) The current-limiting thyristor stacks which control power to the elements are fitted with an adjustable resistor which is factory set to limit the maximum current supplied. In the event of a change of supply voltage, or the fitting of a new thyristor, further adjustment may be required. -
Page 52: Repairs And Replacements
8.0 Repairs and Replacements 8.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Immediately switch the product off in the event of unforeseen circumstances (e.g. large amount of smoke). Allow the product to return to room temperature before inspection. Always ensure that the product is disconnected from the electrical supply before repair work is carried out. -
Page 53: Thyristor Replacement And Adjustment
8.0 Repairs and Replacements Remove the panel by loosening the four fixing screws (behind plastic caps) at the left- hand end of the furnace; do not remove the screws. Lift the panel about 15 mm and then pull off to the side. Thyristor Replacement and Adjustment Replacement To replace the thyristor unit, isolate the furnace from the electrical supply and remove... -
Page 54: Fuse Replacement
8.0 Repairs and Replacements Fuse Replacement Access to internal fuses is by removal of the furnace side cover (see section 8.3). See section 11.0 for details of fuses fitted. Thermocouple Replacement Disconnect the product from the supply and remove the product's element access panel. Make a note of the thermocouple connections. - Page 55 8.0 Repairs and Replacements 1700 °C models: 42 mm 1800 °C models: 45 mm Lower the elements into position, and connect the braids according to the scheme shown below, using the clip tool provided. The braids must be held tightly to the element as the clips are fitted: good contact is essential;...
- Page 56 8.0 Repairs and Replacements Use of Clip Tool The tool comprises two levers. Element Fitting Layout 1. Clip tool 2. Apply hand pressure Braid Roof Insulation Element block D Element Element Clamp See text...
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Page 57: Insulation Replacement
8.0 Repairs and Replacements Element Connections - 5 Elements Insulation Replacement See section 8.2 - wearing a face mask is required. After any replacement of insulation material, run the furnace at 1500 - ° C to burn off volatile matter. Do this in a well ventilated area. Try to ensure that there is some chamber ventilation, but not too much as this could result in cracked insulation. -
Page 58: Fuse Replacement
8.0 Repairs and Replacements In the case of the 380-415 V version, there are three tappings marked 380, 400 and 415. The thermal trip connection forms part of the circuit to the contactor coil. The L and N connection may alternatively be L1 and L2 for a live-to-live supply. The L side should be connected to the correct tapping to match the electrical supply voltage. - Page 59 8.0 Repairs and Replacements...
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Page 60: Fault Analysis
9.0 Fault Analysis 9.0 Fault Analysis Furnace Does Not Heat Up The HEAT An ohm meter applied to light(s) the element circuit shows A heating element has failed. are ON. an open circuit. The HEAT The controller shows a The thermocouple has broken or has light(s) very high temperature or a wiring fault. -
Page 61: Product Overheats
9.0 Fault Analysis Product Overheats The HEAT light goes The controller OFF with the shows a very high The controller is faulty. instrument switch. temperature. The thermocouple may have The controller been shorted out or may shows a low have been moved out of the temperature. -
Page 62: Wiring Diagrams
10.0 Wiring Diagrams 10.0 Wiring Diagrams 10.1 Single Phase 208 V, 220-240 V Thermal cutouts: case temperature sensor transformer temperature sensor Wire colour: Blue Pink Grey... - Page 63 10.0 Wiring Diagrams GR/ Y Green & Yellow...
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Page 64: Fuses And Power Settings
11.0 Fuses and Power Settings 11.0 Fuses and Power Settings 11.1 Fuses F1-F2: Refer to the circuit diagrams. GEC Safeclip of the type shown Fitted if supply cable fitted. Internal (glass type F up to 16 A) Supply Fitted on board to some types 38 mm x 10 mm type F fitted on Fuses of EMC filter. - Page 65 11.0 Fuses and Power Settings Please refer to the rating label for product specific information.
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Page 66: Specifications
12.0 Specifications 12.0 Specifications Carbolite Gero reserves the right to change the specification without notice. Chamber Size Approx Weight Capacity Load Temp Model Power* (kg) (kg) (kW) (°C) HTF 18/04 1800 * Maximum power as measured, included ancillary components and transformer losses. 12.1 Environment The models listed in this manual contains electrical parts and should be stored and used... - Page 67 Notes Service Record Engineer Name Date Record of Work...
- Page 68 The products covered in this manual are only a small part of the wide range of ovens, chamber furnaces and tube furnaces manufactured by Carbolite Gero for laboratory and industrial use. For further details of our standard or custom built products please contact us at the address below, or ask your nearest stockist.