Related Manuals for VERDER CARBOLITE GERO HTF 18/15
Summary of Contents for VERDER CARBOLITE GERO HTF 18/15
- Page 1 Installation, Operation and Maintenance Instructions 1800°C Chamber Furnace - HTF Model: 15 Litres 3508 Controller HTF 18/15 + 3508 Controller MEN-HTF1815-001_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 3.8.8 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 3.9.1 Digital Communications - RS232 3.9.2...
- Page 4 6.0 Operation Operating Cycle Operator Safety Opening the Door Insulation Cracking Atmospheres & Corrosive Materials Pesting Explosive Materials Notes on Temperature Control Thermocouple Warnings 6.10 General Operating Advice 7.0 Maintenance General Maintenance Maintenance Schedule 7.2.1 Cleaning 7.2.2 Safety Switch 7.2.3 Other Electrical Components 7.2.4 Element Glaze...
- Page 5 10.1 239-4-5001 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. General Warnings DANGER –... -
Page 7: Installation
2.0 Installation 2.0 Installation Unpacking & 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 a pallet truck or fork lift to move the product. The product has an electrically actuated door. - Page 8 2.0 Installation Depending on the application of the product, it may be appropriate to position it under an extraction hood. Ensure the extraction hood is switched on during use. Ensure that the product is placed in such a way that it can be quickly switched off or disconnected from the electrical supply.
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Page 9: Fitting The Heating Elements
2.0 Installation Fitting the Heating Elements Please refer to the Element Installation and Replacement in section 8.0. Wear eye protection when handling the heating elements. The molybdenum disilicide elements are EXCEPTIONALLY FRAGILE and are packed separately, together with other items shown in the list. items packed quantity Elements... - Page 10 2.0 Installation When connecting the product to an isolating switch ensure that both conductors (single phase) or on all live conductors (three phase), and should be within reach of the operator. The supply MUST incorporate an earth (ground). Electrical Connection Details: Supply Types Supply Terminal Label...
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Page 11: 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 12: 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... -
Page 13: Controller Layout
3.0 3508 Controller Measurement Temperature 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 Page Key to access further levels, pass codes are required. -
Page 14: Resetting The Programmer
3.0 3508 Controller The controller will immediately attempt to reach the set temperature and maintain it. 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. -
Page 15: 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 16: 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 17: 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 18: Program Cycling
3.0 3508 Controller 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 19: 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 20: 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 21: 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 22: Program Example
3.0 3508 Controller ALM (Alarm) indicator. The alarm may also switch an output – usually a relay to allow external devices to operate when an alarm occurs. Alarms only operate if they have been configured and are dependent on customer requirements. How to acknowledge an alarm will depend on the type of latching which has been configured. - Page 23 3.0 3508 Controller 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. Press page until 'Program Status' is displayed 15.
- Page 24 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 25 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 26: 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 27: 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 28: 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 29: Temperature Controller Replacement
3.0 3508 Controller 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. 3.10 Temperature Controller Replacement Before handling the controller: wear an anti-static wrist strap or... -
Page 30: 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 31: 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 32: 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 33: 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 34 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 35 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 36 4.0 3508 Dual Loop Cascade Power Limit View...
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Page 37: 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 38: 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 39: 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 40: 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 41: Operation
6.0 Operation 6.0 Operation Operating Cycle This product is fitted with an instrument switch which cuts off power to the control circuit. Connect the product to the electrical supply. The cooling fans automatically operate. Electric door models: Before switching on the control instrumentation, check the door switch for correct operation. -
Page 42: Opening The Door
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. Opening the Door Take great care when loading or unloading the furnace chamber. See section 6.2. -
Page 43: Pesting
6.0 Operation The hearth can be protected from abrasion, if required, by the provision of a secondary plate. This consumable item can either be in lightweight ceramic fibre or in dense, hard- wearing alumina refractory. Pesting The furnace is fitted with molybdenum disilicide elements and is therefore susceptible to pesting. -
Page 44: General Operating Advice
6.0 Operation Operators are advised to periodically check the thermocouple output, either by a calibration test or by comparing the output with a new reference thermocouple which has been subjected to high temperatures for a minimum length of time. Failure to check the thermocouple regularly may result in overheating of the work and the furnace, with consequential damage to both. -
Page 45: 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 46 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 47: 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 48: 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 49: 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 50: 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 51: Safety Warning - Molybdenum Disilicide Elements
8.0 Repairs and Replacements Safety Warning - Molybdenum Disilicide Elements Molybdenum disilicide elements form a glazed surface when heated. Internal stresses can form through heating and cooling which render the glaze fragile. The glaze can sometimes splinter into a shower of sharp particles when handled. -
Page 52: Fuse Replacement
8.0 Repairs and Replacements Adjustment After any thyristor unit replacement, or any change of voltage or transformer tapping, the potentiometer on the thyristor must be adjusted to give the correct element current. This should be done by a qualified person, as there are dangerous voltages inside the control compartment. -
Page 53: Element Installation And Replacement
8.0 Repairs and Replacements Disconnect the thermocouple from its terminal block. Bend the metal, or release the thermocouple sheath; withdraw the sheath and shake out any fragments of thermocouple. Re-assemble with a new thermocouple observing the colour coding. Ensure that the thermocouple is not twisted as it is being inserted and that the metal tag is bent back, or the screw inserted, to grip the sheath. - Page 54 8.0 Repairs and Replacements Ensure that the element is correctly placed: the thin part of the element legs should be entirely within the heating chamber; the element should not touch the bottom of the chamber. A guide to the correct placement is given in the table below, using the measurement from the top of the clamp to the top of the element.
- Page 55 8.0 Repairs and Replacements Element Connections - 1-phase Element Connections - 3-phase...
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Page 56: 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 57: 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 58: Wiring Diagrams
10.0 Wiring Diagrams 10.0 Wiring Diagrams 10.1 239-4-5001... - Page 59 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 60 12.0 Specifications 12.0 Specifications Carbolite Gero reserves the right to change the specification without notice. Chamber Size Max Temp Max Power Approx Net Weight (mm) Model (°C) (kW) Capacity (l) (kg) Chamber Furnaces heated by Molybdenum Disilicide elements. HTF 18/15 1800 14.5 12.1...
- Page 61 Notes Service Record Engineer Name Date Record of Work...
- Page 62 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.