VERDER CARBOLITE GERO BLF 17/3 Installation, Operation And Maintenance Instructions
1700 c bottom loading furnace - 3 litres controller
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- Page 1 Installation, Operation and Maintenance Instructions 1700°C Bottom Loading Furnace - BLF Model: 3 Litres 3216 Controller BLF 17/3 + 3216 Controller MEN-BLF1703-002_3216 09-01-2019...
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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 3.7.5 Holdback 3.7.6 Ramp Rate 3.7.7 Target Setpoint 3.7.8 Dwell Time 3.7.9 Running a Program 3.7.10 Program Status 3.7.11 Process Value 3.7.12 PSP, Segment Type and Number Controller Options 3.8.1 Digital Communications - RS232 3.8.2 Digital Communications - RS485 3.8.3 Comms Address 3.8.4 Alarm Option...
- Page 4 General Maintenance Maintenance Schedule 6.2.1 Cleaning Calibration After-Sales Service Recommended Spare Parts and Spare Parts Kit Power Adjustment (Controller) Power Adjustment (Thyristor) 7.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Safety Warning - Refractory Fibre Insulation Safety Warning - Molybdenum Disilicide Elements Temperature Controller Replacement Fuse Replacement Thermocouple Replacement...
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Page 5: 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 6: 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 7 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 8: Tie Wrap Removal Instructions
2.0 Installation Tie Wrap Removal Instructions The motor powered arm that operates the hearth movement has been fixed in place for transit. Please ensure the plastic tie wrap used to fix the arm is removed before operation. 1. Remove the back panel of the furnace. 2. -
Page 9: Fitting The Chimney And Heating Elements
2.0 Installation 2.4 Fitting the Chimney and Heating Elements Please refer to the Element Installation and Replacement in section 7.0. 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. separately packed items Elements Element Clamps... -
Page 10: Electrical Connections
2.0 Installation Transit Clamps – dependent on model: the example shown here is for the 3 litre models; remove any transit clamps as shown. Fit the ceramic chimney to the hole that exits the top of the chamber. Most models are supplied with an insulation piece to fit around the chimney;... - Page 11 2.0 Installation Electrical Connection Details: Supply Types Supply Terminal Label Cable Colour Reversible or Live- Live - Neutral Live to either power conductor 1-phase L Brown to live (For USA 200-240V, connect L1) to the other power conductor Blue to neutral (For USA 200-240V, connect L2) to earth...
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Page 12: 3216 Controller
3.0 3216 Controller 3.0 3216 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. 3216P1 The 3216P1 is a digital temperature controller which uses PID algorithms to give excellent temperature control. -
Page 13: Keys
3.0 3216 Controller 3.4.2 Keys The page key is used to access level 2 when held down Page Key for 3 seconds. Scroll Key The scroll key is used to scroll through parameters. When pressed simultaneously the ACK function is used Page and Return to the Home Menu Scroll... -
Page 14: Understanding User Levels
3.0 3216 Controller 3.5.4 Understanding User Levels There are two user levels in the controller; Level 1 (Operator) and Level 2 (Supervisor). Level 1 (Operator) is for the day to day operation of the controller. These parameters are not protected by a security code. Level 2 (Supervisor) provides access to additional parameters. -
Page 15: Setting Up The Controller
3.0 3216 Controller Setting up the Controller Before using the controller (or during its lifetime) certain parameters may have to be set, depending on specific requirements. To do this the controller must be set to supervisor level (Level 2). 3.6.1 Maximum Output Power Press scroll until the display shows OP.HI <OUTPUT HIGH>. -
Page 16: Customer Calibration
3.0 3216 Controller 3.6.6 Customer Calibration The 3216 Controller series are calibrated for life at manufacture, there may however be sensor or other system errors, which affect the accuracy of the measured temperature. Customer calibration can be used to compensate for these errors. Dual Offset Dual point calibration uses two offset values at two corresponding temperatures;... - Page 17 3.0 3216 Controller e.g. If a holdback value of 10 is set and the program is set to ramp to a setpoint of 600 °C, the program will reach 600 °C, then go into a hold state; the hold indicator will light until the product temperature reaches 590 °C, the program will then continue to control again.
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Page 18: Programming
3.0 3216 Controller Programming 3.7.1 Creating a Program Programs can be created in level 1 or level 2 of the 3216P1 and 3216P5. Each program contains 8 Ramp/ Dwell pairs. Note: A currently active program cannot be altered. Go into 'Reset' mode before starting to create or modify a program 3.7.2 Program Number (3216P5 Only) Press scroll... -
Page 19: Running A Program
3.0 3216 Controller If not all the segments are used for a program, the Ramp & Dwell of each of the subsequent segments should be set to OFF. A program will end in one of two ways, either revert to the control setpoint or dwell at the temperature set in the last segment used. - Page 20 3.0 3216 Controller Working Output Power From the home display, press scroll until the display shows WRK.OP <WORKING OUTPUT POWER>. This shows the power being used as a percentage. Time Remaining Press scroll until the display shows T.REMN <TIME REMAINING>. This shows the dwell time remaining for the current segment.
- Page 21 3.0 3216 Controller Program Example The following sequence of entries creates and runs the program shown graphically below. 1. Press scroll until the display shows RAMP.U <SP RAMP UNITS>. Select MIN. 2. Press scroll until the display shows DWELL.U <DWELL UNITS>. Select MIN. 3.
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Page 22: Controller Options
3.0 3216 Controller RMP.1= 5°C/Min RMP.1= 4°C/Min RMP.1= OFF RMP.1= 3°C/Min RMP.1=5°C T.SP1= 600°C T.SP1= 400°C T.SP1= 600°C T.SP1= 800°C T.SP1= 400°C Dwel.1= 30 Min Dwel.1= 30 Min Dwel.1= 60 Min Dwel.1= OFF Dwel.1= 480 Min Controller Options As options can be ordered in a variety of combinations and for a variety of purposes, exact instructions are not given here. -
Page 23: Alarm Option
3.0 3216 Controller address value, access the level 2 list. In level 2 press the page key until the COMMS parameter is displayed. Press up down to select the address value. 3.8.4 Alarm Option When an alarm board is fitted, which consists of a relay with voltage free contacts, for operator use, the contacts are taken to a panel plug on the control panel, wired as indicated: Temperature Controller... - Page 24 3.0 3216 Controller Hold the Page key for 3 Level 1 Press the Scroll Key seconds Press the Scroll Key multiple Locked - password Level 2 times required Access If configured Unlocked Black = Progress Do not raise the power limit (if Dashed = Through multiple accessible) above the design level Multiple Program Only...
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Page 25: 2132 Over-Temperature Controller Description (If Fitted)
4.0 2132 Over-Temperature 4.0 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 26: Operation
4.0 2132 Over-Temperature 4.2.2 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 27: Audible Alarm
4.0 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 4.2. Note: the alarm may sound during controller start-up. -
Page 28: Operation
5.0 Operation 5.0 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 should automatically operate. The furnace is fitted with a pair of gates that have a safety switch. the hearth can only be lowered or raised if the gates are closed. -
Page 29: Atmospheres & Corrosive Materials
5.0 Operation temperature near the heating elements. However, if a large object is placed in the chamber it may record the average temperature of the object and the elements, this can lead to overheating of the elements. Allow large objects to gain heat at a lower temperature and then reset the controller to a temperature close to the desired maximum, or heat using a slowly controlled ramp rate. -
Page 30: Operator Safety
5.0 Operation Operator Safety This product incorporates a safety switch which interrupts the heating element circuit when the furnace is opened. This prevents the operator touching a live heating element and also prevents the product from heating up if the furnace is left open. The operation of this switch should be checked periodically. -
Page 31: Inverted Crucible Option
5.0 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 32: Maintenance
6.0 Maintenance 6.0 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 33 6.0 Maintenance Tested using certified equipment, frequency Temperature Calibration dependent on the standard required Operational Check Check that all functions are working normally Thorough inspection and report incorporating a Operational Check test of all functions Performance Element Circuit Electrical measurement Measure the current drawn on each phase / cir- Power Consumption cuit...
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Page 34: Cleaning
6.0 Maintenance 6.2.1 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 35: Power Adjustment (Thyristor)
6.0 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 36: Repairs And Replacements
7.0 Repairs and Replacements 7.0 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 37: Safety Warning - Molybdenum Disilicide Elements
7.0 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 38: Element Protection Tube Option Replacement Procedure
7.0 Repairs and Replacements Element Protection Tube Option Replacement Procedure Ensure the furnace is cold and isolated from the electrical connection. On the underside of the front cowl is a stainless steel mesh, which should be removed for access to the underside of the furnace. You will see three crescent shaped stainless steel brackets which will support the protection tube once in place;... -
Page 39: Element Installation And Replacement
7.0 Repairs and Replacements Element Installation and Replacement See section 7.3 - Safety Warning - molybdenum disilicide. 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 40 7.0 Repairs and Replacements Braid Roof Insulation Element block D Element Element Clamp See text Clip Braid Element Connections (3-phase example)
- Page 41 7.0 Repairs and Replacements Use of Clip Tool The distance from the top of the element clamp to the top of the element should be 40 mm. Larger clips require the clip tool, comprising two levers: 1. Clip tool 2. Apply hand pressure...
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Page 42: Fault Analysis
8.0 Fault Analysis 8.0 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 43: Product Overheats
8.0 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 44: Wiring Diagrams
9.0 Wiring Diagrams 9.0 Wiring Diagrams 195-1-1013... -
Page 45: Fuses And Power Settings
10.0 Fuses and Power Settings 10.0 Fuses and Power Settings 10.1 Fuses F1 to F3 - 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... - Page 46 10.0 Fuses and Power Settings The setting for the power limit parameter in the controller (OP.Hi) should be 100% for this product. Please refer to the rating label for product specific information. Please refer to the rating label for product specific information.
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Page 47: Specifications
11.0 Specifications 11.0 Specifications Carbolite Gero reserves the right to change the specification without notice. Approx. Chamber Size (mm) Max Temp Max Power Net Weight Capacity Model (°C) (kW) (kg) Height Diameter Bottom Loading Furnaces heated by Molybdenum Disilicide elements, with electrically operated hearth. - Page 49 Notes Service Record Engineer Name Date Record of Work...
- Page 50 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.
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