VERDER CARBOLITE GERO 3508 Series Handbuch

Installation, Operation and Maintenance Instructions

1700°C Chamber Furnace - HTF Model: 25 Litres

3508 Controller

HTF 17/25 + 3508 Controller

MEN-HTF1725-001_3508 (02-08-2019)

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. Use the product for the purpose for which it is intended.

1.0 Symbols and Warnings 6

1.1 Switches and Lights 6

1.2 Warning Symbols 6

2.0 Installation 8

2.1 Unpacking & Handling 8

2.2 Siting and Setting Up 8

2.3 Fitting the Heating Elements 10

2.4 Electrical Connections 10

3.0 3508 Controller 12

3.1 PID control 12

3.2 3508P1 12

3.3 3508P10 12

3.4 3508P25 12

3.5 Basic Operation 13

3.5.1 Controller Layout 14

3.5.2 Keys 14

3.6 Quick Start Guide 14

3.6.1 Operation as a simple controller 14

3.6.2 Changing the Setpoint 14

3.6.3 Resetting the programmer 15

3.6.4 Understanding User Levels 15

3.7 Setting Up Controller 16

3.7.1 Maximum output power setting 16

3.7.2 Customer ID. 16

3.7.3 Units 17

3.7.4 Language 17

3.8 Programming 17

3.8.1 Programming Notes 17

3.8.2 Holdback 18

3.8.3 Wait Segments 18

3.8.4 Program Cycling 19

3.8.5 Creating a Program 19

3.8.6 Running a Program 20

3.8.7 To pause (hold) a program 21

3.8.8 To stop and reset a program 21

3.8.9 To run a different program (P10 and P25) 21

3.8.10 Program Status 21

3.8.11 Program Hold with Holdback 22

3.8.12 Power Failure Recovery 22

3.8.13 Alarms 23

3.8.14 Program Example 1 23

3.8.15 Program Example 2 25

3.9 Controller Options 27

3.9.1 Digital Communications - RS232 28

3.9.2 Digital Communications - RS485 28

3.9.3 Comms Address 28

3.9.4 Alarm Option 28

3.9.5 Remote Input and Output (Analogue Communications) 29

3.9.6 Program segment output 29

3.10 Temperature Controller Replacement 30

3.11 Controller Navigation Diagrams 30

3.11.1 Operator Level 1 - No Program Running 31

3.11.2 Operator Level 1 - Program Running 32

3.11.3 Supervisor Level 2 33

4.0 3508 Dual Loop Cascade Control (if fitted) 34

4.1 Principle of Cascade Control 34

4.2 Operation of Cascade Control 34

4.3 Bypassing Cascade Control 38

4.4 3508P1 Element Loop (Loop 2) 38

4.5 Caution 38

4.6 Over-Temperature Control 38

5.0 2132 Over-Temperature Controller Description (if fitted) 39

5.1 Description 39

5.2 Operation 39

5.2.1 Controls 39

5.2.2 Operation 40

5.2.3 Over-Temperature Operation 40

5.2.4 Over-Temperature Alarm 40

5.2.5 Resetting the Over-Temperature Alarm 40

5.2.6 Sensor Break 40

5.3 Audible Alarm 41

5.4 Navigation Diagram 41

6.0 Operation 42

6.1 Operating Cycle 42

6.2 Operator Safety 42

6.3 Opening the Door 43

6.4 Insulation Cracking 43

6.5 Atmospheres & Corrosive Materials 43

6.6 Pesting 44

6.7 Explosive Materials 44

6.8 Notes on Temperature Control 44

6.9 Thermocouple Warnings 44

6.10 General Operating Advice 45

7.0 Maintenance 46

7.1 General Maintenance 46

7.2 Maintenance Schedule 46

7.2.1 Cleaning 48

7.2.2 Safety Switch 48

7.2.3 Other Electrical Components 48

7.2.4 Element Glaze 49

7.3 Calibration 49

7.4 After-Sales Service 49

7.5 Recommended Spare Parts and Spare Parts Kit 49

7.6 Power Adjustment (Controller) 49

7.7 Power Adjustment (Thyristor) 50

8.0 Repairs and Replacements 51

8.1 Safety Warning - Disconnection from Power Supply 51

8.2 Safety Warning - Refractory Fibre Insulation 51

8.3 Safety Warning - Molybdenum Disilicide Elements 52

8.4 Temperature Controller Replacement 52

8.5 Side Panel Removal 52

8.6 Thyristor Replacement and Adjustment 52

8.7 Fuse Replacement 53

8.8 Thermocouple Replacement 53

8.9 Element Installation and Replacement 55

9.0 Fault Analysis 58

A. Furnace Does Not Heat Up 58

B. Product Overheats 59

10.0 Wiring Diagrams 60

10.1 Drawing Numbers 60

11.0 Fuses and Power Settings 61

11.1 Fuses 61

11.2 Power Settings 61

12.0 Specifications 62

12.1 Environment 62

1.0 Symbols and Warnings

1.0 Symbols and Warnings

1.1 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.

1.2 Warning Symbols

DANGER – Electric shock. Read any warning printed next to this

symbol.

WARNING: Risk of fatal injury.

DANGER – Hot surface. Read any warning printed next to this

symbol.

WARNING: All surfaces of a product may be hot.

DANGER – Read any warning printed next to this symbol.

FAULT - read any information printed by this symbol.

Caution – Double Pole/Neutral Fusing

1.0 Symbols and Warnings

2.0 Installation

2.0 Installation

2.1 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. The product must be connected to a

power supply before the door can be opened.

NOTE: This product contains Refractory Ceramic Fibre (also known as

Alumino Silicate Wool - ASW). For precautions and advice on handling

this material see section 8.2.

2.2 Siting and Setting Up

Place the product on a level surface in a well ventilated area.

Site away from other sources of heat and on a non-flammable surface that is resistant

to accidental spillage or hot materials.

The surface on which the equipment is mounted should be stable and not subject to

movement or vibrations.

The height of the mounting surface is important to avoid operator strain when loading

and unloading samples.

Unless otherwise stated elsewhere in this manual, ensure that there is at least 150

mm of free space around the back and sides of the product. Clear space is required

above the product to dissipate heat.

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.

Under no circumstances should any objects be placed on top of the product.

Always ensure that any vents on the top of the product are clear of any

obstruction. Always ensure all cooling vents and cooling fans (if fitted) are

clear of any obstruction.

2.0 Installation

2.3 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 6

Element Clamps 12

Element Clips 12

Braids 1 set

Separators/ Block 6

Chimney Unit 1

Remove the top access panel to allow element fitting.

Fit the heating elements vertically into the chamber. Handle the elements with great

care. The installation of these elements is described in section 0.1. Connect the

aluminium braids securely as indicated in the element installation instructions.

2.4 Electrical Connections

Connection by a qualified electrician is recommended.

This model is designed for connection to a three phase power supply. This may be with

neutral or delta, but a product must only be connected to the type and voltage of supply

for which it was made.

Check the product rating label before connection. The supply voltage should agree with

the voltage on the label and the supply capacity should be sufficient for the current on

the label.

The supply should be fused at the next size equal to, or higher than the current on the

label. A table of the most common fuse ratings is also given towards the back of this

manual. When the mains cable is factory fitted, internal fuses are also fitted. It is

essential that the operator ensures that the product is correctly fused.

Products with a factory fitted supply cable are designed to be wired directly to an

isolator or fitted with a line plug.

Products without a factory fitted supply cable require a permanent connection to a fused

and isolated supply. The product's electrical access panel should be temporarily

removed, and connections made to the internal terminals.

If the product is to be connected by line plug. The plug should be within reach of the

operator and should be easy to remove.

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