VERDER CARBOLITE GERO BLF 18/3 Handbuch

Installation, Operation and Maintenance Instructions

1800°C Bottom Loading Furnace - BLF Model: 3 Litres

3508 Controller

BLF 18/3 + 3508 Controller

MEN-BLF1803-001_3508 (09-01-2019)

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 General Warnings 6

2.0 Installation 7

2.1 Unpacking and Handling 7

2.2 Siting and Setting Up 7

2.3 Tie Wrap Removal Instructions 9

2.4 Fitting the Chimney and Heating Elements 10

2.5 Electrical Connections 11

3.0 3508 Controller 13

3.1 PID control 13

3.2 3508P1 13

3.3 3508P10 13

3.4 3508P25 13

3.5 Basic Operation 14

3.5.1 Controller Layout 15

3.5.2 Keys 15

3.6 Quick Start Guide 15

3.6.1 Operation as a simple controller 15

3.6.2 Changing the Setpoint 15

3.6.3 Resetting the programmer 16

3.6.4 Understanding User Levels 16

3.7 Setting Up Controller 17

3.7.1 Maximum output power setting 17

3.7.2 Customer ID. 17

3.7.3 Units 18

3.7.4 Language 18

3.8 Programming 18

3.8.1 Programming Notes 18

3.8.2 Holdback 19

3.8.3 Wait Segments 19

3.8.4 Program Cycling 20

3.8.5 Creating a Program 20

3.8.6 Running a Program 21

3.8.7 To pause (hold) a program 22

3.8.8 To stop and reset a program 22

3.8.9 To run a different program (P10 and P25) 22

3.8.10 Program Status 22

3.8.11 Program Hold with Holdback 23

3.8.12 Power Failure Recovery 23

3.8.13 Alarms 23

3.8.14 Program Example 1 24

3.8.15 Program Example 2 26

3.9 Controller Options 28

3.9.1 Digital Communications - RS232 29

3.9.2 Digital Communications - RS485 29

3.9.3 Comms Address 29

3.9.4 Alarm Option 29

3.9.5 Remote Input and Output (Analogue Communications) 30

3.9.6 Program segment output 30

3.10 Temperature Controller Replacement 31

3.11 Controller Navigation Diagrams 31

3.11.1 Operator Level 1 - No Program Running 32

3.11.2 Operator Level 1 - Program Running 33

3.11.3 Supervisor Level 2 34

4.0 3508 Dual Loop Cascade Control (if fitted) 35

4.1 Principle of Cascade Control 35

4.2 Operation of Cascade Control 35

4.3 Bypassing Cascade Control 39

4.4 3508P1 Element Loop (Loop 2) 39

4.5 Caution 39

4.6 Over-Temperature Control 39

5.0 2132 Over-Temperature Controller Description (if fitted) 40

5.1 Description 40

5.2 Operation 40

5.2.1 Controls 40

5.2.2 Operation 41

5.2.3 Over-Temperature Operation 41

5.2.4 Over-Temperature Alarm 41

5.2.5 Resetting the Over-Temperature Alarm 41

5.2.6 Sensor Break 41

5.3 Audible Alarm 42

5.4 Navigation Diagram 42

6.0 Operation 43

6.1 Operating Cycle 43

6.2 Emergency Stop Button 43

6.3 General Operating Advice 43

6.4 Atmospheres & Corrosive Materials 44

6.5 Operator Safety 45

6.6 Notes on Temperature Control 45

6.7 Insulation Cracking 45

6.8 Thermocouple Warnings 45

6.9 Inverted Crucible Option 46

6.10 Element Protection Tube Option 46

7.0 Maintenance 47

7.1 General Maintenance 47

7.2 Maintenance Schedule 47

7.2.1 Cleaning 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 Fuse Replacement 52

8.6 Thermocouple Replacement 52

8.7 Element Protection Tube Option Replacement Procedure 53

8.8 Insulation Replacement 53

8.9 Element Installation and Replacement 54

9.0 Fault Analysis 57

A. Furnace Does Not Heat Up 57

B. Product Overheats 58

10.0 Wiring Diagrams 59

10.1 195-1-1013 59

11.0 Fuses and Power Settings 60

11.1 Fuses 60

11.2 Power Settings 60

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 General Warnings

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.

Caution – Double Pole/Neutral Fusing

2.0 Installation

2.1 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.

Some models may alternatively be lifted by fitting lifting bolts to captive threads in the

top of the case.

Remove any packing material.

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.

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.

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.

2.3 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. Locate the tie wrap that has been used to prevent the arm from moving. It is

marked with a tag as shown in the photograph below.

3. Cut the tie wrap and discard.

4. Replace the back panel.

2.0 Installation

2.4 Fitting the Chimney and 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.

separately packed items BLF

Elements 6

Element Clamps 6

Elements Clips* 12

Braids* 1 set

Separators 6

* or combined clips and braids may be supplied

BLF /3 transit clamps

Upper Clamp:

1. Remove lower clamp first

2. Remove two M8 nuts and washers, supporting

plate (3) from underneath

3. Remove plate

Lower Clamp:

1. Remove bottom M8 nut

2. Remove two M6 bolts

3. Remove plate

4. Unscrew rod, using spanner on (5) if necessary

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