VERDER CARBOLITE GERO HTF 17/10 Handbuch

Installation, Operation and Maintenance Instructions

1700°C Chamber Furnace - HTF Model: 10 Litres

3508 Controller

HTF 17/10 + 3508 Controller

MEN-HTF1710-001_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 and Handling 8

2.2 Siting and Setting Up 8

2.3 Fitting the Heating Elements 9

2.4 Electrical Connections 10

2.5 Power Supply Notes 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 Operator Safety 43

6.3 Loading The Furnace 44

6.4 Opening the Door 44

6.5 Insulation Cracking 44

6.6 Atmospheres & Corrosive Materials 44

6.7 Pesting 45

6.8 Explosive Materials 45

6.9 Notes on Temperature Control 45

6.10 Thermocouple Warnings 46

6.11 Thermal Cutouts 46

6.12 General Operating Advice 46

7.0 Maintenance 48

7.1 General Maintenance 48

7.2 Maintenance Schedule 48

7.2.1 Cleaning 50

7.2.2 Safety Switch 50

7.2.3 Other Electrical Components 50

7.2.4 Element Glaze 51

7.3 Calibration 51

7.4 After-Sales Service 51

7.5 Recommended Spare Parts and Spare Parts Kit 51

7.6 Power Adjustment (Controller) 51

7.7 Power Adjustment (Thyristor) 52

7.8 Low Voltage Compensation 52

8.0 Repairs and Replacements 53

8.1 Safety Warning - Disconnection from Power Supply 53

8.2 Safety Warning - Refractory Fibre Insulation 53

8.3 Side Panel Removal 53

8.4 Thyristor Replacement and Adjustment 54

8.5 Temperature Controller Replacement 54

8.6 Fuse Replacement 55

8.7 Thermocouple Replacement 55

8.8 Element Installation and Replacement 55

8.9 Insulation Replacement 58

8.10 Transformer Tappings 58

8.11 Fuse Replacement 59

9.0 Fault Analysis 61

A. Furnace Does Not Heat Up 61

B. Product Overheats 62

10.0 Wiring Diagrams 63

10.1 Single Phase 208 V, 220-240 V 63

10.2 Two phase 380/ 220 V - 415/ 240 V 64

11.0 Fuses and Power Settings 66

11.1 Fuses 66

11.2 Power Settings 66

12.0 Specifications 68

12.1 Environment 68

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 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.

Remove any packing material from the door great and from inside the product

chamber. Close the door with care to prevent any damage to insulation surfaces.

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.

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.

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 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.

2.0 Installation

Separately Packed Items 1700 °C Models

Elements 4

Element Clamps 8

Element Clips 8

Braids 1 set of 5

Separators/ Block 4

Chimney Unit 1

The installation of these elements is described in section 8.8

2.4 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.

Check that the supply voltage is compatible with the voltage on the label, and that the

current capacity is sufficient for the current on the label, before connection to the

electrical supply. A table of the most common ratings is given in section 11.0 towards

the back of this manual.

Normally a supply cable is not fitted, and connection is to be made to terminal blocks

accessed by removal of the left-hand end side cover (see section 8.3). The electrical

supply cable must be properly connected and fitted with an appropriate strain relief at

the entry to the case.

The electrical supply cable should be wired to an isolator or fitted with a line plug. The

isolator must be within easy reach of the operator, or the line plug must be easily

removable and on a lead not exceeding 3 m length. The line plug must allow the

protective earth (ground) to be connected before the supply conductors and to be

disconnected after them. The supply point must be marked as the disconnecting device

for the furnace.

The electrical supply MUST incorporate an earth (ground).

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