VERDER CARBOLITE GERO HTF 18/27 Handbuch

Installation, Operation and Maintenance Instructions

1800°C Chamber Furnace - HTF Model: 27 Litres

3508 Controller

HTF 18/27 + 3508 Controller

MEN-HTF1827-001_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 General Warnings 6

2.0 Installation 7

2.1 Unpacking and Handling 7

2.2 Siting and Setting Up 7

2.3 Fitting the Heating Elements 9

2.4 Transit Clamp Removal 10

2.5 Thermocouple Installation 13

2.6 Heating Element Installation 16

2.7 Electrical Connections 18

3.0 3508 Controller 20

3.1 PID control 20

3.2 3508P1 20

3.3 3508P10 20

3.4 3508P25 20

3.5 Basic Operation 21

3.5.1 Controller Layout 22

3.5.2 Keys 22

3.6 Quick Start Guide 22

3.6.1 Operation as a simple controller 22

3.6.2 Changing the Setpoint 22

3.6.3 Resetting the programmer 23

3.6.4 Understanding User Levels 23

3.7 Setting Up Controller 24

3.7.1 Maximum output power setting 24

3.7.2 Customer ID. 24

3.7.3 Units 25

3.7.4 Language 25

3.8 Programming 25

3.8.1 Programming Notes 25

3.8.2 Holdback 26

3.8.3 Wait Segments 26

3.8.4 Program Cycling 27

3.8.5 Creating a Program 27

3.8.6 Running a Program 28

3.8.7 To pause (hold) a program 29

3.8.8 To stop and reset a program 29

3.8.9 To run a different program (P10 and P25) 29

3.8.10 Program Status 29

3.8.11 Program Hold with Holdback 30

3.8.12 Power Failure Recovery 30

3.8.13 Alarms 31

3.8.14 Program Example 1 31

3.8.15 Program Example 2 33

3.9 Controller Options 35

3.9.1 Digital Communications - RS232 36

3.9.2 Digital Communications - RS485 36

3.9.3 Comms Address 36

3.9.4 Alarm Option 36

3.9.5 Remote Input and Output (Analogue Communications) 37

3.9.6 Program segment output 37

3.10 Temperature Controller Replacement 38

3.11 Controller Navigation Diagrams 38

3.11.1 Operator Level 1 - No Program Running 39

3.11.2 Operator Level 1 - Program Running 40

3.11.3 Supervisor Level 2 41

4.0 3508 Dual Loop Cascade Control (if fitted) 42

4.1 Principle of Cascade Control 42

4.2 Operation of Cascade Control 42

4.3 Bypassing Cascade Control 46

4.4 3508P1 Element Loop (Loop 2) 46

4.5 Caution 46

4.6 Over-Temperature Control 46

5.0 2132 Over-Temperature Controller Description (if fitted) 47

5.1 Description 47

5.2 Operation 47

5.2.1 Controls 47

5.2.2 Operation 48

5.2.3 Over-Temperature Operation 48

5.2.4 Over-Temperature Alarm 48

5.2.5 Resetting the Over-Temperature Alarm 48

5.2.6 Sensor Break 48

5.3 Audible Alarm 49

5.4 Navigation Diagram 49

6.0 Operation 50

6.1 Operating Cycle 50

6.2 Operator Safety 50

6.3 Opening the Door 51

6.4 Insulation Cracking 51

6.5 Atmospheres & Corrosive Materials 51

6.6 Pesting 52

6.7 Explosive Materials 52

6.8 Notes on Temperature Control 52

6.9 Thermocouple Warnings 52

6.10 General Operating Advice 53

7.0 Maintenance 54

7.1 General Maintenance 54

7.2 Maintenance Schedule 54

7.2.1 Cleaning 56

7.2.2 Safety Switch 56

7.2.3 Other Electrical Components 56

7.2.4 Element Glaze 57

7.3 Calibration 57

7.4 After-Sales Service 57

7.5 Recommended Spare Parts and Spare Parts Kit 57

7.6 Power Adjustment (Controller) 57

7.7 Power Adjustment (Thyristor) 58

8.0 Repairs and Replacements 59

8.1 Safety Warning - Disconnection from Power Supply 59

8.2 Safety Warning - Refractory Fibre Insulation 59

8.3 Safety Warning - Molybdenum Disilicide Elements 60

8.4 Temperature Controller Replacement 60

8.5 Side Panel Removal 60

8.6 Thyristor Replacement and Adjustment 60

8.7 Fuse Replacement 61

8.8 Thermocouple Replacement 61

8.9 Element Installation and Replacement 62

9.0 Fault Analysis 65

A. Furnace Does Not Heat Up 65

B. Product Overheats 66

10.0 Wiring Diagrams 67

10.1 Drawing Numbers 67

11.0 Fuses and Power Settings 68

11.1 Fuses 68

11.2 Power Settings 68

12.0 Specifications 69

12.1 Environment 69

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. Never lift it by the door

or any other protruding parts. Even the smaller models contain transformers and are

heavy: using lifting equipment is recommended.

Remove any packing material from the door gear and from inside the product chamber.

The door can be lifted manually and supported open. 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.

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 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.

separately packed items HTF 18/27

Elements 9

Element Clamps 18

Element Clips 18

Braids 1 set

Separators/ Block 9

Chimney Unit 1

Element Supports

Remove the complete top access panel using the hidden screw in holes in the top of the

panel; loosen the screws two turns and remove the panel.

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

care.

Connect the aluminium braids securely as indicated in the element installation

instructions.

2.0 Installation

2.4 Transit Clamp Removal

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