VERDER CARBOLITE GERO HTF 18/8 Handbuch

Installation, Operation and Maintenance Instructions

1800°C Chamber Furnace - HTF Model: 8 Litres

3508 Controller

HTF 18/8 + 3508 Controller

MEN-HTF1808-001_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 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 Loading The Furnace 43

6.4 Opening the Door 43

6.5 Insulation Cracking 43

6.6 Atmospheres & Corrosive Materials 43

6.7 Pesting 44

6.8 Explosive Materials 44

6.9 Notes on Temperature Control 44

6.10 Thermocouple Warnings 45

6.11 Thermal Cutouts 45

6.12 General Operating Advice 46

7.0 Maintenance 47

7.1 General Maintenance 47

7.2 Maintenance Schedule 47

7.2.1 Cleaning 49

7.2.2 Safety Switch 49

7.2.3 Other Electrical Components 49

7.2.4 Element Glaze 50

7.3 Calibration 50

7.4 After-Sales Service 50

7.5 Recommended Spare Parts and Spare Parts Kit 50

7.6 Power Adjustment (Controller) 50

7.7 Power Adjustment (Thyristor) 51

7.8 Low Voltage Compensation 51

8.0 Repairs and Replacements 52

8.1 Safety Warning - Disconnection from Power Supply 52

8.2 Safety Warning - Refractory Fibre Insulation 52

8.3 Side Panel Removal 52

8.4 Thyristor Replacement and Adjustment 53

8.5 Temperature Controller Replacement 53

8.6 Fuse Replacement 54

8.7 Thermocouple Replacement 54

8.8 Element Installation and Replacement 54

8.9 Insulation Replacement 57

8.10 Transformer Tappings 57

8.11 Fuse Replacement 58

9.0 Fault Analysis 60

A. Furnace Does Not Heat Up 60

B. Product Overheats 61

10.0 Wiring Diagrams 62

10.1 Single Phase 208 V, 220-240 V 62

10.2 Two phase 380/ 220 V - 415/ 240 V 63

11.0 Fuses and Power Settings 65

11.1 Fuses 65

11.2 Power Settings 65

12.0 Specifications 67

12.1 Environment 67

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.

Separately Packed Items 1800 °C Models

Elements 5

Element Clamps 10

Element Clips 10

Braids 1 set of 6

2.0 Installation

Separators/ Block 5

Chimney Unit 1

The installation of these elements is described in section 0.1.

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).

Supply Terminal Label Cable Colour

Supply Types

Live - Neutral Reversible or Live-

Live

1-phase L Brown to live

to either power

conductor

(For USA 200-240V,

connect L1)

N Blue to neutral

to the other power

conductor

(For USA 200-240V,

connect L2)

PE Green/ Yellow to earth

(ground) to earth (ground)

Electrical Connection Details:

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