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VERDER CARBOLITE GERO HTF 17/10, Installation, Operation And Maintenance Instructions

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VERDER CARBOLITE GERO HTF 17/10 Installation, Operation And Maintenance Instructions Download Page 53

8.0

Repairs and Replacements

8.1

Safety Warning - Disconnection from Power Supply

Immediately switch the product off in the event of unforeseen
circumstances (e.g. large amount of smoke). Allow the product to return
to room temperature before inspection.

Always ensure that the product is disconnected from the electrical supply
before repair work is carried out.

Caution

: Double pole/neutral fusing may be used in this product.

8.2

Safety Warning - Refractory Fibre Insulation

Insulation made from High Temperature Insulation Wool

Refractory Ceramic Fibre, better known as (Alumina silicate
wool - ASW).

This product contains

alumino silicate wool

products in its thermal insulation. These

materials may be in the form of blanket or felt, formed board or shapes, slab or loose
fill wool.

Typical use does not result in any significant level of airborne dust from these materials,
but much higher levels may be encountered during maintenance or repair.

Whilst there is no evidence of any long term health hazards, it is strongly recommended
that safety precautions are taken whenever the materials are handled.

Exposure to fibre dust may cause respiratory disease.

When handling the material, always use approved respiratory protection
equipment (RPE-eg. FFP3), eye protection, gloves and long sleeved clothing.

Avoid breaking up waste material. Dispose of waste in sealed containers.

After handling, rinse exposed skin with water before washing gently with
soap (not detergent). Wash work clothing separately.

Before commencing any major repairs it is recommended to make reference to the
European Association representing the High Temperature Insulation Wool industry
(www.ecfia.eu).

Further information can be provided on request. Alternatively, Carbolite Gero Service
can quote for any repairs to be carried out either on site or at the Carbolite Gero
factory.

8.3

Side Panel Removal

Except where explicitly stated, always disconnect the electrical supply
before removing the side panel.

53

8.0   Repairs and Replacements

Summary of Contents for CARBOLITE GERO HTF 17/10

Page 1: ...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 ...

Page 2: ... 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...

Page 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 ...

Page 4: ... 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 Insulatio...

Page 5: ... 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 5 ...

Page 6: ...ht 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 sym...

Page 7: ...Caution Double Pole Neutral Fusing 7 1 0 Symbols and Warnings ...

Page 8: ...ool 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...

Page 9: ...jects 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 elem...

Page 10: ...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 ele...

Page 11: ... 5 or HTF 18 4 It is not possible to modify and use a furnace manufactured for the 380 415 range on either of the other two voltage ranges listed above there are too many component differences It is possible to modify a furnace manufactured for either 208 and 220 240 provided the thyristor unit is replaced A transformer tapping must also be altered See sections 8 4 and 8 10 It is possible to alter...

Page 12: ... the 208 V transformer tapping and adjust the thyristor stack l to change from a supply of 220 V to 230 V move a cable to the 230 V and adjust the thyristor stack Please contract Carbolite Gero Service for guidance and assistance if the power supply shown on the rating label does not match the power supply available 12 ...

Page 13: ...erature control when properly set This controller can store 10 programs of up to 50 segments each Programs can be operated individually or linked by a Call parameter as sub programs or to form single long programs The 3508P10 can also be used as a simple temperature controller 3 4 3508P25 The 3508P25 is a digital temperature controller which uses PID algorithms to give excellent temperature contro...

Page 14: ... Indicator B Power Output Indicator C Not Used D Runs Holds Resets the current program E Page F Scroll G Down H Up I Power Output Percentage J Program Setpoint Temperature PSP when a program is running K Setpoint Temperature SP when basic controlling 14 ...

Page 15: ...ute the display returns to Home 3 6 Quick Start Guide 3 6 1 Operation as a simple controller When switched on the controller goes through a short test routine and then shows the measured temperature Below it the setpoint temperature SP and percentage of power output The controller will immediately attempt to reach the set temperature and maintain it This will cause the product to heat as quickly a...

Page 16: ...program runs The SP temperature of the controller does not apply when a program is operating To pause the program press RUN HOLD To stop the program and return to simple controlling reset press RUN HOLD for 2 seconds When the program ends the programmer will either Automatically reset to operation as a simple controller Dwell at the last temperature of the program with the RUN indicator flashing u...

Page 17: ...Setting Up Controller Before using the controller or during its lifetime certain parameters may have to be set depending on specific requirements To do this the controller must be set to Supervisor Level 2 see Controller Navigation Diagrams 3 7 1 Maximum output power setting Press page until Control Output Hi is displayed Press up or down to adjust the value Depending on the product model the maxi...

Page 18: ...e second segment type End type Dwell For the P10 and P25 programs can be linked together using a Call segment However a lower number program can not be called and a program can not be ended with a call segment A program can be ended in four ways 1 With End segment set to S OP the power to the elements is turned down to 0 no matter what the Setpoint temperature is 2 With End segment set to Reset an...

Page 19: ...oling Off Holdback is switched off To set the holdback type press page twice then press scroll until the display shows Holdback Type for each segment and press up or down to set The default setting for holdback is OFF 3 8 3 Wait Segments Wait prevents the program proceeding to the next segment in a similar way to holdback until the selected Wait For parameter has been met There are 5 Wait For para...

Page 20: ... the display will show ProgEdit 1 Program number On P10 or P25 models press up or down to select a new program number The display will show that new programs have only one segment Holdback Value Press scroll until the display shows Holdback Value If required Press up or down to set a value This value will be used in any segment where a Holdback Type is set Ramp Units These apply to Rate segments o...

Page 21: ...p or down to select PrgIn1 PrgIn2 PrgIn1In2 PrgIn1orIn2 PVWaitIP GoBack to segment number visible only for GoBack segments Press scroll until the display shows GoBack Seg Press down to select a segment number to go back to GoBack Cycles visible only for GoBack segments Press scroll until the display shows GoBack Cycles Press up or down to set a value Call Cycles Visible only for call segments Pres...

Page 22: ...rogram P10 and P25 To select a program Press page until Program Status Reset appears Press scroll then up or down to select a program number To operate the program Press RUN HOLD or Press scroll until the cursor moves to Reset Press up or down to select Run Run will be displayed 3 8 10 Program Status While a program is operating the home display shows 3 values l Top Measured temperature l Centre P...

Page 23: ...not caught up with the program Programming note For P10 and P25 models other programs can be created or changed whilst the current program is operating 3 8 12 Power Failure Recovery If there is a power interruption to the controller during a program when power is restored the controller pauses the program then ramps the temperature back up to the current program setpoint PSP before continuing the ...

Page 24: ...ed On P10 or P25 models press up or down to select a new program number a program with only 1 segment 3 Press scroll until Holdback Value is displayed Default 0 degrees 4 Press scroll until Ramp Units is displayed Press up or down to set to Min 5 Press scroll until Cycles is displayed Default 1 6 Press scroll until Segment 1 is displayed 7 Press scroll until Segment Type is displayed Press up or d...

Page 25: ...set 13 Press page and scroll together to return to the home display To run the program either press RUN HOLD or 14 Press page until Program Status is displayed 15 Press scroll until the cursor moves to the program status of Reset 16 Press to select Run 25 3 0 3508 Controller ...

Page 26: ...Time 120 min 3 8 15 Program Example 2 The following sequence of entries creates and runs the program shown graphically below 1 Turn the Setpoint to 0 by pressing down 2 Press page until Prog Segments Used is displayed On P10 and P25 models press up or down to select a new program number a program with only 1 segment 3 Press scroll until Holdback Value is displayed Press up or down to set to 5 degr...

Page 27: ...pe Rate Target SP 400 degrees Ramp Rate 2 0 degrees per minute Segment Type Step Target SP 200 degrees Segment Type Dwell Holdback High Duration 30 00 0 minutes Segment Type Call Call Prog next number Call Cycles 2 Finish the program with an End segment 11 Press scroll until Segment Type is displayed Press up or down to select End 12 Press scroll until End Type is displayed Press up or down to sel...

Page 28: ...egment 4 Holdback Value 5 C P10 and P25 only Program 3 Example 3 9 Controller Options As options can be ordered in a variety of combinations and for a variety of purposes exact instructions are not given here The full Eurotherm manual may be required to determine customer parameter settings To reveal or hide parameters in the controllers it is necessary to go into configuration mode a security cod...

Page 29: ...20 Link together 3 9 2 Digital Communications RS485 If an RS485 option is supplied the furnace is fitted with two D sockets Connection between products is by straight cable as follows Product end of cable female 25 pin 9 pin RS485 Cable product to PC Computer end of cable 9 pin 25 pin female 2 3 3 2 Tx 3 2 2 3 Rx Com 7 5 _________________ 5 7 Com 3 9 3 Comms Address Typically the comms address is ...

Page 30: ...uration depends on customer requirements Remote input when specified may be switched on and off using the remote setpoint enable parameter in the controller level 2 if this was made available for a particular application In level 2 press page until REM SP Enable is displayed press up or down to select SP1 the normal controller setpoint or SP2 the remote input setpoint SPX will appear in the top le...

Page 31: ... anti static wrist strap or otherwise avoid any possibility of damage to the unit by static electricity Refer to the detailed instructions supplied with the replacement controller Ease apart the two lugs at the side grip the instrument and withdraw it from its sleeve push in the replacement 3 11 Controller Navigation Diagrams The following diagrams detail how to navigate to the various menu option...

Page 32: ...11 1 Operator Level 1 No Program Running HD Home Display Controller identity when using more than one controller R O Read Only Black Progress Page Key White Return Scroll Key Visible Parameters depend on the Segment Type 32 ...

Page 33: ...ogram Running HD Home Display Controller identity when using more than one controller R O Read Only Black Progress Page Key White Return Scroll Key See previous diagram Operator Level 1 No Program Running 33 3 0 3508 Controller ...

Page 34: ...er Level 2 Scroll Key B Level 2 Locked before Pass Code entered L1 Level 1 Home Display Unlocked L2 Level 2 Home Display Black Progress Page Key See previous diagram Operator Level 1 No Program Running Hold Page Key for 3 seconds If configured Arrow Key 34 ...

Page 35: ...scade control system is configured to limit the element temperature to a band around the load temperature typically of 10 of the set point temperature The set point of the load loop shown at the top of the display can be adjusted by the operator The Element Loop shown at the bottom of the display should not be adjusted by the operator will automatically regulate the element temperature to achieve ...

Page 36: ...0 3508 Dual Loop Cascade Key A Home Display View B Load Loop View C Element Loop View The Element Loop should never be adjusted Note that the elements usually run at a higher temperature than the load 36 ...

Page 37: ...temperature or is slow in the final stages FF Trim can be increased a maximum of 10 is suggested Feed Forward View When attempting to control at very low temperatures it can become a problem to achieve stable control because of excessive power being supplied during heating The available power can be limited using the power limit parameter OP Hi make a note of the original settings before adjusting...

Page 38: ...4 0 3508 Dual Loop Cascade Power Limit View 38 ...

Page 39: ...ooling at low temperatures takes longer per degree than it does at high temperatures 4 5 Caution If the Load Thermocouple is removable leave it in the furnace or oven chamber whenever possible Operating with the Cascade Control active and with the Load Thermocouple in an unheated position such as lying on the work bench may cause the furnace or oven to heat up to its maximum temperature wasting po...

Page 40: ...strument switch which cuts off power to the controller and other parts of the control circuit To operate the controller power must be supplied to the product and the instrument switch must be on If a time switch is included in the product circuit this must be in the ON position When an over temperature condition occurs the controller cuts the power to a contactor which in turn cuts power to the he...

Page 41: ... set at 15 C above the furnace or oven maximum working temperature Press scroll twice view the present temperature as measured by the over temperature controller Press it twice the first press shows the temperature units C 5 2 4 Over Temperature Alarm If an over temperature condition occurs the OP2 indicator flashes and an alarm message 2FSH also flashes alternating with the setpoint Power to the ...

Page 42: ...erature condition and to stop sounding when the alarm is acknowledged as given in section 5 2 Note the alarm may sound during controller start up 5 4 Navigation Diagram HL Home List Page Key Black Progress OTSP Over Temperature Setpoint Scroll Key Dashed Through to other options AL Access List For factory access to list and parameters not available to the operator 42 ...

Page 43: ... instrument switch off The case cooling fans continue to operate Leave the fans on until the product cools to below 300 C If the product is to be left unattended isolate it from the electrical supply 6 2 Operator Safety This product incorporates a safety switch which interrupts the heating element circuit when the furnace is opened This prevents the operator touching a live heating element and als...

Page 44: ...ptible to mechanical shock At all times operate the door gently to avoid mechanical shock Opening the door when the furnace is very hot can cause hot air to be sucked by the case cooling fans towards the thermal cut out and activate it see section 6 11 Avoid excessive door opening and shut it as soon as possible 6 5 Insulation Cracking In these furnaces the insulation material is susceptible to su...

Page 45: ...ng is not a problem and can often be seen occurring naturally on the element terminals operating the furnace for prolonged periods at temperature below 600 C will cause pesting to occur on the element surface and will eventually damage the elements Heating on a slow ramp rate or dwelling at temperatures below 600 C for short periods will not cause a problem providing the furnace is operated above ...

Page 46: ...ery low outputs below approximately 600 C and do not give accurate readings at low temperatures They may show a negative temperature when the furnace is started from cold This furnace is not intended to operate with a setpoint below 600 C 6 11 Thermal Cutouts There is a thermal cutout on the interior case surface at the centre top near the chimney In the event of fan failure or any other reason fo...

Page 47: ...trolled ramp rate For more information refer to the controller instructions The product s elements are very susceptible to mechanical shock Take great care when loading or unloading the chamber If it is necessary to load or unload work at elevated temperatures keep the door open for as short a period as possible The insulation cools quickly and may crack though thermal shock For improved insulatio...

Page 48: ...heater light goes out Safety Switch Function Electrical measurement Over Temperature Safety Circuit if fitted Set an over temperature setpoint lower than the displayed temperature and check for an over temperature alarm as detailed in this manual Over Temperature Safety Circuit if fitted Electrical measurement Door Plug Visual inspection checking the seal and whether it is free of damage Door Plug...

Page 49: ...ection and report incor porating a test of all functions Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase circuit Hearth Visual check for fit and damage Cooling Fans if fitted Check whether the cooling fans are working 49 7 0 Maintenance ...

Page 50: ...emperature controller set a safe temperature above ambient The heater lights should illuminate l Open the door and check the heater lights They should no longer be illuminated If the heater lights remain illuminated when the door is open discontinue use and contact Carbolite Gero Service Annual check The following checks should be carried out by a qualified electrician as specified in the Maintena...

Page 51: ...omers premises throughout the world A telephone call or email often enables a fault to be diagnosed and the necessary parts to be despatched In all correspondence please quote the serial number and model type given on the rating label of the product The serial number and model type are also given on the back of this manual when supplied with the product Carbolite Gero Service and Carbolite Gero co...

Page 52: ...age or the fitting of a new thyristor further adjustment may be required The maximum element currents for this model are listed in section 11 0 Please contact Carbolite Gero for further information 7 8 Low Voltage Compensation If the supply voltage proves to be routinely below the nominal figure for which the furnace has been set up there is a 2 position on the transformer primary side which may b...

Page 53: ...e encountered during maintenance or repair Whilst there is no evidence of any long term health hazards it is strongly recommended that safety precautions are taken whenever the materials are handled Exposure to fibre dust may cause respiratory disease When handling the material always use approved respiratory protection equipment RPE eg FFP3 eye protection gloves and long sleeved clothing Avoid br...

Page 54: ...meter Before connecting the electrical supply turn the potentiometer on the thyristor fully to the left anti clockwise This sets the output current of the thyristor to off Connect the electrical supply with the side cover off TAKE CARE Set the furnace temperature to maximum Allow the furnace to start heating up Measure the current through the element circuit This is carried out with the clip on me...

Page 55: ... inserted to grip the sheath 8 8 Element Installation and Replacement See section 8 2 wearing a face mask is required See section 0 1 Safety Warning molybdenum disilicide Molybdenum disilicide elements form a glazed surface when heated Internal stresses can form through heating and cooling which render the glaze fragile The glaze can sometimes splinter into a shower of sharp particles when handled...

Page 56: ...of 10 mm below the bottom of the element and a minimum clearance of 15 mm from the sides of the chamber The elements should be parallel with the side walls Replacements Read the section above on initial installation Remove the aluminium braids and clips using the clip tool provided with the furnace Lift out the old elements and the insulation blocks handle the insulation pieces with care as they a...

Page 57: ... Fitting Layout Use of Clip Tool The tool comprises two levers 1 Clip tool 2 Apply hand pressure Key A Braid B Roof Insulation C Element block D Element E Element Clamp See text 57 8 0 Repairs and Replacements ...

Page 58: ...ge of transformer tapping is required if the electrical supply voltage differs from the present setting To access the transformer tappings first disconnect the furnace from the electrical supply and then remove the left hand side cover see section 8 3 Positions below are given from a viewing position at the left end of the furnace On the left side are the secondary tappings which should not requir...

Page 59: ...g the 2 requires adjustment of the thyristor current see section 8 4 The terminal between the link connection is not used 8 11 Fuse Replacement Fuses are accessed by removal of the appropriate panel as described in the Panel Removal section Depending on the model supply fuses and control circuit fuses may be mounted in their own holders or may be on a circuit board that contains an EMC filter The ...

Page 60: ...8 0 Repairs and Replacements 60 ...

Page 61: ...e door switch may be faulty or need adjustment The thyristor fuse may have blown The power thyristor could be failing to switch on due to internal failure faulty wiring from the controller or fault controller There are no lights glowing on the controller Check the supply fuses and any fuses in the product control compartment The controller may be faulty or not receiving a supply due to a faulty sw...

Page 62: ...horted out or may have been moved out of the furnace The thermocouple may be connected the wrong way around The controller may be faulty 2 The HEAT light does not go off with the instrument switch and the fault persists when a 2 A control fuse is removed from its fuse holder The power thyristor has failed ON Check for an accidental wiring fault which could have overloaded the thyristor Isolate the...

Page 63: ...10 0 Wiring Diagrams 10 1 Single Phase 208 V 220 240 V Thermal cutouts case temperature sensor transformer temperature sensor Wire colour BU Blue R Red P Pink G Grey 63 10 0 Wiring Diagrams ...

Page 64: ...10 0 Wiring Diagrams GR Y Green Yellow 10 2 Two phase 380 220 V 415 240 V Thermal cutouts case temperature sensor transformer temperature sensor Wire colour BU Blue R Red P Pink 64 ...

Page 65: ...G Grey GR Y Green Yellow 65 10 0 Wiring Diagrams ...

Page 66: ... below for fuse rating Model Phases Volts Supply Fuse Rating Thyristor Fuse Rating Current Limit element circuit HTF 17 10 1 phase 208 32 A 50 A 150 A HTF 17 10 1 phase 220 240 32 A 50 A 150 A HTF 17 10 2 phase N 380 415 20 A 30 A 150 A 2 phase designs use the line to line voltage neutral is used for the control circuit see section 7 7 the current limit setting at lower temperatures is 146 A 11 2 ...

Page 67: ...Please refer to the rating label for product specific information 67 11 0 Fuses and Power Settings ...

Page 68: ... Maximum power as measured included ancillary components and transformer losses 12 1 Environment The models listed in this manual contains electrical parts and should be stored and used in indoor conditions as follows Temperature 5 C 40 C Relative humidity Maximum 80 up to 31 C decreasing linearly to 50 at 40 C altitude not exceeding 2000 m electrical supply fluctuation not exceeding 10 overvoltag...

Page 69: ...Notes Service Record Engineer Name Date Record of Work ...

Page 70: ... us at the address below or ask your nearest stockist For preventive maintenance repair and calibration of all furnace and oven products please contact Carbolite Gero Service Telephone 44 0 1433 624242 Fax 44 0 1433 624243 Email ServiceUK carbolite gero com Carbolite Gero Ltd Parsons Lane Hope Hope Valley S33 6RB England Telephone 44 0 1433 620011 Fax 44 0 1433 621198 Email Info carbolite gero com...

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