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9.0 Fault Analysis

9.0

Fault Analysis

Furnace Does Not Heat Up

The HEAT
light(s)
are ON.

An ohm meter applied to
the element circuit shows
an open circuit.

A heating element has failed.

The HEAT
light(s)
are OFF.

The controller shows a
very high temperature or
a code such as S.br.

The thermocouple has broken or has
a wiring fault.

The controller shows a
low temperature.

The 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
switch or a wiring fault.

Содержание CARBOLITE GERO HTF 18/15

Страница 1: ...Installation Operation and Maintenance Instructions 1800 C Chamber Furnace HTF Model 15 Litres 3508 Controller HTF 18 15 3508 Controller MEN HTF1815 001_3508 02 08 2019 ...

Страница 2: ...Heating Elements 9 2 4 Electrical Connections 9 3 0 3508 Controller 11 3 1 PID control 11 3 2 3508P1 11 3 3 3508P10 11 3 4 3508P25 11 3 5 Basic Operation 12 3 5 1 Controller Layout 13 3 5 2 Keys 13 3 6 Quick Start Guide 13 3 6 1 Operation as a simple controller 13 3 6 2 Changing the Setpoint 13 3 6 3 Resetting the programmer 14 3 6 4 Understanding User Levels 14 3 7 Setting Up Controller 15 3 7 1 ...

Страница 3: ...lacement 29 3 11 Controller Navigation Diagrams 29 3 11 1 Operator Level 1 No Program Running 30 3 11 2 Operator Level 1 Program Running 31 3 11 3 Supervisor Level 2 32 4 0 3508 Dual Loop Cascade Control if fitted 33 4 1 Principle of Cascade Control 33 4 2 Operation of Cascade Control 33 4 3 Bypassing Cascade Control 37 4 4 3508P1 Element Loop Loop 2 37 4 5 Caution 37 4 6 Over Temperature Control ...

Страница 4: ... 7 3 Calibration 48 7 4 After Sales Service 48 7 5 Recommended Spare Parts and Spare Parts Kit 48 7 6 Power Adjustment Controller 48 7 7 Power Adjustment Thyristor 49 8 0 Repairs and Replacements 50 8 1 Safety Warning Disconnection from Power Supply 50 8 2 Safety Warning Refractory Fibre Insulation 50 8 3 Safety Warning Molybdenum Disilicide Elements 51 8 4 Temperature Controller Replacement 51 8 ...

Страница 5: ...10 1 239 4 5001 58 11 0 Fuses and Power Settings 59 11 1 Fuses 59 11 2 Power Settings 59 12 0 Specifications 60 12 1 Environment 60 5 ...

Страница 6: ...ent 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 6 ...

Страница 7: ...vice 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 surfac...

Страница 8: ...e 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 8 ...

Страница 9: ...ve to Neutral reversible or Live to Live Some models may be ordered for 3 phase use which may be star or delta Check the product rating label before connection The supply voltage should agree with the voltage on the label and the supply capacity should be sufficient for the current on the label The supply should be fused at the next size equal to or higher than the current on the label A table of ...

Страница 10: ...e 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 3 phase L1 Black to phase 1 L2 Black to phase 2 L3 Black to phase 3 N Light Blue to neutral except delta PE Green Yellow to earth ground DO NOT connect a ...

Страница 11: ...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...

Страница 12: ... 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 12 ...

Страница 13: ...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...

Страница 14: ...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...

Страница 15: ...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...

Страница 16: ...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...

Страница 17: ...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...

Страница 18: ... 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...

Страница 19: ...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...

Страница 20: ...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...

Страница 21: ...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 ...

Страница 22: ...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...

Страница 23: ...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 23 3 0 3508 Controller ...

Страница 24: ...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...

Страница 25: ...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...

Страница 26: ...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...

Страница 27: ...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 ...

Страница 28: ...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...

Страница 29: ... 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...

Страница 30: ...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 30 ...

Страница 31: ...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 31 3 0 3508 Controller ...

Страница 32: ...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 32 ...

Страница 33: ...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 ...

Страница 34: ...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 34 ...

Страница 35: ...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...

Страница 36: ...4 0 3508 Dual Loop Cascade Power Limit View 36 ...

Страница 37: ...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...

Страница 38: ...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...

Страница 39: ... 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 ...

Страница 40: ...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 40 ...

Страница 41: ... elements are isolated Find and correct the cause before resetting the over temperature controller according to the instructions supplied To switch the product off turn the 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 pro...

Страница 42: ...atmospheres metal oxides react with the silica layer on the surface of the elements and may lead to premature failure Protect the elements from splashes of molten metal and dust when loading the furnace and from fumes developed when melting especially from fluxes Also avoid compounds with a high alkali content The furnace is designed for use up to its maximum temperature in oxidising atmospheres b...

Страница 43: ...minals must be removed in accordance with good health and safety practices 6 7 Explosive Materials The product must not be used to heat materials which could explode or which could emit gases that could form explosive mixtures 6 8 Notes on Temperature Control This product is designed for heating and cooling at controlled rates The heating and cooling rates can be set in the temperature programmer ...

Страница 44: ...nductors avoid shielding the thermocouple from the heating elements The thermocouple is intended to sense the temperature near the heating elements However if a large object is placed in the chamber it may record the average temperature of the object and the elements this can lead to overheating of the elements Allow large objects to gain heat at a lower temperature and then reset the controller t...

Страница 45: ...ctrical 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 Replacement where necessary Chimney Extraction ...

Страница 46: ...t 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 46 ...

Страница 47: ...oller 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 Maintenance Schedule sec...

Страница 48: ...tory and at customers 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 C...

Страница 49: ...stable resistor which is factory set to limit the maximum current supplied In the event of a change of supply voltage 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 49 7 0 Maintenance ...

Страница 50: ...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 respirator...

Страница 51: ...Side Panel Removal Except where explicitly stated always disconnect the electrical supply before removing the side panel Remove the panel by loosening the four fixing screws behind plastic caps at the left hand end of the furnace do not remove the screws Lift the panel about 15 mm and then pull off to the side 8 6 Thyristor Replacement and Adjustment Replacement To replace the thyristor unit isola...

Страница 52: ...an ammeter reading of between 149 to 150 A for the HTF 1700 or 139 to 140 A for theHTF 1800 This adjustment should be set up within the first 5 minutes of heat up from ambient and should finally be checked when the furnace temperature is approximately 100 C below its maximum temperature Make further adjustments if necessary at this temperature Disconnect the electrical supply to ensure safe replac...

Страница 53: ...n contact Handle the heating elements with extreme care as they are VERY FRAGILE Also avoid touching the heating surface the thin part of the element Replacement Note the length of element above the fixing clamps before starting Remove the aluminium braids and clips Remove the clamp which has a screw fixing Lift out the old element and insulation piece element block handle the insulation piece wit...

Страница 54: ...t Replacement heat up the furnace to a moderate temperature and ensure that the furnace is controlling properly in case the previous element failure resulted from a fault in the control system After installing new elements operate the furnace at 1500 C for an hour This creates a protective glaze on the element surface Element Fitting Layout Use of Clip Tool The distance from the top of the element...

Страница 55: ...Element Connections 1 phase Element Connections 3 phase 55 8 0 Repairs and Replacements ...

Страница 56: ...has broken or has a wiring fault The controller shows a low temperature The 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...

Страница 57: ...ave 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 furnace if this fa...

Страница 58: ...10 0 Wiring Diagrams 10 0 Wiring Diagrams 10 1 239 4 5001 58 ...

Страница 59: ...See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating Type HTF 18 15 1 phase 220 240 50 A ES50 HTF 18 15 3 phase N 380 220 415 240 16 A type F1 HTF 18 15 3 phase delta 220 240 32 A NS32 11 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures represent the maximum percentage of time that controlled po...

Страница 60: ...denum Disilicide elements HTF 18 15 1800 9 220 220 300 14 5 270 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 overvoltage category II IE...

Страница 61: ...Notes Service Record Engineer Name Date Record of Work ...

Страница 62: ... 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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