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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.

59

8.0 Repairs and Replacements

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Содержание CARBOLITE GERO HTF 18/27

Страница 1: ...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 ...

Страница 2: ...ting 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 Re...

Страница 3: ...munications 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 ...

Страница 4: ...ety 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 Molyb...

Страница 5: ...ce 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 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: ...ino 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 ...

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: ...ist 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...

Страница 10: ...2 0 Installation 2 4 Transit Clamp Removal 10 ...

Страница 11: ...p cover of the furnace case Photograph 1 To remove the four transit clamps unscrew the fixing screw and remove from the clamp see photograph 2 below then discard the clamp carefully Photograph 2 11 2 0 Installation ...

Страница 12: ...2 0 Installation The four transit clamps are circled on the photograph below Photograph 3 12 ...

Страница 13: ...2 5 Thermocouple Installation 13 2 0 Installation ...

Страница 14: ...ocouple assemblies into the holes in the top of the insulation assembly Photograph 1 Photograph 2 Fix in place with the fixing screws as shown in photograph 3 Connect the thermocouple cables into the ceramic connector blocks The cables and connector blocks are marked with symbols Make sure the on the cable is connected to the on the connector block 14 ...

Страница 15: ...Photograph 3 Photograph 4 Photograph 5 Photograph 6 15 2 0 Installation ...

Страница 16: ...lator between the heating element terminals Place each heating element through the slot in the top insulation as shown in photographs 2 and 3 Be very careful as the elements are very fragile Photograph 2 Photograph 3 Fit the element supports in place as shown in photographs 4 and 5 16 ...

Страница 17: ...lement clamps oven the element terminals as shown in photograph 6 The element clamps have be superseded by the type shown in photograph 7 These are interchangeable with those shown in photograph 6 Photograph 6 Photograph 7 17 2 0 Installation ...

Страница 18: ... chamber Photograph 8 Photograph 9 Fit the element braids using braid clips and the clip tool as shown in photograph 10 Photograph 11 below shows all the element braids fitted Photograph 10 Photograph 11 2 7 Electrical Connections Connection by a qualified electrician is recommended This model is designed for connection to a three phase power supply This may be with neutral or delta but a product ...

Страница 19: ...lator or fitted with a line plug Products without a factory fitted supply cable require a permanent connection to a fused and isolated supply The product s electrical access panel should be temporarily removed and connections made to the internal terminals If the product is to be connected by line plug The plug should be within reach of the operator and should be easy to remove When connecting the...

Страница 20: ... give excellent temperature 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 excellen...

Страница 21: ...or 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 L Measurement Temperature 21 3 0 3508 Controller ...

Страница 22: ... 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 as possible which may not be appropr...

Страница 23: ...ly 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 until the operator presses RUN HOLD for 2 seconds to manually r...

Страница 24: ... now in level 1 3 7 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 pr...

Страница 25: ...e 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 and the Setpoint tempe...

Страница 26: ...eating only High Applies to cooling only Band Applies to both heating and cooling 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 ...

Страница 27: ...times to get to the programming page 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 ...

Страница 28: ...ows Wait For Press up 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 fo...

Страница 29: ...o 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 Program Setpoint PSP ...

Страница 30: ...started again by pressing the RUN HLD button the HLD indicator will flash again if the measured temperature has 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 ...

Страница 31: ...cally below 1 Turn the controller SP down to 0 by pressing down 2 Press page until Prog Segments Used is displayed 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 De...

Страница 32: ...l until End Type is displayed Press up or down to select Reset 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 32 ...

Страница 33: ...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 degrees 4 Press scroll u...

Страница 34: ...am models Segment Type 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 Pre...

Страница 35: ...lue 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 code is needed Please c...

Страница 36: ... together 1 4 6 6 8 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 t...

Страница 37: ... 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 left corner of the d...

Страница 38: ...the controller wear an 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 t...

Страница 39: ...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 39 3 0 3508 Controller ...

Страница 40: ... Operator Level 1 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 See previous diagram Operator Level 1 No Program Running 40 ...

Страница 41: ...y 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 41 3 0 3508 Controller ...

Страница 42: ...the load In practice the cascade 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 elem...

Страница 43: ...y 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 43 4 0 3508 Dual Loop Cascade ...

Страница 44: ...does not reach the desired 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 origina...

Страница 45: ...Power Limit View 45 4 0 3508 Dual Loop Cascade ...

Страница 46: ...rameter to Also note that cooling 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 max...

Страница 47: ... 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 heating elements Power is no...

Страница 48: ... with the over temperature 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 ...

Страница 49: ...top 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 49 5 0 2132 Over Temperature ...

Страница 50: ...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 product incorporates a safety switch which interrupts the heating elem...

Страница 51: ...tal 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 but can be oper...

Страница 52: ...he element terminals 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 temperatu...

Страница 53: ... 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 to a temperatur...

Страница 54: ...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...

Страница 55: ...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 55 7 0 Maintenance ...

Страница 56: ...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...

Страница 57: ...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...

Страница 58: ...ted with an adjustable 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 58 ...

Страница 59: ...irborne 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...

Страница 60: ...e temperature controller 8 5 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 rep...

Страница 61: ... 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 replacement of the side panel See s...

Страница 62: ...t Refer to section 2 6 for more information on heating element installation 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 ...

Страница 63: ...nace 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 clamp to the top of the elem...

Страница 64: ...8 0 Repairs and Replacements Element Connections 3 phase 9 elements 64 ...

Страница 65: ... 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...

Страница 66: ...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...

Страница 67: ... 0 Wiring Diagrams 10 1 Drawing Numbers Please see the separate enclosure or request drawing 197 1 5001 3 phase N or 197 1 5002 3 phase delta from Carbolite Gero if it is required 67 10 0 Wiring Diagrams ...

Страница 68: ...if no supply cable fitted Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating Type HTF 18 27 3 phase N 380 415 32 A NS32 HTF 18 27 3 phase delta 220 240 50 A ES63 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 contro...

Страница 69: ...ements HTF 18 27 1800 18 300 300 300 27 440 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 IEC60364 4 443 polluti...

Страница 70: ......

Страница 71: ...Notes Service Record Engineer Name Date Record of Work ...

Страница 72: ... 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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