Carbolite Gero HTF 17/10 Manual

Installation, Operation and Maintenance Instructions
1700 °C Chamber Furnace - HTF: 10 Litres
3216 Controller
HTF 17/10 + 3216 Controller
MEN-HTF1710-002_3216_V01

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 5
1.1 Switches and Lights 5
1.2 Warning Symbols 5
2.0 Installation 7
2.1 Unpacking and Handling 7
2.2 Siting and Setting Up 7
2.3 Fitting the Heating Elements 7
2.4 Electrical Connections 8
2.5 Power Supply Notes 9
3.0 3216 Controller 11
3.1 PID control 11
3.2 3216P1 11
3.3 3216P5 11
3.4 Operation 11
3.4.1 Controller Layout 11
3.4.2 Keys 12
3.5 Quick Start Guide 12
3.5.1 Operation as a simple controller 12
3.5.2 Changing the Setpoint 12
3.5.3 Using the Controller 13
3.5.4 Understanding User Levels 13
3.6 Setting up the Controller 14
3.6.1 Maximum Output Power 14
3.6.2 Customer ID 14
3.6.3 Units 14
3.6.4 Language 15
3.6.5 Scrolling Text 15
3.6.6 Customer Calibration 15
3.6.7 Holdback 16
3.7 Programming 17
3.7.1 Creating a Program 17
3.7.2 Program Number (3216P5 Only) 17
3.7.3 Ramp Units 17
3.7.4 Dwell Units 17
2

3.7.5 Holdback 17
3.7.6 Ramp Rate 17
3.7.7 Target Setpoint 17
3.7.8 Dwell Time 17
3.7.9 Running a Program 18
3.7.10 Program Status 18
3.7.11 Process Value 18
3.7.12 PSP, Segment Type and Number 19
3.8 Controller Options 22
3.8.1 Digital Communications - RS232 22
3.8.2 Digital Communications - RS485 22
3.8.3 Comms Address 22
3.8.4 Alarm Option 22
3.9 Temperature Controller Replacement 23
3.10 3216 Controller Navigation Diagram 24
4.0 2132 Over-Temperature Controller Description (if fitted) 25
4.1 Description 25
4.2 Operation 25
4.2.1 Controls 25
4.2.2 Operation 25
4.2.3 Over-Temperature Operation 26
4.2.4 Over-Temperature Alarm 26
4.2.5 Resetting the Over-Temperature Alarm 26
4.2.6 Sensor Break 26
4.3 Audible Alarm 26
4.4 Navigation Diagram 27
5.0 Operation 28
5.1 Operating Cycle 28
5.2 Operator Safety 28
5.3 Loading The Furnace 29
5.4 Opening the Door 29
5.5 Insulation Cracking 29
5.6 Atmospheres & Corrosive Materials 29
5.7 Pesting 30
5.8 Explosive Materials 30
5.9 Notes on Temperature Control 30
5.10 Thermocouple Warnings 31
5.11 Thermal Cutouts 31
3

5.12 General Operating Advice 31
6.0 Maintenance 33
6.1 General Maintenance 33
6.1.1 Cleaning 33
6.1.2 Safety Switch 33
6.1.3 Other Electrical Components 33
6.1.4 Element Glaze 33
6.2 Calibration 33
6.3 After-Sales Service 34
6.4 Recommended Spare Parts and Spare Parts Kit 34
6.5 Power Adjustment (Controller) 34
6.6 Power Adjustment (Thyristor) 34
6.7 Low Voltage Compensation 34
7.0 Repairs and Replacements 35
7.1 Safety Warning - Disconnection from Power Supply 35
7.2 Safety Warning - Refractory Fibre Insulation 35
7.3 Side Panel Removal 35
7.4 Thyristor Replacement and Adjustment 36
7.5 Temperature Controller Replacement 36
7.6 Fuse Replacement 37
7.7 Thermocouple Replacement 37
7.8 Element Installation and Replacement 37
7.9 Insulation Replacement 39
7.10 Transformer Tappings 40
7.11 Fuse Replacement 41
8.0 Fault Analysis 42
A. Furnace Does Not Heat Up 42
B. Product Overheats 43
9.0 Wiring Diagrams 44
9.1 Single Phase 208 V, 220-240 V 44
9.2 Two phase 380/ 220 V - 415/ 240 V 45
10.0 Fuses and Power Settings 46
10.1 Fuses 46
10.2 Power Settings 46
11.0 Specifications 47
11.1 Environment 47
4

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.
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1.0 Symbols and Warnings

1.0 Symbols and Warnings
Caution – Double Pole/Neutral Fusing
6

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 7.2.
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.
Ensure that there is free space around the sides and back 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 7.0.
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.
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2.0 Installation

2.0 Installation
Separately Packed Items 1700 °C Models
Elements 4
Element Clamps 8
Element Clips 8
Braids 1 set of 5
Separators/ Block 4
Chimney Unit 1
The installation of these elements is described in section 7.8
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 10.0 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 7.3). 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).
8

Supply Terminal Label Cable Colour
Supply Types
Live - Neutral Reversible or Live-
Live
1-phase L Brown to live to either power
conductor
N Blue to neutral to the other power
conductor
PE Green/ Yellow to earth (ground) to earth (ground)
Electrical Connection Details:
2-phase L1 Black to phase 1
L2 Black to phase 2
N Light Blue to neutral
PE Green/ Yellow to earth (ground)
2.5 Power Supply Notes
Each model is manufactured for one of the following voltage ranges:
l208 V
l220 to 240 V
l380 to 415 V (not HTF 17/5 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
7.4 and 7.10.
It is possible to alter the voltage within any of the ranges above, by reconnecting the
incoming cable to the transformer to the appropriate primary tapping. The tappings are
208 - 220 - 230 - 240 V, or 380 - 400 - 415 V, and are labelled on the primary side of
the transformer - see section 7.10. It is also necessary to adjust the setting of the
thyristor stack: see section 7.4.
Examples:
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2.0 Installation

2.0 Installation
lto alter a furnace made for a 240 V supply to 208 V: replace thyristor stack,
move a cable to the 208 V transformer tapping, and adjust the thyristor stack.
lto 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.
10

3.0 3216 Controller
3.1 PID control
This controller uses PID (Proportional Integral Derivative) temperature control. This
type of control uses a complex mathematical control system to adjust the heating
power and achieve the desired temperature.
3.2 3216P1
The 3216P1 is a digital temperature controller which uses PID algorithms to give
excellent temperature control. This controller can store and operate a single program of
8 ramp/ dwell segments. The 3216P1 can also be used as a simple temperature
controller.
3.3 3216P5
The 3216P5 is a digital temperature controller which uses PID algorithms to give
excellent temperature control. This controller can store up to 5 programs of 8 ramp/
dwell segments. The 3216P5 can also be used as a simple temperature controller.
3.4 Operation
3.4.1 Controller Layout
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3.0 3216 Controller

3.0 3216 Controller
3.4.2 Keys
Page Key The page key is used to access level 2 when held down
for 3 seconds.
Scroll Key The scroll key is used to scroll through parameters.
Ack
Page and
Scroll
+
When pressed simultaneously the ACK function is used
to:
lReturn to the Home Menu
lAcknowledge an alarm if activated.
lReset a program after the program has ended.
Arrow Keys +
The arrow keys are used individually to adjust the
selected parameters and in combinations to operate a
program.
Note: If a parameter is selected and no further action is taken, the display will time
out and revert back to the home display in its working level after approximately 1
minute.
3.5 Quick Start Guide
3.5.1 Operation as a simple controller
When switched on, the controller goes through a short test routine and then shows the
measured temperature (PV = Process Value) in the upper part of the display and below
it, the desired temperature (Setpoint).
3.5.2 Changing the Setpoint
Press Up or Down to select the required SP. If the SP is higher than the
measured temperature, the OP1 indicator will illuminate in the top left corner of the
display, indicating that the controller is calling for power (giving an output).
The controller will immediately attempt to reach the setpoint and then maintain it.
This will cause the product to heat as quickly as possible which may not be appropriate
where the product contains sensitive ceramic components. For products with ceramic
components, e.g. a tube furnaces fitted with a long ceramic work tube, use the ramp
rate feature set with a low heating rate such as 5°C per minute (300°C per hour), to
prevent damage.
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 appropriate
where the product contains sensitive ceramic components. For products with ceramic
components, e.g. a tube furnaces fitted with a long ceramic work tube, use the ramp
rate feature set with a low heating rate such as 5°C per minute (300°C per hour), to
prevent damage.
12

3.5.3 Using the Controller
The parameters in the controller are first shown by a short code (mnemonic). After 5
Seconds a description of the parameter will scroll once along the display and then revert
back to the mnemonic. The scrolling text can be interrupted at any time by a single
press of any of the buttons, but will not scroll again until the parameter is returned to.
In this manual the mnemonic will be shown first, followed by the scrolling text in
brackets; e.g. PROG <PROGRAM NUMBER>
3.5.4 Understanding User Levels
There are two user levels in the controller; Level 1 (Operator) and Level 2 (Supervisor).
Level 1 (Operator) is for the day to day operation of the controller. These parameters
are not protected by a security code.
Level 2 (Supervisor) provides access to additional parameters. Access to this level
protected by a security code
To Enter Level 2
1. Press and hold the page key for 3 seconds.
2. The display will show LEu 1 GOTO
3. Release the page Key
4. Press the up or down to choose LEu 2 (level 2)
5. Press the up or down to enter the code (Level 2 Code = 9).
If the correct code is entered, PASS should momentarily be displayed and then revert
to the level 2 home display.
If an incorrect code is entered the display reverts back to Level 1 home display.
When level 2 operations have been completed, the supervisor must return to Level 1
either manually or by switching the instrument off and back on. There is no time out
function.
To Return to Level 1
1. Press and hold the page Key
2. Press down to select LEu 1
It is not necessary to enter a code when going from a higher level to a lower level.
When level 1 is selected, the display reverts to the home display (See Controller Layout)
Table showing parameters accessible in level 1 and Level 2
Operator LEVEL 1 Supervisor LEVEL 2
home display home display
Programming Programming
Program Status Program Status
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3.0 3216 Controller

3.0 3216 Controller
Alarms (if configured)
Current Transformer Input (if configured)
Comms (if configured)
Controller Setup
Customer Calibration
TIP
If while navigating the controller, a parameter has been passed or you need to access
parameters which would be at the end of a scroll list, press and hold scroll and use up
to return to a previous parameter.
3.6 Setting up the 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 (Level 2), see section 3.5.
3.6.1 Maximum Output Power
Press scroll until the display shows OP.HI <OUTPUT HIGH>. Use the up and
down keys to select the output power required as a percentage. Once the setting is
made, turn the instrument switch off and on to power cycle the temperature controller.
Depending on the furnace or oven model, the maximum output power setting OP.Hi
may be accessible or locked.
For silicon carbide heated furnaces, the parameter is accessible to allow compensation
for element ageing.
In many models the maximum output power setting depends on the supply voltage, see
section 10.0.
3.6.2 Customer ID
A furnace or oven identification number can be entered if required. This maybe used to
identify one of many units for production or quality control systems.
Press scroll until the display shows ID <CUSTOMER ID>. Use the up and down
keys to enter your own identification number. This can range from 1-9999.
3.6.3 Units
Press scroll until the display shows UNITS <DISPLAY UNITS>. Use the up or
down keys to select the required units.
14

Mnemonic Description
NONE No units (Default °C)
°C Celsius
°F Fahrenheit
°K Kelvin
PERC % (shows °C value)
3.6.4 Language
The scrolling text on the 3216 can be shown in different languages, this can only be set
at the factory and therefore must be specified at the time of placing an order.
3.6.5 Scrolling Text
If at any time the scrolling text is not required.
Press and hold the page for three seconds until “GOTO” is displayed.
Press scroll until the display shows. TEXT <ENABLE/ DISABLE SCROLLING TEXT>
Use the up and down keys to select ON or OFF.
3.6.6 Customer Calibration
The 3216 Controller series are calibrated for life at manufacture, there may however be
sensor or other system errors, which affect the accuracy of the measured temperature.
Customer calibration can be used to compensate for these errors.
Dual Offset
Dual point calibration uses two offset values at two corresponding temperatures; this
changes the calibration linearly as the temperature increases or decreases.
Press scroll until the display shows CAL.P (Enter Calibration Code) Use the up
down keys to enter the password code. (Calibration Pass Code = 95). When the
correct password has been entered the display will show PNT.LO. If the wrong pass
code is entered the display will revert to zero pass code, until the correct pass code is
entered.
When the correct pass code is entered and PNT.LO (Adjust Low Point) is displayed. Use
the up and down keys to enter the Low Temperature Point, which you want to
apply an Offset.
Press scroll until the display shows OFS.LO (Adjust Low OFFset). Use the up
and down keys to enter the amount Offset you want to apply to the Low
Temperature Point.
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3.0 3216 Controller

3.0 3216 Controller
Press scroll until the display shows PNT.HI (Adjust High Point). Use the up and
down keys to enter the High Temperature Point, which you want to apply an Offset.
Press scroll until the display shows OFS.HI (Adjust High OFFset). Use the up
and down keys to enter the amount Offset you want to apply the High Temperature
Point.
Once the calibration details have been entered, press scroll until the display shows
the next required parameter or return to the home list. The calibration data will now be
protected by the pass code. To edit the data the above procedure must be followed.
Single Offset
If a constant offset is required across the temperature range, set the required “High
Point” (PNT.HI) and “Low Point” (PNT.LO) to the required values (not the same), then
set the “low Offset” (OFS.LO) and “High Offset” (OFS.HI) to the same value.
Caution! - Do not make PNT.LO and PNT.HI the same value as the
controller will not work correctly and could cause the product to
overheat.
3.6.7 Holdback
If the temperature ramp rate of the program is quicker than the product can achieve,
the program will wait until the temperature of the product catches up.
e.g. If a holdback value of 10 is set and the program is set to ramp to a setpoint of 600
°C, the program will reach 600 °C, then go into a hold state; the hold indicator will light
until the product temperature reaches 590 °C, the program will then continue to control
again.
The holdback will only apply once per segment, therefore when control has been re-
established, the holdback will not apply again to that segment, even if the product
temperature goes outside the holdback band.
Holdback can only be accessed in supervisor level (level 2) by scrolling with the scroll
until the display shows H.BACK <PROGRAM HOLDBACK>: Use the up and down
keys to select the required Holdback value.
If a multi programmer is used, each program can have its own holdback value assigned
to it.
Note: When a holdback is set, each segment used must have a Ramp Rate assigned
to it, in order for it to be recognised by the program.
16

3.7 Programming
3.7.1 Creating a Program
Programs can be created in level 1 or level 2 of the 3216P1 and 3216P5. Each program
contains 8 Ramp/ Dwell pairs.
Note: A currently active program cannot be altered. Go into 'Reset' mode before
starting to create or modify a program
3.7.2 Program Number (3216P5 Only)
Press scroll until the display shows PROG <PROGRAM NUMBER.> Select the program
number.
3.7.3 Ramp Units
Press scroll until the display shows RAMP.U <Ramp Units>: Use the up down
to select the Ramp Units of Hour, Min or Seconds.
3.7.4 Dwell Units
Press scroll until the display shows DWEL.U <Dwell Units>: Use the up down
to select the Dwell Units of Hour or Min.
3.7.5 Holdback
see section 3.6. Press scroll until the display shows H.BACK <Program Holdback>: If
a holdback value is required, use the up down to enter the required value or
select “OFF” if no holdback is required.
3.7.6 Ramp Rate
Press scroll until the display shows RMP.1 <Ramp Rate 1>: Using the up down
enter the value for the first ramp rate depending on the Ramp Units selected. If the
Ramp segment is not required select “OFF”.
3.7.7 Target Setpoint
Press scroll until the display shows T.SP 1 <Target SP 1>: Enter the temperature
that you want the product to ramp up to using “Ramp rate 1”.
If “Ramp Rate 1” has been set to “OFF”. The product will Heat/ Cool directly to the
Target SP.
3.7.8 Dwell Time
Press scroll until the display shows DWELL. 1 <DWELL TIME 1>: Enter the time to
dwell at “Target SP 1”. If the dwell segment is not required, use the down
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3.0 3216 Controller

3.0 3216 Controller
to select OFF, which is below the Zero value.
This Process is repeated for each of the 8 segments of the program.
If not all the segments are used for a program, the Ramp & Dwell of each of the
subsequent segments should be set to OFF.
A program will end in one of two ways, either revert to the control setpoint or dwell at
the temperature set in the last segment used. When a program finishes on a dwell and
the dwell time expires the temperature will revert to the control setpoint.
Note: Before operating a program ensure that the control setpoint is set to Zero to
avoid unexpected heating at the end of the program.
3.7.9 Running a Program
If using the 3216P5 controller press scroll to display PROG <PROGRAM NUMBER>.
Select the required Program Number before operating a Program.
Table below shows the key presses to operate a program.
Operation Action Indication
To RUN a program
Press and quickly release
+
Indicator – RUN = ON
Scrolling Display – Current
Program state
To HOLD a program
Press and quickly release
+
Indicator – RUN = Flashing
Scrolling Display – Program Hold
To RESET a program Press and hold + for
more than 1 second
Indicator – RUN = OFF
Scrolling Display - None
Program Ended Indicator – RUN = OFF
Scrolling Text – Program End
To RESET a
program after it has
completed
Press and hold + for
more than 1 second or press
and quickly release Ack
Indicator – RUN = OFF
Scrolling Display - None
3.7.10 Program Status
While the program is operating in level 1 or level 2, the home display shows two values
at any one time:
3.7.11 Process Value
The upper display shows the current temperature of the product.
18

3.7.12 PSP, Segment Type and Number
The lower display continually alternates between the programs current set value
(Program SP = PSP) and scrolling text, indicating the current status of the program
whether RAMP or DWELLING followed by the segment number.
Additional information can be obtained using the scroll key while the program is
operating.
Working Output Power
From the home display, press scroll until the display shows WRK.OP <WORKING
OUTPUT POWER>. This shows the power being used as a percentage.
Time Remaining
Press scroll until the display shows T.REMN <TIME REMAINING>. This shows the
dwell time remaining for the current segment. There is no value for “Ramp Time
Remaining” therefore when the program is ramping the dwell time set will be shown
and will only begin to count down when the ramp has finished.
Program Review
Further presses of scroll will reveal the settings of the current program operating.
These parameters are locked, while the program is operating.
Program Hold with Holdback
If a holdback value has been set (see section 3.6) and the program goes into a hold
state, the red “HLD” indicator will light, until the current temperature catches up.
If while in this condition the program itself is put into “Hold” by pressing the up , down
together, the “HLD” indicator will turn off and the “Run” indicator will flash, indicating
the program is on hold. When the program is started again by pressing the up , down
together, the “Run“indicator will stop flashing and show continually and the “HLD”
indicator will light, if the current temperature has not caught up with the program.
Power Failure
If there is a power failure while the program is operating and the power is subsequently
restored, the scrolling text will read <POWER FAIL - PROGRAM RESET>.
Press the “ACK” function to acknowledge this message, press the “ACK” function again
to reset the program.
Alarms
Alarms are used to alert the operator when a pre-set level has been exceeded or a
function error has occurred such as a sensor break. They are indicated by a scrolling
message on the display and a flashing red ALM (Alarm) indicator. The alarm may also
switch an output – usually a relay to allow external devices to be operated when an
alarm occurs. Alarms only operate if they have been configured and are dependent on
customer requirements.
How to acknowledge an alarm will depend on the type of latching which has been
configured. A non-latched alarm will reset itself when the alarm condition is removed. A
latched alarm requires acknowledgement with the “ACK” function before it is reset.
If an alarm has been activated the red “ALM” indicator will light and the scrolling text will
indicate the type of alarm.
19
3.0 3216 Controller

3.0 3216 Controller
To acknowledge an alarm and cancel the “ALM” indicator, press “ACK” function.
Note: The alarm indicator may seem to be permanently on when viewed from above.
When an alarm is active the indicator should only be flashing, to confirm this, the
controller must be viewed directly from the front.
20