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.
5
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.
7
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:
9
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