VERDER CARBOLITE GERO HTF 18/27 Manual

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)

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 6
1.1 Switches and Lights 6
1.2 General Warnings 6
2.0 Installation 7
2.1 Unpacking and Handling 7
2.2 Siting and Setting Up 7
2.3 Fitting the Heating 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 Resetting the programmer 23
3.6.4 Understanding User Levels 23
3.7 Setting Up Controller 24
3.7.1 Maximum output power setting 24
3.7.2 Customer ID. 24
3.7.3 Units 25
3.7.4 Language 25
3.8 Programming 25
3.8.1 Programming Notes 25
3.8.2 Holdback 26
3.8.3 Wait Segments 26
3.8.4 Program Cycling 27
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3.8.5 Creating a Program 27
3.8.6 Running a Program 28
3.8.7 To pause (hold) a program 29
3.8.8 To stop and reset a program 29
3.8.9 To run a different program (P10 and P25) 29
3.8.10 Program Status 29
3.8.11 Program Hold with Holdback 30
3.8.12 Power Failure Recovery 30
3.8.13 Alarms 31
3.8.14 Program Example 1 31
3.8.15 Program Example 2 33
3.9 Controller Options 35
3.9.1 Digital Communications - RS232 36
3.9.2 Digital Communications - RS485 36
3.9.3 Comms Address 36
3.9.4 Alarm Option 36
3.9.5 Remote Input and Output (Analogue Communications) 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
4.4 3508P1 Element Loop (Loop 2) 46
4.5 Caution 46
4.6 Over-Temperature Control 46
5.0 2132 Over-Temperature Controller Description (if fitted) 47
5.1 Description 47
5.2 Operation 47
5.2.1 Controls 47
5.2.2 Operation 48
5.2.3 Over-Temperature Operation 48
5.2.4 Over-Temperature Alarm 48
5.2.5 Resetting the Over-Temperature Alarm 48
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5.2.6 Sensor Break 48
5.3 Audible Alarm 49
5.4 Navigation Diagram 49
6.0 Operation 50
6.1 Operating Cycle 50
6.2 Operator Safety 50
6.3 Opening the Door 51
6.4 Insulation Cracking 51
6.5 Atmospheres & Corrosive Materials 51
6.6 Pesting 52
6.7 Explosive Materials 52
6.8 Notes on Temperature Control 52
6.9 Thermocouple Warnings 52
6.10 General Operating Advice 53
7.0 Maintenance 54
7.1 General Maintenance 54
7.2 Maintenance Schedule 54
7.2.1 Cleaning 56
7.2.2 Safety 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 - Molybdenum Disilicide Elements 60
8.4 Temperature Controller Replacement 60
8.5 Side Panel Removal 60
8.6 Thyristor Replacement and Adjustment 60
8.7 Fuse Replacement 61
8.8 Thermocouple Replacement 61
8.9 Element Installation and Replacement 62
9.0 Fault Analysis 65
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A. Furnace 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
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1.0 Symbols and Warnings
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 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
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2.0 Installation
2.1 Unpacking and Handling
When unpacking or moving the product always lift it by its base. Never lift it by the door
or any other protruding parts. Even the smaller models contain transformers and are
heavy: using lifting equipment is recommended.
Remove any packing material from the door gear and from inside the product chamber.
The door can be lifted manually and supported open. 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 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 surface is important to avoid operator strain when loading
and unloading samples.
Unless otherwise stated elsewhere in this manual, ensure that there is at least 150
mm of free space around the back and sides of the product. Clear space is required
above the product to dissipate heat.
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2.0 Installation

2.0 Installation
Depending on the application of the product, it may be appropriate to position it under
an extraction hood. Ensure the extraction hood is switched on during use.
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.
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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 elements are EXCEPTIONALLY FRAGILE and
are packed separately, together with other items shown in the list.
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 braids securely as indicated in the element installation
instructions.
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2.0 Installation

2.0 Installation
2.4 Transit Clamp Removal
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Remove the top 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
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2.0 Installation

2.0 Installation
The four transit clamps are circled on the photograph below:
Photograph 3
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2.5 Thermocouple Installation
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2.0 Installation

2.0 Installation
The fixing screws that hold the thermocouple assemblies in place are located in the
frame, remove these fixing screws. Fit the two thermocouple 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.
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Photograph 3 Photograph 4
Photograph 5 Photograph 6
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2.0 Installation

2.0 Installation
2.6 Heating Element Installation
Photograph 1
Fit the element insulator 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.
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Photograph 4 Photograph 5
Position the element 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
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2.0 Installation

2.0 Installation
Lift each element and clamp in the correct position as shown in photographs 8 and
9. Ensure that the element is correctly placed: the thin part of the element legs
should be entirely within the heating chamber; the element should not touch the
bottom or walls of the 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 must only be connected to the type and voltage of supply
for which it was made.
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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 the most common fuse ratings is also given towards the back of this
manual. When the mains cable is factory fitted, internal fuses are also fitted. It is
essential that the operator ensures that the product is correctly fused.
Products with a factory fitted supply cable are designed to be wired directly to an
isolator 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 product to an isolating switch ensure that both conductors (single
phase) or on all live conductors (three phase), and should be within reach of the
operator.
The supply MUST incorporate an earth (ground).
Supply Terminal Label Cable Colour Supply Type
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)
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2.0 Installation

3.0 3508 Controller
3.0 3508 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 3508P1
The 3508P1 is a digital temperature controller which uses PID algorithm to give
excellent temperature control when properly set. This controller can store and operate a
single program of up to 20 segments. The 3508P1 can also be used as a simple
temperature controller.
3.3 3508P10
The 3508P10 is a digital controller which uses PID algorithms to 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
excellent temperature control when properly set. This controller has a maximum of 500
segments or 25 programs; each program has a maximum of 50 segments. For example
3508P25 could store 10 programs with 50 segments or 25 programs with 20 segments.
Programs can be operated individually or linked by a Call parameter as sub-programs or
to form single long programs. The 3508P25 can also be used as a simple temperature
controller.
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