Gilson HM-378, Operating Manual

Page 1: ...Gilson Binder Ignition System HM 378 Rev 02 01 2018 PHONE 800 444 1508 P O Box 200 Lewis Center Ohio 43035 0200 FAX 800 255 5314 740 548 7298 E mail customerservice gilsonco com Website www globalgilson com 740 548 5314 ...

Page 2: ...8 8 0 Custom Applications 8 8 1 Ramp Hold Programming 8 8 2 Delayed Firing Programming 9 9 0 Additional Controller Operating Details 9 10 0 Maintenance 11 10 1 Electrical Problems 11 10 2 Elements 11 10 2 1 Reseating the Elements 11 10 2 2 Replacing Main Chamber Elements 12 10 2 3 Replacing Afterburner Elements 13 10 3 Firebrick Damage 14 11 0 The Temperature Controller Troubleshooting 15 12 0 Rep...

Page 3: ...jury Damage from failure to follow instructions is NOT covered by warranty NOTE READBEFORECONNECTING OPERATING OR SERVICING FURNACE If any questions call Gilson Technical Support at 800 444 1508 1 Place the furnace only on a noncombustible surface positioned no closer than 12in 305mm to any com bustible surface Allow a minimum of 6in 152mm clearance around the unit for proper air circulation 2 Ele...

Page 4: ...tores or can be purchased from Gilson as model HMA 814 The two 10 x 20in Hearth Plates are to be placed on the floor of the main chamber They are designed as a wear ing surface to prevent erosion of the firebrick 1 Place the furnace in a well ventilated covered and protectedarea DONOT storegasoline paintorother flammable liquids in that room 2 Provide a minimum of 12in 305mm clearance be tween the...

Page 5: ...l purpose controller enabling it to also be used for custom Ramp Hold programming as described in Section 8 0 see Figure 1 Times and temperatures in Program 1 have been pro grammed into the controller at the factory The furnace is ready to operate upon installation using this default program To vary temperatures or times re program the controller in the sequence of this sample Values to be program...

Page 6: ...850 Indicates 850 C is setpoint for Afterburner chamber Press ENTER Press ENTER again to accept displayed value or input new exhaust fan activation tem perature then press ENTER CFN 850 Indicates exhaust fan will activate at 850 C After burner temperature Ending display IdLE Programming sequence is complete ready for contin ued operation Action Display Starting display IdLE Press DELAY DELA XX XX ...

Page 7: ...out set point and the actual main chamber temperature To checkafter burnertemperature press 2 AFTbwill alternate display with the after burner temperature When the main chamber temperature reaches the burn out setpoint the display will alternate between TEST and the actual main chamber temperature The onset of ignition can be confirmed by observation of flames in the chamber FROM A DISTANCE via th...

Page 8: ...RT XXXX main chamber temperature Then press ANY key and the display will show IdLE XXXX main chamber temperature The furnace is now shut down The Gilson HM 378 is designed for asphalt binder igni tion tests of asphaltic hot mix to determine binder content percentage in the mix Refer to and follow instructions for that procedure as described in Section 7 0 While the programming procedure described ...

Page 9: ...of the program the furnace will shut off and the display will show CPLT A Operation The first time the furnace is powered the HM 378 controller will display IdLE and the alarm will sound briefly The controller will self test for a period of 10 15 seconds and the display will alternately display IdLE and the Main Chamber temperature B Programming Programming begins from IdLE If the display shows FA...

Page 10: ...emperature When the alarm sounds during a firing shut it off by pressing ANY key except the STOP key If it sounds as soon as the furnace begins firing it is because the alarm was set too low J Setting Alarm During Firing After shutting off the alarm during firing it can be set to go off again later at either a higher or lower temperature To set the alarm during a firing perform these steps 1 When ...

Page 11: ...fuse socket even in a new fuse box Slow Firing The furnace should preheat to desired conditions in one hour or less If not the probable cause is a low voltage supply A minimum of 200V is required If the furnace fires too slowly have the power company check your voltage and readjust transformer if necessary Hot Plug or Outlet If the plug or outlet is hot the probable cause is a defec tive plug or o...

Page 12: ...o stress the wiring c Remove the screws in the element connectors that hold the element lead wires to the element you are replacing d On the same connectors loosen the screws that hold the element and throw old connectors away NOTE ALWAYSusethenewconnectorsfurnished with the new element e Remove and save the porcelain insulators that were under the element connectors f Using long nose pliers remov...

Page 13: ...en the screw Tighten the screw until it squeaks and then tighten some more Cut off twisted end of element even with side of element connectors NOTE Leavingtheexcesselementstickingoutpast element connector could ruin your new element The element can short against something in the switch box As you move the switch box back into place check to see that no wire touches an element connector Wires and w...

Page 14: ...ad some of it Gently stretch it in your hands Avoid stretching only a short portion of the element It is better to distribute the stretch over a longer section Press the element down into the lower part of the groove with a plastic comb or wooden tongue depressor Reinstall the porcelain insula tors Push them flush against the furnace case They protect the element from contact with the case so they...

Page 15: ...s ENTER or removes power from the furnace Upon pressing ENTER the display will alternately show AFT and the temperature in the Afterburner chamber Leave the furnace in this condition for several minutes and note the readings for the Afterburner chamber temperature They should be increasing indicating the Afterburner chamber is getting warmer If the readings are decreasing the thermocouple leads ar...

Page 16: ...tive thermocouple 2 Disconnected thermocouple lead wires 3 Reversed thermocouple lead wires 4 Defective board The controller displays TC2 when the thermocouple tem perature sensor in the firing chamber burns out and FAIL when the thermocouple in the Afterburner chamber burns out Disconnect and lock out power supply Remove the four screws holding the controller faceplate to the switch box Lift the ...

Page 17: ... Afterburner Chamber RPHM 378 12 NEMA 6 50 Receptacle RPHM 378 13 Gaskets top or Bottom 2 Required RPHM 378 14 Gaskets Sides 2 Required RPHM 378 15 Gasket Conversion Kit includes Gaskets and Bracket RPHM 378 16 Door Lock Solenoid RPHM 378 17 Firebrick Repair Compound RPHM 378 18 Exhaust Fan Assembly RPHM 378 19 Door Lock Assembly complete with Housing RPHM 378 20 Adapter Exhaust Fan Adapter Flange...

Page 18: ...Gilson Company Inc Gilson Binder Ignition System HM 378 Page 18 Figure 1 Parts Accessories Diagram ...

Page 19: ...Gilson Company Inc Gilson Binder Ignition System HM 378 Page 19 Control Panel Figure 2 ...

Page 20: ...Gilson Company Inc Gilson Binder Ignition System HM 378 Page 20 Figure 3 Wiring Diagram 208 240V 50 60Hz ...

Page 21: ...en door to load sample heat escapes 4 Close door and start test 5 Burnout temperature programmed by user Could be the same as 2 6 Peak temperature as asphalt ignites and burns off Varies 7 Temperature returns to programmed burnout setting Hold time decoking starts 8 End of hold time Door can be opened sample is removed heat escapes 9 Door is closed 10 Furnace returns to programmed preheat temperat...

Page 22: ... Assembly Main Chamber 2 required one on each side RPHM 378 32 Bottom Firebrick Assembly Main Chamber RPHM 378 38 Firebrick Assembly For Door RPHM 378 33 Back Firebrick Assembly Main Chamber Afterburner Bottom Gilson Binder Ignition Furnace Fire Brick Replacement Assemblies Figure 5 Vent holes to be drilled by installer Main Chamber Top NOTE Ventholesarepredrilled from manufacturer on Top Fire Bri...

Page 23: ...ective under normal and proper use during the specified period providing the furnace has not been subjected to misuse or the listed exclusions Gilson will furnish and install replacement parts at the factory with transportation costs paid by the owner or upon receipt of defective parts at the factory and after factory examination of the defect replacements complete with installation instructions w...