VERDER CARBOLITE GERO HST 12/200, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1200 C Split Tube Furnace HST Model 200mm No Controller HST 12 200 No Controller MEN HST12200 005_NOCTRL 02 08 2019 ...

Page 2: ...3 Electrical Connections 9 3 0 Temperature Controller 12 4 0 2132 Over Temperature Controller Description if fitted 13 4 1 Description 13 4 2 Operation 13 4 2 1 Controls 13 4 2 2 Operation 14 4 2 3 Over Temperature Operation 14 4 2 4 Over Temperature Alarm 14 4 2 5 Resetting the Over Temperature Alarm 14 4 2 6 Sensor Break 14 4 3 Audible Alarm 15 4 4 Navigation Diagram 15 5 0 Operation 16 5 1 Oper...

Page 3: ...ature Controller Replacement 24 7 4 Solid State Relay Replacement 25 7 5 Thermocouple Replacement 25 7 6 Fuse Replacement 25 7 7 Element Replacement 26 8 0 Fault Analysis 27 A Furnace Does Not Heat Up 27 B Product Overheats 28 9 0 Wiring Diagrams 29 9 1 WA 11 00 29 9 2 WA 11 70 30 9 3 WA 11 71 31 9 4 WA 11 30 32 9 5 WA 11 31 33 10 0 Fuses and Power Settings 34 10 1 Fuses 34 10 2 Power Settings 34 ...

Page 4: ...d to the elements Heat switch the switch disconnects power to the heating elements unless this switch is OFF there is a danger of electric shock when inserting objects into the product 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 ...

Page 5: ...Caution Double Pole Neutral Fusing 5 1 0 Symbols and Warnings ...

Page 6: ...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 f...

Page 7: ...on shields is similar to that of plugs If stainless steel seals with gas inlets are supplied they are to be fitted as shown in fig 3 the stem of any insulating plug should touch the seal For vertical models with stainless steel seals a hook and eye arrangement holds the upper insulating plug assembly Horizontal models if heavy fittings are to be clamped to the end of an extended work tube they can...

Page 8: ...2 0 Installation Fig 1 Insulating Plug standard length tube Key A Tube B Insulating Plug C Stem Fig 2 Insulating Plug long work tube 8 ...

Page 9: ...p End Seal For assembly details refer to the separate work tube end seal manual 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 Electrical Connections Connection by a qualified electrician is recomm...

Page 10: ...ctory 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 r...

Page 11: ...o phase 2 L3 Black to phase 3 N Light Blue to neutral except delta PE Green Yellow to earth ground DO NOT connect a product ordered for three phase use to a single phase supply or to the wrong type of three phase supply 11 2 0 Installation ...

Page 12: ...3 0 Temperature Controller 3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 12 ...

Page 13: ... 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...

Page 14: ... 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 4 2 4 Over Temperature Alarm If an over temperature condition occurs the OP2 indicator flashes and an alarm message 2FSH also flashes alternating with ...

Page 15: ...top sounding when the alarm is acknowledged as given in section 4 2 Note the alarm may sound during controller start up 4 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 15 4 0 2132 Over Temperature ...

Page 16: ...re controller flashes and the heating elements are isolated Find and correct the cause before resetting the over temperature controller according to the instructions supplied To switch off power to the heating elements use the heater switch To switch the product off use both the heater switch and the instrument switch If the product is to be left switched off and unattended isolate it from the ele...

Page 17: ...it when the furnace is opened This prevents the operator touching a live heating element and also prevents the product from heating up if the furnace is left open The operation of this switch should be checked periodically Depending on use the surfaces in the working chamber and the chamber load may still be very hot after the appliance is switched off Touching these surfaces may cause burns Use s...

Page 18: ... both the heating and cooling rate 5 5 Pressure Work tubes are not able to accept high internal pressure When gas seals or similar fittings are in use the gas pressure should be restricted to a maximum of 0 2 bar 3 psi A pressure of approximately half of that should normally be sufficient to achieve the desired flow rate The operator must ensure that the exhaust path from the tube is not blocked s...

Page 19: ...Refer to section 3 0 for power adjustment instructions 5 7 Running at Low Temperatures The power limit may be adjusted to a low level in order to achieve better control when operating the product at a low temperature Before changing the power limit record the default settings for possible future use Refer to the Power Settings section of this manual for default power limits If the product fails to...

Page 20: ...ure Safety Circuit if fitted Electrical measurement Safety Switch Function split models only Set a safe temperature above ambient and open the furnace to see if the heater light goes out Safety Switch Function split models only Electrical measurement Electrical Safety external Visual check of external cables and plugs Electrical Safety internal Physically check all connections and clean ing of the...

Page 21: ...ck all seals and O rings and clamps Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase circuit Cooling Fans if fitted Check whether the cooling fans are work ing 21 6 0 Maintenance ...

Page 22: ...eck can be carried out by a general operator l On the temperature 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 ...

Page 23: ...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 contact information can be found on the back page of this manual 6 5 Recommend...

Page 24: ... 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 sleev...

Page 25: ...Disconnect the thermocouple from its terminal block Carefully withdraw the thermocouple from the product and remove any broken bits of thermocouple Bend the new thermocouple carefully to match the shape of the original working from the terminal end Should the length differ from that of the original this is usually not important provided that the thermocouple tip is within a work tube diameter s di...

Page 26: ...nt to be replaced save any insulation sleeves for possible reuse Bend or cut the new element tails as necessary and fit any insulation sleeves feed the tails through and fit the element into place Refit the keep plates on each side Refit the tail termination plates ensuring that the element tails do not touch any metal parts Refit the thermocouple s Connect all the wiring according to the plan pre...

Page 27: ...The door switch es if fitted may be faulty or need adjustment The contactor relay if fitted may be faulty The heater switch if fitted may be faulty or need adjustment The SSR could be failing to switch on due to internal failure faulty logic wiring from the controller or faulty controller There are no lights glowing on the controller Check the supply fuses and any fuses in the furnace control comp...

Page 28: ...aulty The controller shows a low temperature The thermocouple may be faulty or may have been removed out of the heating chamber The thermocouple may be connected the wrong way around The controller may be faulty 2 Product heats up when the instrument switch is OFF The SSR has failed ON Check for an accidental wiring fault that could have overloaded the SSR 28 ...

Page 29: ...1 F2 F3 Fuses FIL Filter C Temperature Controller TC Control Thermocouple SSR Solid State Relay H Heat Lamp EL Element s SW Instrument Switch es FM Fan Motor Fan Models Only N Neutral L Live PE Earth Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 29 9 0 Wiring Diagrams ...

Page 30: ...y F1 F2 F3 Fuses FIL Filter R1 1 R1 2 Relay Contactor R1 Relay C Temperature Controller TC Control Thermocouple SSR Solid State Relay SSW A SSW B Safety Switch es H Heat Lamp EL Element s SW Instrument Switch es N Neutral L Live PE Earth Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 30 ...

Page 31: ... Relay Contactor R1 Relay C Temperature Controller TC Control Thermocouple OT Over Temperature Con troller OTC Over Temperature Ther mocouple SSR Solid State Relay SSW A SSW B Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L Live PE Earth Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 31 9 0 Wiring Diagrams ...

Page 32: ...witch es Key F1 F2 F3 Fuses FIL Filter R1 1 R1 2 Relay Contactor R1 Relay C Temperature Controller TC Control Thermocouple SSR Solid State Relay SSW Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L Live PE Earth Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 32 ...

Page 33: ... Relay Contactor R1 Relay C Temperature Controller OT Over Temperature Controller OTC Over Temperature Thermocouple TC Control Thermocouple SSR Solid State Relay SSW Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L Live PE Earth If Fitted Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 33 9 0 Wiring Diagrams ...

Page 34: ...mm Customer Fuses Required 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 HST 12 200 1 phase 100 120 10 A HST 12 200 1 phase 200 240 6 A 10 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 c...

Page 35: ... in an opening case HST 12 200 1200 1 0 25 100 350 650 200 26 Also models based on above but of other lengths supplied to special order Note Weights are approximate for horizontal models and do not include fittings or vertical stands 11 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 Relativ...

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Page 37: ...Notes Service Record Engineer Name Date Record of Work ...

Page 38: ... 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...