Carbonite Furnace HST User's Manual
Contents
1. Installation Operation amp Maintenance Instructions 1200 C Split Tube furnaces types HST amp VST This manual is for the guidance of operators of the above Carbolite products and should be read before the furnace is connected to the electricity supply CONTENTS Section page 1 0 Introduction 1 2 0 Installation 3 3 0 Operation 5 4 0 Maintenance 7 5 0 Repairs amp Replacements 8 6 0 Fault Analysis 11 7 0 Circuit Diagrams 12 8 0 Fuses amp Power Settings 15 9 0 Specifications 16 Manuals are supplied separately for the furnace controller and overtemperature controller when fitted Please read the controller manuals before operating the furnace 1 0 MF13 3 31 HST VST 1 1 1 2 1 3 1 4 2 0 INTRODUCTION VST amp HST models The VST range comprises split tube furnaces designed for use vertically with several mounting options the furnace may be provided with no stand or with a wall bracket or it may be fitted to one of two stand designs near and far The HST range uses the same insulated split case as the VST fitted inside an outer case designed for horizontal use though this may be fitted to an L stand which allows for both horizontal and vertical use All models have a separate control box connected by electrical conduits or leads Voltage and Power Control All models in this range from March 2001 are supplied with heating elements designed for use over the voltage range 200V 22. The furnaces contain electrical parts and should be stored and used in indoor conditions as follows temperature 5 C 40 C relative humidity maximum 80 up to 31 C decreasing linearly to 50 at 40 C The products covered in this manual are only a small part of the wide range of ovens chamber furnaces and tube furnaces manufactured by Carbolite for laboratory and industrial use For further details of our standard or custom built products please contact us at the address below or ask your nearest stockist For preventive maintenance repair and calibration of all Furnace and Oven products please contact Keison Products Telephone UK 01245 600560 Int 44 1245 600560 Fax UK 01245 600030 Int 44 1245 600030 Email info keison co uk
3. 7 3 3 phase with neutral N a i Filter if fitted Db Fal eg e e E contactor l oan F2 e i Q Supply light amp i e Instrument Switch n heat i t T eee Oe 2 on sey switch if fitted thermocouple SSR temperature HT SSR controller LH thermocouple T ssp note on 3 phase depending on filter s fitted there may be 3 separate neutral wires from the elements to the neutral supply 12 aot soB0oro niet Ne BoBo 0 N e Ne MF13 HST VST 7 4 3 phase without neutral delta Filter if fitted il F3 ms Le 1 1 1 i Supply light amp e e e i Instrument Switch i m m m l i _ L e e bheat e AN DO A RS n n on n safety t t t _switch s s s 7 5 7 6 Z overtemp controller Thermocouple _ temperature Fs controller F3 thermocouple og ll 3 phase without neutral star e g 380 to 415V Filter if fitted contactor soBo0ro sa30 o sa3o0 o Supply light amp Instrument Switch Nn or Ne Nn or Ne Nn or Ne lam oN lam safety switch overtemp controller temperature controller Note in this configuration the fuses F2 on the supply side of the transformer may be GEC Safeclip not 32 x 6mm glass as stated in section 8 1 Higher Voltages e g 254V 440V 480V 3 phase The diagram above 7 5 no
4. No hard and fast rules can be given but as an example to run at temperatures only up to 600 C try a power limit of 50 Control stability may fall off again if a setting below about 40 is used Before changing the power limit record its factory setting for possible future use MF13 4 1 4 2 4 3 4 4 5 0 HST VST MAINTENANCE General Maintenance No routine maintenance is required The outer surfaces may be cleaned with a damp cloth Do not allow water to enter the case chamber or control box Do not clean with organic solvents Calibration After prolonged use the controller and or thermocouple could require recalibration This would be important for processes which require accurate temperature readings or which use the furnace close to its maximum temperature A quick check using an independent thermocouple and temperature indicator should be made from time to time to determine whether full calibration is required These items can be supplied by Carbolite Depending on the controller the controller manual may contain calibration instructions After Sales Service Carbolite s service division Thermal Engineering Services has a team of Service Engineers capable of repair calibration and preventive maintenance of furnace and oven products at our customers premises throughout the world We also sell spares by mail order A telephone call or fax often enables a fault to be diagnosed and the necessary spare part desp
5. desired flow rate The customer must ensure that the exhaust path from the tube is not blocked so that excess pressure does not occur Power Adjustment The furnace control system incorporates electronic power limiting The power limit parameter OP Hi is accessible to the operator and can be used to adjust the furnace to the actual supply voltage The models covered by this manual March 2001 onwards are designed for use over the range of voltages 200V 250V or if ordered 1OOV 125V and the power limit parameter is set accordingly These models may be relocated to a different voltage within the range the power limit should be reset to match the voltage See section 8 2 To alter the power limit Set the Heater Switch to Off to prevent heating while adjusting the power limit Press Page D until oP output list is displayed Press Scroll U until OP Hi Output High is displayed Press Down V or Up A once to display the value of OP Hi it is good practice to write down the original value To alter the parameter to the desired value use Down WV or Up A A power setting of zero prevents the furnace from heating useful for demonstrating the controls without taking power Do not increase the power limit simply to get more power The elements could burn out or a fuse could blow Running at Low Temperatures The power limit may be adjusted to a low level to achieve better control when running the furnace at a low temperature
6. of the most common fuse ratings is also given in section 8 1 of this manual Where a supply cable is present there are internal supply fuses customer fusing is preferred but not essential Furnace with supply cable either wire directly to an isolator or fit with a line plug Furnace without supply cable a permanent connection to a fused and isolated supply should be made to the internal terminals after temporary removal of the furnace back panel Connection by line plug the plug should be within reach of the operator and should be quickly removable Connection to isolating switch this should operate on 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 CONNECTION DETAILS supply type Supply Terminal label Cable colour Live Neutral Reversible or Live Live ia T EL N Blue To neutral PE supply Terminal label Cable colour Cd o ae A 2 3 N PE Do not connect a furnace ordered for three phase use to a single phase supply or to the wrong type of three phase supply except as indicated in sections 2 5 and 7 7 2 5 Universal Wiring _ year 2000 onwards When and only when ordered for 3 phase use these furnaces are supplied in a form in which they can be easily rewired between l phase and 3 phase supplies This applies to 3 phase N and 3 phase delta in the ranges 380 220V 415 240V and 200 240V but d
7. of the supply Before March 2001 please check with Carbolite if in doubt 8 2 Power Settings The standard power limit settings parameter OP Hi are as follows 100V 110V 120V 127V 200V 208V 220V 230V 240V 254V HST or VST 12 380V 400V 415V 440V before March 2001 all models 100 100 100 100 100 s9 from March 2001 100 ioo s9 s2 73s 6 See section 3 6 for further detail if you have specially ordered model 600 for use in UK on a 13A supply then the power limit is 100 and the amps rating is 12 5A please check your rating label MF13 15 9 0 MF13 3 31 SPECIFICATIONS Carbolite reserves the right to change specifications without notice 9 1 Models Covered by this Manual Max Max Heated Net j Temp Power Length Weight CC kW Split Tube furnaces heated by resistance wire moulded in refractory fibre Horizontal Models in an opening case HST 12 200 1200 C HST 12 300 1200 C HST 12 400 1200 C HST 12 500 1200 C HST 12 600 1200 C HST 12 900 1200 C Vertical Models with a variety of stand and fixing options VST 12 200 1200 C VST 12 300 1200 C VST 12 400 1200 C VST 12 500 1200 C VST 12 600 1200 C VST 12 900 1200 C also models based on the above but of other lengths supplied to special order note 1 Weights are approximate and do not include fittings or vertical stands 9 2 Environment
8. 40V or 3 phase equivalents The Carbolite control system incorporates a power limit which effectively limits the voltage to 208V It is most important that any alternative system provided by the customer should be able to limit the power accordingly See sections 3 6 and 8 2 Switches and Lights Supply Light when the furnace is connected to the electrical supply the light in the adjacent switch glows UY Heat Switch the switch disconnects power to the heating elements unless PEA S this switch is off there is a danger of electric shock when inserting objects N Z Allik VN Warning Symbols Heat Light the adjacent light glows or flashes to indicate that power is being supplied to the elements DANGER of electrical shock read any warning printed by this symbol DANGER hot surface Read any warning printed by this symbol WARNING all surfaces of a furnace may be hot DANGER read any warning printed by this symbol MF13 2 1 2 2 2 3 stem HST VST INSTALLATION Unpacking amp Handling When unpacking or moving the furnace always lift it by its case or main body Never lift it by its insulation or by a fitted work tube If possible use two people to carry the furnace and remote control box Remove any packing material from inside the furnace before use If an optional or special stand is separately supplied assemble the furnace on to it These models may be supplied for customer mounting and may requir
9. ack panel from control box Make a note of how the wires are connected to the solid state relay and disconnect them Remove the solid state relay from the base panel or aluminium plate Replace and reconnect the solid state relay ensuring that the heat conducting thermal pad is sandwiched between the relay and the base panel or aluminium plate Alternatively a thin layer of white heat conducting silicon paste may be applied between the new relay and the plate The new solid state relay contains a built in MOV which protects it from short periods of excess voltage If the old relay had a separate disc shaped MOV connected between the high voltage terminals of the old relay discard the old MOV Replace the removed panel MF13 5 5 5 6 5 7 HST VST Thermocouple Replacement The coverings and guards which must be removed to gain access to the thermocouple depend on the model and any mounting options or fittings Study the furnace layout and consult Carbolite if in doubt Disconnect the furnace from the supply and remove covers and guards as necessary Make a note of the thermocouple connections The negative leg of the thermocouple is marked blue Compensating cable colour codings are negative positive type N white pink Disconnect the thermocouple from its terminal block Withdraw the thermocouple from its sheath the narrow bore built in tube and remove any broken bits of thermocouple Bend the new thermocoupl
10. atched Each furnace has its own record card at Carbolite In all correspondence please quote the serial number model type and voltage given on the rating label of the furnace The serial number and model type are also given on the front of this booklet when supplied with a furnace To contact Thermal Engineering Services or Carbolite see the back page of this manual Recommended Spares Kits Carbolite can supply individual spares or a kit of the items most likely to be required Ordering a kit in advance can save time in the event of a breakdown Each kit comprises one thermocouple one solid state relay and two heating elements models 900 2 of each length When ordering spares please quote the model details as requested above MF13 7 HST VST 5 1 5 2 5 3 5 4 REPAIRS amp REPLACEMENTS Safety Warning Disconnection from Supply Always ensure that the furnace is disconnected from the supply before repair work is carried out Safety Warning Refractory Fibrous Insulation This furnace contains refractory fibres in its thermal insulation These materials may be in the form of fibre blanket or felt vacuum formed board or shapes mineral wool slab or loose fill fibre Normal use of the furnace does not result in any significant level of airborne dust from these materials but much higher levels may be encountered during maintenance or repair Whilst there is no evidence of any long term health hazards we stro
11. d grounded Switch off the Heater switch whenever loading or unloading the furnace The elements are isolated when the Heater switch is OFF This switch cuts both sides of the circuit directly or via a contactor a contactor is used in models where the rated current exceeds 16 Amps Tube Life A ceramic work tube may be cracked if workpieces are inserted too quickly or at temperatures below 900 C when the tube is more brittle Large pieces should also be heated slowly tube to ensure that large temperature differences do not arise Poor thermal contact should be encouraged between the crucible workpiece and the tube crucibles or boats should be of low Fig 4 thermal mass and should have feet to reduce the contact with av idance oF thermal contact the tube fig 4 MF13 5 HST VST 3 5 3 6 3 7 4 0 Do not set too high a heating rate Large diameter tubes are more susceptible to thermal shock than smaller Tubes which extend beyond the heated part of the furnace are more at risk A general rule for maximum heating rate is 400 internal diameter C min for 75mm i d tubes this comes to 5 C per minute The controller can be set to limit the heating rate 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 about half of that should normally be sufficient to achieve the
12. e 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 tube diameter s distance from the furnace centre for models with an even number of element modules the tip should be a quarter to a third of one element s length from the furnace centre Insert the new thermocouple into position restoring any removed porcelain spacers and ensuring correct polarity Re assemble the furnace Fuse Replacement Fuses are marked on the circuit diagram section 7 0 with type codes e g F1 F2 A list of the correct fuses is given in section 8 1 Depending on model and voltage the different fuse types may or may not be fitted If any fuse has failed it is advisable for an electrician to check the internal circuits Replace any failed fuses with the correct type For safety reasons do not fit larger capacity fuses without first consulting Carbolite The fuses are near the cable entry point and access is by removal of the back panel of the base or control box MF13 9 HST VST AN 6 0 10 Element Replacement Please see safety note 5 2 please wear a face mask HST and VST with far hinge Remove the three screws from each end and lift out the half circular insulation assembly Make a plan of all the cable connections and disconnect the cables Remove the thermocouple s by withdraw
13. e customer preparation of mounting components before installation Siting Place the furnace in a well ventilated room away from other sources of heat and on a surface which is resistant to accidental spillage of hot materials Do not mount the furnace on an inflammable surface Ensure that there is free space around the furnace Do not obstruct any of the vents in the control box they are needed to keep the controls cool Ensure that the control box is placed in such a way that it can be quickly switched off or disconnected from the electrical supply see below Setting Up If the furnace is supplied with a work tube or any accessories fit these into position For optimum temperature uniformity insulating plugs should be placed in the tube ends as shown in fig 1 With a long inner work tube the stem of the plug assembly should line up with the end of the tube as in fig 2 Alignment of radiation shields is similar to that of plugs With these models split end plugs are supplied unless ordered for a specific tube size these require shaping to fit the tube or work piece use a round file 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 Stainless steel seals for vertical use a hook and eye arrangement holds the upper insulating plug assembly alternatively a gland nut Horizontal models if heavy fittings are to be clamped to the end o
14. ents in parallel each pair in series HST amp VST 12 600 200 240V 3 pairs of 200mm 100 120V_ 3 pairs of 200mm elements in parallel elements in parallel each pair in series HST amp VST 12 900 200 240V_ 2 pairs of 150mm 100 120V_ 2 pairs of 150mm and elements in parallel 3 pairs of 200mm and 3 pairs of 200mm elements in parallel elements in parallel each pair in series Wherever two different sizes of elements are fitted the 150mm elements are at the ends and the 200mm elements in the centre MF13 FAULT ANALYSIS A Furnace Does Not Heat Up 1 The HEAT light gt The heating is ON element has failed 2 The HEAT light is OFF The controller shows a very high temperature or a code such as S br The controller shows a low temperature There are no gt The SUPPLY HST VST Check also that the SSR is working correctly The thermocouple has broken or has a wiring fault The door switch es if fitted may be faulty or need adjustment The contactor if fitted may be faulty The SSR could be failing to switch on due to internal failure faulty logic wiring from the controller or faulty controller gt The controller may be lights glowing light is ON faulty or not receiving a on the supply due to a faulty controller switch or a wiring fault gt The SUPPLY gt Check the supply fuses and light is OFF any fuses in the furnace B Furnace Overheats 1 The HEAT light gt The c
15. f an extended work tube they can increase the bending stress at the centre of the tube Support such fittings in such a way that expansion of the tube is allowed If a metal work tube is being used in the furnace ensure that it is earthed for operator safety radiation shield shown furnace body or insulating plug ring clip insulating plug wing nut insulating plug 7 So hook if i ie oe ea _ E gas nozzle t pa 4 stainless steel SS stem sealing ring plate Fig 1 _ Fig 2 insulating plug insulating plug Fig 3 standard length tube long work tube worktube seal MF13 3 HST VST 2 4 Electrical Connections Connection by a qualified electrician is recommended The furnaces covered by this manual normally require a single phase A C supply which may be Live to Neutral non reversible Live to Neutral reversible or Live to Live Some models may be ordered for 3 phase use and if so are universal see section 2 5 Check the furnace rating label before connection The supply voltage should agree with the voltage on the label and the supply capacity should be sufficient for the amperage on the label A If the actual supply is not the same as the voltage on the label then the controller power limit may need to be adjusted set the Heater Switch to off connect the furnace and see section 3 6 The supply should be fused at the next size equal to or higher than the amperage on the label A table
16. g to the instructions in the appropriate manual Switch on the Heater switch located on the instrument panel Unless a time switch is fitted and is off the furnace starts to heat up The Heat light s glow steadily at first and then flash as the furnace approaches the desired temperature or a program setpoint Overtemperature option only If the overtemperature trip operates then an indicator in the over temperature controller flashes and the heating elements are isolated Find and correct the cause before resetting the overtemperature controller according the instructions supplied To switch off power to the heating elements use the Heater Switch To switch the furnace off use both the Heater switch and the Instrument switch If the furnace is to be left off isolate it from the electrical supply General Operating Advice Heating element life is shortened by use at temperatures close to maximum Do not leave the furnace at high temperature when not required The maximum temperature is shown on the furnace rating label and on the back page of this manual Operator Safety The ceramic materials used in furnace manufacture become electrically conductive to some extent at high temperatures In these models there are partially exposed heating coils in the chamber and there is danger of contact even with the furnace closed DO NOT use any conductive tools within the work tube without isolating it If a metal work tube is used it must be earthe
17. ing them from the sheaths built into the elements Remove the plates through which the element tails are located Remove the keep plates from each side of the insulation assembly Lift out the element 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 previously made and complete the reassembly of the furnace Check that the furnace is controlling properly to rule out the possibility that the element failed because of a fault in the control system HST amp VST Elements each element is a half cylinder HST amp VST 12 200 200 240V 1 pair of 200mm 100 120V_ 1 pair of 200mm elements in series elements in parallel HST amp VST 12 300 200 240V_ 2 pairs of 150mm 100 120V_ 2 pairs of 150mm elements in parallel elements in parallel each pair in series HST amp VST 12 400 200 240V 2 pairs of 200mm 100 120V_ 2 pairs of 200mm elements in parallel elements in parallel each pair in series HST amp VST 12 500 200 240V_ 2 pairs of 150mm 100 120V_ 2 pairs of 150mm and elements in parallel 1 pair of 200mm and 1 pair of 200mm elements in parallel elem
18. ngly recommend that safety precautions are taken whenever the materials are handled Exposure to dust from fibre which has been used at high temperatures may cause respiratory disease When handling fibre always use an approved mask eye protection gloves and long sleeved clothing Avoid breaking up waste material Dispose of waste fibre in sealed containers After handling rinse exposed skin with water before washing gently with soap not detergent Wash work clothing separately Before commencing any major repairs we recommend reference to the European Ceramic Fibre Industry Association Bulletin No 11 and the UK Health and Safety Executive Guidance Note EH46 We can provide further information on request Alternatively our service division can quote for any repairs to be carried out at your premises or ours Temperature Controller Replacement 201 This controller is fitted to the back of the control panel in many models this can be separated from the base by removal of two screws Before handling the controller wear an anti static wrist strap or otherwise avoid any possibility of damage to the unit by static electricity Refer to the detailed instructions supplied with the replacement controller 2132 2416 2408 etc Ease apart the two lugs at the side grip the instrument and withdraw it from its sleeve push in the replacement Solid state Relay Replacement Disconnect the furnace from the supply and remove the furnace b
19. no 3 MF13 HST VST FUSES amp POWER SETTINGS 8 1 Fuses F1 F3 Refer to the circuit diagrams F1 Internal Fitted if supply cable fitted on board and up to 16 Amps supply Fitted on board to some types of EMC filter 32mm x 6mm type F fuses other GEC Safeclip F2 Auxiliary Fitted on board to some types of EMC filter 2 Amps glass type F oo May be omitted up to 25Amp phase supply On board 20mm x 5mm rating Other 32mm x 6mm Heat Light May be omitted up to 25 Amp phase supply 2 Amps glass type F fuses rating 32mm x 6mm Customer Required if no supply cable fitted See rating label for amperage fuses Recommended if cable fitted see table below for fuse rating Model phases Volts Supply Fuse Volts Supply Fuse from March 2001 Rating Rating HST amp VST 12 200 200 240 110 120 HST amp VST 12 300 200 240 110 120 HST amp VST 12 400 200 240 110 120 HST amp VST 12 500 1 phase 200 240 110 120 25A HST amp VST 12 500 3 phase N_ 380 220 415 240 HST amp VST 12 500 3 phase delta 200 240 10A HST amp VST 12 600 1 phase 200 240 15 16A HST amp VST 12 600 3 phase N_ 380 220 415 240 5A HST amp VST 12 600 3 phase delta 200 240 10A HST amp VST 12 900 1 phase 200 240 25A HST amp VST 12 900 3 phase N 380 220 415 240 10A HST amp VST 12 900 3 phase delta 220 240 15A Other models or voltages check the rating label for details
20. oes not apply to 3 phase star without neutral e g 380V or 440V To alter the configuration remove the control box back panel and alter the connections between the supply terminal block and the EMC filters using the appropriate diagram from section 7 7 Models ordered for single phase only are not affected and cannot be converted to 3 phase If in doubt please consult Carbolite 3 0 4 MF13 3 1 3 2 HST VST OPERATION The instructions for operating the temperature controller are given in a separate manual If the furnace is fitted with a time switch see also the supplementary manual MS03 If cascade control is fitted see the supplementary manual MS07 Operating Cycle The furnace is fitted with a combined Supply light and Instrument switch The light is on whenever the furnace is connected to the supply The switch cuts off power to the control circuit There is also a Heater switch which can be used to disconnect power to the elements Connect the furnace to the electrical supply The Supply light should glow Operate the instrument switch to activate the temperature controller the O position is off the I position on The controller becomes illuminated and goes through a short test cycle Set the temperature controller to the desired setpoint or program see the controller manual Overtemperature option only If the overtemperature controller has not yet been set as required set it and activate it accordin
21. ontroller goes OFF with shows a very high the instrument temperature switch gt The controller shows a low temperature 2 The HEAT light gt The SSR has failed does not go off ON with the instrument switch 7 0 MF13 control compartment gt The controller is faulty The thermocouple may have been shorted out or may have been moved out of the heating chamber The thermocouple may be mounted the wrong way round The controller may be faulty Check for an accidental wiring fault which could have overloaded the SSR HST VST CIRCUIT DIAGRAMS Safety Switches type A a 2 pole Heater Switch is fitted directly in the element circuit in models up to 16A rating Two door switches are also fitted in the element circuit up to 25A rating Safety Switch type B a Heater Switch is fitted into the contactor coil circuit in models over 16A A door switch is fitted into the contactor coil circuit over 25A rating 7 1 Single Phase Filter 1 if fitted pon contactor i if fitted Supply light Instrument Switch O E overtemp controller E gt C temperature ________________ controller BoBo 0 N e Ne LD thermocouple 7 2 2 phase with neutral As 3 phase with phase L3 not present and with two SSRs and element circuits In models up to 25A safety switches type A are fitted in the L1 and L2 circuits instead of type B in the contactor coil circuit
22. rmally applies with neutral if present not being used For single phase models of 254V or above diagram 7 1 applies except that a control circuit transformer is included as in diagram 7 5 MF13 13 HST VST 7 7 3 phase universal wiring Filters if fitted a N ee N __ L ot i A e e Frenne l l i Supply light amp Contactors e 2 Instrument Switch i 2or3 i m m i i e e t switch s s AE T Pt A aa a controller Thermocouple FESS C temperature cH SR kaz controller M gt thermocouple tc SSR Fuses F1 are always present in this wiring design Fuses F2 could be absent in some circumstances if the circuit does not exceed 10A Fuses F3 are present if the circuit exceeds 25A but otherwise are usually absent il F3 e 1 e heat P5 QD on n t s ll F3 3 phase neutral 3 phase delta Supply Fuses or Supply Fuses or Terminals EMC filters Terminals EMC filters Circuit no 1 Circuit no 2 Circuit no 3 1 phase Circuit no 1 Circuit no 2 Circuit no 3 to i Supply Fuses or A model made to this diagram can be TeHAIAIR EMC filters converted by the customer between the following supply voltages between 3 phase neutral in the range 380 220V 415 240V and 3 phase delta in the range 200V 240V and single phase in the range 200V 240V 8 0 14 Circuit no 1 Circuit no 2 Circuit
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