Nabertherm HTCT 01/14, HTCT 01/16, HTCT 01/15 Operating Instructions Manual
Operating Instructions
High-Temperature Furnace
(Tabletop Model)
HTCT 01/14 - HTCT 01/16
-> 08.2010
Original instructions
www.nabertherm.com
Made
in
Germany
Copyright
© Copyright by
Nabertherm GmbH
Bahnhofstrasse 20
28865 Lilienthal
Federal Republic of Germany
Reg: M01.0016 ENGLISCH
Rev: 2010-08
No responsibility is accepted for the correctness of this information. We
reserve the right to make technical alterations.
2
1 Introduction...........................................................................................................................................................5
1.1 Product Description ......................................................................................................................................... 6
1.2 Overview of the Complete Oven ..................................................................................................................... 7
1.3 Key to the Model Names................................................................................................................................. 8
1.4 Scope of Delivery ............................................................................................................................................ 9
2 Specifications .......................................................................................................................................................10
2.1 Warranty and Liability................................................................................................................................... 11
3 Safety.................................................................................................................................................................... 12
3.1 Intended Use..................................................................................................................................................12
3.2 Requirements for the Oven Operator............................................................................................................. 13
3.3 Requirements for the Operating Personnel.................................................................................................... 14
3.4 Protective Clothing........................................................................................................................................14
3.5 Basic Measures During Normal Operation.................................................................................................... 14
3.6 Basic Measures in Case of Emergency.......................................................................................................... 15
3.6.1 What to do in an Emergency..................................................................................................................... 15
3.7 Basic Measures for Servicing and Maintenance............................................................................................16
3.8 Environmental Regulations ...........................................................................................................................17
3.9 Explanation of the Symbols and Warnings....................................................................................................18
3.10 General Risks with the Oven ......................................................................................................................... 21
4 Transportation, Installation, and Commissioning............................................................................................21
4.1 Delivery ......................................................................................................................................................... 21
4.2 Unpacking...................................................................................................................................................... 24
4.3 Transportation Securing Equipment/Packaging ............................................................................................25
4.4 Constructional and Connection Requirements............................................................................................... 27
4.4.1 Installation (Oven Location) ..................................................................................................................... 27
4.5 Assembly, Installation, and Connection ........................................................................................................ 28
4.5.1 Waste Gas System ....................................................................................................................................28
4.5.2 Connecting the Oven to the Power Supply ............................................................................................... 29
4.5.3 Installation/Connection if a Transformer is Used.....................................................................................30
4.5.4 Insertion of the Base Plate ........................................................................................................................ 32
4.6 Commissioning..............................................................................................................................................33
4.7 Recommendations for Heating the Oven for the First Time.......................................................................... 33
5 Operation .............................................................................................................................................................34
5.1 Over-Temperature Limit Controller with Manual Reset and Adjustable Cut-Off Temperature.................... 35
5.2 Air Inflow Lever............................................................................................................................................36
5.3 Loading/charging........................................................................................................................................... 37
6 Servicing, Cleaning, and Maintenance.............................................................................................................. 38
6.1 Shutting the system down for maintenance...................................................................................................39
6.2 Regular Maintenance of the Oven ................................................................................................................. 40
6.3 Operating and Auxiliary Materials ................................................................................................................ 41
6.4 Cleaning Products.......................................................................................................................................... 41
7 Faults.................................................................................................................................................................... 42
8 Spare Parts/Wearing Parts................................................................................................................................. 43
8.1 Replacing a Heating Element ........................................................................................................................ 45
3
8.2 Replacing a Thermocouple............................................................................................................................48
8.3 Replacement/Readjustment of the Door Insulation Structure........................................................................ 51
8.4 Replacing a Fuse............................................................................................................................................ 52
8.5 Separate the Snap-In Coupling (Plug) from the Furnace Housing ................................................................53
8.6 Repairing the Insulation................................................................................................................................. 53
9 Electrical Connections (Circuit Diagram)......................................................................................................... 54
10 Nabertherm Service ............................................................................................................................................ 55
11 Shut-Down, Dismantling, and Storage...............................................................................................................56
11.1 Transportation/Return Transportation ........................................................................................................... 57
12 Declaration of Conformity.................................................................................................................................. 58
13 For Your Notes.................................................................................................................................................... 59
4
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1 Introduction
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Dear Customer,
Thank you for choosing a quality product from Nabertherm GmbH.
You can be proud that you have chosen an oven which has been especially tailored to suit
your manufacturing and production conditions.
This product is characterized by
• professional workmanship
• high performance due to its high efficiency
• high-quality insulation
• low power consumption
• low noise level
• simple installation
• easy to maintain
• high availability of spare parts
Your Nabertherm Team
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Note
These documents are intended only for buyers of our products and may not be copied or
disclosed to third parties without our written consent.
(Law governing copyright and associated protective rights, German Copyright Law from
Sept. 9, 1965)
Protective Rights
Nabertherm GmbH owns all rights to drawings, other documents and authorizations, also in
case of applications for protective rights.
Note
All the figures in the instructions have a descriptive character; in other words, they do not
represent the exact details of the oven.
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1.1 Product Description
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This high-temperature laboratory furnace is a quality product which will give you many
years of reliable service if it is properly cared for and maintained. One basic requirement is
that the furnace is used for the purposes for which it was intended.
During development and production high priority was placed on safety, functionality and
economy.
High-temperature furnaces in the HTCT range. Designed as table-top models, these
compact high-temperature furnaces offer many benefits. These furnaces are all-rounders in
research facilities and laboratories. They are made from expertly finished, high-quality
materials and are easy to operate. The furnaces are also ideally suited for sintering technical
ceramics, such as zirconium oxide dental bridges. The very best insulation materials permit
energy-saving operation and fast heating times thanks to low heat storage and thermal
conductivity. High-temperature furnaces in the HTCT range reach a chamber temperature
of max. 1400°C (2552°F),1500°C (2732°F) or 1600°C (2912°F).
Other features of this product are:
• High-quality silicon carbide (SiC) heating elements
• Heating elements are easy to replace
• High-quality fiber material designed for the furnace temperatures
• Stainless steel structured housing
• Double-wall housing with additional fan cooling for low external temperatures
• Adjustable fresh air opening, exhaust air vent in the top
• Lift door, with the hot side facing away from the operator
• Type S thermocouples
• Switchgear with semi-conductor relays calibrated for the heating elements
Additional equipment
• Over-temperature limit controller with manual reset for thermal protection class 2 in
accordance with EN 60519-2 as a temperature limiter to protect the furnace and the
load
• Rectangular batch containers, can be stacked for charging in several levels
• Manual or automatic gas supply system
• RS 422 digital interface, can be used, for example, for process control and
documentation via Controltherm MV software package
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1.2 Overview of the Complete Oven
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Exhaust air tube
Lift door
Lift door handle
Thermocouple
Exhaust air tube
Heating element
Insert plate (to protect the base of the
furnace)
Collar insulation
Fresh air lever to control the feed of
fresh air
Over-temperature limit controller with
manual reset (accessory)
Controller
Power switch (ON/OFF)
Switchgear fan
Rear side of oven
Fuse
RS 422 digital interface
Power cable with snap-in coupling
Additional power connection (fuse for additional power
connection), e.g. for manual or automatic gas supply system
(accessory)
Fig. 1: Overview: The example here is a high-temperature furnace, Model HTCT 01/.. with accessories
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7
1.3 Key to the Model Names
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Example Explanation
HTCT 01/16
HTCT = high-temperature furnace (tabletop model)
HTCT 01/16
01 = 1-liter furnace chamber (volume in L)
HTCT 01/16
14 = Tmax 1400 °C (2552 °F)
15 = Tmax 1500 °C (2732 °F)
16 = Tmax 1600 °C (2912 °F)
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HTCT 01/16
LC011H6SN 1600 °C 2010
220-240 V 1/N/PE~ 15.2 A 50 Hz 3.5 kW
www.nabertherm.de Made in Germany
Fig. 2: Example model designation (type plate)
SN xxxxxx
8
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1.4 Scope of Delivery
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The scope of supply includes:
System component Quantity Comment
HTCT ../.. high-temperature furnace (tabletop
1 x Nabertherm GmbH
model)
Allen key
Exhaust air pipe
1 x Nabertherm GmbH
1 x Nabertherm GmbH
Insert plate
1 x Nabertherm GmbH
T
4
A
2
5
0
V
V
A
0
4
5
2
T
H
Fuse *)
1 x *) Nabertherm GmbH
Mains power cable *)
1 x Nabertherm GmbH
Gas supply system *)
1 x Nabertherm GmbH
Tansformer *)
1 x Nabertherm GmbH
Other components depending on variant - - - See delivery documents
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Type of document Quantity Comment
Operating instructions, HTCT ../.. high-
1 x Nabertherm GmbH
temperature furnace (tabletop model)
Operating instructions, controller *) 1 x Nabertherm GmbH
Operating instructions, gas supply system *) 1 x Nabertherm GmbH
Other documents depending on variant - - -
*) = in scope of delivery depending on variant
Note
Please carefully retain all documents. During fabrication and before delivery, all the
functions of this furnace system have been tested.
9
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2 Specifications
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High-temperature furnace
Electrical specifications are on the type plate located on the side of the oven.
Model Tmax
°C
Dimensions,
interior in mm
w d h
Dimensions,
exterior in mm
W D H+c
Volume
in L
Output
kW
Weight
kg
Minutes
to
Tmax
HTCT 01/14 1400 110 120 120 340 300 500+185 1 max. 3.5 25 40
HTCT 01/15 1500 110 120 120 340 300 500+185 1 max. 3.5 25 50
HTCT 01/16 1600 110 120 120 340 300 500+185 1 max. 3.5 25 60
c
D
H
d
H
h
w
W
Fig. 3: Dimensions of high-temperature furnace
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Electrical connection
Thermal protection class
Protection class
Ambient conditions for electrical
equipment
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Emissions
1-phase: (1/N/PE)
Model: HTCT 01/14 – HTCT 01/16
Voltage: 220 V – 240 V
Frequency: 50 or 60 Hz
Power plug Protective contact plug
Furnaces:
Furnaces IP20
Temperature: Humidity: +5°C to + 40°C, max. 80% non-
Continuous sound pressure
level:
(with snap-in socket)
As per DIN EN 60519-2
Without safety controller: Class 0
condensing
< 80 dB(A)
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2.1 Warranty and Liability
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As regards warranty and liability, the normal Nabertherm warranty terms apply,
unless individual terms and conditions have been agreed. However, the following
conditions also apply:
Warranty and liability claims for personal injury or damage to property shall be excluded if
they are attributable to one or more of the following causes:
• Everyone involved in operation, installation, maintenance, or repair of the oven must
have read and understood the operating instructions. No liability will be accepted for
damage or disruptions to operation resulting from non-compliance with the operating
instructions.
• Not using the oven as intended,
• Improper installation, start-up, operation, or maintenance of the oven,
• Operation of the oven with defective safety equipment or improperly installed or non-
functioning safety and protective equipment,
• Not observing the references in the operating instructions to transportation, storage,
installation, start-up, operation, maintenance, or equipping the oven,
• Making unauthorized changes to the oven,
• Making unauthorized changes to the operating parameters,
• Making unauthorized changes to the parameterization, the settings, or the program,
• Original parts and accessories are designed especially for Nabertherm ovens. Replace
parts only with original Nabertherm parts. Otherwise the warranty will be void.
Nabertherm accepts absolutely no liability for damage caused by using parts that are
not original Nabertherm parts.
• Catastrophes due to third-party causes and force majeure.
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§
11
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3 Safety
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3.1 Intended Use
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Safety
This Nabertherm system was designed and manufactured after careful selection of the
harmonized standards to be observed as well as other technical specifications. It therefore
corresponds to the state of the art, ensuring the highest possible degree of safety.
Only materials with known characteristics and melting temperatures may be used. Check
the material safety data sheets if necessary.
Use of the furnace for any other purpose whatsoever such as processing
products other than those intended or handling hazardous substances or
substances posing a health hazard constitutes improper use and must be
agreed upon with Nabertherm in writing.
Whether or not the materials used in the furnace can potentially corrode or destroy
the insulation or heating elements must be ascertained.
For furnaces with over-temperature limit controllers, the cutoff temperature must be set to
prevent overheating of the material.
Modifications to system equipment must be agreed upon with
Nabertherm in writing. It is not permitted to remove, bypass, or shut down safety devices.
The installation instructions and safety guidelines must be observed. Otherwise, the furnace
will not be considered as being used as designated, and all claims against Nabertherm
GmbH will be void.
Opening the furnace when hot (temperature greater than 200/392 °C/°F) can lead to
accelerated wear of the following components: insulation, heating elements, and furnace
housing.
Operating with power sources, products, operating equipment, additives,
etc. that are subject to the Ordinance on Hazardous Substances or cause
risks to the health of operating personnel in any way is not permitted.
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- This furnace is designed for commercial use. The furnace must not be used
for heating food, animals, wood, grain, etc.
- The furnace must not be used as a workplace heater.
- Do not use the furnace to melt ice or similar materials.
- Do not use the furnace as a clothes dryer.
Note
See safety instructions in the individual sections.
Note
The oven must not be operated with explosive gases or mixtures and it must be ensured that
explosive gases or mixtures do not form during the process.
This oven has no safety technology for processes in which ignitable mixtures could form,
e.g. debinding.
If the oven is to be used for such processes, the concentration of organic gases must never
exceed 3% of the lower explosive limit (LEL) in the oven. This requirement not only
applies to normal operation, but also especially to exceptions, such as process faults (e.g.
due to the failure of a unit, etc.).
Nabertherm offers a wide range of ovens and furnaces that were especially developed for
12
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processes with ignitable gases.
Note
This product does not
comply with the ATEX Directive and may not be used in ignitable
atmospheres. It must not be operated with explosive gases or mixtures or during processes
where explosive gases or mixtures are produced.
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3.2 Requirements for the Oven Operator
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The set-up instructions and safety regulations must be followed, otherwise the oven will be
deemed to have been used improperly, effectively cancelling any claims against
Nabertherm GmbH.
This level of safety when operating the oven can be achieved only if all the necessary
measures have been taken. It depends on the oven operator's diligence in planning these
measures and controlling how they are carried out.
The operator must ensure that
• all harmful gases are removed from the workplace, for example by an extraction
system,
• the extraction system is switched on,
• the workplace is properly ventilated,
• the oven is operated only in a perfect operating condition and, in particular, that the
functions of the safety components are checked regularly.
• the required personal protective equipment is available for and used by the
operating, maintenance, and repair personnel.
• these operating instructions, including the supplier documentation, are kept near the
oven. These instructions must be available at all times for anyone working with or
on the oven;
• all the safety and operating instruction signs on the oven can be read properly.
Damaged or unreadable signs must be replaced immediately,
• oven personnel are informed regularly about all issues involving occupational safety
and environmental protection and are familiar with all the operating instructions,
especially those involving safety,
• a risk assessment is carried out (in Germany, covered by Section 5 of the
Occupational Safety Act) to determine any other hazards that may result from the
working conditions particular to the oven's location,
• all other instructions and safety guidelines that have been determined in a risk
assessment for the workplace are compiled in an operation manual (in Germany,
covered by Section 6 of the Ordinance Regulating the Use of Operating
Equipment).
• operating personnel still in training initially perform their work at the oven under the
supervision of an experienced person. Successful completion of the training period
must be confirmed in writing.
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Note
In Germany, the VBG and BGZ accident prevention regulations must be followed. The
accident prevention regulations applicable in the country where the oven is installed must
be followed.
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3.3 Requirements for the Operating Personnel
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The oven may be operated only by persons who are trained, instructed, and authorized to do
so. These persons must know the operating instructions and act accordingly. The
authorizations of the operating personnel must be clearly defined.
Only adequately qualified and authorized persons may operate, maintain, or repair the oven.
Operating personnel are instructed regularly in all aspects of occupational safety and
environmental protection and are familiar with all the operating instructions, in particular,
safety instructions.
Only trained personnel may operate the control and safety equipment.
The operator should complete these details:
• Operator____________________________________________________
• The oven may only be transported by _____________________________
• The oven may only be installed by _____________________________
• The oven may only be commissioned by___________________________
• Initial instructions may only be given by____________________________
• Faults may only be rectified by _____________________________
• The oven may only be maintained by _____________________________
• The oven may only be cleaned by _____________________________
• The oven may only be serviced by _____________________________
• The oven may only be repaired by _____________________________
• The oven may only be shut down by _____________________________
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3.4 Protective Clothing
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Wear heat-resistant gloves to protect your hands.
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3.5 Basic Measures During Normal Operation
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Risks during Normal Operation!
Before switching the oven on, check and ensure that only authorized persons are in the
working area of the oven and that no one can be injured as a result of operating the oven.
Before starting production each time, check and ensure that all the safety equipment works
properly.
Before starting production each time, check the oven for obvious damage and ensure that it
is operated only in a perfect condition. Report any defects to a supervisor immediately.
Before starting production each time, remove all materials and objects that are not needed
for production from the working area.
At least once every day (see also Servicing and Maintenance) check the following:
• Check the oven for obvious external damage,
• Check that all safety equipment is working as intended (e.g. emergency stop button),
14
• Check all hydraulic or pneumatic hoses, make sure that they are not leaking and that
they are connected properly (if applicable),
• Check all gas and oil lines, make sure that they are not leaking and that they are
connected properly (if applicable),
• Check that the fan works properly,
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3.6 Basic Measures in Case of Emergency
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3.6.1 What to do in an Emergency
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Note
The power plug is to be pulled out to stop the oven in case of an emergency. Therefore,
the power plug must be accessible at all times when the oven is operating so that it can be
pulled out quickly in case of an emergency.
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Fig. 4: Pulling the power plug
Risks during Normal Operation!
Switch the oven off immediately in case of unexpected occurrences in the oven (e.g. a lot of
smoke or unusual smells). Wait until the oven has cooled naturally to room temperature.
15
DANGER
• Danger of electric shock.
• Risk of fatal injury.
• Work on electrical
equipment may be carried out only by
qualified electricians
or by trained personnel authorized by
Nabertherm.
• Before starting work, pull out the
power plug
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3.7 Basic Measures for Servicing and Maintenance
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Maintenance work must be performed by authorized persons following the maintenance
instructions and the accident prevention regulations. We recommend that the maintenance
and repair work be carried out by the service team of Nabertherm GmbH. Non-compliance
may cause injuries, death, or considerable damage to property.
Switch off the oven and make sure it cannot be switched on again inadvertently (lock the
main switch and secure it with a padlock), or pull out the power plug.
Clear an adequate area around the oven to facilitate the repair work.
Suspended loads are dangerous. Working beneath a suspended load is prohibited. There is a
risk of fatal injury.
Relieve the pressure on hydraulic equipment before carrying out maintenance or repair
work (if applicable).
When cleaning ovens, control cabinets, or electrical equipment housings, never spray them
with water.
When maintenance or repair work has been completed, before recommencing production
ensure the following:
• Check that loosened screw connections have been re-tightened,
• Reinstall protective equipment, screens, and filters,
• Remove all material, tools, and other equipment used for the maintenance or repair
work from the working area of the oven,
• Remove any liquids that have leaked,
• Check that all safety functions (e.g. emergency stop button) work properly,
Power cables may be replaced only with similar, approved cables.
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3.8 Environmental Regulations
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All statutory duties regarding waste avoidance, proper recycling, and disposal must be
observed when work is carried out on and with the oven.
Problem materials that are no longer needed, such as lubricants or batteries, must not be
placed in normal waste disposal systems or allowed to enter the sewage system.
During installation, repair, and maintenance work, substances that are hazardous to water,
such as
• lubricating grease and oils
• hydraulic oils
• refrigerants
• solvent-based cleaning fluids must not be allowed to contaminate the soil or enter the
sewage system.
These substances must be stored, transported, collected, and disposed of in suitable
containers.
Note
The operator must ensure that national environmental regulations are observed.
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When it is delivered, this oven contains no substances that make a hazardous waste
classification necessary. However, residues of process materials may accumulate in the
oven insulation during operation. These may be hazardous to health and/or the
environment.
• Dismantle the electronic components and dispose of them as electric scrap.
• Remove the insulation and dispose of it as hazardous waste (See Servicing, Cleaning,
and Maintenance with Ceramic Fiber Material)
• Dispose of the housing as scrap metal.
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3.9 Explanation of the Symbols and Warnings
Note
NOTICE
In the following operating instructions, specific warnings are given to draw attention to
residual risks that cannot be avoided when the oven is operating. These residual risks
include dangers for humans/products/ the oven, and the environment.
The symbols used in the operating instructions are especially intended to draw attention to
safety information.
The symbols used cannot replace the text of the safety information. Therefore, always read
the entire text.
Graphic symbols correspond to ISO 3864. In accordance with the American National
Standard Institute (ANSI) Z535.6 the following warning information and words are used in
this document:
The general hazard symbol, in combination with the words CAUTION, WARNING and
DANGER warns about the risk of serious injury. Observe the following information to
prevent injury or death.
Refers to a hazard that could damage or destroy the equipment.
CAUTION
WARNING
DANGER
Refers to a hazard with a minor or medium risk of injury.
Refers to a hazard that could cause death, serious or irreversible injury.
Refers to a hazard that could directly cause death, serious or irreversible injury.
Structure of the warning: All warnings are structured as follows
Hazard symbol
Indicates the risk of injury
Signal word
Classifies the danger
WARNING
• Type and source of the danger
• Consequences of non-compliance
• Action to prevent danger
Graphical symbols (optional)
according to ISO 3864:
Consequences, measures, and
prohibitions
Reference texts:
• Type and source of the danger
• Possible consequences of noncompliance
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