VERDER CARBOLITE GERO 2416 Series Installation, Operation And Maintenance Instructions Download Page 27 | Manualshive

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Summary of Contents for CARBOLITE GERO 2416 Series

Page 1: ...Installation Operation and Maintenance Instructions 1200 C E Range Tube Furnace EVA Model 600mm 2416 Controller EVA 12 600B 2416 Controller MEN EVA12600B 003_2416 09 07 2019 ...

Page 2: ...o the vertical stand 10 2 3 4 Figure Tube furnace positioned horizontally on the stand 11 2 3 5 Figure Exploded view showing how to fit the work tube in the EVA 12 2 3 6 Figure Tube support 13 2 3 7 Figure Tube support assembly 13 2 3 8 Figure Tube support and end seal assembly 14 2 3 9 Figure Tube support and end seal assembly 14 2 3 10 Figure View showing how to support the work tube in a vertic...

Page 3: ...or Break 29 4 3 Audible Alarm 30 4 4 Navigation Diagram 30 5 0 Operation 31 5 1 Operating Cycle 31 5 2 Safe Operation of the Furnace 31 5 3 General Operating Advice 32 5 4 Operator Safety 32 5 5 Tube Life 33 5 6 Pressure 33 5 7 Gas Tightness 34 6 0 Maintenance 35 6 1 General Maintenance 35 6 2 Maintenance Schedule 35 6 2 1 Cleaning 37 6 3 Calibration 37 6 4 After Sales Service 37 6 5 Recommended S...

Page 4: ...nalysis 41 A Furnace Does Not Heat Up 41 B Product Overheats 42 9 0 Wiring Diagrams 43 9 1 WA 11 30 43 9 2 WA 11 31 44 9 3 WA 12 30 45 9 4 WA 12 31 45 10 0 Fuses and Power Settings 46 10 1 Fuses 46 10 2 Power Settings 47 11 0 Specifications 48 11 1 Environment 48 Furnace drying out process 49 4 ...

Page 5: ...itch 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 may be hot DANGER Read an...

Page 6: ...work tube and correspond work tube adaptors or it could be possible for an operator to access electrically live element coils that could cause serious injury or death 8 Warning label Switch off the furnace before loading and unloading The furnace heaters must be switched OFF using the heater switch item 2 in figure 1 3 1 when the furnace is being loaded or unloaded The work tube can become electri...

Page 7: ...ace heating elements 3 Heater ON light indicates that the furnace heating elements are energized 4 Product rating label indicating the product serial number and electrical inform ation 5 Access holes to front panel fixing screws 6 Warning label Disconnect the mains supply before removing this cover 7 Warning label Do not operate without a work tube 8 Warning label Switch OFF the furnace before loa...

Page 8: ...stant 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 ...

Page 9: ...nd mounting the furnace Tools required 4 mm Allen key The assembly of the vertical stand is as follows with reference to 2 3 1 2 3 2 and 2 3 3 Place the vertical stand base item 1 on the floor or bench on which it is to be assembled l Position the vertical stand upright 2 on the stand base in line with the fixing holder l Secure the stand upright to the base using the 6 x M6 dome cap screws 4 and ...

Page 10: ...2 3 2 Figure Assembling the stand Index to numbered items in Figure 2 3 2 and Figure 2 3 3 1 Vertical stand base 2 Vertical stand upright 3 Fixing screws M6 x 16 dome cap screw 4 Washer M6 5 Tube furnace 6 M6 screw knob 2 3 3 Figure Mounting the fur nace onto the vertical stand 10 ...

Page 11: ... standard length work tubes are also referred to as tubes suitable for working in air they are 150 mm longer than the heated length of the furnace see the table in section 11 0 Read section 7 2 before fitting the work tube l Remove the top work tube end guard item 8 hen remove the work tube adaptor fix ing bracket 4 that holds the work tube end stop 7 and the work tube adaptor 3 in place Note 1 it...

Page 12: ...f clamps are used without an end seal care should be taken not to over tighten on to a bare tube especially if the tube is either quartz or thin wall section l Before the extended work tube can be fitted the work tube end stops for the stand ard length work tube must be removed from both ends of the furnace This is done by removing the furnace end guard 8 and the work tube adaptor brackets 4 to re...

Page 13: ... Figure 2 2 shows an exploded view of all the required parts l Figure 2 2 shows the assembled parts as they would be used 2 3 6 Figure Tube support 2 3 7 Figure Tube support assembly 13 2 0 Installation ...

Page 14: ...nstallation 2 3 8 Figure Tube support and end seal assembly 2 3 9 Figure Tube support and end seal assembly For extra stability of the tube repeat the assembly instructions above as shown in figure 2 3 10 14 ...

Page 15: ...rig mounting frame It is the customer s responsibility to carry out a risk assessment on the siting and mounting of the furnace and to ensure that it is operated in a safe manner see section 2 2 for the recommended siting instructions The fitting of the work tube is covered in the previous section 2 4 1 Figure Tube furnace shown without a stand for customers own mounting as an example Index to num...

Page 16: ...ation shields is similar to that of insulation plugs see figure C If a metal work tube is being used in the furnace ensure that it is earthed See the safety warning in section 5 4 Figure A Cross section view showing standard length work tube insulation plug fitted Figure B Cross section view showing extended work tube insulation plug fitted Figure C Cross section view showing an extended length wo...

Page 17: ...ternal supply fuses in which case customer fusing is preferred but not essential See section 10 0 for furnace rating power current and fusing information The external connection should be either a permanent connection to a fused isolator supply or to a socket on a fused isolator supply the isolating switch must operate on both conductors Make sure that the isolator switch is within easy reach of t...

Page 18: ...ture controller where on setting the required tem perature the controller immediately attempts to reach and maintain it Fig 1 indic ates the type of temperature response when used in this way l By using one program segment the control can be extended to include ramp to set point Fig 2 shows the effect l Alternatively the 2416 Controller may be used as an 8 segment programmer with each segment bein...

Page 19: ...ntrol Fig 2 Control with Ramp to Setpoint Seg 1 Ramp Sep 2 End Dwell Fig 3 A Program Key T1 Temperature T2 Time SP Setpoint AT Actual Temperature WSP Working Setpoint R Ramp D Dwell S Step E End 19 3 0 2416 Controller ...

Page 20: ...nace or oven circuit this must be in an ON position 2416CG Operation When switched on the controller lights up goes through a short test routine and then displays the measured temperature and setpoint Depending on its state when it was last switched off it may start to control to the current setpoint of program The output light glows or flashes to indicate that the control is occurring The buttons...

Page 21: ... displays the temperature units further presses reveal the parameters in the current list Some parameters are display only others may be altered by the operator Page Scroll Press together to cause an immediate return to the Home List Run Hold Indicate the current mode Run Hold or Reset Reset both lights off Run flashes at the end of a program Hold flashes during holdback when the program is paused...

Page 22: ...ss all program segments are used Segments after End are ignored Segment Type Parameter Function RmP r TGt rATE The target setpoint for this segment The ramp rate rate of temperature change in minute RmP t TGt dur The target setpoint for this segment The duration of the segment The controller calculates the rate of temperature rise necessary to achieve this duration Dwel dur The time in minutes to ...

Page 23: ...pplies to heating only Hi Holdback applies to cooling only Off Holdback is off Set Hb V to the value in C beyond which holdback is to operate Type BAnd and a value of 10 C is often a suitable combination if holdback is required In this case if the actual temperature deviates outside 10 C from the working setpoint the holdback lamp of the front of the controller flashes and the program is held up u...

Page 24: ...scroll until tYPE is displayed and use the arrow key to select dwEl 9 Press scroll until dur is displayed and use the arrow key to select 60 0 10 Press scroll until SEG n is displayed and use the arrow key to select 3 11 Press scroll until tYPE is displayed and use the arrow key to select rmP t 12 Press scroll until tGt is displayed and use the arrow key to select 400 13 Press scroll until dur is ...

Page 25: ...S232 Cable product to PC Computer end of cable 9 pin 25 pin male Rx 2 3 _________________ 3 2 Tx Tx 3 2 _________________ 2 3 Rx Com 7 5 _________________ 5 7 Com 7 8 4 5 Link together 1 4 6 6 8 20 Link together 3 4 2 Digital Communications RS485 If an RS485 option is supplied the furnace is fitted with two D sockets Connection between products is by straight cable as follows Product end of cable ...

Page 26: ...ent configuration and parameters available to the operator depend on the customer requirements 3 5 Temperature Controller Replacement 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 Ease apart the two lugs at the side grip the ins...

Page 27: ...3 6 Navigation Diagram 27 3 0 2416 Controller ...

Page 28: ...strument switch which cuts 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 he...

Page 29: ... 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 the setpoint Power to the ...

Page 30: ...erature condition and to stop 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 30 ...

Page 31: ...ct will start to heat up The Heat light s glow steadily at first and then flash as the product approaches the desired temperature or a program setpoint Over Temperature option only If the over temperature circuit has tripped an indicator on the over temperature controller flashes and the heating elements are isolated Find and correct the cause before resetting the over temperature controller accor...

Page 32: ...h item 2 in Warning Labels when the furnace is being loaded or unloaded The work tube can become electrically conductive at high temperatures If an element has failed and collapsed onto the work tube the work tube will become live causing serious injury or death 5 3 General Operating Advice Heating element life is shortened by overheating Do not leave the product at high temperature when it is not...

Page 33: ...eneral rule for maximum heating or cooling rate is 400 internal diameter in mm to give C min for 75 mm i d tubes this comes to 5 C per minute The controller can be set to limit both the heating and cooling rate 5 6 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 pre...

Page 34: ...s Tightness Work tubes of IAP material are impervious Sillimanite may look similar but is porous Ensure that the correct tube material is in use before connecting and using gases other than inert gases such as nitrogen 34 ...

Page 35: ...tted 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 cleaning of the power plate area Functio...

Page 36: ...ted Check 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 36 ...

Page 37: ...ales Service Carbolite Gero Service has a team of Service Engineers who can offer repair calibration and preventive maintenance of furnace and oven products both at the Carbolite Gero factory and at customers premises throughout the world A telephone call or email often enables a fault to be diagnosed and the necessary parts to be despatched In all correspondence please quote the serial number and...

Page 38: ... 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 39: ... colour codings are thermocouple leg colour positive type N pink negative white 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 ...

Page 40: ...e 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 Gero The fuses are located at the cable entry point Remove the back panel or control box back panel to gain access to the fuses 4...

Page 41: ...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 42: ...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 42 ...

Page 43: ...ey 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 43 9 0 Wiring Diagrams ...

Page 44: ...FIL Filter R1 1 R1 2 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 44 ...

Page 45: ...9 3 WA 12 30 9 4 WA 12 31 Connections below show single phase with safety switches and over temperature control 45 9 0 Wiring Diagrams ...

Page 46: ...type F fitted on EMC filter circuit board s F2 Auxiliary Circuit Fuses Fitted on board to some types of EMC filter May be omitted up to 25 Amp phase supply rating 2 Amps glass type F On board 20 mm x 5 mm Other 32 mm x 6 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...

Page 47: ... to the Changing the Maximum Output Power of the control section of the manual All standard models covered by this manual are fitted with elements designed for use over the range of voltages 100 V 120 V and 200 V 240 V the power limit parameter is set according to the table below The power limit depends on the voltages follows Voltage 100 V 120 V 200 V 208 V 220 V 230 V 240 V Percentage 100 100 89...

Page 48: ...arbolite Gero for work tubes with outside diameters of 32 mm 46 mm and 60 mm 11 1 Environment The furnaces contain electrical parts and should be stored and used in indoor conditions as follows Ambient temperature working range Temperature 5 C to 40 C Note when operating the furnace at temperatures close to the maximum and the ambient temperature is above 30 C the allowed external temperature defi...

Page 49: ...lation procedure see section 2 1 Step 3 After reading the controller operation instructions heat the furnace following the temperature profile given below This will need to be done manually on furnaces with basic control option or programmed into the controller if an advanced control option is fitted l Ramp the setpoint temperature 2 C minute to 100 C and dwell for 2 hours l Ramp the setpoint temp...

Page 50: ......

Page 51: ...Notes Service Record Engineer Name Date Record of Work ...

Page 52: ... 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...

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