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VERDER CARBOLITE GERO 3016, Installation, Operation And Maintenance Instructions

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VERDER CARBOLITE GERO 3016 Installation, Operation And Maintenance Instructions Download Page 6

2.0

Navigation

Users navigate through the controller by pressing the four buttons positioned below the
display. For some functions, a combination of buttons must be pressed simultaneously.

1

Display

2

Alarm Indicator

3

Segment Indicator

4

Page Button

5

Scroll Button

6

Down Button

7

Up Button

8

Output Indicator

9

Setpoint Temperature

10 Actual Temperature

Note:

The output indicator 1 icon will appear to

show that power is being directed to the product
heating elements. Output indicators 2 and 3 are
linked to other outputs within the controller.

6

Summary of Contents for CARBOLITE GERO 3016

Page 1: ...Installation Operation and Maintenance Instructions Controller Manual 3016 Controller 3016 Controller MEN 3016_CTRL 19 08 2020 ...

Page 2: ...erator Level 8 4 1 1 Operator Level 2 8 4 1 2 Operator Level 3 9 4 1 3 Configuration Level 9 4 1 4 Logging Out of Operator Level 3 and Configuration Level 10 5 0 Simple Temperature Control 11 5 1 Sensorbreak 11 6 0 Programming 12 6 1 Run Hold Reset a Program 12 6 1 1 Run 12 6 1 1 1 Shortcut Run Program 12 6 1 2 Hold 12 6 1 2 1 Shortcut Hold Program 13 6 1 3 Reset 13 6 1 3 1 Shortcut Reset Program ...

Page 3: ...43 12 0 Communications Connections 45 12 1 Configuring iTools Communications Settings 45 12 1 1 Ethernet Connections 46 12 1 2 RS485 Connections optional 48 12 2 Establishing a Connection Windows 10 49 13 0 Navigation Diagrams 51 13 1 Operator Level 1 51 13 2 Operator Level 2 51 13 3 Operator Level 3 52 13 4 Configuration Level 53 13 5 Controller Replacement 53 3 ...

Page 4: ...e within the product Users navigate through the controller by pressing the four buttons positioned below the display 1 1 Features The 3016 features l 1 program slot with up to 24 configurable segments l Ramp Dwell Step Call and End segment types l 2 relay outputs that can be pre configured as event outputs or alarms must be spe cified when ordered l Ethernet connection l Cybersecurity communicatio...

Page 5: ...ing temperature PID Proportional Integral Derivative the mathematical control system used by the controller Program A series of instructions that tell the controller how to behave A program is divided into sections called segments Segment A section of a program A program can have 24 individual segments There are 6 different segment types that can be configured The segments define how the controlle...

Page 6: ...imultaneously 1 Display 2 Alarm Indicator 3 Segment Indicator 4 Page Button 5 Scroll Button 6 Down Button 7 Up Button 8 Output Indicator 9 Setpoint Temperature 10 Actual Temperature Note The output indicator 1 icon will appear to show that power is being directed to the product heating elements Output indicators 2 and 3 are linked to other outputs within the controller 6 ...

Page 7: ...e display shows an overview of the controller including details such as the actual temperature and setpoint Functionality permissions are set as Operator Level 1 by default Note If the controller is power cycled while being used at a higher permission level it will return to Operator Level 1 and the user must login again to access higher level functionality 7 ...

Page 8: ...1 Operator Level 2 To access Operator Level 2 1 From the Home display press and hold the page button for 3 seconds until the GOTO display appears 2 Use the up and down arrow buttons to select the operator level you wish to access 3 Press the scroll button to confirm The CODE display will appear You now have to input a passcode 4 Use the up and down arrows to change the number input 5 Press the scr...

Page 9: ... 5 When you have finished inputting the passcode wait for 2 seconds If entered cor rectly PASS will appear on the display and you will now have access to additional functionality Note The passcode to access Operator Level 3 is 0005 4 1 3 Configuration Level To access Configuration Level Config 1 Press and hold the page button until Lev3 GOTO appears 2 Press the up button until CONF appears 3 Press...

Page 10: ...ation Level To log out of operator levels with higher permissions 1 Press and hold the page button until the GOTO display appears 2 Use the up and down buttons to select the next user level you want to log into Note If logging out of Configuration Level the user can only log out to Operator Level 1 The controller will go through a short test cycle to accept any new configuration applied Note Passc...

Page 11: ...ol the temperature according to the new setpoint Changing the Setpoint Note The output indicator 1 icon will appear to show that power is being directed to the product heating elements 5 1 Sensorbreak If a thermocouple becomes disconnected or fails the controller display will flash between the error messages S brk and bAd indicating that the thermocouple is unable to read a temperature The control...

Page 12: ...m mode from rESET to RUN The program will start to run 6 1 1 1 Shortcut Run Program l Press the up and down buttons together The program will start to run l If scrolling text is configured PROGRAM RUNNING will appear on the display l The segment indicator will appear to show whether the program setpoint is ramping up dwelling or ramping down 6 1 2 Hold To hold a program that is currently running 1...

Page 13: ... configured PROGRAM HOLD will appear on the display 6 1 3 Reset To reset a program that is currently running 1 From the home display press the page button to access the PROG LIST Program List display 2 Press the scroll button until you reach the P MODE Program Mode parameter 3 Press the up and down buttons to change the program mode from RUN to rESET The program will reset and stop running 13 ...

Page 14: ...er see section 6 2 6 2 Programmer List When a program is running additional parameters become available in the Programmer List menu To access the programmer list when a program is running 1 From the home display press the page button display Prog List 2 Press the scroll button to cycle through the available parameters PROG List Program running Display Parameter Description Use P NUM Program Number...

Page 15: ...of time The value displayed does not take into account the effect of holdback within a program P CYC L Program Cycles Left Displays the amount of program cycles left to run This parameter is read only S NUM Segment Number Displays the number of the current program segment This parameter is read only S NAME Segment Name Displays the name of the current program segment This parameter is read only S ...

Page 16: ...n twice to reach the P Set option 2 Press the scroll button to access the list of parameters 3 Continue to press the scroll button to navigate through the list of parameters 4 Adjust parameter options using the up and down buttons 5 When you have finished setting up the program press the page button multiple times to return to the top of the menu you are currently in S NUM P NUM P SEt Home display...

Page 17: ...e SEGm style is selected the HB TYP parameter will only become available when editing an individual seg ment HB TYP Holdback Type Used to define the Holdback Type for the entire program l Off holdback does not operate l Low holdback operates only during heating l High holdback operates only during cooling l Band holdback operates during both heating and cooling HB VAL Holdback Value Sets the numbe...

Page 18: ...he segment number A program can have up to 24 segments Use the up and down buttons to select the segment number that you wish to view edit S NAME Segment Name Displays the name of the segment The first segment is named S1 by default S TYPE Segment Type Used to set the segment type see below for further details on segment types l RAtE l tImE l dwEL l StEP l ENd Note When first setting up a program ...

Page 19: ...th event output 1 and 2 are ON tImE TSP Used to define the Target Setpoint for that segment i e the temperature C that is to be reached at that point in the program R TIME The desired time in hours minutes or seconds that the user wants the controller to take to reach the desired setpoint Dependent on Ramp Units parameter Maximum time values if the Ramp Units are l SECS 99 59 l MINS 99 59 l HRS 50...

Page 20: ...et Setpoint for that segment i e the temperature C that is to be reached at that point in the program EV OP Note The 3016 is available with 2 optional relay outputs which may be configured as event outputs or alarms Any parameters above 3 are not applicable to this controller and should not be used Do not use values above the number of events configured If the 3016 has been ordered without the rel...

Page 21: ... value reads mINS then press the scroll button P END appears 7 Press the up and down arrows to select RSEt 8 Press the scroll button to access values for segment 1 9 Press the scroll button until S TYPE appears 10 Press the up and down buttons until RAte appears then press the scroll button 11 Press the up and down buttons until the TSP reads 400 C then press the scroll but ton 12 Press the up and...

Page 22: ...ars then press the scroll button 27 Press the up and down buttons until the TSP reads 200 C then press the scroll but ton 28 Press the up and down buttons until the R TIME value reads 01 20 then press the scroll button 29 Press the scroll button to access values for segment 6 30 Press the scroll button until S TYPE appears The default value is ENd The program is now ready to run Segment 1 2 3 4 5 ...

Page 23: ...n temperatures can be set by adjusting the threshold THLD or deviation DEV parameter in controller settings see section 8 0 7 0 1 Alarm State When the controller is in an alarm state a red alarm bell icon will begin flashing and the text on the top of the screen will turn red When the alarm is acknowledged the alarm bell icon will stop flashing but the controller will remain in the alarm state unt...

Page 24: ...hold value is set to 100 C The alarm activates a door lock The product temperature is fluctuating slightly between 99 C and 100 C To prevent the relay from switching ON and OFF too rapidly as the temperature changes a hysteresis value can be set to create a buffer A hysteresis value of 5 C would only deactivate the door lock at 95 C so any small temperature fluctuations would not continually influ...

Page 25: ...m outputs connections must be specified at the time of order If you have ordered the 3016 with multiple alarm outputs please make a note of what the alarm function is This is for your own future reference Alarm Output 1 Alarm Output 2 Alarm Output 3 Alarm Output 4 Alarm Output 5 Alarm Output 6 25 ...

Page 26: ...down buttons to adjust the parameter values as desired Scrolling through Controller Settings at Operator Level 2 Parameter List Display Parameter Description Use w out Working Output Displays the amount of power being used by the product Note This parameter is also available when logged in at Operator Level 1 cs id Customer ID Displays the customer identification number This maybe used to identify...

Page 27: ... the DEV deviation parameter Note If more than one Absolute High and or Absolute Low alarm is specified at the time of order multiple THLD parameters will be available They appear in the order that the alarms were set up so if Alarm 1 is an AbS H and Alarm 2 is an AbS L the threshold value for the AbS H alarm will be appear first when scrolling though the parameter list DEV Deviation Only availabl...

Page 28: ...nd 550 C and deactivate when the temperature is between 450 C and 550 C Note See section 7 0 for more information on Hysteresis Note If more than one Deviation alarm is specified at the time of order multiple DEV parameters will be available They appear in the order that the alarms were set up so if Alarm 1 is an DeV H and Alarm 2 is an DeV L the deviation value for the dEV H alarm will be appear ...

Page 29: ...ssed by pressing the page button Note Not all parameters displayed within the 3016 are applicable to Carbolite Gero products Only parameters referenced in this manual should be regarded or adjusted Changing non referenced parameter values may damage the product and prevent it from functioning safely To access the menu lists 1 From the home display press the page button to scroll through the menu l...

Page 30: ...olite Gero products and should not cannot be adjusted Display Parameter Description Use A1 List LIN Linearisation Displays the type of thermocouple used in the product RNG HI Range High Displays the maximum temperature of the product RNG LO Range Low Displays the minimum temperature of the product PV OFS PV Offset Used during offset calibration to adjust the display temperature Refer to section 10...

Page 31: ...etected PV Process Variable Displays the current actual temperature of the product PV ST Process Variable Status Displays the status of the Process Variable actual temperature If the PV Status displays anything but Good please contact Carbolite Gero Service LOOP List s list Sublist Use the up and down arrows to view sublists of additional parameters Use the scroll button to select a sublist l MaIN...

Page 32: ...evel 3 T STAT Autotune Status Displays the current status of the autotune l Off Autotune is unavailable l Rdy The controller is ready to run an autotune l triG An autotune has been triggered to run but is waiting for another process to complete before run ning l Run The autotune function is running l donE The autotune completed successfully and tun eset parameters have been updated l Abor The auto...

Page 33: ...round when the controller Note Also adjustable at Operator Level 3 OP HI Output High Limit Used to set the gain scheduled upper limit for PID set 1 Note Also adjustable at Operator Level 3 OP HI2 Output High Limit 2 Used to set the gain scheduled upper limit for PID set 2 Note Also adjustable at Operator Level 3 OP Sublist OUT HI Output High Limit Used to set the maximum output power delivered by ...

Page 34: ...ator Level 3 L BRK Loop Break Detected Indicates whether a loop break has been detected l Yes A loop break has been detected l No The loop is functioning normally DEMO Enable Demo Mode Used to turn on a simulation for demonstration purposes l On Demo mode is enabled l Off Demo mode is disabled Note Also adjustable at Operator Level 3 PROg List Note The following parameters are only accessible at C...

Page 35: ...INST Alarm Number Used to select the alarm whose parameters you wish to edit There are 6 alarms available Note Also adjustable at Operator Level 3 Type Type Displays the alarm type see section 7 0 stat Alarm Status Displays the status of the alarm l Off The alarm is off l ACT The alarm is active but has been acknowledged l INA The alarm is active and the conditions that triggered the alarm have pa...

Page 36: ...dition has been removed and the alarm has been acknowledged The alarm can only be acknowledged after the alarm condition has been removed l EVnt Same as a non latching alarm except the alarm is used as a trigger and therefore will not be announced Ack Acknowledge Used to acknowledge an alarm when the controller is in an alarm state l Yes The alarm will be acknowledged but the alarm state may remai...

Page 37: ...ny Hysteresis value set REF DEV HYST e g if the target setpoint is 500 C the alarm relay will activate if the tem perature is outside the range of 450 C and 550 C and deactivate when the temperature is between 450 C and 550 C Note Also adjustable at Operator Level 3 Comm List s list Sublist Use the up and down arrows to view sublists of additional parameters Use the scroll button to select a subli...

Page 38: ...ead written via scaled integer comms l mSEC Milliseconds l SeC Seconds l mIN Minutes l HOur Hours Note Also adjustable at Operator Level 3 Nwrk Sublist IP A1 IP Address 1st byte of the IP Address XXX xxx xxx xxx Default 192 IP A2 IP Address 2 2nd byte of the IP Address xxx XXX xxx xxx Default 168 IP A3 IP Address 3 3rd byte of the IP Address xxx xxx XXX xxx Default 111 IP A4 IP Address 4 4th byte ...

Page 39: ...adcast Storm active l No Broacdact Storm inactive R PRT Rate Protection Indicates whether Rate protection active If rate at which Ethernet unicast packets are received becomes too high the instrument will enter a special mode that slows down Ethernet processing to preserve core functionality l Yes Rate Protection active l No Rate Protection inactive INst List INST Instrument Use the up and down ar...

Page 40: ...s the actual tem perature and program time left l LPU The home display shows only the actual tem perature l PV1 The home display shows only the PV for analogue input 1 l PV PS The home display will show the actual tem perature and the current running program number and segment number K LOCK Keylock Used to disable the buttons on the front of the controller l On The controller buttons are disabled ...

Page 41: ... load samples The difference between the temperature read by the control thermocouple and the independent thermocouple by their samples could be calculated as the offset value For example If the controller is displaying a temperature of 1080 C and the independent thermocouple reads 1075 C this means that the control thermocouple in the product is reading an extra 5 C This would make the offset val...

Page 42: ...croll button until you reach the PV OFS Process Value Offset para meter 3 Use the up and bown buttons to adjust the value The new value will be auto matically accepted after 3 seconds 4 If no further adjustments are required log out of Operator Level 3 Adjusting the Offset Value 42 ...

Page 43: ...0 4 Navigate to the AtuN sublist in for the main controller see section 9 0 5 Use the up and down buttons to switch the TUNE parameter from Off to On The auto tune function will now go into stand by mode for 30 seconds 6 Before the stand by mode period lapses navigate to the home display and set the product setpoint to the temperature you wish to optimise the product for e g 400 C 7 The controller...

Page 44: ...nE Tip If you are tuning to optimise the controller for low temperature use the output power OUT HI value can be reduced before autotune is used Output power can be returned to a higher value if the product is subsequently required to operate at higher temperatures The OUT HI parameter can be found within the OP sublist in the controller configuration see section 9 0 44 ...

Page 45: ...Studio software Note Please refer to the separate iTools Quick Start Guide for instructions on installing iTools 12 1 Configuring iTools Communications Settings Before trying to connect the 3016 to iTools it is first necessary to configure the communications settings To do this l Open the Control Panel on your com puter and double click on the iTools icon l The Registry Settings iTools Con figurat...

Page 46: ...hernet to USB adapters must be configured with IP addresses different to those of the controller but within the same address range in order to establish a successful iTools connection 2 Switch on the product l Select the TCP IP tab l Click on the Add button l In the Name field type the name you wish to give to the port con nection In this example the port has been named 3016 l Click on the Add but...

Page 47: ...ired IP address The default address is 192 168 111 222 l Click the OK button l Click the OK button l Click the Apply button then the OK button l Restart iTools Engin eering Studio for the new port to be recog nised 47 ...

Page 48: ... l Select a port by clicking on the checkbox This will enable the serial port to be used for the connection In this example the com puter has two serial ports COM1 and COM3 Note If using a 9 pin RS485 to USB converter and a connection is moved to a different USB port on the same computer it may have a different COM port number The Carbolite Gero supplied converter will retain the port numbers l Cl...

Page 49: ...e computer l Click on the Windows icon in your toolbar then scroll through the list of programs until you find Eurotherm Tools l Expand the folder and double click on iTools Engin eering Studio l Within iTools Engineering Stu dio click on Scan The Enable Background Scan window will appear 49 ...

Page 50: ...ns are selected then click OK l When iTools scans the address of the controller con nected to the computer an image of the instrument will appear l The connection between the controller and the computer is established l Once all controllers have been found and connected click on Scan to stop search ing 50 ...

Page 51: ...13 0 Navigation Diagrams 13 1 Operator Level 1 13 2 Operator Level 2 51 ...

Page 52: ...13 3 Operator Level 3 52 ...

Page 53: ...procedures Note Before handling the controller wear an anti static wrist strap and avoid any possibility of damage to the unit by static electricity Refer to the detailed instructions supplied with the replacement controller 1 Ease apart the two lugs at the side 2 Grip the instrument and withdraw it from its sleeve 3 Push in the replacement 53 ...

Page 54: ......

Page 55: ...Notes Service Record Engineer Name Date Record of Work ...

Page 56: ... 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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