VERDER CARBOLITE GERO CFM 14/2 Installation, Operation And Maintenance Instructions Download Page 36 | Manualshive

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8.0 Fault Analysis

B.

Product Overheats

1.

Product only heats up
when the instrument
switch is ON

The controller
shows a very high
temperature

The controller is faulty

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

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Summary of Contents for CARBOLITE GERO CFM 14/2

Page 1: ...Installation Operation and Maintenance Instructions 1400 C Combustion Tube Furnace CFM Model 14 2 2416 Controller CFM 14 2 2416 Controller MEN CFM1402 003_2416 09 01 2019 ...

Page 2: ...Connections 9 3 0 2416 Controller 11 3 1 Description 11 3 2 Operation 13 3 3 Programming 15 3 3 1 Programming Tips 15 3 3 2 Multi program model 2416P8 16 3 3 3 Holdback 16 3 3 4 Program Cycling 16 3 3 5 Running a Program 16 3 3 6 Program example 17 3 4 Controller Options 18 3 4 1 Digital Communications RS232 18 3 4 2 Digital Communications RS485 18 3 4 3 Comms Address 18 3 4 4 Alarm Option 19 3 5 ...

Page 3: ...6 6 Power Adjustment 29 6 7 Element Ageing 30 7 0 Repairs and Replacements 31 7 1 Safety Warning Disconnection from Power Supply 31 7 2 Safety Warning Refractory Fibre Insulation 31 7 3 Temperature Controller Replacement 31 7 4 Solid State Relay Replacement 32 7 5 Thermocouple Replacement 32 7 6 Element Fitting and Replacement 1400 C Models 33 7 7 Fuse Replacement 34 8 0 Fault Analysis 35 A Furnac...

Page 4: ...User Power Setting Adjustments 41 11 0 Specifications 42 11 1 Environment 42 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: ...1 0 Symbols and Warnings Caution Double Pole Neutral Fusing 6 ...

Page 7: ...non flammable surface that is resistant to accidental spillage or hot materials The surface on which the equipment is mounted should be stable and not subject to movement or vibrations The height of the mounting surface is important to avoid operator strain when loading and unloading samples Unless otherwise stated elsewhere in this manual ensure that there is at least 150 mm of free space around ...

Page 8: ... place If a metal work tube is being used in the product ensure that it is earthed and that it is mounted so as not to touch the products ceramic tube or insulation Under no circumstances should any objects be placed on top of the product Always ensure that any vents on the top of the product are clear of any obstruction Always ensure all cooling vents and cooling fans if fitted are clear of any o...

Page 9: ...upply cable are designed to be wired directly to an isolator or fitted with a line plug Products without a factory fitted supply cable require a permanent connection to a fused and isolated supply The product s electrical access panel should be temporarily removed and connections made to the internal terminals If the product is to be connected by line plug The plug should be within reach of the op...

Page 10: ...s an electronically controlled power limit Do not attempt to calculate the Amps from the Wattage High break capacity fuses should be used Avoid fast blow fuses and magnetic trip circuit breakers consult Carbolite Gero if in doubt 10 ...

Page 11: ...e 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 being a Ramp a Step a Dw...

Page 12: ...ller Fig 1 Simple Control 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 12 ...

Page 13: ... 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 and indicators are ...

Page 14: ... list A single press 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 t...

Page 15: ...nts 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 remain at the previo...

Page 16: ...ooling Lo Holdback applies 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 ...

Page 17: ... 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 displayed and use th...

Page 18: ...d 9 pin at the computer but other alternatives are shown in parentheses Product end of cable female 25 pin 9 pin RS232 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 furn...

Page 19: ...cuit to prevent overloading on the circuit due to high voltage The instrument 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 t...

Page 20: ...3 0 2416 Controller 3 6 Navigation Diagram 20 ...

Page 21: ... off power to the controller and other parts of the control circuit To operate the controller power must be supplied to the product and the instrument switch must be on If a time switch is included in the product circuit this must be in the ON position When an over temperature condition occurs the controller cuts the power to a contactor which in turn cuts power to the heating elements Power is no...

Page 22: ...supplied with the over temperature set at 15 C above the furnace or oven maximum working temperature Press scroll twice view the present temperature as measured by the over temperature controller Press it twice the first press shows the temperature units C 4 2 4 Over Temperature Alarm If an over temperature condition occurs the OP2 indicator flashes and an alarm message 2FSH also flashes alternati...

Page 23: ...top sounding when the alarm is acknowledged as given in section 4 2 Note the alarm may sound during controller start up 4 4 Navigation Diagram HL Home List Page Key Black Progress OTSP Over Temperature Setpoint Scroll Key Dashed Through to other options AL Access List For factory access to list and parameters not available to the operator 23 4 0 2132 Over Temperature ...

Page 24: ...re controller flashes and the heating elements are isolated Find and correct the cause before resetting the over temperature controller according to the instructions supplied To switch off power to the heating elements use the heater switch To switch the product off use both the heater switch and the instrument switch If the product is to be left switched off and unattended isolate it from the ele...

Page 25: ...per minute The controller can be set to limit both the heating and cooling rate 5 4 Operator Safety The ceramic materials used in the product manufacture become electrically conductive to some extent at high temperatures DO NOT use any conductive tools within the product without isolating it If a metal work tube is used it must be earthed grounded Switch off the heater switch whenever loading or u...

Page 26: ...ssurisation of the work tube Please note A product should not be heated up if any valves that have been fitted are closed to create a sealed volume A sealed work tube should not be heated from cold due to the pressure increase caused by the trapped air or gas expanding during the heating process 26 ...

Page 27: ...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 28: ...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 28 ...

Page 29: ...e 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 model type given on the rating label of the product The serial number and model type are also given on the back of this manual when supplied with the product Carbolite Gero Service and Carbolite Gero contact information can be fou...

Page 30: ...settings and the date of the adjustment in section 10 0 Increase the power limit in steps of 5 until the product regains its original performance If the power limit is set to 100 a new set of heating elements is required Please note it is not possible to use the cold resistance of the element as a measure of ageing as the cold resistance is not an accurate indicator of hot resistance Hot resistanc...

Page 31: ...ered 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 sleeved clothing Avoid breaking up...

Page 32: ... the base panel or aluminium plate Replace the access panel 7 5 Thermocouple Replacement Disconnect the product from the power supply Remove terminal cover to gain access to the thermocouple connections Make a note of the thermocouple connections Thermocouple cable colour codings are thermocouple leg colour positive type R orange negative white Disconnect the thermocouple from its terminal block r...

Page 33: ...raid and cable connections to the elements Disconnect the clips with the special tool provided or with finger pressure depending on the type of clips supplied lift off the braids and carefully withdraw each element See fig 5 Carefully insert the new elements into the product Attach the connection braids according to the note made above or to the appropriate diagram fig 6 Use the special tool or fi...

Page 34: ...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 3...

Page 35: ...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 36: ...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 36 ...

Page 37: ...9 0 Wiring Diagrams 9 1 WA 11 10 Single Phase 37 9 0 Wiring Diagrams ...

Page 38: ...9 0 Wiring Diagrams 9 2 WA 11 11 Single phase with over temperature control 38 ...

Page 39: ...3 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 39 9 0 Wiring Diagrams ...

Page 40: ...omer 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 CFM 14 2 1 phase 110 120 32 A CFM 14 2 1 phase 220 240 16 A 10 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures represent the maximum percentage of time that controlled ...

Page 41: ...justments Date Power Comments Note If a new set of elements are fitted then return the power settings to the original value Please refer to the rating label for product specific information 41 10 0 Fuses and Power Settings ...

Page 42: ... The 1400 C models are also available with an auxiliary heater attachment All models are designed to accept 1 or 2 work tubes 25 mm internal diameter by 750 mm long The number of tubes is indicated by the model name 1 or 2 11 1 Environment The models listed in this manual contains electrical parts and should be stored and used in indoor conditions as follows Temperature 5 C 40 C Relative humidity ...

Page 43: ...Notes Service Record Engineer Name Date Record of Work ...

Page 44: ... 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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