VERDER CARBOLITE GERO E Series Installation, Operation And Maintenance Instructions Download | Manualshive

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6.0 Operation

than inert gases, such as nitrogen.

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Summary of Contents for CARBOLITE GERO E Series

Page 1: ...Installation Operation and Maintenance Instructions 1200 C E Range Tube Furnaces EHA Model 300mm 2416 Controller EHA 12 300B 2416 Controller MEN EHA12300B 003_2416 09 07 2019 ...

Page 2: ...g Up 9 2 4 Electrical Connections 15 3 0 2416 Controller 16 3 1 Description 16 3 2 Operation 18 3 3 Programming 20 3 3 1 Programming Tips 20 3 3 2 Multi program model 2416P8 21 3 3 3 Holdback 21 3 3 4 Program Cycling 21 3 3 5 Running a Program 21 3 3 6 Program example 22 3 4 Controller Options 23 3 4 1 Digital Communications RS232 23 3 4 2 Digital Communications RS485 23 3 4 3 Comms Address 23 3 4...

Page 3: ... 3 Safe Operation of the Furnace 33 6 4 3 Zone Control Methods 34 A Back to Back Thermocouples 35 B Retransmission of Setpoint 35 C Independent Control 36 6 5 General Operating Advice 36 6 6 Operator Safety 36 6 7 Tube Life 37 6 8 Pressure 37 6 9 Gas Tightness 37 7 0 Maintenance 39 7 1 General Maintenance 39 7 2 Maintenance Schedule 39 7 2 1 Cleaning 41 7 3 Calibration 41 7 4 After Sales Service 4...

Page 4: ...Relay Replacement 46 9 5 Thermocouple Replacement 46 9 6 Element Replacement 46 9 7 Fuse Replacement 47 10 0 Fault Analysis 48 A Furnace Does Not Heat Up 48 B Product Overheats 49 11 0 Wiring Diagrams 50 11 1 WA 11 30 50 11 2 WA 11 31 51 11 3 WA 12 30 52 11 4 WA 12 31 53 12 0 Wiring Diagrams 54 12 1 WC 13 30 54 12 2 WC 13 31 54 13 0 Fuses and Power Settings 55 13 1 Fuses 55 13 2 Power Settings 56 ...

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: ...aries between tube furnaces Note If a metal work tube is being used in the furnace ensure that it is earthed See 6 6 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 obstruction Fitting the standard length work tube...

Page 10: ...ace the work tube end stop 5 and the end adaptor 3 from one side only Note that if a different work tube with a different outer diameter is being fitted it will be necessary to fit new correctly sized work tube adaptors 3 in which case both end guards and work tube adaptor fixing brackets 4 will need removing l Slide the work tube into the furnace through the work tube adaptor 3 until it reaches t...

Page 11: ...gure 2 3 5 Use the M6 button head screws and washers supplied l Re fit furnace end guard 3 figure 2 3 6 Use the M6 button head screws and wash ers supplied l If supplied fit the optional tube end seal assembly as shown in figures 2 3 9 and 2 3 10 Refer to manual MEN ENDSEALS 01 for detailed fitting instructions l Fit the tube support bracket 1 figure 2 3 7 Use the M6 button head screws and washers...

Page 12: ...2 0 Installation Figure 2 3 4 Figure 2 3 5 Figure 2 3 6 Figure 2 3 7 Figure 2 3 8 12 ...

Page 13: ...ure 2 3 9 Tube support and end seal assembly Figure 2 3 10 Tube support and end seal assembly Index to numbered items in figure 2 3 3 2 3 10 1 Tube support bracket 2 Tube support collar 13 2 0 Installation ...

Page 14: ... end seal is fitted either horizontally or vertically the insulation plug hooks onto the end seal hook see figure B Alignment of radiation 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 6 6 Figure A Cross section view showing standard length work tube insulation plug fitted Fi...

Page 15: ...ternal supply fuses in which case customer fusing is preferred but not essential See section 13 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 16: ...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 17: ...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 17 3 0 2416 Controller ...

Page 18: ...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 19: ... 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 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...3 6 Navigation Diagram 25 3 0 2416 Controller ...

Page 26: ...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 27: ... 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 28: ...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 28 ...

Page 29: ...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 30: ...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 31: ...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 32: ...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 32 ...

Page 33: ...ram 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 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 ...

Page 34: ... coils that could cause serious injury of death Switch off the furnace before loading and unloading The furnace elements must be switched off using the heater switch 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 causi...

Page 35: ... zone controllers try to compensate for this by switching on the end zone elements preventing the furnace from cooling B Retransmission of Setpoint Three independent thermocouples are connected to three controllers The three controllers are linked together and the centre zone controller communicates the desired setpoint to the end zone controllers If the centre zone controller is set to a setpoint...

Page 36: ...l Operating Advice Heating element life is shortened by overheating Do not leave the product at high temperature when it is not required The maximum temperature is shown on the product rating label and in section 14 0 towards the back of this manual Lightweight ceramic fibre insulation can easily be marked by accidental contact Some fine cracks may develop in the surface of the insulation due to t...

Page 37: ...ting and cooling rate 6 8 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 approximately half of that should normally be sufficient to achieve the desired flow rate The operator must ensure that the exhaust path from the tube is not blocked so that excess...

Page 38: ...6 0 Operation than inert gases such as nitrogen 38 ...

Page 39: ...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 40: ...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 40 ...

Page 41: ...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 42: ...ure Safety Circuit if fitted 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 clean ing of the...

Page 43: ...ck 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 43 8 0 Maintenance ...

Page 44: ...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 model type g...

Page 45: ...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 46: ...onnections Thermocouple cable 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 ...

Page 47: ... 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 47 9 0 Repairs and Replacement...

Page 48: ...s a low temperature 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 ...

Page 49: ...r 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 49 10 0 Fault Analysis ...

Page 50: ...ct safety switch es Key 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 50 ...

Page 51: ... 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 51 11 0 Wiring Diagrams ...

Page 52: ...11 0 Wiring Diagrams 11 3 WA 12 30 52 ...

Page 53: ...11 4 WA 12 31 Connections below show single phase with safety switches and over temperature control 53 11 0 Wiring Diagrams ...

Page 54: ...12 0 Wiring Diagrams 12 0 Wiring Diagrams 12 1 WC 13 30 12 2 WC 13 31 Connections below show single phase with indirect safety switches and over temperature control 54 ...

Page 55: ... 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 Amps F1 EHA 12 300B 1 phase 100 120 16 A EHA 12 300B 1 phase 200 208 ...

Page 56: ...er 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 77 1...

Page 57: ...kW Minimum Work Tube Length mm Tube length for use with modified atmosphere mm Heated Length mm Weight kg Horizontal 3 zone tube furnaces Work tube adaptors extended work tube supports insulation plugs and gas vacuum end seals are available from Carbolite Gero for work tubes with outside diameters of 32 mm 46 mm and 60 mm 14 1 Environment The furnaces contain electrical parts and should be stored ...

Page 58: ...w it to dry out in ambient temperature for at least 24 hours If the problem persists ensure that the furnace is isolated and contact Carbolite Gero Service for more information Step 2 Complete the Installation 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 furn...

Page 59: ...Notes Service Record Engineer Name Date Record of Work ...

Page 60: ... 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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