VERDER CARBOLITE GERO 2416 Series Installation, Operation And Maintenance Instructions
1200c e-range tube furnace controller
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- 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...
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Page 2: Table Of Contents
Contents This manual is for guidance on the use of the Carbolite Gero product specified on the front cover. This manual should be read thoroughly before unpacking and using the furnace or oven. The model details and serial number are shown on the back of this manual. - Page 3 3.4.1 Digital Communications - RS232 3.4.2 Digital Communications - RS485 3.4.3 Comms Address 3.4.4 Alarm Option Temperature Controller Replacement Navigation Diagram 4.0 2132 Over-Temperature Controller Description (if fitted) Description Operation 4.2.1 Controls 4.2.2 Operation 4.2.3 Over-Temperature Operation 4.2.4 Over-Temperature Alarm 4.2.5 Resetting the Over-Temperature Alarm 4.2.6...
- Page 4 Thermocouple Replacement Element Replacement Fuse Replacement 8.0 Fault Analysis Furnace Does Not Heat Up Product Overheats 9.0 Wiring Diagrams WA-11-30 WA-11-31 WA-12-30 WA-12-31 10.0 Fuses and Power Settings 10.1 Fuses 10.2 Power Settings 11.0 Specifications 11.1 Environment Furnace drying out process...
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Page 5: Symbols And Warnings
1.0 Symbols and Warnings 1.0 Symbols and Warnings Switches and Lights Instrument switch: when the instrument switch is operated the temperature control circuit is energised. Heat light: the adjacent light glows or flashes to indicate that power is being supplied to the elements. Heat switch: the switch disconnects power to the heating elements;... -
Page 6: Warning Labels
1.0 Symbols and Warnings Caution – Double Pole/Neutral Fusing Warning Labels On the front control panel there are 2 warning labels as shown in figure 1.3.1; they are numbered 7 and 8. These warnings must be followed for the safe operation of this furnace. - Page 7 1.0 Symbols and Warnings Figure 1.3.1 - Control Box layout and warning Figure 1.3.2- Back of control box showing labels. mains lead socket Index to numbered items in Figure 1.3.1 and 1.3.2 1. Electrical supply switch - switches electrical power ON and OFF to the furnace. 2.
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Page 8: Installation
2.0 Installation 2.0 Installation If the product has been transported or stored in humid conditions it must be dried out completely before operating the furnace. Contact Carbolite Gero Service for instructions. Unpacking and Handling When unpacking or moving the product, always lift it by its base or both ends of the main body. -
Page 9: Setting Up
2.0 Installation If the product is to be used in a process which could liberate hazardous gases, then it should be installed together with a suitable fume extraction system. Ensure that the product is placed in such a way that it can be quickly switched off or disconnected from the electrical supply. - Page 10 2.0 Installation 2.3.1 Figure - Vertical tube furnace model 2.3.2 Figure - Assembling the mounted on its stand. 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.
- Page 11 2.0 Installation Using the tube furnace horizontally The furnace can be used either with the stand vertically as shown in 2.3.3 or horizontally as shown in 2.3.4. To use horizontally simply tip the stand over into the horizontal position making sure that the flexible conduits are not trapped beneath the frame.
- Page 12 2.0 Installation Index to numbered items in Figure 2.3.5 1. Tube furnace 2. Work tube adaptor (size dependent on work tube diameter) 3. Work tube (size diameter customer option) 4. Work tube adaptor fixing bracket 5. Fixing screws M6 x 15 6.
- Page 13 2.0 Installation Figure 2.2 - shows an exploded view of all the required parts. 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...
- Page 14 2.0 Installation 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...
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Page 15: Setting Up - Without A Stand
2.0 Installation 2.3.10 Figure - View showing how to support the work tube in a vertical orientation. Setting Up - Without a Stand Any of the E-range vertical furnaces can be supplied without a stand for either wall mounting (using wall bracket order option) or installation in customer's test rig/mounting frame. - Page 16 2.0 Installation 3. Connecting conduit between furnace and control box Fitting the Optional Insulation Plugs and Radiation Shield For optimum temperature uniformity, insulation plugs or radiation shields should be placed in the work tube ends as shown below. With a standard work tube, the insulation plug must be fitted as shown in figure A.
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Page 17: Electrical Connections
2.0 Installation Electrical Connections Connection by a qualified electrician is recommended. All furnaces in the range are single-phase and operate over the voltage ranges 100 to 110 volts or 200 - 240 volts. Check the rating label before connection, see "Warning Labels"... -
Page 18: 2416 Controller
3.0 2416 Controller 3.0 2416 Controller Description This manual applies to the 2416, 2416CG and 2416P8 controllers. Special customer requirements may result in changes to the available parameters and the navigation diagram. It is not possible to list all the possibilities in this manual. 2416CG Controller The Eurotherm model 2416CG is a digital instrument with PID control algorithms which may be used as a simple controller or an 8-segment programmer. - Page 19 3.0 2416 Controller Fig 2 - Control with Ramp-to- Setpoint Fig 1 -Simple Control Fig 3 - A Program Seg 1 = Ramp Sep 2 = End (Dwell) Temperature Time Setpoint Actual Temperature WSP Working Setpoint Ramp Dwell Step...
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Page 20: Operation
3.0 2416 Controller Operation Most Carbolite Gero products are fitted with an instrument switch which cuts off power to the controller and other parts of the control circuit. See section 5.0 for operating instructions. To operate the 2416 Controller there must be power to the furnace or oven and the instrument switch must be on. - Page 21 3.0 2416 Controller Auto/ Disabled. The unit is always in 'Auto' mode Manual Used to start, stop or pause a program. Short presses cause it to alternate between 'Run' and 'Hold', but if it is RUN/HOLD held for 2 seconds the programmer goes into 'Reset' mode where it behaves as a simple controller.
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Page 22: Programming
3.0 2416 Controller Programming Note that a currently active segment cannot be altered - put the programmer into 'Hold' or 'Reset' whenever it is necessary to do so to alter a parameter. Go into 'Reset' mode (i.e. press RUN/HOLD for 2 seconds) before starting to create or modify a program. Press page until 'ProG LiSt' is displayed. -
Page 23: Multi-Program Model (2416P8)
3.0 2416 Controller If all segments are used so that there is no 'End' segment, then on completion the program automatically goes into 'Dwell'. Dwell segments of length zero can be included. This is a way of allowing space for future program changes. -
Page 24: Program Example
3.0 2416 Controller For a more detailed view, press page to access the 'Run' list page and scroll to see its contents as shown in the Navigation Diagram below. Provided the unit is first put into 'Hold' mode, temporary changes may be made to parameters; these apply only until the program ends or is reset. -
Page 25: Controller Options
3.0 2416 Controller Controller Options As options can be ordered in a variety of combinations and for a variety of purposes, exact instructions are not given here. The full Eurotherm manual may be required to determine customer parameter settings. To reveal or hide parameters in the controllers it is necessary to go into configuration mode, a security code is needed. -
Page 26: Temperature Controller Replacement
3.0 2416 Controller indicated: Temperature Controller Fuse (2A) Supply Load Normally open relay contacts Relay Output 240V 2A The purpose of the 2 amp fuse is to break the circuit to prevent overloading on the circuit due to high voltage. The instrument configuration and parameters available to the operator depend on the customer requirements. -
Page 27: Navigation Diagram
3.0 2416 Controller Navigation Diagram... -
Page 28: 2132 Over-Temperature Controller Description (If Fitted)
4.0 2132 Over-Temperature 4.0 2132 Over-Temperature Controller Description (if fitted) Description Alarm Light Page Scroll D Down Display This over-temperature controller is fitted and supplied ready to use by Carbolite Gero. It is a digital instrument with a latching alarm, requiring no additional panel controls. The controller features easy setting of over-temperature setpoint and reading of current temperature by the over-temperature sensor. -
Page 29: Operation
4.0 2132 Over-Temperature 4.2.2 Operation When switched on, the controller lights up, goes through a short test routine and then displays the measured temperature or the over-temperature setpoint. The page key allows access to parameter lists within the controller. A single press of the page key displays the temperature units, normally set to °C;... -
Page 30: Audible Alarm
4.0 2132 Over-Temperature Audible Alarm If an audible alarm is supplied for use with the over-temperature controller, it is normally configured to sound on over-temperature 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. -
Page 31: Operation
5.0 Operation 5.0 Operation Operating Cycle This product is fitted with an instrument switch which cuts off power to the control circuit. Connect the product to the electrical supply. Turn on the instrument switch to activate the temperature controllers. The controllers illuminate and go through a short test cycle. -
Page 32: General Operating Advice
5.0 Operation Explosive Materials The furnace must not be used to heat materials which could explode, or which could emit gases that could form explosive mixtures. If the safe heating of a material is dependent on its temperature, only heat these type of materials if the furnace has the optional over-temperature protection device fitted. -
Page 33: Tube Life
5.0 Operation Switch off the heater switch whenever loading or unloading the product. The elements are isolated when the heater switch is OFF. This switch cuts both sides of the circuit via a contactor. Tube Life A ceramic work tube may crack if work pieces are inserted too quickly or at temperatures below 900 °C (when the tube is more brittle). -
Page 34: Gas Tightness
5.0 Operation Gas 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. -
Page 35: Maintenance
6.0 Maintenance 6.0 Maintenance General Maintenance Preventive rather than reactive maintenance is recommended. The type and frequency depends on the product use; the following are recommended. Maintenance Schedule CUSTOMER QUALIFIED PERSONNEL DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically qualified personnel should attempt these maintenance procedures. - Page 36 6.0 Maintenance Seals (if fitted) Check all seals and O-rings and clamps Performance Element Circuit Electrical measurement Measure the current drawn on each Power Consumption phase / circuit Check whether the cooling fans are work- Cooling Fans (if fitted)
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Page 37: Cleaning
6.0 Maintenance 6.2.1 Cleaning Soot deposits may form inside the furnace, depending on the process. At appropriate intervals remove these by heating as indicated in the General Operation Notes. The product's outer surface may be cleaned with a damp cloth. Do not allow water to enter the interior of the case or chamber. -
Page 38: Repairs And Replacements
7.0 Repairs and Replacements 7.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Immediately switch the product off in the event of unforeseen circumstances (e.g. large amount of smoke). Allow the product to return to room temperature before inspection. Always ensure that the product is disconnected from the electrical supply before repair work is carried out. -
Page 39: Solid-State Relay Replacement
7.0 Repairs and Replacements Solid-state Relay Replacement Disconnect the product from the power supply and remove the appropriate cover as given above. Make a note of the wire connections to the solid state relay and disconnect them. Remove the solid state relay from the base panel or aluminium plate. Replace and reconnect the solid state relay ensuring that the bottom of it has good thermal contact with the base panel or aluminium plate. -
Page 40: Fuse Replacement
7.0 Repairs and Replacements Fuse Replacement Fuses are marked on the wiring diagram with type codes, e.g. F1, F2. For more information on fuses refer to section 10.0. Depending on model and voltage, the 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. -
Page 41: Fault Analysis
8.0 Fault Analysis 8.0 Fault Analysis Furnace Does Not Heat Up The HEAT The heating element Check also that the SSR is working light is ON has failed correctly The controller shows a The HEAT The thermocouple has broken or has very high temperature light is OFF a wiring fault... -
Page 42: Product Overheats
8.0 Fault Analysis Product Overheats Product only heats up The controller when the instrument shows a very high The controller is faulty switch is ON temperature The thermocouple may be The controller faulty or may have been shows a low removed out of the heating temperature chamber... -
Page 43: Wiring Diagrams
9.0 Wiring Diagrams 9.0 Wiring Diagrams WA-11-30 Connections below show single phase with indirect safety switch(es). F1, F2, F3 Fuses Filter R1/1, R1/2 Relay Contactor Relay Cables Temperature Controller Blue Control Thermocouple Solid State Relay GR/Y Green + Yellow Safety Switch Grey Heat Lamp Pink... - Page 44 9.0 Wiring Diagrams WA-11-31 Connections below show single phase with safety switches and over-temperature control. F1, F2, F3 Fuses Filter R1/1, R1/2 Relay Contactor Relay Temperature Controller Cables Over-Temperature Controller Blue Over-Temperature Thermocouple Control Thermocouple GR/Y Green + Yellow Solid State Relay Grey Safety Switch Pink...
- Page 45 9.0 Wiring Diagrams WA-12-30 WA-12-31 Connections below show single phase with safety switches and over-temperature control.
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Page 46: Fuses And Power Settings
10.0 Fuses and Power Settings 10.0 Fuses and Power Settings 10.1 Fuses F1 - F2: Refer to the circuit diagrams. GEC Safeclip of the type shown Fitted if supply cable fitted. Internal (glass type F up to 16 A) Supply Fitted on board to some types 38 mm x 10 mm type F fitted on Fuses... -
Page 47: Power Settings
10.0 Fuses and Power Settings 10.2 Power Settings The power limit settings (OP.Hi) for this model is as follows. The figures represent the maximum percentage of time that controlled power is supplied to the elements. Do not attempt to "improve performance" by setting a value higher than the one from the table. -
Page 48: Specifications
11.0 Specifications 11.0 Specifications Carbolite Gero reserves the right to change the specification without notice. All models have cylindrical elements with wire mounted in the surface of the insulation material. All models can accept work tubes up to a maximum outside diameter of 60 mm. All models have a maximum operation temperature of 1200°C (1100°C continuous). -
Page 49: Furnace Drying Out Process
11.0 Specifications Furnace drying out process Step 1. Before the furnace is connected to the electrical supply, remove the back panel and check for signs of moisture on the electrical circuits. If visible signs of moisture are present then allow 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. - Page 51 Notes Service Record Engineer Name Date Record of Work...
- Page 52 The products covered in this manual are only a small part of the wide range of ovens, chamber furnaces and tube furnaces manufactured by Carbolite Gero for laboratory and industrial use. For further details of our standard or custom built products please contact us at the address below, or ask your nearest stockist.