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VERDER CARBOLITE GERO EPC3000 Series Installation, Operation And Maintenance Instructions

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Installation, Operation and Maintenance Instructions
Controller Manual
3016 Controller
3016 Controller
MEN-3016_CTRL
19-08-2020
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Summary of Contents for VERDER CARBOLITE GERO EPC3000 Series

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

  • 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: Operator Level

    9.0 Controller Configuration 9.0.1 Menu Lists 10.0 Offset Calibration 10.1 Single-Point Calibration 11.0 Using Autotune to Optimise Temperature Control 12.0 Communications Connections 12.1 Configuring iTools Communications Settings 12.1.1 Ethernet Connections 12.1.2 RS485 Connections (optional) 12.2 Establishing a Connection (Windows 10) 13.0 Navigation Diagrams 13.1 Operator Level 1...

  • Page 4: Introduction

    1.0 Introduction The 3016 programmable temperature controller is part of the EPC3000 range of temperature controllers. It uses PID (Proportional Integral Derivative) algorithms to adjust the heating power and control the temperature within the product. Users navigate through the controller by pressing the four buttons positioned below the display.

  • Page 5: Technical Terms

    Technical Terms Due to the complex nature of temperature control, this manual uses technical terms. Here is a list of some of the terms used within this manual, alongside their explanation: Term Description Setpoint The target temperature the furnace or oven is trying to reach (°C) A system to prevent the product or process being damaged if the temperature has increased above a temperature specified by the user Over-...

  • Page 6: Navigation

    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. Display Alarm Indicator Segment Indicator Page Button Scroll Button Down Button Up Button Output Indicator Setpoint Temperature 10 Actual Temperature...

  • Page 7: Start Up

    3.0 Start Up When powered on, the 3016 controller will cycle through a series of initial test screens. After 7 seconds, it will default to the home display. The home display shows an overview of the controller, including details such as the actual temperature and setpoint.

  • Page 8: Operator Levels

    4.0 Operator Levels There are 4 operator levels available within the 3016. These user levels control access to functionality within the controller via permissions. The default operator level is Level 1. Level 1 Level 2 Level 3 Config. Level Functionality Permissions Login / Change User Level Access Home Display...

  • Page 9: Configuration Level

    Changing Operator Level to Level 2 4.1.2 Operator Level 3 To access Operator Level 3: 1. Press and hold the page button until Lev3 GOTO appears. 2. Press the scroll button to confirm. The CODE display will appear. You now have to input a passcode.

  • Page 10: Logging Out Of Operator Level 3 And Configuration Level

    5. Press the scroll button to move to the next digit. 6. 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.

  • Page 11: Simple Temperature Control

    5.0 Simple Temperature Control The 3016 can be used as a programmer or as a simple temperature controller. The controller has been configured so that it cannot heat above the maximum stated temperature for the product you have purchased. To set a setpoint temperature: 1.

  • Page 12: Programming

    6.0 Programming The 3016 is supplied with one program slot containing 24 configurable segments. All users can run a pre-existing program, however to create or edit a program the user must be logged in to Operator Level 2 (see section 4.0). Run / Hold / Reset a Program 6.1.1 Run To run an existing program:...

  • Page 13: Shortcut: Hold Program

    6.1.2.1 Shortcut: Hold Program Press the up and down buttons together while the program is run- ning. The program will hold until the up and down buttons are pressed again. If scrolling text is configured, <PROGRAM HOLD> will appear on the display.

  • Page 14: Shortcut: Reset Program

    6.1.3.1 Shortcut: Reset Program Press and hold the up and down but- tons for 3 seconds to reset the pro- gram. The program will stop running and return to the home display. Note: When a program is running a "Programmer List" becomes available within the controller.
  • Page 15 Program Displays the name of the program. This parameter is read P.NAME Name only. Current Displays the number of the program currently running. This P.CUR Program parameter is read only. Number Current Displays the name of the program currently running. This C.NAME Program parameter is read only.

  • Page 16: Create / Edit A Program

    The number displayed is dependent on the amount of Event 2 outputs or alarms configured. This parameter is read only. Enables the operator to force the program to advance to the next segment. Program P.ADVN Advance Note: This parameter can only be edited when logged in at Operator Level 2.
  • Page 17 Program Setup Display Parameter Description/ Use Displays the program number. This parameter is 1 by Program P.NUM Number default. Displays the name of the program. This parameter is P1 by Program P.NAME Name default. Used to define whether the same holdback settings should apply for the entire program, or whether they can be defined for each individual segment.
  • Page 18 (P.seC), °C per minute (P.mIN), or °C per hour (P.HR). Used to define whether the dwell units are seconds (SECS), DWEL.U Dwell Units minutes (mINS), or hours (HRS). How many times the program is set to run. Setting the Program P.CYC value to "cont"...
  • Page 19 Note: The minimum possible rate value is 0.1°C per ramp unit. It is possible to set a ramp rate that far exceeds the achievable ramp rate of the product. Only set ramp rates that can be reasonably achieved. Tube furnaces with ceramic work tubes need slow heating rates in order to protect the work tube.

  • Page 20: Event Outputs - Customer Notes

    previous segment in the program. Dependent on "Dwell Units" parameter. Maximum values if the "Dwell Units" are: SECS= 99:59 MINS = 99:59 HRS = 500.0 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.

  • Page 21: Program Example

    If you have ordered the 3016 with multiple event outputs, please make a note of what the event output function is. This is for your own future reference: Event Output 1 Event Output 2 Event Output 3 Event Output 4 Event Output 5 Event Output 6 Event Output 7...
  • Page 22 21. Press the scroll button until S.TYPE appears. 22. Press the up and down buttons until dWEL appears, then press the scroll button. 23. Press the up and down buttons until the DUR value reads 00:30, then press he scroll button.

  • Page 23: Alarm Relays (Optional)

    7.0 Alarm Relays (optional) The 3016 controller has two available relays (electrically operated switches) that are used to control additional features and components, such as door locks, solenoid valves, fans and audible alarms; they can also be used to control external equipment if necessary.

  • Page 24: Hysteresis

    Acknowledging an Alarm Note: An alarm can also be acknowledged by simultaneously pressing both the page and scroll buttons. 7.0.2 Hysteresis Hysteresis is the difference between the point at which an alarm switches ON and the point at which it switches OFF. It can be used to define a short temperature range wherein the alarm relay activates in order to prevent the relay switching on and off repeatedly if the product temperature fluctuates by a few degrees when close to the threshold / deviation value.

  • Page 25: Alarm Outputs - Customer Notes

    Adjusting the Hysteresis Value Alarm Outputs - Customer Notes The 3016 has six available alarm 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.

  • Page 26: Controller Settings

    8.0 Controller Settings Additional controller settings are accessible from the home display. Limited access is granted at Operator Level 1. To access the full list of settings, the user must first be logged in at Operator Level 2 (see section 4.0). To adjust controller settings: 1.
  • Page 27 alarm state. Values: Yes - The alarm will be acknowledged, but the alarm state may remain until the required conditions are met. No - The alarm is not acknowledged and the controller remains in an alarm state. Note: This parameter is also available when logged in at Operator Level 1.
  • Page 28 Deviation values [REF + DEV], and will remain activated until the temperature rises above the sum of the Refer- ence and Deviation values plus any Hysteresis value set [REF+ DEV + HYST] Deviation Band - The alarm relay will activate if the temperature deviates above or below the Reference value plus or minus the Deviation value [REF±...

  • Page 29: Controller Configuration

    9.0 Controller Configuration Note: The adjustment of the parameters mentioned in this section is not required for day to day operations. Any adjustments should be carried out by suitably qualified and trained personnel. Please contact Carbolite Gero for advice before proceeding to change any configuration parameter values.

  • Page 30: Menu Lists

    Scrolling through all available Menu Lists - (Greyed-out lists should be disregarded) 9.0.1 Menu Lists Note: Lists and parameters other than those mentioned below may appear at Operator Level 3 and Configuration Level, however these parameters are not applicable to Carbolite Gero products and should not/cannot be adjusted. Display Parameter Description/ Use A1 List...
  • Page 31 Note: Also adjustable at Operator Level 3. A filter is provided to reduce the frequency of electrical noise picked up by the controller, which may interfere with its function. The higher the Filter Time Constant value, the more the effects of electrical noise are reduced. The default value is 1.6.
  • Page 32 Used to adjust the setpoint temperature. TGT.sp Target Setpoint Note: Also adjustable at Operator Level 3. Working w.sp Displays the current working setpoint. Setpoint w.out Displays the current power output in %. Working Output AtuN Sublist: Used to enable or disable an autotune. On - Autotune is enabled Tune Off - Autotune is disabled...
  • Page 33 Lo - Minimum output applied. R2G - Relative channel 2 gain test is running. Pd - The autotuner is trying to control to the setpoint and is examining the response. AnLs - The autotuner is calculating the new tuning para- meters.
  • Page 34 Note: Also adjustable at Operator Level 3. Used to limit the rate at which the output from the PID terms can decrease (% per second). Output Rate OP.DWN Down Note: Also adjustable at Operator Level 3. dIAG Sublist: Used to set the loop break time. If there is a loss of control within the control loop, this parameter determines the amount of time before the loop break alarm (L.BRK)is L.BRK.T Loop Break Time...
  • Page 35 rate prior to the power outage. Rset - The program will be reset. CONt - The program will continue to run from the point at which it was interrupted. Used to set the display resolution of segment ramp rate parameters when read/written via scaled integer comms. nnnnn - No decimal places Ramp Rate R.RESN...
  • Page 36 High - the alarm relay will activate when the tem- perature exceeds the threshold value Low - the alarm relay will activate when the tem- perature drops below the threshold value Note: Also adjustable at Operator Level 3. Used to set the amount of hysteresis applied. (See section 7.0 for details on hysteresis.) HYST Hysteresis...
  • Page 37 Deviation High - The alarm relay will activate if the temperature rises above the sum of the Reference and Deviation values [REF± DEV], and will remain activated until the temperature drops below the sum of the Refer- ence and Deviation values minus any Hysteresis value set [REF+ DEV - HYST] Deviation Low - The alarm relay will activate if the temperature drops below the sum of the Reference and...
  • Page 38 mAn - The Watchdog flag must be cleared manually Auto - The Watchdog flag will clear automatically w.actn Watchdog Action Note: Also adjustable at Operator Level 3. Only displayed when W.ACTN is set to Auto. The Watchdog Recovery is a timer that determines the delay before the Watchdog Flag is cleared after the Watchdog W.RCOV...
  • Page 39 Default Gateway 4th byte of the Default Gateway: xxx.xxx.xxx.XXX. Default: ip.g4 MAC1 Mac 1 1st byte of the MAC address in decimal: XX:xx:xx:xx:xx:xx MAC2 Mac 2 2nd byte of the MAC address in decimal: xx:XX:xx:xx:xx:xx Mac3 Mac 3 3rd byte of the MAC address in decimal: xx:xx:XX:xx:xx:xx mac4 Mac 4 4th byte of the MAC address in decimal: xx:xx:xx:XX:xx:xx...
  • Page 40 dEG.F - °Farenheit k - Kelvin Used to set the product identification number can be cs.id Customer ID entered if required. This may be used to identify one of many units for production or quality control systems. HMISublist: Used to select the information that appears on the home display.

  • Page 41: Offset Calibration

    10.0 Offset Calibration After prolonged use the controller and/or thermocouple could require recalibration. A quick check using an independent thermocouple and temperature indicator should be made from time to time to determine whether full calibration is required. For some processes the difference of just a few degrees can have negative implications, so it is highly important that temperature readings are as accurate as possible.
  • Page 42 1. From the home display, press the page button until A1 list appears. 2. Press the scroll 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.

  • Page 43: Using Autotune To Optimise Temperature Control

    11.0 Using Autotune to Optimise Temperature Control All Carbolite Gero products are preconfigured for optimum performance when used within their normal expected operating temperature range. Depending on the intended application, it may be necessary for the product to be used outside of this normal range, in which case some tuning may be required in order to optimise the PID controls within the temperature controller e.g.
  • Page 44 Graphical Example of Autotuning a Product to 700°C 8. When the autotuning cycle successfully completes, the autotune status (T.STAT) parameter in the AtuN list will display donE. 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.

  • Page 45: Communications Connections

    12.0 Communications Connections The 3016 enables ethernet or RS485 communications (optional) connections to allow users to monitor functions, create programs and load data into the controller via Eurotherm's iTools Engineering Studio software. Note: Please refer to the separate iTools Quick Start Guide for instructions on installing iTools.

  • Page 46: Ethernet Connections

    12.1.1 Ethernet Connections 1. Connect the product to the computer/network via an ethernet cable. If required, you can use an Ethernet-to-USB adapter to connect a product directly to a single computer. Note: Ethernet-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.
  • Page 47 Enter the desired IP address. (The default address is 192.168.111.222). Click the OK button. Click the OK button. Click the Apply button, then the OK button. Restart iTools Engin- eering Studio for the new port to be recog- nised.

  • Page 48: Rs485 Connections (Optional)

    12.1.2 RS485 Connections (optional) 1. Connect the computer's 9 pin serial connector (male) to the 9 pin connector on the product (female) via an adapter cable supplied by Carbolite Gero. Note: A 9 pin "RS485 to USB" converter may be required to connect through a USB port on the computer.

  • Page 49: Establishing A Connection (Windows 10)

    12.2 Establishing a Connection (Windows 10) Ensure that the controller is conntected to the computer. Click on the Windows icon in your toolbar, then scroll through the list of programs until you find Eurotherm Tools. Expand the folder and double-click on iTools Engin- eering Studio.
  • Page 50 Ensure the Scan all device addresses (255 first, then 1 to 254) and Scan for Eur- otherm devices only options are selected, then click OK. When iTools scans the address of the controller con- nected to the computer, an image of the instrument will appear.

  • Page 51: Navigation Diagrams

    13.0 Navigation Diagrams 13.1 Operator Level 1 13.2 Operator Level 2...
  • Page 52 13.3 Operator Level 3...

  • Page 53: Configuration Level

    13.4 Configuration Level 13.5 Controller Replacement Note: Disconnect the product from the electrical supply before carrying out any maintenance 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.
  • Page 55 Notes Service Record Engineer Name Date Record of Work...
  • Page 56 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.

This manual is also suitable for:

Carbolite gero 3016

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