VERDER CARBOLITE GERO 2416 Series Installation, Operation And Maintenance Instructions
1500 c tube furnace
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- Page 1 Installation, Operation and Maintenance Instructions 1500 °C Tube Furnace - STF Model: 610mm 2416 Controller STF 15/610 + 2416 Controller MEN-STF15610-03_2416 07-02-2019...
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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 4.2.5 Resetting the Over-Temperature Alarm 4.2.6 Sensor Break Audible Alarm Navigation Diagram 5.0 Operation Operating Cycle General Operating Advice Operator Safety Tube Life Pressure 6.0 Maintenance General Maintenance Maintenance Schedule 6.2.1 Cleaning Calibration After-Sales Service Recommended Spare Parts and Spare Parts Kit Power Adjustment Element Ageing 7.0 Repairs and Replacements...
- Page 4 10.0 Fuses and Power Settings 10.1 Fuses 10.2 Power Settings User Power Setting Adjustments 11.0 Specifications 11.1 Environment...
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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 1.0 Symbols and Warnings Caution – Double Pole/Neutral Fusing...
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Page 7: Installation
2.0 Installation 2.0 Installation Unpacking and Handling When unpacking or moving the product always lift it by its base or by both ends of the main body. Never lift it by its work tube or the surrounding insulation. Use two or more people to carry the product and control box. - Page 8 2.0 Installation Depending on the application of the product, it may be appropriate to position it under an extraction hood. Ensure the extraction hood is switched on during use. Ensure that the product is placed in such a way that it can be quickly switched off or disconnected from the electrical supply.
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Page 9: Tube Fitting
2.0 Installation Tube Fitting Vertical Mode. The product (if a tube is also supplied) has a plate or clip to retain the tube in position. See fig.1. A End guard B Plate C Standard tube D Long tube E Strap F Ring clip Fig 1 - Vertical Tube Retention A Furnace body... - Page 10 2.0 Installation Expanded View of "Twin Clamp" End Seals: A Clamp B Seal plate C 'O' Ring seal D Seal sleeve E Clamp seal F End plate A Clamp B End plate Clamp seal (between Seal sleeve and Clamp D Seal sleeve Seal plate &...
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Page 11: Heating Elements
2.0 Installation 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. - Page 12 2.0 Installation Electrical Connection Details: Supply Types Supply Terminal Label Cable Colour Reversible or Live- Live - Neutral Live to either power conductor 1-phase L Brown to live (For USA 200-240V, connect L1) to the other power conductor Blue to neutral (For USA 200-240V, connect L2) to earth...
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Page 13: 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 14 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 15: 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 16 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 17: 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 18: 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 19: 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 20: 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 21: Alarm Option
3.0 2416 Controller 3.4.4 Alarm Option When an alarm board is fitted, which consists of a relay with voltage free contacts, for operator use, the contacts are taken to a panel plug on the control panel, wired as indicated: Temperature Controller Fuse (2A) Supply Load... -
Page 22: Navigation Diagram
3.0 2416 Controller Navigation Diagram... -
Page 23: 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 24: 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 25: 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 26: 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 27: Operator Safety
5.0 Operation 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 unloading the product. - Page 28 5.0 Operation It is recommended that a pressure relief system should be used to avoid an over pressurisation 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.
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Page 29: 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 30 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 31: Cleaning
6.0 Maintenance 6.2.1 Cleaning 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. Do not clean with organic solvents. 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. -
Page 32: Element Ageing
6.0 Maintenance Element Ageing Silicon carbide elements gradually increase in resistance with use; a process known as ageing. Their heating power reduces correspondingly. To ensure sufficient power to the product, it may be necessary to adjust the power limit and, ultimately, replace the elements - taking care to readjust the power limit. -
Page 33: 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 34: 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 35: Element Fitting And Replacement
7.0 Repairs and Replacements Element Fitting and Replacement Replacements: see section 6.7. If at any time the power limit has been increased, reset it to its original value (see section 10.0 at the back of this manual for the original value). New elements must not be mixed with aged elements. -
Page 36: Fuse Replacement
7.0 Repairs and Replacements Element Fitting - Figures Use of Clip Tool Element Connections - 6 elements, 3 phase Clip Braid Clip tool 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. -
Page 37: 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 38: 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 39: Wiring Diagrams
9.0 Wiring Diagrams 9.0 Wiring Diagrams WA-12-30... - Page 40 9.0 Wiring Diagrams WA-12-31 Connections below show single phase with safety switches and over-temperature control.
- Page 41 9.0 Wiring Diagrams WA-22-30 Connections below show 2-phase +N with indirect safety switches. 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 Element(s) Instrument Switch(es)
- Page 42 9.0 Wiring Diagrams WA-22-31 Connections below show 2-phase +N with indirect safety switches and over- temperature control. F1, F2, F3 Fuses Filter R1/1, R1/2 Relay Contactor Relay Temperature Controller Cables Control Thermocouple Blue Over-Temperature Over-Temperature Thermocouple GR/Y Green + Yellow Safety Switch Grey Heat Lamp...
- Page 43 9.0 Wiring Diagrams WA-43-30 Connections below show 3-phase delta with temperature control.
- Page 44 9.0 Wiring Diagrams WA-43-31 Connections below show 3-phase +N with indirect safety switches and over- temperature control.
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Page 45: Fuses And Power Settings
10.0 Fuses and Power Settings 10.0 Fuses and Power Settings 10.1 Fuses F1 - F3: 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 46: User Power Setting Adjustments
10.0 Fuses and Power Settings Model Volts: 200 V 208 V 220 V 230 V 240 V 380 V 400 V 415 V STF 15/610 (1-phase/ 2-phase+N) STF 15/610 (3-phase) User Power Setting Adjustments Date % Power Comments Note: If a new set of elements are fitted then return the power settings to the original value. -
Page 47: Specifications
11.0 Specifications 11.0 Specifications Carbolite Gero reserves the right to change the specification without notice. Work Tube Heated Work Tube Model Temp Power Length Length Weight Bore (mm) (°C) (kW) (mm) (mm) (kg) Tube furnaces heated by silicon carbide elements STF 15/610 1500 1200-1500... - Page 49 Notes Service Record Engineer Name Date Record of Work...
- Page 50 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.