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.
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3.8.9 To run a different program (P10 and P25) 3.8.10 Program Status 3.8.11 Program Hold with Holdback 3.8.12 Power Failure Recovery 3.8.13 Alarms 3.8.14 Program Example 1 3.8.15 Program Example 2 Controller Options 3.9.1 Digital Communications - RS232 3.9.2 Digital Communications - RS485 3.9.3 Comms Address 3.9.4...
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5.3.3 Running with the Timer 5.3.4 Stopping the Timer 5.3.5 End of Time Period 5.3.6 Cancelling the Alarm 5.3.7 Program Example Altering Power Limit Audible Alarm Temperature Controller Replacement Navigation Diagram 6.0 2132 Over-Temperature Controller Description (if fitted) Description Operation 6.2.1 Controls 6.2.2...
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Calibration After-Sales Service Recommended Spare Parts and Spare Parts Kit 9.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Safety Warning - Refractory Fibre Insulation Temperature Controller Replacement Solid-state Relay Replacement Thermocouple Replacement Fuse Replacement Element Replacement 10.0 Fault Analysis Furnace Does Not Heat Up Product Overheats 11.0 Wiring Diagrams...
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;...
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.
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2.0 Installation Ensure that the product is placed in such a way that it can be quickly switched off or disconnected from the electrical supply. If the product is supplied with a work tube or any accessories fit these into position. For optimum temperature uniformity, insulating plugs should be placed in the tube ends as shown in fig.1.
2.0 Installation Clamp Seal plate 'O' Ring seal D Seal sleeve Clamp seal End plate Clamp End plate Clamp seal (between Seal sleeve and Clamp D Seal sleeve Seal plate & 'O' Ring seal (underneath clamp) Tube Fig 3 'Twin Clamp' End Seal For assembly details refer to the separate work tube end seal manual.
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2.0 Installation The product covered by this manual normally requires a single phase A.C. supply, which may be Live to Neutral non-reversible, Live to Neutral reversible or Live to Live. Some models may be ordered for 3-phase use, which may be star or delta. Check the product rating label before connection.
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2.0 Installation 3-phase L1 Black to phase 1 Black to phase 2 Black to phase 3 Light Blue to neutral (except delta) Green/ Yellow to earth (ground) DO NOT connect a product ordered for three phase use to a single phase supply or to the wrong type of three phase supply.
3.0 3508 Controller 3.0 3508 Controller PID control This controller uses PID (Proportional Integral Derivative) temperature control. This type of control uses a complex mathematical control system to adjust the heating power and achieve the desired temperature. 3508P1 The 3508P1 is a digital temperature controller which uses PID algorithm to give excellent temperature control when properly set.
3.0 3508 Controller Basic Operation Alarm Indicator Power Output Indicator Not Used Runs, Holds, Resets the current program Page Scroll Down Power Output Percentage Program Setpoint Temperature (PSP) when a program is running Setpoint Temperature (SP) when basic controlling Measurement Temperature...
3.0 3508 Controller Measurement Units 3.5.1 Controller Layout 3.5.2 Keys A/ Man Disabled Runs, Holds or Resets the current program. Hold down for 3 RUN/ HOLD seconds to Reset. Scrolls through the page headings. Hold down for 3 seconds to Page Key access further levels, pass codes are required.
3.0 3508 Controller This will cause the product to heat as quickly as possible which may not be appropriate where the product contains sensitive ceramic components. For products with ceramic components, e.g. a tube furnaces fitted with a long ceramic work tube, use the ramp rate feature set with a low heating rate such as 5°C per minute (300°C per hour), to prevent damage.
3.0 3508 Controller To Enter Level 2: 1. Press and hold page for 3 seconds. The display will show “Access Goto Level 1” 2. Press up to select level 2. After a short pause the display will show “Access Pass code”. 3.
3.0 3508 Controller 3.7.3 Units Press page until "Units" is displayed. Press up or down to select: Celsius Fahrenheit Kelvin 3.7.4 Language The text on the 3508 Controller can be shown in different languages, this can only be set at the factory and therefore must be specified at the time of placing an order. Programming 3.8.1 Programming Notes Programs can be created in Level 1 or Level 2 of the 3508 Controller.
3.0 3508 Controller To alter parameters or segments of an operating program, this program must be held or reset. Press RUN/ HOLD to pause the program, or press RUN/ HOLD for 2 seconds to reset. 3.8.2 Holdback Holdback can be used to prevent the program from operating ahead of the actual heating or cooling.
3.0 3508 Controller 3. 'Dev Hi’ Wait until the measured temperature exceeds a fixed* threshold by an amount ‘WaitVal’ set for that segment. 4. ‘Dev Lo’ Wait until the measured temperature drops below a fixed* threshold by an amount ‘WaitVal’ set for that segment. * The fixed threshold used by deviation parameters is set in the configuration level of the programmer and if required should be requested when purchasing a product from Carbolite Gero.
3.0 3508 Controller Holdback Type Press scroll until the display shows 'Holdback Type'. If required, press up or down to select 'Off', 'Low', 'High' or 'Band'. Target Setpoint (Visible only for Rate, Time and Step segments) Press scroll until the display shows 'Target SP'. Press up or down to set a value.
3.0 3508 Controller 3.8.7 To pause (hold) a program Press RUN/HOLD Press page until 'Program Status Reset' appears Press scroll until the cursor moves to 'Reset' Press up or down to select 'Hold' RUN/HLD will be displayed 3.8.8 To stop and reset a program Press and hold RUN/HOLD Press page until 'Program Status Reset' appears...
3.0 3508 Controller Current program number (P10 and P25 only) Current segment number Time remaining for that segment Further presses of the scroll key while a program is operating will reveal additional information: Status. This can be changed to 'Hold', 'Reset' or 'Run' by pressing up or down Program Setpoint (PSP) Current Segment Type.
3.0 3508 Controller 3.8.13 Alarms Alarms are used to alert the operator when a pre-set level has been exceeded or a function error has occurred such as a sensor break. They are indicated by a flashing red ALM (Alarm) indicator. The alarm may also switch an output – usually a relay to allow external devices to operate when an alarm occurs.
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3.0 3508 Controller 11. Press scroll until 'Segment Type' is displayed. Press up or down to select 'End' 12. Press scroll until 'End Type' is displayed. Press up or down to select 'Reset' 13. Press page and scroll together to return to the home display. To run the program either press RUN/HOLD or: 14.
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3.0 3508 Controller Time Display Examples 10:05:3 Min/Sec/10th Sec 21:10:05 Hour/Min/Sec 196:10 Hour/Min Segment Type 'Rate' Type 'Dwell' Type 'Step' Type 'Dwell' Type 'Time' Type 'End' Target 400°C Duration 30 min Target 600° Duration 30 min Target 200° End Type 'Reset' Rate 5.0°/Min Time 120 min 3.8.15 Program Example 2...
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3.0 3508 Controller 5. Press scroll until 'Cycles' is displayed. Default ‘1’ 6. Press scroll until 'Segment 1' is displayed 7. Press scroll until 'Segment Type' is displayed. Press up or down to select ‘Time’ 8. Press scroll until 'Holdback Type' is displayed. Default ‘Off’ 9.
3.0 3508 Controller Segment Type 'Time' Type 'Rate' Type 'Step' Type 'Dwell' Type 'Call' Type 'End' Target 600°C Target 400°C Target 200°C Duration 30 min Call prog 3 End Type 'Dwell' Duration 30min Rate 2°C/min H back type 'High' Call cycles 2n * Segment 4 'Holdback Value' 5°C ** P10 and P25 only *** Program 3 Example...
3.0 3508 Controller 3.9.1 Digital Communications - RS232 If the RS232 option is supplied, the furnace is fitted with one sub-miniature D-socket connected to the controller comms module. RS232 is suitable for direct connection to a personal computer (PC) using a “straight through” cable as follows (the linked pins at the computer end are recommended but may not be necessary).
3.0 3508 Controller 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.
3.0 3508 Controller is set to on, then the relay closes during the segment and a small 1 appears in the top left of the screen. If more than one program segment output is fitted, then there are extra boxes depending on how many event outputs there are.
3.0 3508 Controller 3.11.1 Operator Level 1 - No Program Running Home Display Controller identity when using more than one controller Read Only Black = Progress Page Key White = Return Scroll Key Visible Parameters depend on the Segment Type...
3.0 3508 Controller 3.11.2 Operator Level 1 - Program Running Home Display Controller identity when using more than one controller Read Only Black = Progress Page Key White = Return Scroll Key See previous diagram: Operator Level 1- No Program Running...
3.0 3508 Controller 3.11.3 Supervisor Level 2 To enter Level 2 Scroll Key Level 2 Locked before Pass Code entered Level 1 Home Display Unlocked Level 2 Home Display Black = Progress See previous diagram: Page Key Operator Level 1- No Program Running Hold Page Key for 3 seconds If configured Arrow Key...
4.0 3508 Dual Loop Cascade 4.0 3508 Dual Loop Cascade Control (if fitted) Principle of Cascade Control When cascade control is fitted, the Load Loop 3508 senses the temperature of the workload, and the Element Loop 3508 senses the element temperature. Depending on the oven or furnace model, the Load Thermocouple may be in a fixed position, or may be movable.
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4.0 3508 Dual Loop Cascade Home Display View Load Loop View Element Loop View The Element Loop should never be adjusted. Note that the elements usually run at a higher temperature than the load.
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4.0 3508 Dual Loop Cascade Because the details of the customer’s cascade application (in particular the nature of the load) are generally not known, the feed forward parameter (FF Trim) is made easily accessible in level 2 (Refer to instrument operating instructions). Its default setting is 2%.
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4.0 3508 Dual Loop Cascade Power Limit View...
4.0 3508 Dual Loop Cascade Bypassing Cascade Control This applies where the Control Thermocouple is a removal probe (e.g. in a tube furnace), or where for other reasons it may be required to operate the furnace or oven directly from the Element Loop. To operate without Cascade Control the load thermocouple has to remain connected at all time;...
5.0 2132 Controller 5.0 2132 Controller Description The 2132 Controller is made by Eurotherm, and is fitted and configured by Carbolite Gero for immediate use. It is a digital instrument with PID control algorithms. The 2132 Controller features: Easy use as a simple temperature controller, where on setting the required tem- perature the controller immediately attempts to reach and maintain it.
5.0 2132 Controller 5.2.2 2132 Controller Operation Alarm Light Page Scroll D Down Display 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.
5.0 2132 Controller 5.2.5 Stopping and Starting Control It is possible to stop and start the controller without altering the setpoint. Press scroll until the legend 'm-A' (manual/ auto) appears. In this controller, manual means OFF and auto means ON. Press down or up once to show the current on/ off state: 'mAn' for OFF and 'Auto' for ON.
5.0 2132 Controller Fig 1 - Control without Ramp-to-Setpoint Fig 2 - Control with Ramp-to-Setpoint Temperature Time Setpoint WSP Working Setpoint Actual Temperature Operating with the Timer This controller can be used as a process timer allowing timed heating or timed delay, according to the options in the table.
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5.0 2132 Controller Timer Mode Description Timer Light The timer starts timing when the actual temperature is within 1 °C On while temperature is mode 1 of the setpoint. At the end of the reaching setpoint. On during timing period, control switches Timed dwell and the timing period.
5.0 2132 Controller 5.3.1 Setting the Timer Mode Scroll to 'tm.OP'; use to view and alter the mode. The mode shows as 'OPt.1' to 'OPt.5'. It is not possible to alter the mode while the timer is operating; if the mode cannot be altered, scroll to the 'StAt' parameter and set its value to OFF.
5.0 2132 Controller 5.3.5 End of Time Period Modes 1 and 3: heating stops at the end of timing; the 'm-A' parameter changes to 'mAn'. Modes 2 and 4: heating continues at the end of timing; the 'm-A' parameter remains at 'Auto'.
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5.0 2132 Controller For silicon carbide heated furnaces the parameter is accessible to allow for compensation for element ageing. In wire-heated chamber or tube furnaces, reducing the power limit is a convenient method of improving control at low temperatures, as outlined below.
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5.0 2132 Controller The controller is calibrated for life at manufacture against known reference sources, but there may be sensor errors or other system errors. User calibration allows compensation for such errors and this controller allows for a user 2-point calibration. This setting is password protected to avoid accidental alteration.
5.0 2132 Controller User Temperature Reading Factory Temperature Reading UC User Calibration UF Factory Calibration Audible Alarm If an audible alarm is supplied for use with the timer function, then it is normally configured to sound at the 'End' condition and to go off when the alarm is acknowledged as given in section 5.3.6.
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5.0 2132 Controller HL Home List Input List OL Output List AL Access List Measured temperature; use arrow keys to access setpoint Output power (read only) Present only if SPrr in use Manual/Auto (mAn = off, Auto = on) Setpoint ramp rate OFF or value Timer mode Time remaining Dwell time for timer...
6.0 2132 Over-Temperature 6.0 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.
6.0 2132 Over-Temperature 6.2.2 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;...
6.0 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 6.2. Note: the alarm may sound during controller start-up.
7.0 Operation 7.0 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. There is also a heater switch which can be used to disconnect power to the elements. Operate the instrument switch to activate the temperature controller.
7.0 Operation The two images below are typical examples of control panel layouts. 3-Zone Control Methods There are three different control options (A, B & C). (A) Back to back thermocouples (B) Retransmission of Setpoint (C) Independent control The models listed in this manual are designed to achieve an extended uniform temperature zone, through use of three control zones, rather than achieving different temperatures in each zone.
7.0 Operation Note: Option A is NOT applicable when using the CC-T1 controller Option B is NOT applicable when using the Eurotherm 2132 End Zone Controller A. Back-to-Back Thermocouples This is the most commonly supplied option. The centre zone of the tube furnace is controlled directly by the centre zone temperature controller.
7.0 Operation It is possible to set an offset (local trim) between the centre and end zone controllers. This can be either a positive or negative difference from the centre zone temperature. Once entered, this offset will always be added to, or subtracted from, the retransmitted setpoint temperature.
7.0 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).
7.0 Operation Power Adjustment The control system incorporates electronic power limiting. The power limit parameter OP.Hi is accessible to the operator and can be used to adjust the furnace to the actual supply voltage. The models covered by this manual are designed for use over the range of voltages 200 V - 250 V (or, if ordered, 100 V - 125 V), and the power limit parameter is set accordingly.
8.0 Maintenance 8.0 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.
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8.0 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)
8.0 Maintenance 8.2.1 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.
8.0 Maintenance thermocouple and temperature indicator should be made from time to time to determine whether full calibration is required. Carbolite Gero can supply these items. Depending on the controller fitted, the controller instructions may contain calibration instructions. After-Sales 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’...
9.0 Repairs and Replacements 9.0 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.
9.0 Repairs and Replacements Solid-state Relay Replacement Disconnect the product from the power supply and remove the appropriate cover as given above. 1. Make a note of the wire connections to the solid state relay, then disconnect them. 2. Remove the solid state relay from the base panel or aluminium plate. 3.
9.0 Repairs and Replacements The fuses are located at the cable entry point. Remove the back panel or control box back panel to gain access to the fuses. Element Replacement See section 9.2 - wearing a face mask is required. Remove the three screws from each end and lift out the half-circular insulation assembly.
10.0 Fault Analysis 10.0 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...
10.0 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...
11.0 Wiring Diagrams 11.0 Wiring Diagrams 11.1 WC-13-70 Safety Switch A - A 2-pole Heater Switch is fitted directly in the element circuit in models up to 16 A rating. Safety Switch B - A door switch is fitted into the contactor coil circuit. Above 16 A a 1- pole Heater Switch is fitted into the same circuit, in series.
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11.0 Wiring Diagrams 11.2 WC-13-71 Connections below show single phase with indirect safety switches and over- temperature control.
11.0 Wiring Diagrams 11.3 2- and 3-phase With Neutral Each SSR is connected to a different phase. The control circuit is taken between L1 and Safety switch A applies for 2-phase. Safety switch B applies for 3-phase. If type F1 fuse is present, one per phase if fitted. If type F2 fuse is present, one is fitted;...
11.0 Wiring Diagrams 11.7 Higher Voltages For 254 V or above 1-phase or 440/254 V or above 3-phase, an isolating transformer is included in the control circuit after the F2 fuses.
12.0 Fuses and Power Settings 12.0 Fuses and Power Settings 12.1 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...
12.0 Fuses and Power Settings 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. Please refer to the rating label for product specific information.
13.0 Specifications 13.0 Specifications Carbolite Gero reserves the right to change the specification without notice. Work Tube Heated Recommended Work Tube Model Temp Power Bore Length Weight Length for use in air (mm) (°C) (kW) (mm) (mm) (kg) 3-zone Split Tube furnaces heated by resistance wire moulded in refractory fibre 1200 1050 12/900...
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Notes Service Record Engineer Name Date Record of Work...
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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.
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