VERDER CARBOLITE GERO E Series Installation, Operation And Maintenance Instructions
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VERDER CARBOLITE GERO E Series Installation, Operation And Maintenance Instructions

1200 c tube furnaces + 2416 controller
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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
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  • 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: 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 Safe Operation of the Furnace General Operating Advice Operator Safety Tube Life Pressure Gas Tightness 6.0 Operation Operating Cycle Control Method Safe Operation of the Furnace 3-Zone Control Methods A.
  • Page 4 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 Element Replacement Fuse Replacement 10.0 Fault Analysis Furnace Does Not Heat Up Product Overheats 11.0 Wiring Diagrams...

  • 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.

  • 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 mm longer than the heated length of the furnace (see the Specifications table at the back of this manual). Read section 9.2 before fitting the work tube. Figure 2.3.1 - Furnace model mounted on a Figure 2.3.2 - Exploded view showing how to fit control box the work tube in the furnace Index to numbered items in Figure 2.3.2...
  • Page 11 2.0   Installation Fitting of the work tube is as follows with reference to Figure 2.3.2 to 2.3.8. Before the extended work tube can be fitted, the work tube end stops for the stand- ard length work tube (item 5 in figure 2.3.2 ) must be removed from both ends of the furnace.
  • 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...
  • Page 13 2.0   Installation Figure 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...
  • Page 14 2.0   Installation 3. End guards 4. Extended work tube guard 5. End adaptor 6. Fluted grip knob 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.

  • Page 15: 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 16: 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 17 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...

  • Page 18: 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 6.0 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 19 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.

  • Page 20: 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 21: 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 22: 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 23: 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 24: 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 25: Navigation Diagram

    3.0   2416 Controller Navigation Diagram...

  • Page 26: 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 27: 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 28: 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 29: 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 30: 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 31: 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 32: 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 33: Operation

    6.0   Operation 6.0 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 34: 3-Zone Control Methods

    6.0   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 35: Back-To-Back Thermocouples

    6.0   Operation 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. The two end zone thermocouples are wired in opposition to the centre zone reference thermocouple. If the temperatures of the centre and end zones are the same then 0°C will be displayed on the end zone controllers.

  • Page 36: Independent Control

    6.0   Operation For products with the CC-T1 controller, please refer to the separate CC-T1 controller manual for details on how to set an offset trim. To make this adjustment on other controllers, enter thelevel 2 menu of the end zone controllers (see controller operating instruction), scroll to LOC.T (local trim) and use the down buttons to enter the desired positive or negative value.

  • Page 37: Tube Life

    6.0   Operation 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). Large work pieces should also be heated slowly to ensure that large temperature differences do not arise.
  • Page 38 6.0   Operation than inert gases, such as nitrogen.

  • Page 39: Maintenance

    7.0   Maintenance 7.0 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 40 7.0   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)

  • Page 41: Cleaning

    7.0   Maintenance 7.2.1 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 42: Maintenance

    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.
  • Page 43 8.0   Maintenance rect positioning 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)

  • Page 44: Cleaning

    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.

  • Page 45: Repairs And Replacements

    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.

  • Page 46: Solid-State Relay Replacement

    9.0   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 47: Fuse Replacement

    9.0   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 13.0. 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 48: Fault Analysis

    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...

  • Page 49: Product Overheats

    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...

  • Page 50: Wiring Diagrams

    11.0   Wiring Diagrams 11.0 Wiring Diagrams 11.1 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...
  • Page 51 11.0   Wiring Diagrams 11.2 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...
  • Page 52 11.0   Wiring Diagrams 11.3 WA-12-30...
  • Page 53 11.0   Wiring Diagrams 11.4 WA-12-31 Connections below show single phase with safety switches and over-temperature control.

  • Page 54: Wiring Diagrams

    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.

  • Page 55: Fuses And Power Settings

    13.0   Fuses and Power Settings 13.0 Fuses and Power Settings 13.1 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 56: Power Settings

    13.0   Fuses and Power Settings 13.2 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 57: Specifications

    14.0   Specifications 14.0 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 58: Furnace Drying Out Process

    14.0   Specifications Important safety notice: After transportation or storage in humid conditions, the furnace could fail to meet all the safety requirements of BSEN 61010-2-010 until it has completed the drying out process to restore its normal condition. Warning: It cannot be assumed that the furnace will meet all the safety requirements of BSEN 61010-2-010 during the drying out process.
  • Page 59 Notes Service Record Engineer Name Date Record of Work...
  • Page 60 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 eha 12/300b

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