VERDER CARBOLITE GERO E Series Installation, Operation And Maintenance Instructions
1200 c tube furnace
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- Page 1 Installation, Operation and Maintenance Instructions 1200°C E-Range Tube Furnace - EVA Model: 450mm 3216 Controller EVA 12/450B + 3216 Controller MEN-EVA12450B-004_3216 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 3.5.4 Understanding User Levels Setting up the Controller 3.6.1 Maximum Output Power 3.6.2 Customer ID 3.6.3 Units 3.6.4 Language 3.6.5 Scrolling Text 3.6.6 Customer Calibration 3.6.7 Holdback Programming 3.7.1 Creating a Program 3.7.2 Program Number (3216P5 Only) 3.7.3 Ramp Units 3.7.4 Dwell Units 3.7.5...
- Page 4 Navigation Diagram 5.0 Operation Operating Cycle Safe Operation of the Furnace General Operating Advice Operator Safety Tube Life Pressure Gas Tightness 6.0 Maintenance General Maintenance Maintenance Schedule 6.2.1 Cleaning Calibration After-Sales Service Recommended Spare Parts and Spare Parts Kit 7.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Safety Warning - Refractory Fibre Insulation Temperature Controller Replacement...
- Page 5 11.0 Specifications 11.1 Environment Furnace drying out process...
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Page 6: 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 7: 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 8 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 9: 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 10: 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 11 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 12 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 13 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 14 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 15 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 16: 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 17 2.0 Installation Index to numbered items in Figure 2.4.1 1. Control Box 2. Furnace Body 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.
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Page 18: Electrical Connections
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 19: 3216 Controller
3.0 3216 Controller 3.0 3216 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. 3216P1 The 3216P1 is a digital temperature controller which uses PID algorithms to give excellent temperature control. -
Page 20: Keys
3.0 3216 Controller 3.4.2 Keys The page key is used to access level 2 when held down Page Key for 3 seconds. Scroll Key The scroll key is used to scroll through parameters. When pressed simultaneously the ACK function is used Page and Return to the Home Menu Scroll... -
Page 21: Understanding User Levels
3.0 3216 Controller In this manual the mnemonic will be shown first, followed by the scrolling text in brackets; e.g. PROG <PROGRAM NUMBER> 3.5.4 Understanding User Levels There are two user levels in the controller; Level 1 (Operator) and Level 2 (Supervisor). Level 1 (Operator) is for the day to day operation of the controller. -
Page 22: Setting Up The Controller
3.0 3216 Controller If while navigating the controller, a parameter has been passed or you need to access parameters which would be at the end of a scroll list, press and hold scroll and use up to return to a previous parameter. Setting up the Controller Before using the controller (or during its lifetime) certain parameters may have to be set, depending on specific requirements. -
Page 23: Scrolling Text
3.0 3216 Controller 3.6.5 Scrolling Text If at any time the scrolling text is not required. Press and hold the page for three seconds until “GOTO” is displayed. Press scroll until the display shows. TEXT <ENABLE/ DISABLE SCROLLING TEXT> Use the up and down keys to select ON or OFF. -
Page 24: Holdback
3.0 3216 Controller Caution! - Do not make PNT.LO and PNT.HI the same value as the controller will not work correctly and could cause the product to overheat. 3.6.7 Holdback If the temperature ramp rate of the program is quicker than the product can achieve, the program will wait until the temperature of the product catches up. -
Page 25: Programming
3.0 3216 Controller Programming 3.7.1 Creating a Program Programs can be created in level 1 or level 2 of the 3216P1 and 3216P5. Each program contains 8 Ramp/ Dwell pairs. Note: A currently active program cannot be altered. Go into 'Reset' mode before starting to create or modify a program 3.7.2 Program Number (3216P5 Only) Press scroll... -
Page 26: Running A Program
3.0 3216 Controller If not all the segments are used for a program, the Ramp & Dwell of each of the subsequent segments should be set to OFF. A program will end in one of two ways, either revert to the control setpoint or dwell at the temperature set in the last segment used. - Page 27 3.0 3216 Controller Working Output Power From the home display, press scroll until the display shows WRK.OP <WORKING OUTPUT POWER>. This shows the power being used as a percentage. Time Remaining Press scroll until the display shows T.REMN <TIME REMAINING>. This shows the dwell time remaining for the current segment.
- Page 28 3.0 3216 Controller Program Example The following sequence of entries creates and runs the program shown graphically below. 1. Press scroll until the display shows RAMP.U <SP RAMP UNITS>. Select MIN. 2. Press scroll until the display shows DWELL.U <DWELL UNITS>. Select MIN. 3.
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Page 29: Controller Options
3.0 3216 Controller RMP.1= 5°C/Min RMP.1= 4°C/Min RMP.1= OFF RMP.1= 3°C/Min RMP.1=5°C T.SP1= 600°C T.SP1= 400°C T.SP1= 600°C T.SP1= 800°C T.SP1= 400°C Dwel.1= 30 Min Dwel.1= 30 Min Dwel.1= 60 Min Dwel.1= OFF Dwel.1= 480 Min Controller Options As options can be ordered in a variety of combinations and for a variety of purposes, exact instructions are not given here. -
Page 30: Alarm Option
3.0 3216 Controller address value, access the level 2 list. In level 2 press the page key until the COMMS parameter is displayed. Press up down to select the address value. 3.8.4 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... - Page 31 3.0 3216 Controller Hold the Page key for 3 Level 1 Press the Scroll Key seconds Press the Scroll Key mul- Locked - password Level 2 tiple times required Access If configured Unlocked Black = Progress Do not raise the power limit (if Dashed = Through multiple accessible) above the design level Multiple Program Only...
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Page 32: 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 33: 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 34: 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 35: 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 36: 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 37: 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 38: 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 39: 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 40 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 41: 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 42: 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 43: 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 44: 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 45: 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 46: 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 47: 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 48 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 49 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 50: 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 51: 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 52 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 53 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 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.