VERDER CARBOLITE GERO G Series Installation, Operation And Maintenance Instructions
1200c tube furnace + 2416 controller
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- Page 1 Installation, Operation and Maintenance Instructions 1200°C G-Range Tube Furnace - GHA Model: 900mm 2416 Controller GHA 12/900 + 2416 Controller MEN-GHA120900-003_2416 09-01-2019...
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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 Gas Tightness 5.7 Running at Low Temperatures 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...
- Page 4 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. General Warnings DANGER –... -
Page 6: 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 7 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. This horizontal tube product is supplied with the controls in an integral base (or, to order, with the base control panel blanked off and the controls in a separate box).
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Page 8: Work Tubes And Fittings
2.0 Installation Work Tubes and Fittings Tubes of various diameters and lengths may be fitted. Type C: minimum length for the product. Type D: 400 mm longer than C, to allow for the fitting of end seals. A pair of removable 'end adaptors' form part of the end insulation. These may be blank (no hole) or may have a hole to suit a work tube, depending on the customer order. - Page 9 2.0 Installation Fig 1 - Insulating Plug (standard length tube) Tube Insulating Plug Stem Fig 2 - Insulating Plug (long work tube)
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Page 10: Electrical Connections
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. - Page 11 2.0 Installation Check the product rating label before connection. The supply voltage should agree with the voltage on the label and the supply capacity should be sufficient for the current on the label. The supply should be fused at the next size equal to, or higher than the current on the label.
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Page 12: Reconfiguring And Adjusting For Voltage
2.0 Installation 2.5 Reconfiguring and Adjusting for Voltage The standard single-phase models can operate over the voltage range 200 - 240 V. The 2-phase models can operate over the range 380/220 V to 415/240 V. The 3-phase models can operate over the range 380/220 V to 415/240 V. The product is wired according to the original order and conversion from 1-phase to 2- phase or 1-phase to 3-phase is not possible. -
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: Gas Tightness
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. -
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 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 32: 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 33: 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 34: Element Replacement
7.0 Repairs and Replacements Element Replacement See section 7.2 - wearing a face mask is required. Disconnect the product from the electrical supply. Remove all outer guards, meshes and terminal covers from the product body. For a horizontally mounted product remove the product body from its base; to reach the bolts or screws that fix the body to the base, remove the back panel from the base. -
Page 35: 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 36: 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 37: 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 38: Wiring Diagrams
9.0 Wiring Diagrams 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... -
Page 39: Wa-U3-31
9.0 Wiring Diagrams WA-U3-31 Connections below show 3-phase +N with safety switches and over-temperature control. - Page 40 9.0 Wiring Diagrams F1, F2, F3 Fuses Filter (if fitted) Controller Control Thermocouple Cables Over-Temperature Controller Blue Over-Temperature Thermocouple R1, R2, R3 Relay Black R1/1, R1/2, R2/1, R2/2, R3/1, R3/2 Relay contactor GR/Y Green + Yellow Instrument Switch(es) Grey Safety Switch Pink Element Solid State Relay...
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Page 41: 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 42: 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 43 11.0 Specifications 11.0 Specifications Carbolite Gero reserves the right to change the specification without notice. All models have cylindrical elements with wire formed in the surface of the insulation material. All models can accept work tubes up to a maximum outside diameter of 170 mm. All models have a maximum operating temperature of 1200 °C (1100°C continuous).
- Page 45 Notes Service Record Engineer Name Date Record of Work...
- Page 46 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.