VERDER CARBOLITE GERO 3216P1 Installation, Operation And Maintenance Instructions
30-3000 c, 1100 c ashing furnace - 3 litres, controller
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- Page 1 Installation, Operation and Maintenance Instructions 1100°C Ashing Furnace - AAF Model: 3 Litres 3216 Controller AAF 11/3 + 3216 Controller MEN-AAF1103-004_3216 01-08-2019...
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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 3.7.6 Ramp Rate 3.7.7 Target Setpoint 3.7.8 Dwell Time 3.7.9 Running a Program 3.7.10 Program Status 3.7.11 Process Value 3.7.12 PSP, Segment Type and Number Controller Options 3.8.1 Digital Communications - RS232 3.8.2 Digital Communications - RS485 3.8.3 Comms Address 3.8.4 Alarm Option Temperature Controller Replacement...
- Page 4 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 Solid-State Relay Replacement Thermocouple Replacement Element Replacement Door Plug Replacement Fuse Replacement 8.0 Fault Analysis Furnace Does Not Heat Up...
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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 and handling the product, always lift it by its base. Do not use the door or any other projecting cover or component to support the equipment when moving it. Use two or more people to carry the product where possible. Carefully remove any packing material from inside and around the product before use. -
Page 7: Chimney
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. -
Page 8: Electrical Connections
2.0 Installation Duct (75mm-150mm diameter) Ambient air is drawn into duct Chimney D 25mm vertical gap between chimney and duct Electrical Connections Connection by a qualified electrician is recommended. This product requires a single-phase A.C. supply with earth (ground), which may be Live to Neutral non-reversible (polarised), Live to Neutral reversible (non-polarised), or Live to Live. - Page 9 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 10: 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 11: 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 12: Understanding User Levels
3.0 3216 Controller 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. These parameters are not protected by a security code. Level 2 (Supervisor) provides access to additional parameters. -
Page 13: Setting Up The Controller
3.0 3216 Controller Setting up the Controller Before using the controller (or during its lifetime) certain parameters may have to be set, depending on specific requirements. To do this the controller must be set to supervisor level (Level 2). 3.6.1 Maximum Output Power Press scroll until the display shows OP.HI <OUTPUT HIGH>. -
Page 14: Customer Calibration
3.0 3216 Controller 3.6.6 Customer Calibration The 3216 Controller series are calibrated for life at manufacture, there may however be sensor or other system errors, which affect the accuracy of the measured temperature. Customer calibration can be used to compensate for these errors. Dual Offset Dual point calibration uses two offset values at two corresponding temperatures;... - Page 15 3.0 3216 Controller e.g. If a holdback value of 10 is set and the program is set to ramp to a setpoint of 600 °C, the program will reach 600 °C, then go into a hold state; the hold indicator will light until the product temperature reaches 590 °C, the program will then continue to control again.
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Page 16: 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 17: 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 18 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 19 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 20: 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 21: 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 22 3.0 3216 Controller Hold the Page key for 3 Level 1 Press the Scroll Key seconds Press the Scroll Key multiple Locked - password Level 2 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 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: Use Of Probes
5.0 Operation materials that emit smoke or fumes, regularly heat it up to maximum temperature for one hour with the chamber empty to burn away the soot. Materials such as case hardening compounds and other reactive salts may penetrate the furnace chamber lining and attack the wire elements, causing premature failure. Use of a hearth tile may be advisable: please consult the Carbolite Gero technical department. -
Page 28: Thermal Catalytic Oxidiser Option
5.0 Operation When the product is opened during operation there is considerable radiated heat. Do not keep any flammable objects near the product, nor objects which could be damaged by radiated heat. Thermal Catalytic Oxidiser Option Catalytic oxidation allows the purification of exhaust air from volatile organic components at low temperature without an open flame. -
Page 29: Power Adjustment
5.0 Operation Power Adjustment The product control system incorporates electronic power limiting. Depending on the model and the destination country the power limit maybe set to 100% or a lower figure. Where appropriate the power limit parameter OP.Hi is accessible to the operator, but it should not generally be altered. -
Page 30: 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 31 6.0 Maintenance Operational Check Check that all functions are working normally Thorough inspection and report incor- Operational Check porating a test of all functions Performance Element Circuit Electrical measurement Measure the current drawn on each phase / Power Consumption circuit Hearth Visual check for fit and damage Cooling Fans (if fitted)
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Page 32: 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 33: After-Sales Service
6.0 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’... -
Page 34: 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 35: 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. 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. -
Page 36: Element Replacement
7.0 Repairs and Replacements Element Replacement See section 7.2 - wearing a face mask is required. The chamber of this type of furnace is formed by winding resistance heating wire on to a refractory muffle former. In the event of failure, the whole "wound muffle" assembly must be replaced. - Page 37 7.0 Repairs and Replacements Check that the furnace is controlling properly to rule out the possibility that previous element failed because of a fault in the control circuit.
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Page 38: Door Plug Replacement
7.0 Repairs and Replacements Door Plug Replacement See section 7.2 - wearing a face mask is required. Open the door and remove the door cover from the plug carrier assembly. Remove the old door plug by sliding it upwards out of its carrier. Slide the new plug into the carrier assembly making sure that the plug is the correct way Refit the door cover. - Page 39 7.0 Repairs and Replacements If any fuse has failed, it is advisable for an electrician to check the internal circuits. Replace any failed fuses with the correct type. For safety reasons do not fit larger capacity fuses without first consulting Carbolite Gero. The fuses are located at the cable entry point.
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Page 40: 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 41: 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 42: 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 43 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...
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Page 44: 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 of EMC filter. -
Page 45: Specifications
11.0 Specifications 11.0 Specifications Carbolite Gero reserves the right to change the specification without notice. External Size Chamber Size (mm) (mm) Model Temp Power Weight (°C) (kW) (kg) Ashing Burn-off and Coal and Coke Testing Furnace 585 375 485 90 AAF 11/3 1100 150 250... - Page 47 Notes Service Record Engineer Name Date Record of Work...
- Page 48 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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