Carbolite Gero 3216CC, Installation, Operation And Maintenance Instructions

Page 1: ...eration and Maintenance Instructions 1200 C Tube Furnace 3 zone EVZ Model 600mm No Controller 3216CC End Zone Controllers EVZ 12 600B No Controller 3216CC End Zone Controllers MEN EVZ12600B 13_NOCTRL_3216CC 02 08 2019 ...

Page 2: ...3 3 Figure Mounting the furnace onto the vertical stand 11 2 3 4 Figure Tube furnace positioned horizontally on the stand 12 2 3 5 Figure Tube support 13 2 3 6 Figure Tube support assembled 13 2 3 7 Figure Tube support and end seal 14 2 3 8 Figure Tube support and end seal assembly 14 2 3 9 Figure View showing how to support the work tube in a vertical ori entation 15 2 4 Setting Up Without a Stan...

Page 3: ...26 4 7 4 Running Dwell Timer with Ramp Rate Threshold 27 4 7 5 Delayed Switch on Timer 27 4 7 6 Running Delay Timer with Ramp Rate 28 4 7 7 Delay timer with ramp rate functions 28 4 7 8 Power Failure While Using Delay Timer 28 4 7 9 Soft start Timer 29 4 7 10 Power Failure While Using Soft Start Timer 29 4 7 11 Ramp Rate with Soft Start Timer 29 4 7 12 Time Remaining 29 4 7 13 Alarms 29 4 8 Contro...

Page 4: ... Operator Safety 39 6 7 Tube Life 40 6 8 Pressure 40 6 9 Gas Tightness 40 7 0 Maintenance 42 7 1 General Maintenance 42 7 2 Maintenance Schedule 42 7 2 1 Cleaning 44 7 2 2 Safety Switch 44 7 3 Calibration 44 7 4 After Sales Service 45 7 5 Recommended Spare Parts and Spare Parts Kit 45 8 0 Repairs and Replacements 46 8 1 Safety Warning Disconnection from Power Supply 46 8 2 Safety Warning Refractor...

Page 5: ...erheats 50 10 0 Wiring Diagrams 51 10 1 WC 13 70 51 10 2 WC 13 71 52 11 0 Fuses and Power Settings 53 11 1 Fuses 53 11 2 Power Settings 54 12 0 Specifications 55 12 1 Environment 55 Furnace drying out process 56 5 ...

Page 6: ...d to the elements Heat switch the switch disconnects power to the heating elements unless this switch is OFF there is a danger of electric shock when inserting objects into the product 1 2 General Warnings DANGER Electric shock Read any warning printed next to this symbol WARNING Risk of fatal injury DANGER Hot surface Read any warning printed next to this symbol WARNING All surfaces of a product ...

Page 7: ...work tube adaptors or it could be possible for an operator to access electrically live element coils that could cause serious injury or death 8 Warning label Switch off the furnace before loading and unloading The furnace heaters must be switched OFF using the heater switch item 2 in figure 1 3 1 when the furnace is being loaded or unloaded The work tube can become electrically conductive at high ...

Page 8: ...er ON and OFF to the furnace heating ele ments 3 Heater ON light indicates that the furnace heating elements are energized 4 Product rating label indicating the product serial number and electrical inform ation 5 Access holes to front panel fixing screws 6 Warning label Disconnect the mains supply before removing this cover 7 Warning label Do not operate without a work tube 8 Warning label Switch ...

Page 9: ...al spillage or hot materials The surface on which the equipment is mounted should be stable and not subject to movement or vibrations The height of the mounting surface is important to avoid operator strain when loading and unloading samples Unless otherwise stated elsewhere in this manual ensure that there is at least 150 mm of free space around the back and sides of the product Clear space is re...

Page 10: ...ling the stand and mounting the furnace Tools required 4 mm Allen key The assembly of the vertical stand is as follows with reference to 2 3 1 2 3 2 and 2 3 3 Place the vertical stand base item 1 on the floor or bench on which it is to be assembled l Position the vertical stand upright 2 on the stand base in line with the fixing holder l Secure the stand upright to the base using the 6 x M6 dome c...

Page 11: ...mbling the 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 Washer M6 5 Tube furnace 6 M6 screw knob 2 3 3 Figure Mounting the fur nace onto the vertical stand 11 2 0 Installation ...

Page 12: ...it the work tube with the furnace in the horizontal position as shown in figure 2 3 4 To fit the work tube in a vertical orientation follow the steps below Omit the use of the end seal if not required The same tube support design will work with or without the tube end seal in place WARNING If clamps are used without an end seal care should be taken not to over tighten on to a bare tube especially ...

Page 13: ...5 using item 6 until the tube is secure enough for use in a vertical arrangement Fitting arrangement is shown in figure 2 2 l Figure 2 2 shows an exploded view of all the required parts l Figure 2 2 shows the assembled parts as they would be used 2 3 5 Figure Tube support 2 3 6 Figure Tube support assembled 13 2 0 Installation ...

Page 14: ...n 2 3 7 Figure Tube support and end seal 2 3 8 Figure Tube support and end seal assembly For extra stability of the tube repeat the assembly instructions above as shown in figure 2 3 8 on the other end of the tube 14 ...

Page 15: ...mounting frame It is the customer s responsibility to carry out a risk assessment on the siting and mounting of the furnace and to ensure that it is operated in a safe manner see section 2 2 for the recommended siting instructions The fitting of the work tube is covered in the previous section 2 4 1 Figure Tube furnace shown without a stand for customers own mounting as an example Index to numbere...

Page 16: ...ation shields is similar to that of insulation plugs see figure C If a metal work tube is being used in the furnace ensure that it is earthed See the safety warning in section 6 6 Figure A Cross section view showing standard length work tube insulation plug fitted Figure B Cross section view showing extended work tube insulation plug fitted Figure C Cross section view showing an extended length wo...

Page 17: ...ernal supply fuses in which case customer fusing is preferred but not essential See section 11 0 for furnace rating power current and fusing information The external connection should be either a permanent connection to a fused isolator supply or to a socket on a fused isolator supply the isolating switch must operate on both conductors Make sure that the isolator switch is within easy reach of th...

Page 18: ...3 0 Temperature Controller 3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 18 ...

Page 19: ...mperature controller it cannot be programmed 4 2 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 4 3 Operation 4 3 1 Controller Layout Key A Power Output Indicator B Alarm Indicator C Remote Indicator when configured D Page E Scro...

Page 20: ...sired temperature Setpoint 4 4 2 Changing the Setpoint Press Up or Down to select the required SP If the SP is higher than the measured temperature the OP1 indicator will illuminate in the top left corner of the display indicating that the controller is calling for power giving an output The controller will immediately attempt to reach the setpoint and then maintain it This will cause the product ...

Page 21: ...red PASS should momentarily be displayed and then revert to the level 2 home display If an incorrect code is entered the display reverts back to Level 1 home display When level 2 operations have been completed the supervisor must return to Level 1 either manually or by switching the instrument off and back on There is no time out function To Return to Level 1 1 Press and hold the page Key 2 Press ...

Page 22: ...rate When the process temperature has reached the setpoint value at the given ramp rate the run indicator will turn off and the instrument will control at the required setpoint temperature Any further modifications to setpoint will cause the ramp rate to be activated and the instrument to control as described above NOTE Ensure timer configuration is set to none see section 4 6 to use the setpoint ...

Page 23: ...n identification number can be entered if required This maybe used to identify one of many units for production or quality control systems Press scroll until the display shows ID CUSTOMER ID Use the up and down keys to enter your own identification number This can range from 1 9999 4 5 4 Units Press scroll until the display shows UNITS DISPLAY UNITS Use the up or down keys to select the required u...

Page 24: ...red Press scroll until the display shows THres TIMER THRESHOLD Use the up down to select the temperature threshold that you require the timer to start at The threshold value is n around the setpoint n threshold value Example If the setpoint is set to 800 C and the timer threshold is set to 2 after the timer is activated it will not start until the process value reaches 798 C if ramping up or 802 C...

Page 25: ...t SF st When Soft Start parameter is selected the Timer Resolution TM RES Time Duration DWELL Soft Start Setpoint SS SP and Soft Start Power Limit SS PWR functions become available Press scroll until the display shows TM RES Time resolution Use the up down to select the timer units in minutes or hours Press scroll until the display shows DWELL SET TIME DURATION Use the up down to enter the time du...

Page 26: ...crolling Text Timer End Static Text OFF To re RUN Timer Press and quickly release Indicator RUN ON Scrolling Display Timer Running To RESET timer and return to home menu after timer end Press and quickly release Ack Indicator RUN OFF Scrolling Display None Press and hold for more than 1 second Indicator RUN OFF Display A M LOOP MODE AUTO MANUAL OFF Use the up down to select 4 7 2 Power Failure Whi...

Page 27: ...shold value see example 4 6 3 The scrolling display will indicate timer running and the run indicator will be illuminated while the ramp rate is active while the process value is reaching the threshold value and during the timer count down after which the display will indicate the instrument has switched off power to the elements see section 4 7 1 4 7 5 Delayed Switch on Timer Operation Action Ind...

Page 28: ...hether the timer has timed out or not can be done with the T REMN function see section 4 7 12 The delay timer with ramp rate will function as outlined in the table above with the addition of the functions in the following table 4 7 7 Delay timer with ramp rate functions Timer Ended When ramp rate active Indicator RUN ON if ramp rate active Scrolling Text Timer Running To HOLD timer Press and quick...

Page 29: ...ating and the power is subsequently restored the timer will reset and will re run from the power on time 4 7 11 Ramp Rate with Soft Start Timer It is not recommended that the ramp rate function be used with a soft start timer Note If the temperature is already above the threshold when the timer is set to operate the timer will time out immediately 4 7 12 Time Remaining The time remaining of any Ti...

Page 30: ...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 Please consult Carbolite Gero 4 8 1 Digital Communications RS232 If the RS232 option is supplied the furn...

Page 31: ...ee contacts for operator use the contacts are taken to a panel plug on the control panel wired as indicated Key C Temperature Controller F Fuse 2A S Supply L Load Normally open relay contacts RO Relay Output 240V 2A MAX 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 operato...

Page 32: ...4 0 3216CC Controller 4 9 3216CC Navigation Diagram 32 ...

Page 33: ... off power to the controller and other parts of the control circuit To operate the controller power must be supplied to the product and the instrument switch must be on If a time switch is included in the product circuit this must be in the ON position When an over temperature condition occurs the controller cuts the power to a contactor which in turn cuts power to the heating elements Power is no...

Page 34: ... with the over temperature set at 15 C above the furnace or oven maximum working temperature Press scroll twice view the present temperature as measured by the over temperature controller Press it twice the first press shows the temperature units C 5 2 4 Over Temperature Alarm If an over temperature condition occurs the OP2 indicator flashes and an alarm message 2FSH also flashes alternating with ...

Page 35: ...top sounding when the alarm is acknowledged as given in section 5 2 Note the alarm may sound during controller start up 5 4 Navigation Diagram HL Home List Page Key Black Progress OTSP Over Temperature Setpoint Scroll Key Dashed Through to other options AL Access List For factory access to list and parameters not available to the operator 35 5 0 2132 Over Temperature ...

Page 36: ...ped an indicator on the over temperature controller flashes and the heating elements are isolated Find and correct the cause before resetting the over temperature controller according to the instructions supplied To switch off power to the heating elements use the heater switch To switch the product off use both the heater switch and the instrument switch If the product is to be left switched off ...

Page 37: ...ce elements must be switched off using the heater switch item 2 in Warning Labels when the furnace is being loaded or unloaded The work tube can become electrically conductive at high temperatures If an element has failed and collapsed onto the work tube the work tube will become live causing serious injury or death 6 4 3 Zone Control Methods There are three different control options A B C A Back ...

Page 38: ... Three independent thermocouples are connected to three controllers The three controllers are linked together and the centre zone controller communicates the desired setpoint to the end zone controllers If the centre zone controller is set to a setpoint or is running a program the end zone controllers will automatically follow For products with the CC T1 controller please refer to the separate CC ...

Page 39: ...the product at high temperature when it is not required The maximum temperature is shown on the product rating label and in section 12 0 towards the back of this manual Lightweight ceramic fibre insulation can easily be marked by accidental contact Some fine cracks may develop in the surface of the insulation due to the progressive shrinkage of the insulation materials Cracks are not usually detri...

Page 40: ...t both the heating and cooling rate 6 8 Pressure Work tubes are not able to accept high internal pressure When gas seals or similar fittings are in use the gas pressure should be restricted to a maximum of 0 2 bar 3 psi A pressure of approximately half of that should normally be sufficient to achieve the desired flow rate The operator must ensure that the exhaust path from the tube is not blocked ...

Page 41: ...than inert gases such as nitrogen 41 6 0 Operation ...

Page 42: ...ure Safety Circuit if fitted Electrical measurement Safety Switch Function split models only Set a safe temperature above ambient and open the furnace to see if the heater light goes out Safety Switch Function split models only Electrical measurement Electrical Safety external Visual check of external cables and plugs Electrical Safety internal Physically check all connections and clean ing of the...

Page 43: ...ck all seals and O rings and clamps Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase circuit Cooling Fans if fitted Check whether the cooling fans are work ing 43 7 0 Maintenance ...

Page 44: ...eck can be carried out by a general operator l On the temperature controller set a safe temperature above ambient The heater lights should illuminate l Open the door and check the heater lights They should no longer be illuminated If the heater lights remain illuminated when the door is open discontinue use and contact Carbolite Gero Service Annual check The following checks should be carried out ...

Page 45: ...es throughout the world A telephone call or email often enables a fault to be diagnosed and the necessary parts to be despatched In all correspondence please quote the serial number and model type given on the rating label of the product The serial number and model type are also given on the back of this manual when supplied with the product Carbolite Gero Service and Carbolite Gero contact inform...

Page 46: ... higher levels may be encountered during maintenance or repair Whilst there is no evidence of any long term health hazards it is strongly recommended that safety precautions are taken whenever the materials are handled Exposure to fibre dust may cause respiratory disease When handling the material always use approved respiratory protection equipment RPE eg FFP3 eye protection gloves and long sleev...

Page 47: ...able colour codings are thermocouple leg colour positive type N pink negative white Disconnect the thermocouple from its terminal block Carefully withdraw the thermocouple from the product and remove any broken bits of thermocouple Bend the new thermocouple carefully to match the shape of the original working from the terminal end Should the length differ from that of the original this is usually ...

Page 48: ...e 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 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 Remove the back panel or control box back panel to gain access to the fuses 4...

Page 49: ...The door switch es if fitted may be faulty or need adjustment The contactor relay if fitted may be faulty The heater switch if fitted may be faulty or need adjustment The SSR could be failing to switch on due to internal failure faulty logic wiring from the controller or faulty controller There are no lights glowing on the controller Check the supply fuses and any fuses in the furnace control comp...

Page 50: ...aulty The controller shows a low temperature The thermocouple may be faulty or may have been removed out of the heating chamber The thermocouple may be connected the wrong way around The controller may be faulty 2 Product heats up when the instrument switch is OFF The SSR has failed ON Check for an accidental wiring fault that could have overloaded the SSR 50 ...

Page 51: ...le 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 51 10 0 Wiring Diagrams ...

Page 52: ...10 0 Wiring Diagrams 10 2 WC 13 71 Connections below show single phase with indirect safety switches and over temperature control 52 ...

Page 53: ...ircuit board s F2 Auxiliary Circuit Fuses Fitted on board to some types of EMC filter May be omitted up to 25 Amp phase supply rating 2 Amps glass type F On board 20 mm x 5 mm Other 32 mm x 6 mm Customer Fuses Required if no supply cable fitted Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating Amps F1 EVZ 600B 1 phase 200...

Page 54: ... table To adjust the parameter refer to the Changing the Maximum Output Power of the control section of the manual All standard models covered by this manual are fitted with elements designed for use over the range of voltages 100 V 120 V and 200 V 240 V the power limit parameter is set according to the table below The power limit depends on the voltages follows Voltage 200 V 208 V 220 V 230 V 240...

Page 55: ...tubes with outside diameters of 32 mm 46 mm and 60 mm 12 1 Environment The furnaces contain electrical parts and should be stored and used in indoor conditions as follows Ambient temperature working range Temperature 5 C to 40 C Note when operating the furnace at temperatures close to the maximum and the ambient temperature is above 30 C the allowed external temperature defined in EN 61010 1 2010 ...

Page 56: ... Complete the Installation procedure see section 2 1 Step 3 After reading the controller operation instructions heat the furnace following the temperature profile given below This will need to be done manually on furnaces with basic control option or programmed into the controller if an advanced control option is fitted l Ramp the setpoint temperature 2 C minute to 100 C and dwell for 2 hours l Ra...

Page 57: ...Notes Service Record Engineer Name Date Record of Work ...

Page 58: ... us at the address below or ask your nearest stockist For preventive maintenance repair and calibration of all furnace and oven products please contact Carbolite Gero Service Telephone 44 0 1433 624242 Fax 44 0 1433 624243 Email ServiceUK carbolite gero com Carbolite Gero Ltd Parsons Lane Hope Hope Valley S33 6RB England Telephone 44 0 1433 620011 Fax 44 0 1433 621198 Email Info carbolite gero com...