VERDER CARBOLITE GERO AAF-BAL 11/17, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1100 C Ashing Furnace AAF BAL Model 17 Litres 3216CC Controller AAF BAL 11 17 3216CC Controller MEN AAF BAL 1117 006_3216CC 01 08 2019 ...

Page 2: ... 7 2 4 Electrical Connections 8 2 5 Balance and Weighing Platform 10 3 0 3216CC Controller 12 3 1 3216CC 12 3 2 PID control 12 3 3 Operation 12 3 3 1 Controller Layout 12 3 3 2 Keys 13 3 4 Quick Start Guide 13 3 4 1 Operation as a simple controller 13 3 4 2 Changing the Setpoint 13 3 4 3 Using the Controller 13 3 4 4 Understanding User Levels 14 3 5 Setting up the Controller 15 3 5 1 Setpoint Ramp...

Page 3: ...me Remaining 22 3 7 13 Alarms 23 3 8 Controller Options 23 3 8 1 Digital Communications RS232 23 3 8 2 Digital Communications RS485 24 3 8 3 Comms Address 24 3 8 4 Alarm Option 24 3 9 3216CC Navigation Diagram 25 4 0 2132 Over Temperature Controller Description if fitted 26 4 1 Description 26 4 2 Operation 26 4 2 1 Controls 26 4 2 2 Operation 27 4 2 3 Over Temperature Operation 27 4 2 4 Over Tempe...

Page 4: ... 36 7 2 Safety Warning Refractory Fibre Insulation 36 7 3 Temperature Controller Replacement 36 7 4 Solid State Relay Replacement 37 7 5 Thermocouple Replacement 37 7 6 Panel Element Replacement 37 7 7 Door Plug Replacement 39 7 8 Fuse Replacement 39 8 0 Fault Analysis 41 A Furnace Does Not Heat Up 41 B Product Overheats 42 9 0 Wiring Diagrams 43 9 1 WA U3 30 44 9 2 WA U3 31 46 10 0 Fuses and Powe...

Page 5: ...s to indicate that power is being supplied to the elements 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 may be hot DANGER Read any warning printed next to this symbol Caution Double Pole Neutral Fusing 5 1 0 Symbols and Warnings ...

Page 6: ...no Silicate Wool ASW For precautions and advice on handling this material see section 7 2 2 2 Siting and Setting Up Place the product on a level surface in a well ventilated area Site away from other sources of heat and on a non flammable surface that is resistant to accidental spillage or hot materials The surface on which the equipment is mounted should be stable and not subject to movement or v...

Page 7: ... the product are clear of any obstruction Always ensure all cooling vents and cooling fans if fitted are clear of any obstruction 2 3 Chimney The chimney is a length of tubing If it is supplied unfitted then fit it through the hole in the top of the case If the product is to be used to heat substances that emit fumes a fume extraction duct of approximately 75 mm 150 mm inlet diameter may be placed...

Page 8: ...on fuse ratings is also given towards the back of this manual When the mains cable is factory fitted internal fuses are also fitted It is essential that the operator ensures that the product is correctly fused Products with a factory fitted supply cable are designed to be wired directly to an isolator or fitted with a line plug Products without a factory fitted supply cable require a permanent con...

Page 9: ...sible or Live Live 1 phase L Brown to live to either power conductor For USA 200 240V connect L1 N Blue to neutral to the other power conductor For USA 200 240V connect L2 PE Green Yellow to earth ground to earth ground Electrical Connection Details 9 2 0 Installation ...

Page 10: ...ance as detailed in the balance manufacturer s instruction manual 5 Open the furnace door 6 One by one insert the 3 ceramic tubes through the holes in the hearth and locate them over the three corresponding placement guides on the top of the balance Note Due to the secure fit you may need to twist the tubes down the guides in order for them to make full contact with the weighing platform 7 If requ...

Page 11: ...nect the DC power lead and RS 232 plug at the rear of the balance 10 Before turning on the power supply connect the earth cable to the earthing bolt on the support plate Important Note The balance will not stabilise if the ceramic tubes touch the sides of the holes in the hearth 11 2 0 Installation ...

Page 12: ... be programmed 3 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 3 3 Operation 3 3 1 Controller Layout Key A Power Output Indicator B Alarm Indicator C Remote Indicator when configured D Page E Scroll F Down G Up H Run Indicator...

Page 13: ...t 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 to heat as quickly as possible which may not be appropriate where the product co...

Page 14: ...yed 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 down to select LEu 1 It is not necess...

Page 15: ...mperature 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 3 6 to use the setpoint ramp rate feature withou...

Page 16: ...er ID A furnace or oven 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 3 5 4 Units Press scroll until the display shows UNITS DISPLAY UNITS Use the up or down keys to...

Page 17: ...l 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 if it is cooling Not...

Page 18: ...ss scroll until the display shows TM CFG TIMER CONFIGURATION Using the up down select 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 ...

Page 19: ... OFF Display A M LOOP MODE AUTO MANUAL OFF Use the up or down to select AUTO Timer Ended Indicator RUN OFF Scrolling 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 seco...

Page 20: ...imer is set to operate with a set ramp rate and threshold the timer will not start to count down until the process temperature has reached the threshold value see example 3 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 t...

Page 21: ...e combinations of parameters is that the scrolling text will continue to indicate timer running when the timer has timed out Checking whether the timer has timed out or not can be done with the T REMN function see section 3 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 3 7 7 Delay timer with ramp rate func...

Page 22: ...rate the scrolling display will indicate timer running and the setpoint temperature not the soft start setpoint 3 7 10 Power Failure While Using Soft Start Timer If there is a power failure while the timer is operating and the power is subsequently restored the timer will reset and will re run from the power on time 3 7 11 Ramp Rate with Soft Start Timer It is not recommended that the ramp rate fu...

Page 23: ...tor should only be flashing to confirm this the controller must be viewed directly from the front 3 8 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 int...

Page 24: ... 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 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...

Page 25: ...Ease apart the two lugs at the side grip the instrument and withdraw it from its sleeve push in the replacement 3 9 3216CC Navigation Diagram 25 3 0 3216CC Controller ...

Page 26: ...strument switch which cuts 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 he...

Page 27: ... 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 4 2 4 Over Temperature Alarm If an over temperature condition occurs the OP2 indicator flashes and an alarm message 2FSH also flashes alternating with the setpoint Power to the ...

Page 28: ...erature 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 4 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 28 ...

Page 29: ...ontroller display will go blank If the product is to be left unattended isolate it from the electrical supply 5 2 General Operating Notes Heating element life is shortened by overheating Do not leave the product at high temperature when it is not required The maximum temperature is shown on the product rating label and in section 11 0 towards the back of this manual When heating large objects in p...

Page 30: ...sage may be high and the chamber is always likely to contain some air Residual oxygen of approximately 1 to 2 is to be expected 5 5 Operator Safety This product incorporates a safety switch which interrupts the heating element circuit when the furnace is opened This prevents the operator touching a live heating element and also prevents the product from heating up if the furnace is left open The o...

Page 31: ...ed See section 10 0 for details of the power limit settings DO NOT adjust the power to a level higher than the design level states this may cause a fuse to blow and could damage the heating elements The power limit may be set to a lower limit if the product is to be used at a low temperature only this may give better control stability It may be set to zero to permit demonstration of the controls w...

Page 32: ...heater light goes out Safety Switch Function Electrical measurement Over Temperature Safety Circuit if fitted Set an over temperature setpoint lower than the displayed temperature and check for an over temperature alarm as detailed in this manual Over Temperature Safety Circuit if fitted Electrical measurement Door Plug Visual inspection checking the seal and whether it is free of damage Door Plug...

Page 33: ...ection and report incor porating a test of all functions Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase circuit Hearth Visual check for fit and damage Cooling Fans if fitted Check whether the cooling fans are working 33 6 0 Maintenance ...

Page 34: ...fe 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 by a qualified electrician as specified in the Maintenance Schedule section of this m...

Page 35: ...y 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 information can be found on the back page of this manual 6 5 Recommended Spare Parts and Spare Parts Kit Carbo...

Page 36: ... 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 37: ... sheath by bending the metal tag or releasing the screw to release It is also advisable to remove the sheath and shake out any broken pieces of thermocouple Re assemble with a new thermocouple observing the colour coding ensuring that the thermocouple is not twisted as it is being inserted and that the metal tag is bent back to grip the sheath Refit the element access panel 7 6 Panel Element Repla...

Page 38: ... back insulation piece and metal piece together with the thermocouple s and sheath s As necessary shorten the element tails by clipping to length Remake all the thermocouple and element connections according to the individual plan Refit the back panel and operate the furnace for 30 minutes at 800 C without interruption to ensure complete burn off of any organic binders Some smoke may be observed d...

Page 39: ...the door cover When first heating the furnace after a replacement ensure that the ventilation is good emission of some fumes is to be expected Key A Door seen from the back A1 Door Cover A2 Fixing Screws A3 Door Plug Carrier A4 Door Link Arms B Door Plug B1 Top 7 8 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 ...

Page 40: ...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 40 ...

Page 41: ...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 42: ...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 42 ...

Page 43: ...9 0 Wiring Diagrams 43 9 0 Wiring Diagrams ...

Page 44: ...9 0 Wiring Diagrams 9 1 WA U3 30 Connections below show 3 phase N with indirect safety switches 44 ...

Page 45: ...reen Yellow G Grey P Pink Products with this wiring arrangement may be converted between the following supply voltages please refer to the table within section 10 0 for compatible phases with the product l 3 phase neutral in the range 380 220 V 415 240 V l 3 phase delta in the range 220 V 240 V l Single phase in the range 220 V 240 V l 208 V model can be converted between 208 V delta and 208 V 1 p...

Page 46: ...9 0 Wiring Diagrams 9 2 WA U3 31 Connections below show 3 phase N with safety switches and over temperature control 46 ...

Page 47: ...Cables BU Blue R Red BL Black GR Y Green Yellow G Grey P Pink Products with this wiring arrangement may be converted between the following supply voltages please refer to the table within section 10 0 for compatible phases with the product l 3 phase neutral in the range 380 220 V 415 240 V l 3 phase delta in the range 220 V 240 V l Single phase in the range 220 V 240 V l 208 V model can be convert...

Page 48: ... if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating AAF BAL 11 17 1 phase 200 208 16 A AAF BAL 11 17 1 phase 220 240 63 A AAF BAL 11 17 3 phase delta 220 240 12 A per phase AAF BAL 11 17 3 phase no Neutral 380 415 12 A per phase 10 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figur...

Page 49: ... kg H W D H W D Ashing Burn off and Coal and Coke Testing Furnace AAF BAL 11 17 1100 7 08 705 505 675 215 196 400 70 11 1 Environment The models listed in this manual contains electrical parts and should be stored and used in indoor conditions as follows Temperature 5 C 40 C Relative humidity Maximum 80 up to 31 C decreasing linearly to 50 at 40 C 49 11 0 Specifications ...

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Page 51: ...Notes Service Record Engineer Name Date Record of Work ...

Page 52: ... 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...