VERDER CARBOLITE GERO ABF 8/28, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 800 C Afterburner Ashing Furnace ABA Model 28 Litres 2416 Controller ABF 8 28 2416 Controller MEN ABF0828 002_2416 08 10 2018 ...

Page 2: ...tems List 6 2 1 Parts Supplied 6 2 2 Tools Required 6 3 0 Installation 7 3 1 Unpacking Handling 7 3 2 Siting and Setting Up 7 3 3 Fitting the Chimney 8 3 4 Ducting 9 3 5 Electrical Connections 10 4 0 2416 Controller 12 4 1 Description 12 4 2 Operation 14 4 3 Programming 16 4 3 1 Programming Tips 16 4 3 2 Multi program model 2416P8 17 4 3 3 Holdback 17 4 3 4 Program Cycling 17 4 3 5 Running a Progr...

Page 3: ...arm 29 5 3 7 Program Example 29 5 4 Altering Power Limit 29 5 5 Audible Alarm 32 5 6 Temperature Controller Replacement 32 5 7 Navigation Diagram 33 6 0 2132 Over Temperature Controller Description if fitted 35 6 1 Description 35 6 2 Operation 35 6 2 1 Controls 35 6 2 2 Operation 36 6 2 3 Over Temperature Operation 36 6 2 4 Over Temperature Alarm 36 6 2 5 Resetting the Over Temperature Alarm 36 6 ...

Page 4: ...y Warning Refractory Fibre Insulation 45 9 3 Solid State Relay Replacement 45 9 4 Thermocouple Replacement 46 9 5 Element Replacement 46 9 6 Door Plug Replacement 46 10 0 Fault Analysis 47 A Furnace Does Not Heat Up 47 B Product Overheats 48 C Furnace Slow to Heat Up 48 D Chimney Emits Smoke 49 11 0 Wiring Diagrams 50 11 1 00348 1 5003 D 50 12 0 Fuses and Power Settings 51 12 1 Fuses 51 12 2 Custo...

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: ...taking any work involving exposure to the internal insulation material The operator should disconnect the equipment from the electrical supply before removing panels to access the electrical connections and control equipment 2 0 Supplied Items List 2 1 Parts Supplied The following items should be present These should all be checked and identified as soon as possible after receipt of the equipment ...

Page 7: ...y Ceramic Fibre also known as Alumino Silicate Wool ASW For precautions and advice on handling this material see section 9 2 3 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 stab...

Page 8: ...onnected from the electrical supply 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 3 3 Fitting the Chimney l Remove the chimney panel see Fig 10 l Fasten the chimney to the top of the product using the...

Page 9: ...1 metre above the level of the building Rules for ducting l Ducting diameter must be 76 mm or more l Ducting must be 76 mm where it connects to the chimney l Ducting length must not exceed 3 metre for 76 mm diameter for longer lengths con sult a ducting engineer l Flexible ducting if used must be suitable for exhaust gas extraction l If an extraction fan is fitted an extraction hood is required wi...

Page 10: ...which the product is configured If there is a difference between the actual supply and the rating label please call Carbolite Gero Either wire directly to an isolator or fit with a line plug An isolating switch should operate on all live conductors three phase it should be within reach of the operator A line plug should be easily removable and should be within reach of the operator The electrical ...

Page 11: ...Fig 14 Schematic for Mains Electrical Connections 11 3 0 Installation ...

Page 12: ...ture controller where on setting the required tem perature the controller immediately attempts to reach and maintain it Fig 1 indic ates the type of temperature response when used in this way l By using one program segment the control can be extended to include ramp to set point Fig 2 shows the effect l Alternatively the 2416 Controller may be used as an 8 segment programmer with each segment bein...

Page 13: ...ntrol Fig 2 Control with Ramp to Setpoint Seg 1 Ramp Sep 2 End Dwell Fig 3 A Program Key T1 Temperature T2 Time SP Setpoint AT Actual Temperature WSP Working Setpoint R Ramp D Dwell S Step E End 13 4 0 2416 Controller ...

Page 14: ...nace or oven circuit this must be in an ON position 2416CG Operation When switched on the controller lights up goes through a short test routine and then displays the measured temperature and setpoint Depending on its state when it was last switched off it may start to control to the current setpoint of program The output light glows or flashes to indicate that the control is occurring The buttons...

Page 15: ... displays the temperature units further presses reveal the parameters in the current list Some parameters are display only others may be altered by the operator Page Scroll Press together to cause an immediate return to the Home List Run Hold Indicate the current mode Run Hold or Reset Reset both lights off Run flashes at the end of a program Hold flashes during holdback when the program is paused...

Page 16: ...ss all program segments are used Segments after End are ignored Segment Type Parameter Function RmP r TGt rATE The target setpoint for this segment The ramp rate rate of temperature change in minute RmP t TGt dur The target setpoint for this segment The duration of the segment The controller calculates the rate of temperature rise necessary to achieve this duration Dwel dur The time in minutes to ...

Page 17: ...pplies to heating only Hi Holdback applies to cooling only Off Holdback is off Set Hb V to the value in C beyond which holdback is to operate Type BAnd and a value of 10 C is often a suitable combination if holdback is required In this case if the actual temperature deviates outside 10 C from the working setpoint the holdback lamp of the front of the controller flashes and the program is held up u...

Page 18: ...scroll until tYPE is displayed and use the arrow key to select dwEl 9 Press scroll until dur is displayed and use the arrow key to select 60 0 10 Press scroll until SEG n is displayed and use the arrow key to select 3 11 Press scroll until tYPE is displayed and use the arrow key to select rmP t 12 Press scroll until tGt is displayed and use the arrow key to select 400 13 Press scroll until dur is ...

Page 19: ...S232 Cable product to PC Computer end of cable 9 pin 25 pin male Rx 2 3 _________________ 3 2 Tx Tx 3 2 _________________ 2 3 Rx Com 7 5 _________________ 5 7 Com 7 8 4 5 Link together 1 4 6 6 8 20 Link together 4 4 2 Digital Communications RS485 If an RS485 option is supplied the furnace is fitted with two D sockets Connection between products is by straight cable as follows Product end of cable ...

Page 20: ...ent configuration and parameters available to the operator depend on the customer requirements 4 5 Temperature Controller Replacement Before handling the controller wear an anti static wrist strap or otherwise avoid any possibility of damage to the unit by static electricity Refer to the detailed instructions supplied with the replacement controller Ease apart the two lugs at the side grip the ins...

Page 21: ...4 6 Navigation Diagram 21 4 0 2416 Controller ...

Page 22: ...th the timer for example to give an audible alarm at the end of the timing period 5 2 2132 Controller Operation 5 2 1 Controls Most Carbolite Gero products are fitted with an instrument 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...

Page 23: ...A single press of the scroll key in the Home list displays the temperature units further presses reveal the parameters in the current list indicated in the navigation diagram To return to the Home list at any time press page and scroll together or wait for 45 seconds The down and up keys are used to alter the setpoint or other parameter values 5 2 3 Basic Operation Normally no operator action is r...

Page 24: ...2 6 Altering the Ramp Rate It is only possible to limit the rate of heating by setting a ramp rate if the timer feature is not in use To enable direct setting of the ramp rate first ensure that the StAt parameter and dwEll parameter are both set to OFF see sections 5 3 1 and 5 3 2 Press scroll until SPrr setpoint ramp rate is displayed Use down or up to display and adjust the value The ramp rate s...

Page 25: ...n be used as a process timer allowing timed heating or timed delay according to the options in the table There are 5 timer modes but 2 of them are affected by whether the setpoint ramp rate feature is being used making 7 entries in the table The table also shows the status of the timer light on the controller A visual impression of the different modes is given in fig 3 25 5 0 Afterburner 2132 Cont...

Page 26: ... Off from the end of the timing period mode 3 with SPrr active Dwell from working setpoint and switch off The timer starts timing when the working setpoint is within 1 C of the setpoint At the end of the timing period control switches off i e goes into Manual to allow cooling and End flashes on the display On during the timing period Off from the end of the timing period mode 4 with SPrr off Time ...

Page 27: ... run Note that the tmr display shows 0 zero during the last minute of timing and also shows 0 when the time has expired The timer light indicates whether timing is still in progress Method 2 Scroll to dwEll and use or to set the timing duration The advantage of method 2 is that dwEll need only be set once if repeated use of the same time period is required Scroll to StAt and use or to set the para...

Page 28: ...Temperature Modes 1 2 3 Modes 1 2 4 Modes 3 4 with setpoint ramp rate 5 Modes 3 4 with setpoint ramp rate off 6 Reaching temperature and continuing temperature Mode 5 7 Continuing at temperature modes 2 4 or cooling down modes 1 3 5 3 4 Stopping the Timer To stop the timer at any time while it is operating change the StAt User Calibration parameter to OFF This is the same as reducing tmr to zero T...

Page 29: ... then to allow to cool down This example uses timing mode 1 as on the first row of the timer table but also includes the use of ramp rate To create this program 1 Start with display at home use arrow keys to alter the setpoint to 500 2 Press scroll until sp rr shows use arrow key to set value to 10 if you do not want to limit the ramp rate ignore this step or set the value to OFF 3 Press scroll un...

Page 30: ...eating elements could burn out or other damage could be caused Control at Low Temperatures If a product is to be used at temperatures much lower than its design maximum control stability can often be improved by reducing the power limit Remember to make a record of the original setting before altering the power limit Example It is desired to operate a 1200 C furnace at 300 C The normal control set...

Page 31: ...of the controller or of the complete system remember to reset the controller to factory calibration values by setting the CAL P parameter to FACt To enter a user calibration scroll to each of the following parameters in turn and set the desired values Pnt L low temperature for which an offset is to be entered OFS L offset value for the low temperature Pnt H high temperature for which an offset is ...

Page 32: ...ed as given in section 5 3 6 It is not feasible to cover all possible alarm features which may be included by customer special order within this manual 5 6 Temperature Controller Replacement Before handling the controller wear an anti static wrist strap or otherwise avoid any possibility of damage to the unit by static electricity Refer to the detailed instructions supplied with the replacement co...

Page 33: ...5 7 Navigation Diagram 33 5 0 Afterburner 2132 Controller ...

Page 34: ...r read only 3 Present only if SPrr in use 4 Manual Auto mAn off Auto on 5 Setpoint ramp rate OFF or value 6 Timer mode 7 Time remaining 8 Dwell time for timer 9 Timer status run or OFF 10 Enter password 11 If User Calibration 12 User 2 Point Calibration 13 Power limit setting if present 14 For factory acess to lists and parameters not available to the operator 34 ...

Page 35: ... 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 36: ...supplied 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 6 2 4 Over Temperature Alarm If an over temperature condition occurs the OP2 indicator flashes and an alarm message 2FSH also flashes alternati...

Page 37: ...top sounding when the alarm is acknowledged as given in section 6 2 Note the alarm may sound during controller start up 6 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 37 6 0 2132 Over Temperature ...

Page 38: ...ielding the thermocouple from the heating elements The thermocouple is intended to sense the temperature near the heating elements However if a large object is placed in the chamber it may record the average temperature of the object and the elements this can lead to overheating of the elements Allow large objects to gain heat at a lower temperature and then reset the controller to a temperature c...

Page 39: ...rotective equipment or wait until the appliance cools down to ambient temperature Before removing a hot object from the product make sure there is a safe place to put it down If necessary use tongs face masks and heat resistant gloves Heat resistant clothing and face protection can guard against the effects of radiated heat when the furnace is open Do not open the product door during an ashing pro...

Page 40: ...7 0 Operation Photo 3 5 40 ...

Page 41: ...ctrical 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 Replacement where necessary Chimney Extraction ...

Page 42: ...t 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 42 ...

Page 43: ...to remove the motor impeller assembly from the back of the plenum chamber to give good access for cleaning Fig 75 Access to the Plenum Chamber Fig 76 Plenum Chamber Access Panel 8 4 Calibration After prolonged use the controller and or thermocouple may require recalibration This is important for processes that require accurate temperature readings or for those that use the product close to its max...

Page 44: ...er 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 8 6 Recommended Spare Parts and Spare Parts Kit Carbolite Gero can supply individual spare parts or a kit of the items most likely to be required Ordering a kit in advance can save time in the event of ...

Page 45: ... 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 sleeved clothing Avoid bre...

Page 46: ...re Thermocouple leg Colour positive type K green negative white Disconnect the thermocouple from its terminal block and withdraw the thermocouple from its 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 thermoc...

Page 47: ...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 48: ...ve 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 C Furnace Slow to Heat Up 1 One of the Heat lights does not light up A fuse may have blown Check the Supply fuses 2 The heat l...

Page 49: ...high enough Set the secondary controller temperature to 900 C The after burner elements or control may have failed Investigate or contact Carbolite Gero A fuse may have blown Check the supply fuses A Load containing too much carbon has been loaded Reduce the size of the load set a much slower heating rate see temperature control instructions 49 10 0 Fault Analysis ...

Page 50: ...11 0 Wiring Diagrams 11 0 Wiring Diagrams 11 1 00348 1 5003 D A full size wiring diagram is available on request Please contact Carbolite Gero Service 50 ...

Page 51: ...g should be as follows Phases Volts Supply Fuse Rating 3 phase with neutral 380 220 V to 415 240 V 16 A per phase 12 3 Power Settings The furnace control system incorporates electronic power control including a power limit parameter that is used to reduce the effective voltage to 208 V or 104 V the values of the power limit for different voltages are as follows ABF 8 28 Voltage 200 V 208 V 220 V 3...

Page 52: ...m Height with Chimney 1160 mm Width 600 mm Depth length 750 mm Optional Stand 600 mm high Weight 120 kg approximately Power Rating 8000 Watts Maximum Temperature 800 C 13 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...

Page 53: ...Notes Service Record Engineer Name Date Record of Work ...

Page 54: ... 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...