VERDER CARBOLITE GERO CFM 12/2, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1200 C Combustion Tube Furnace CFM Model 12 2 2416 Controller CFM 12 2 2416 Controller MEN CFM1202 003_2416 09 01 2019 ...

Page 2: ...Controller 10 3 1 Description 10 3 2 Operation 12 3 3 Programming 14 3 3 1 Programming Tips 14 3 3 2 Multi program model 2416P8 15 3 3 3 Holdback 15 3 3 4 Program Cycling 15 3 3 5 Running a Program 15 3 3 6 Program example 16 3 4 Controller Options 17 3 4 1 Digital Communications RS232 17 3 4 2 Digital Communications RS485 17 3 4 3 Comms Address 17 3 4 4 Alarm Option 17 3 5 Temperature Controller ...

Page 3: ...stment 28 7 0 Repairs and Replacements 29 7 1 Safety Warning Disconnection from Power Supply 29 7 2 Safety Warning Refractory Fibre Insulation 29 7 3 Temperature Controller Replacement 29 7 4 Solid State Relay Replacement 30 7 5 Thermocouple Replacement 30 7 6 Element Replacement 1200 C Models 31 7 7 Fuse Replacement 32 8 0 Fault Analysis 33 A Furnace Does Not Heat Up 33 B Product Overheats 34 9 0...

Page 4: ...11 1 Environment 39 4 ...

Page 5: ...itch 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 may be hot DANGER Read an...

Page 6: ...1 0 Symbols and Warnings Caution Double Pole Neutral Fusing 6 ...

Page 7: ...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 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 ...

Page 8: ...ce common to tube products Fit any work tube s ordered into place If a metal work tube is being used in the product ensure that it is earthed and that it is mounted so as not to touch the products ceramic tube or insulation 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 ...

Page 9: ...ired directly to an isolator or fitted with a line plug Products without a factory fitted supply cable require a permanent connection to a fused and isolated supply The product s electrical access panel should be temporarily removed and connections made to the internal terminals If the product is to be connected by line plug The plug should be within reach of the operator and should be easy to rem...

Page 10: ...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 11: ...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 11 3 0 2416 Controller ...

Page 12: ...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 13: ... 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 14: ...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 15: ...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 16: ...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 17: ...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 3 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 18: ...ent configuration and parameters available to the operator depend on the customer requirements 3 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 19: ...3 6 Navigation Diagram 19 3 0 2416 Controller ...

Page 20: ...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 21: ...perature 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...

Page 22: ...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 22 ...

Page 23: ...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 and unattended isolate it from the electrical supply...

Page 24: ...in for 75 mm i d tubes this comes to 5 C per minute The controller can be set to limit both the heating and cooling rate 5 4 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 of...

Page 25: ...d 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 25 5 0 Operation ...

Page 26: ...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 27: ...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 27 6 0 Maintenance ...

Page 28: ...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 29: ...ered 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 breaking up...

Page 30: ... the base panel or aluminium plate Replace the access panel 7 5 Thermocouple Replacement Disconnect the product from the power supply Remove terminal cover to gain access to the thermocouple connections Make a note of the thermocouple connections Thermocouple cable colour codings are thermocouple leg colour positive type R orange negative white Disconnect the thermocouple from its terminal block r...

Page 31: ...nd remove sufficient insulation to allow access to the heating element Check and replace damaged insulation Fit the new heating element ensuring that the tails are separated from the element by at least 25 mm of insulation Feed the heating element tails through the terminal blocks and tighten the clamping screws using two spanners as before Cut off excess element tails Refit the insulation and ref...

Page 32: ...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 3...

Page 33: ...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 34: ...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 34 ...

Page 35: ...ey F1 F2 F3 Fuses FIL Filter R1 1 R1 2 Relay Contactor R1 Relay C Temperature Controller TC Control Thermocouple SSR Solid State Relay SSW Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L Live PE Earth Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 35 9 0 Wiring Diagrams ...

Page 36: ...FIL Filter R1 1 R1 2 Relay Contactor R1 Relay C Temperature Controller OT Over Temperature Controller OTC Over Temperature Thermocouple TC Control Thermocouple SSR Solid State Relay SSW Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L Live PE Earth If Fitted Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 36 ...

Page 37: ...y cable fitted Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating CFM 12 2 1 phase 110 120 16 A CFM 12 2 1 phase 220 240 10 A 10 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures represent the maximum percentage of time that controlled power is supplied to the elemen...

Page 38: ...Settings User Power Setting Adjustments Date Power Comments Note If a new set of elements are fitted then return the power settings to the original value Please refer to the rating label for product specific information 38 ...

Page 39: ...200 1 0 2 X 38 35 All models are designed to accept 1 or 2 work tubes 25 mm internal diameter by 750 mm long The number of tubes is indicated by the model name 1 or 2 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 ...

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Page 41: ...Notes Service Record Engineer Name Date Record of Work ...

Page 42: ... 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...