VERDER CARBOLITE GERO G Series, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1200 C G Range Tube Furnace GHA Model 750mm 2416 Controller GHA 12 750 2416 Controller MEN GHA120750 003_2416 09 01 2019 ...

Page 2: ...l Connections 10 2 5 Reconfiguring and Adjusting for Voltage 12 3 0 2416 Controller 13 3 1 Description 13 3 2 Operation 15 3 3 Programming 17 3 3 1 Programming Tips 17 3 3 2 Multi program model 2416P8 18 3 3 3 Holdback 18 3 3 4 Program Cycling 18 3 3 5 Running a Program 18 3 3 6 Program example 19 3 4 Controller Options 20 3 4 1 Digital Communications RS232 20 3 4 2 Digital Communications RS485 20...

Page 3: ...3 Calibration 31 6 4 After Sales Service 31 6 5 Recommended Spare Parts and Spare Parts Kit 31 7 0 Repairs and Replacements 32 7 1 Safety Warning Disconnection from Power Supply 32 7 2 Safety Warning Refractory Fibre Insulation 32 7 3 Temperature Controller Replacement 32 7 4 Solid state Relay Replacement 33 7 5 Thermocouple Replacement 33 7 6 Element Replacement 34 7 7 Fuse Replacement 35 8 0 Fau...

Page 4: ...11 0 Specifications 43 11 1 Environment 43 4 ...

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: ...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 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 f...

Page 7: ...odels the two end elements one at each end are rated at 1170 W maximum while the other centre elements are rated at 780 W All models are supplied with a pair of tube adaptors which can be made to suit any work tube size up to 170 mm outside diameter Spare or replacement adaptors can be ordered The horizontal models generally require no special setting up Observe the above paragraph on siting See s...

Page 8: ... a long pole such as a broom handle to guide it into the far end of the product For optimum temperature uniformity insulating plugs should be placed in the tube ends as shown in fig 1 With a long work tube the stem of the plug assembly should line up with the end of the tube as in fig 2 Alignment of radiation shields is similar to that of plugs If stainless steel seals with gas inlets are supplied...

Page 9: ...Fig 1 Insulating Plug standard length tube Key A Tube B Insulating Plug C Stem Fig 2 Insulating Plug long work tube 9 2 0 Installation ...

Page 10: ... plate O Ring seal underneath clamp F Tube Fig 3 Twin Clamp End Seal For assembly details refer to the separate work tube end seal manual 2 4 Electrical Connections Connection by a qualified electrician is recommended All models covered by this manual may be ordered for single phase A C supply which may be Live to Neutral non reversible Live to Neutral reversible or Live to Live 10 ...

Page 11: ... 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 remove When connecting the product to an isolating switch ensure that both conductors single phase or on all live conductors three phase and should be within reach of the ...

Page 12: ...er and conversion from 1 phase to 2 phase or 1 phase to 3 phase is not possible To check for voltage setting within the appropriate range or to change to another setting follow the instructions in section 10 0 Special Voltages The products can be specially made to suit certain special voltages such as 440 254 or 480 277 Due to unbalanced phases the furnaces cannot be made to suit 3 phase without n...

Page 13: ...e 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 being a Ramp a Step a Dw...

Page 14: ...ller Fig 1 Simple Control 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 14 ...

Page 15: ... 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 and indicators are ...

Page 16: ... list A single press 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 t...

Page 17: ...nts 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 remain at the previo...

Page 18: ...ooling Lo Holdback applies 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 ...

Page 19: ... 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 displayed and use th...

Page 20: ...d 9 pin at the computer but other alternatives are shown in parentheses Product end of cable female 25 pin 9 pin RS232 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 furn...

Page 21: ...cuit to prevent overloading on the circuit due to high voltage The instrument 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 t...

Page 22: ...3 0 2416 Controller 3 6 Navigation Diagram 22 ...

Page 23: ... 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 24: ...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 4 2 4 Over Temperature Alarm If an over temperature condition occurs the OP2 indicator flashes and an alarm message 2FSH also flashes alternati...

Page 25: ...top 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 25 4 0 2132 Over Temperature ...

Page 26: ...re 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 and unattended isolate it from the ele...

Page 27: ...ld be of low thermal mass and should have feet to reduce the contact with the tube fig 4 Key A Tube B Crucible Fig 4 Avoidance of thermal contact Do not set too high a heating or cooling rate As tubes are susceptible to thermal shock and may break Tubes which extend beyond the heated part of the furnace are more at risk A general rule for maximum heating or cooling rate is 400 internal diameter in...

Page 28: ...material are impervious Sillimanite may look similar but is porous Ensure that the correct tube material is in use before connecting and using gases other than inert gases such as nitrogen 5 7 Running at Low Temperatures The power limit may be adjusted to a low level in order to achieve better control when operating the product at a low temperature Before changing the power limit record the defaul...

Page 29: ...tted 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 cleaning of the power plate area Functio...

Page 30: ...ted Check 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 30 ...

Page 31: ...o 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 premises 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 r...

Page 32: ... 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 33: ... 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 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 careful...

Page 34: ...ut the elements through the end of the cylindrical case Check the cylindrical case and clean out as appropriate Remove any insulation sleeving from the tails of the old element and fit to the replacement element Slide in the new element s Close up the product again refitting the terminal strip and the end caps Any cut made in the insulation should close up completely if the insulation appears loos...

Page 35: ... 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 35 7 0 Repairs and Replacement...

Page 36: ... a low temperature 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 f...

Page 37: ...r 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 37 8 0 Fault Analysis ...

Page 38: ... F3 Fuses 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 38 ...

Page 39: ...9 2 WA U3 31 Connections below show 3 phase N with safety switches and over temperature control 39 9 0 Wiring Diagrams ...

Page 40: ...L2 L3 Live PE Earth 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 ...

Page 41: ... 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 GHA 12 750 1 phase 200 208 10 A GHA 1...

Page 42: ...an the one from the 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 200 V 240 V the power limit parameter is set according to the table below 200 V 208 V 220 V 230 V 240 V 380 V 400 V 415 V 440 V 480 V 100 100 89 82 75 90 ...

Page 43: ...mum operating temperature of 1200 C 1100 C continuous Model Max Temp C Max Power kW Minimum Work Tube Length mm Heated Length mm Type C Work Tube Type D Work Tube Horizontal single zone tube furnaces GHA 12 750 1200 4 6 950 750 1050 1350 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 Rel...

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Page 45: ...Notes Service Record Engineer Name Date Record of Work ...

Page 46: ... 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...