VERDER CARBOLITE GERO STF 16/180, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1600 C Tube Furnace STF Model 180mm 2416 Controller STF 16 180 2416 Controller MEN STF16180 03_2416 10 01 2019 ...

Page 2: ...ting Elements 11 2 5 Electrical Connections 11 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 3 4 3 Comms Addr...

Page 3: ...ed Spare Parts and Spare Parts Kit 31 6 6 Power Adjustment 31 6 7 Element Ageing 32 7 0 Repairs and Replacements 33 7 1 Safety Warning Disconnection from Power Supply 33 7 2 Safety Warning Refractory Fibre Insulation 33 7 3 Temperature Controller Replacement 33 7 4 Solid State Relay Replacement 34 7 5 Thermocouple Replacement 34 7 6 Element Fitting and Replacement 35 7 7 Fuse Replacement 36 8 0 Fa...

Page 4: ...User Power Setting Adjustments 42 11 0 Specifications 43 11 1 Environment 43 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: ...r of any obstruction If the product is supplied with a work tube then the holes at the end of the product chamber should be supplied at the correct size Carefully line up the tube and ease it through the chamber For a tube of customer supply ensure that there is approximately 1 mm free play at each end if the tube is too tight it may crack when heated Increase the diameter of the hole by rotating ...

Page 9: ...End guard E Stem Fig 2 Insulating End Plug Fit any accessories supplied For optimum temperature uniformity ceramic insulation plugs or radiation shields should be placed in the tube ends as shown in fig 2 The ends of the insulation plugs or radiation shields should not protrude outside of the work tube NOTE Insulation plugs or Radiation shields are strongly recommended for this product Contact Car...

Page 10: ...itted as shown in fig 3 the stem of any insulating plug should touch the end plate When stainless steel end seals are fitted in the vertical mode a hook and eye on the end of the plate holds the upper insulating plug or radiation shield assembly If heavy fittings are to be clamped to the end of an extended work tube they can increase the bending stress at the centre of the tube Support the fitting...

Page 11: ... supply should be fused at the next size equal to or higher than the current on the label A table of the most common 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 directl...

Page 12: ...arth ground to earth ground Electrical Connection Details 2 or 3 phase L1 Black to phase 1 L2 Black to phase 2 L3 Black to phase 3 except 2 phase N Light Blue to neutral except delta PE Green Yellow to earth ground Technical Notes This model has an electronically controlled power limit Do not attempt to calculate the Amps from the Wattage High break capacity fuses should be used Avoid fast blow fu...

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: ...ssurisation 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 28 ...

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: ...libration 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 rating label of the product The serial number and model type are a...

Page 32: ...settings and the date of the adjustment in section 10 0 Increase the power limit in steps of 5 until the product regains its original performance If the power limit is set to 100 a new set of heating elements is required Please note it is not possible to use the cold resistance of the element as a measure of ageing as the cold resistance is not an accurate indicator of hot resistance Hot resistanc...

Page 33: ...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 34: ... 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 and withdraw the thermocouple from its sheath by bending the metal tag or releasing the screw to release...

Page 35: ...an be damaged by contamination handle them with care and keep them clean Replacements make a note of the actual braid and cable connections to the elements For rod elements disconnect the clips lift off the braids and carefully withdraw each element Refer to the image below Carefully insert the new elements into the product Ensure that the rod elements are placed centrally the same length should b...

Page 36: ...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 37: ...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 38: ...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 38 ...

Page 39: ...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 39 9 0 Wiring Diagrams ...

Page 40: ...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 40 ...

Page 41: ... type F 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 STF 16 180 1 phase 200 240 V 25 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 p...

Page 42: ...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 42 ...

Page 43: ...by silicon carbide elements STF 16 180 1600 2 5 60 600 900 180 29 Note Weights are approximate for horizontal models and do not include fittings or vertical stands 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 43 ...

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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...