Carbolite Gero ELF 11/14B Manual

Installation, Operation and Maintenance Instructions
1100 °C Chamber Furnace - ELF Model: 14 Litres
301 Controller
ELF 11/14B + 301 Controller
MEN-ELF1114B-01_301 (28-11-2017)

Contents
This manual is for guidance on the use of the Carbolite Gero product specified on the
front cover. This manual should be read thoroughly before unpacking and using the
furnace or oven. The model details and serial number are shown on the back of this
manual. Use the product for the purpose for which it is intended.
1.0 Symbols and Warnings 5
1.1 Switches and Lights 5
1.2 General Warnings 5
2.0 Installation 6
2.1 Unpacking and Handling 6
2.2 Siting and Setting Up 6
2.3 Chimney 6
2.4 Hearth 7
2.5 Door Vents 7
2.6 Electrical Connections 7
3.0 301 Controller 9
3.1 PID control 9
3.2 Basic Operation of the 301 Controller 9
3.2.1 Menu System 10
3.2.2 Navigation Diagram 10
3.2.3 Basic Function Guide 12
3.2.4 Home Display 12
3.2.5 Hold Mode 13
3.2.6 Checking the Temperature Setpoint from the Home Display 14
3.2.7 Changing the Temperature Setpoint 14
3.2.8 Changing the Temperature Setpoint Ramp Rate 14
3.2.9 Changing the Timer Time 15
3.3 Advanced Operation 15
3.3.1 Entering the Setup menu 15
3.3.2 Changing the Timer Type 15
3.3.3 Changing the Timer Band 16
3.3.4 Changing the Maximum Output Power 16
3.3.5 Changing the Customer Calibration Type 17
3.3.6 Calibration Password 17
3.4 Temperature Setpoint Ramp Rate 17
3.4.1 Setpoint Ramp Rate 17
3.4.2 Limitations of Setpoint Ramp Rate 17
3.5 The Timer 18
3.5.1 Starting the Timer 18
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3.5.2 Checking the Time Remaining 18
3.5.3 Pausing the Timer 18
3.5.4 Resetting the Timer 19
3.5.5 Timer Function Description 19
3.5.6 The Timer Temperature Band 20
3.5.7 Timer Function Table 21
3.6 Ramp Dwell Programming 22
3.6.1 Setting up a Ramp Dwell program 22
3.7 Maximum Output Setting 24
3.8 Customer Calibration 24
3.8.1 Factory Calibration - FAct 24
3.8.2 Single Point Calibration - C.CL1 24
3.8.3 Changing the Single Point Calibration Offset - OFSt 25
3.8.4 Dual Point Calibration - C.CL2 25
3.8.5 Changing the Calibration, Low Temperature - CAL.L 26
3.8.6 Changing the Calibration, Low Temperature Offset - OFS.L 26
3.8.7 Changing the Calibration, High Temperature - CAL.H 26
3.8.8 Changing the Calibration, High Temperature Offset - OFS.H 27
3.9 Over-Temperature Protection 28
3.9.1 Over-Temperature (O/T) home display 28
3.9.2 Changing the Over-Temperature Limit 29
3.9.3 Checking the Over-Temperature Sensor Temperature 29
3.9.4 Over-Temperature Protection Calibration 30
3.9.5 Over-Temperature Activation 30
3.9.6 Resetting Over-Temperature Activation 31
3.10 RS232 Communication Option 32
3.11 Temperature Controller Replacement 32
3.12 Glossary of Terms 33
3.13 Controller Fault 33
4.0 Operation 34
4.1 Operating Cycle 34
4.2 General Operating Notes 34
4.3 Use of Probes 35
4.4 Atmospheres 35
4.5 Operator Safety 35
4.6 Power Adjustment 35
5.0 Maintenance 37
5.1 General Maintenance 37
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5.1.1 Cleaning 37
5.1.2 Safety Switch 37
5.2 Calibration 37
5.3 After-Sales Service 37
5.4 Recommended Spare Parts and Spare Parts Kit 38
6.0 Repairs and Replacements 39
6.1 Safety Warning - Disconnection from Power Supply 39
6.2 Safety Warning - Refractory Fibre Insulation 39
6.3 Temperature Controller Replacement 39
6.4 Solid-state Relay Replacement 40
6.5 Thermocouple Replacement 40
6.6 Element Replacement 41
6.7 Fuse Replacement 42
6.8 Door Plug Replacement 42
6.9 Air Inlet Adjustment 43
7.0 Fault Analysis 44
A. Furnace Does Not Heat Up 44
B. Product Overheats 45
8.0 Wiring Diagrams 46
8.1 WA-11-30 46
8.2 WA-11-31 47
9.0 Fuses and Power Settings 48
9.1 Fuses 48
9.2 Power Limit 48
10.0 Specifications 49
10.1 Environment 49
4

1.0 Symbols and Warnings
1.1 Switches and Lights
Instrument switch: when the instrument switch is operated the
temperature control circuit is energised.
Heat light: the adjacent light glows or flashes 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

2.0 Installation
2.0 Installation
2.1 Unpacking and Handling
When unpacking and handling the product, always lift it by its base. Do not use the door
or any other projecting cover or component to support the equipment when moving it.
Use two or more people to carry the product where possible.
Carefully remove any packing material from inside and around the product before use.
Avoid damaging the surrounding insulation when removing packing materials.
NOTE: This product contains Refractory Ceramic Fibre (also known as
Alumino Silicate Wool - ASW). For precautions and advice on handling
this material see section 6.2.
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 vibrations. The height of the mounting surface is important to avoid
operator strain when loading and unloading samples.
Ensure that there is free space around the sides and back of the product. Clear space is
required above the product to dissipate heat.
Depending on the application of the product, it may be appropriate to position it under
an extraction hood. Ensure the extraction hood is switched on during use.
Ensure that the product is placed in such a way that it can be quickly switched off or
disconnected 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.
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 directly above the
chimney outlet.
Do not make a sealed connection to the product chimney as this causes excessive
airflow through the chamber and results in poor temperature uniformity.
6

Key
A Duct (75mm-150mm diameter)
B Ambient air is drawn into duct
C Chimney
D 25mm vertical gap between chimney and duct
2.4 Hearth
The chamber floor (hearth) is supplied with a ceramic tile. This may already be in
position in the chamber. If it is packed separately, unwrap it and place it carefully on
the chamber floor.
2.5 Door Vents
There is a plate fixed to the inner door panel (door plug carrier), accessible by removing
the door insulation piece. This can be positioned to open up holes in the inner door, to
allow an increased air flow in the chamber. Decide on the required position and fix the
plate accordingly (see section 6.9 ).
2.6 Electrical Connections
Connection by a qualified electrician is recommended.
The product covered by this manual normally requires a single phase A.C. supply, which
may be Live to Neutral non-reversible, Live to Neutral reversible or Live to Live. Some
models may be ordered for 3-phase use, which may be star or delta.
Check the product rating label before connection. The supply voltage should agree with
the voltage on the label and the supply capacity should be sufficient for the current on
the label.
The 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
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2.0 Installation

2.0 Installation
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 connection to a
fused and isolated supply should be made to the internal terminals after temporary
removal of the product's electrical access panel.
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
operator.
The supply MUST incorporate an earth (ground).
Supply Terminal Label Cable Colour
Supply Types
Live - Neutral Reversible or Live-
Live
1-phase L Brown to live to either power
conductor
N Blue to neutral to the other power
conductor
PE Green/ Yellow to earth
(ground) to earth (ground)
Electrical Connection Details:
3-phase L1 Black to phase 1
L2 Black to phase 2
L3 Black to phase 3
N Light Blue to neutral (except delta)
PE Green/ Yellow to earth (ground)
DO NOT connect a product ordered for three phase use to a single
phase supply or to the wrong type of three phase supply.
8

3.0 301 Controller
Due to the complex nature of the furnace or oven control the use of technical terms
throughout this manual is unavoidable. Explanations of these terms can be found in
the"Glossary of Terms".
3.1 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.
3.2 Basic Operation of the 301 Controller
Key Description
A Display
BOver-Temperature
Key (if fitted)
The Over-Temperature key is used to access the over-
temperature menu. Note: Over-Temperature is an option.
CPage Key The Page key is used to scroll through the parameters and
switch between menus.
DTimer Key The Timer key is used to start, view, pause and reset the
timer.
EArrow Keys The Arrow keys are used to adjust the value of the selected
parameter and pause the output power.
FOver-Temperature
Indicator (if fitted)
The Over-Temperature indicator shows green in normal use.
It flashes red when over-temperature is triggered and is
constantly red when over-temperature is reset and waiting
for the temperature to drop.
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3.0 301 Controller

3.0 301 Controller
GTimer Indicator The Timer indicator shows when the timer is active.
HOutput Indicator The Output indicator shows when the controller is switching
on the heating elements.
3.2.1 Menu System
The 301 Controller is divided into two menus; the Home Menu and the Setup Menu. The
Home Menu contains all the basic operating controls: setpoint, setpoint ramp rate and
timer time. The Setup menu contains all the set up features: timer type, timer band,
output power and customer calibration. The features available vary depending on
operator input or product specification.
3.2.2 Navigation Diagram
The following diagram details how to navigate to the various menu options within the
301 Controller. At each option, values can be set using the arrow keys.
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HM SM OTHM OTSM
Home
Menu
Setup
Menu
Over-Tem-
perature
Home Menu
Over-
Temperature
Setup Menu
Page
Key
Press
Page Key
multiple
times
Arrow
Key
Press
Arrow Key
multiple
times
Over-Tem-
perature Key
Hold for
1.5
seconds
Keep
Held
Black =
Progress
White =
Return
Please note that the Over-Temperature Menu is only available when the Over-
Temperature Protection option is fitted.
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3.0 301 Controller

3.0 301 Controller
3.2.3 Basic Function Guide
HOLd Used to pause the current program and set new parameters.
SP"C Used to set the desired temperature (setpoint) of the product
(°C).
SPrr Used to set the heating rate of the product, e.g. increase by
5°C per minute.
t1,t2,t3,t4,t5 Indicates the timer type in use. See section 3.5 for more
details.
t.typ Used to set the timer type.
t.bnd Available when t1 or t4 is in use. Allows the timer to start the
countdown before the desired setpoint is reached.
rSt Used to reset the timer.
OPHi Used to set the maximum output power.
CL.St Used to set the customer calibration type.
FAct Used to select the factory calibration settings.
PASS Flashes when a password is required to access further
options.
C.CL1 Select to access the single point calibration option.
C.CL2 Select to access the dual point calibration options.
OFSt Used to set the single point calibration offset temperature
(°C).
CAL.L Used to set the low temperature point(°C) for dual point
calibration.
CAL.H Used to set the high temperature point(°C) for dual point
calibration.
OFS.L Used to set the offset value for the low temperature point
(°C) for dual point calibration.
OFS.H Used to set the offset value for the high temperature point
(°C) for dual point calibration.
Ot Used to set the Over-Temperature limit (°C).
Ott Displayed when the Over-Temperature protection has been
activated.
PV Displayed before the current temperature when checking the
Over-Temperature sensor temperature.
3.2.4 Home Display
The Home Display is the first display you see when the controller is switched on, it shows
the actual temperature of the product. When entering the menus, the controller will
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automatically return to the Home Display if no keys are pressed for 30 seconds.
Finding the Home Display
lTo find the Home Display from the Home Menu, press the
Page key until the current temperature is shown on the
display.
lTo find the Home Display from the Setup Menu, press
and hold the Page key for 1.5 seconds.
3.2.5 Hold Mode
'Hold' mode turns the output off; this allows parameters to be set without the controller
instantly trying to control at the new settings.
When the output indicator is off, the Home Display flashes between the current
temperature and HOLd.
To enter 'Hold' mode:
lStart at the Home Display.
lPress and hold the up and down Arrow keys together for
1.5 seconds
lThe display will flash HOLd to show that 'Hold' mode has
been entered.
To exit 'Hold' mode:
lStart at the Home Display.
lPress and hold the up and down Arrow keys together for
1.5 seconds OR start the timer (See "The Timer ").
lNote: The 'Hold' mode function is disabled when the
timer function is operating.
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3.0 301 Controller

3.0 301 Controller
3.2.6 Checking the Temperature Setpoint from the Home Display
lStart at the Home Display.
lPress either the up or down Arrow key.
lThe setpoint will show on the display for 3 seconds before
returning to the home display.
3.2.7 Changing the Temperature Setpoint
lStart at the Home Display.
lRepeatedly press the Page key to scroll through the
Home Menu until SP"C is displayed.
lUse the up and down Arrow keys to alter the value.
lA single press of the up or down Arrow key shows the cur-
rent setting.
lTo alter this, either keep the key pressed or press it
again. The value will then be stored without any further
input.
3.2.8 Changing the Temperature Setpoint Ramp Rate
lStart at the Home Display.
lRepeatedly press the Page key to scroll through home
menu until SPrr is displayed.
lUse the up and down Arrow keys to turn off or alter the
value.
lA single press of either the up or down Arrow key shows
the current setting. To alter, either keep pressed or press
again. The value will then be stored without any further
input.
lSee section 3.4 for more information.
This will cause the product to heat as quickly as possible which may not be appropriate
where the product contains sensitive ceramic components. For products with ceramic
components, e.g. a tube furnaces fitted with a long ceramic work tube, use the ramp
rate feature set with a low heating rate such as 5°C per minute (300°C per hour), to
prevent damage.
14

3.2.9 Changing the Timer Time
lStart at the Home Display.
lRepeatedly press the Page key to scroll through the
Home Menu until t1,t2,t3,t4 or t5 shows on the dis-
play.
lUse the up and down Arrow keys to turn off, or alter the
value.
lA single press of either the up or down Arrow key shows
the current setting (Hr:Min).
lTo alter this, either keep pressed or press again.The
value will then be stored without any further input.
lSee 3.5 for more information.
3.3 Advanced Operation
3.3.1 Entering the Setup menu
lStart at the Home Display.
lPress and hold the Page key for 1.5 seconds
lThe display will change to the first parameter in the
Setup Menu.
3.3.2 Changing the Timer Type
lStart at the Home Display.
lHold the Page key for 1.5 seconds to enter the set-up
menu.
lOnce entered, repeatedly press the Page key until
t.typis displayed.
lUse the up and down Arrow keys to alter the value.
To alter this, either keep pressed or press again. The value will then be stored
without any further input. A single press of the up or down key shows the current
setting.
Note: This function is disabled when the timer is operating. see section 3.5 for more
information on the timer types and functions.
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3.0 301 Controller

3.0 301 Controller
3.3.3 Changing the Timer Band
lStart at the Home Display.
lHold the Page key for 1.5 seconds to enter the Setup
Menu.
lOnce entered, repeatedly press the Page key until t.bnd
is displayed.
lUse the up and down Arrow keys to turn off or alter the
value.
A single press of the up or down key shows the current setting. To alter this, either
keep pressed or press again. The value will then be stored without any further input.
see section 3.5 for more information .
Note: This is only available when timer type 1 or 4 is selected.
3.3.4 Changing the Maximum Output Power
Note: Output Power is a product specific setting and will not appear on all furnaces
and ovens.
lStart at the Home Display.
lHold the Page key for 1.5 seconds to enter the set-up menu.
lOnce entered, repeatedly press the Page key until OP.Hi is dis-
played.
lUse the up and down Arrow keys to alter the value.
A single press shows the current setting. To alter this, either keep pressed or press
again. The value will then be stored without any further input.
Caution: Do not increase the power limit value to a value above the
design level for the oven or furnace model, or to a value above that
correctly calculated for silicon carbide elements. The heating elements
could burn out, or other damage could be caused. Refer to the Fuses
and Power Settings section of your product manual (section 9.0 for
more information on power limits.
16

3.3.5 Changing the Customer Calibration Type
lStart at the Home Display.
lHold page key for 1.5 seconds to enter the set-up menu.
lOnce entered, repeatedly press page key until CL.St is
displayed.
lUse the up and down Arrow keys to display the current
calibration type.
lUse the up and down Arrow keys to display the password
screen.
lUse the up and down Arrow keys to enter the Calibration
Password (see 3.3.6
lPress the page key to confirm password. The value will
then be stored without any further input.
lSee section 3.8 for more information.
3.3.6 Calibration Password
Once entered the calibration password remains active for 30 seconds after leaving the
set up menu to allow time to revisit if necessary.
The Calibration Password for this instrument is: 525
3.4 Temperature Setpoint Ramp Rate
3.4.1 Setpoint Ramp Rate
The SPrr controls the rate at which the temperature in a furnace or oven changes per
minute. When SPrr has a numeric value, e.g. 5 °C/ min, the product will attempt to
heat or cool at that rate. When the value of Sprr = off, the product will heat or cool as
quickly as possible.
Setpoint ramp rate is useful when materials susceptible to thermal shock are being
heated.
3.4.2 Limitations of Setpoint Ramp Rate
The setpoint ramp rate should not be set higher than the maximum heat up or cool
down rate of the furnace or oven.
The setpoint ramp rate only resets its start position when the ramp rate is changed or
the controller is taken out of 'Hold' mode.
Changes in the temperature setpoint do not affect the ramp rate.
If the temperature is set below the current temperature of the furnace or oven then
after a period of time adjusted to a temperature higher than the current temperature
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3.0 301 Controller

3.0 301 Controller
without adjustment of the ramp rate, the controller can become out of step and appear
to switch off.
Putting the controller into, then out of 'Hold' mode will reset the ramp rate and force the
controller back into control.
3.5 The Timer
3.5.1 Starting the Timer
lStart at the Home Display.
lPress the Timer key once to start the timer.
If the 301 Controller is in 'Hold' mode, pressing the Timer key will automatically exit
'Hold' mode and the controller will start to operate.
3.5.2 Checking the Time Remaining
lStart at the Home Display
lPress the Timer key once to check the time remaining.
lThe display will flash t- 3 times.
lIt will return to the Home Display automatically.
3.5.3 Pausing the Timer
lStart at the Home Display
lPress and hold the Timer key for 1.5 seconds; the dis-
play alternately shows t1 and the current temperature.
lTo resume the timer, press the Timer key once.
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3.5.4 Resetting the Timer
lWhen the timer count has ended, or the timer is
paused, start at the Home Display.
lPress and hold the Timer key for 1.5 seconds.
lrSt is displayed to indicate timer reset.
3.5.5 Timer Function Description
The 301 Controller has an in-built timer, which can be set to one of five types:
Timer Type t1
On pressing the Timer key; 'Timer Type 1' waits for the setpoint to be reached, then
begins the countdown. On completion of the countdown, the product switches off power
to the elements ('End' flashes on the display).
Timer Type t2
On pressing the Timer key; 'Timer Type 2' starts the countdown immediately. On
completion of the countdown, the product switches off power to the elements ('End'
flashes on the display).
Timer Type t3
On pressing the Timer key; 'Timer Type 3' immediately switches the product heating off
and starts to countdown. On completion of the countdown, the furnace or oven switches
on the power to the elements. This can be used to delay the start of heating.
Timer Type t4
On pressing the Timer key; 'Timer Type 4' waits for the setpoint to be reached, then
begins the countdown. On completion of the countdown, the product continues to
control as normal ('End' flashes on the display).
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3.0 301 Controller

3.0 301 Controller
Timer Type t5
On pressing the Timer key; 'Timer Type 5' starts the countdown immediately. On
completion of the countdown, the product continues to control as normal ('End' flashes
on the display).
3.5.6 The Timer Temperature Band
Timer type t1 or t4 starts the countdown when the setpoint temperature is reached. It
is possible to set the timer running before the setpoint is reached by adjustment of the
timer temperature band 't.bnd', e.g. 't.bnd' set to a value of 3 will result in the timer
starting to countdown 3°C before the temperature setpoint is reached. This is useful
when furnaces or ovens that take a long time to reach setpoint, are at a sufficiently high
temperature for a specific customer process to occur.
20