VERDER CARBOLITE GERO 3216 Series Manual

Installation, Operation and Maintenance Instructions
Controller Manual
3216 Controller
3216 Controller
MEN-3216_CTRL (07-10-2021)

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 3216 Controller 4
1.1 PID control 4
1.2 3216P1 4
1.3 3216P5 4
1.4 Operation 4
1.4.1 Controller Layout 4
1.4.2 Keys 5
1.5 Quick Start Guide 5
1.5.1 Operation as a simple controller 5
1.5.2 Changing the Setpoint 5
1.5.3 Using the Controller 5
1.5.4 Understanding User Levels 6
1.6 Setting up the Controller 7
1.6.1 Maximum Output Power 7
1.6.2 Customer ID 7
1.6.3 Units 7
1.6.4 Language 7
1.6.5 Scrolling Text 7
1.6.6 Customer Calibration 8
1.6.7 Holdback 9
1.7 Programming 10
1.7.1 Creating a Program 10
1.7.2 Program Number (3216P5 Only) 10
1.7.3 Ramp Units 10
1.7.4 Dwell Units 10
1.7.5 Holdback 10
1.7.6 Ramp Rate 10
1.7.7 Target Setpoint 10
1.7.8 Dwell Time 10
1.7.9 Running a Program 11
1.7.10 Program Status 11
1.7.11 Process Value 11
1.7.12 PSP, Segment Type and Number 11
1.8 Controller Options 14
1.8.1 Digital Communications - RS232 14
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1.8.2 Digital Communications - RS485 14
1.8.3 Comms Address 14
1.8.4 Alarm Option 15
1.9 Temperature Controller Replacement 15
1.10 3216 Controller Navigation Diagram 15
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1.0 3216 Controller
1.1 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.
1.2 3216P1
The 3216P1 is a digital temperature controller which uses PID algorithms to give
excellent temperature control. This controller can store and operate a single program of
8 ramp/ dwell segments. The 3216P1 can also be used as a simple temperature
controller.
1.3 3216P5
The 3216P5 is a digital temperature controller which uses PID algorithms to give
excellent temperature control. This controller can store up to 5 programs of 8 ramp/
dwell segments. The 3216P5 can also be used as a simple temperature controller.
1.4 Operation
1.4.1 Controller Layout
Key
A Power Output Indicator
B Alarm Indicator
CRemote Indicator
(when configured)
D Page
E Scroll
F Down
G Up
H Run Indicator
I Hold Indicator
JSetpoint Temperature
(SP)
KMeasurement Tem-
perature
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1.4.2 Keys
Page Key The page key is used to access level 2 when held down
for 3 seconds.
Scroll Key The scroll key is used to scroll through parameters.
Ack
Page and
Scroll
+
When pressed simultaneously the ACK function is used
to:
lReturn to the Home Menu
lAcknowledge an alarm if activated.
lReset a program after the program has ended.
Arrow Keys +
The arrow keys are used individually to adjust the
selected parameters and in combinations to operate a
program.
Note: If a parameter is selected and no further action is taken, the display will time
out and revert back to the home display in its working level after approximately 1
minute.
1.5 Quick Start Guide
1.5.1 Operation as a simple controller
When switched on, the controller goes through a short test routine and then shows the
measured temperature (PV = Process Value) in the upper part of the display and below
it, the desired temperature (Setpoint).
1.5.2 Changing the Setpoint
Press Up or Down to select the required SP. If the SP is higher than the
measured temperature, the OP1 indicator will illuminate in the top left corner of the
display, indicating that the controller is calling for power (giving an output).
The controller will immediately attempt to reach the setpoint and then maintain it.
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.
1.5.3 Using the Controller
The parameters in the controller are first shown by a short code (mnemonic). After 5
Seconds a description of the parameter will scroll once along the display and then
revert back to the mnemonic. The scrolling text can be interrupted at any time by a
single press of any of the buttons, but will not scroll again until the parameter is
returned to. In this manual the mnemonic will be shown first, followed by the scrolling
text in brackets; e.g. PROG <PROGRAM NUMBER>
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1.5.4 Understanding User Levels
There are two user levels in the controller; Level 1 (Operator) and Level 2 (Supervisor).
Level 1 (Operator) is for the day to day operation of the controller. These parameters
are not protected by a security code.
Level 2 (Supervisor) provides access to additional parameters. Access to this level
protected by a security code
To Enter Level 2
1. Press and hold the page key for 3 seconds.
2. The display will show LEu 1 GOTO
3. Release the page Key
4. Press the up or down to choose LEu 2 (level 2)
5. Press the up or down to enter the code (Level 2 Code = 9).
If the correct code is entered, PASS should momentarily be displayed and then revert
to the level 2 home display.
If an incorrect code is entered the display reverts back to Level 1 home display.
When level 2 operations have been completed, the supervisor must return to Level 1
either manually or by switching the instrument off and back on. There is no time out
function.
To Return to Level 1
1. Press and hold the page Key
2. Press down to select LEu 1
It is not necessary to enter a code when going from a higher level to a lower level.
When level 1 is selected, the display reverts to the home display (See Controller
Layout)
Table showing parameters accessible in level 1 and Level 2
Operator LEVEL 1 Supervisor LEVEL 2
home display home display
Programming Programming
Program Status Program Status
Alarms (if configured)
Current Transformer Input (if configured)
Comms (if configured)
Controller Setup
Customer Calibration
TIP
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If while navigating the controller, a parameter has been passed or you need to access
parameters which would be at the end of a scroll list, press and hold scroll and use
up to return to a previous parameter.
1.6 Setting up the Controller
Before using the controller (or during its lifetime) certain parameters may have to be
set, depending on specific requirements. To do this the controller must be set to
supervisor level (Level 2).
1.6.1 Maximum Output Power
Press scroll until the display shows OP.HI <OUTPUT HIGH>. Use the up and
down keys to select the output power required as a percentage. Once the setting is
made, turn the instrument switch off and on to power cycle the temperature controller.
Depending on the furnace or oven model, the maximum output power setting OP.Hi
may be accessible or locked.
For silicon carbide heated furnaces, the parameter is accessible to allow compensation
for element ageing.
In many models the maximum output power setting depends on the supply voltage.
1.6.2 Customer ID
A furnace or oven identification number can be entered if required. This maybe used to
identify one of many units for production or quality control systems.
Press scroll until the display shows ID <CUSTOMER ID>. Use the up and down
keys to enter your own identification number. This can range from 1-9999.
1.6.3 Units
Press scroll until the display shows UNITS <DISPLAY UNITS>. Use the up or
down keys to select the required units.
Mnemonic Description
NONE No units (Default °C)
°C Celsius
°F Fahrenheit
°K Kelvin
PERC % (shows °C value)
1.6.4 Language
The scrolling text on the 3216 can be shown in different languages, this can only be set
at the factory and therefore must be specified at the time of placing an order.
1.6.5 Scrolling Text
If at any time the scrolling text is not required.
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Press and hold the page for three seconds until “GOTO” is displayed.
Press scroll until the display shows. TEXT <ENABLE/ DISABLE SCROLLING TEXT>
Use the up and down keys to select ON or OFF.
1.6.6 Customer Calibration
The 3216 Controller series are calibrated for life at manufacture, there may however be
sensor or other system errors, which affect the accuracy of the measured temperature.
Customer calibration can be used to compensate for these errors.
Dual Offset
Dual point calibration uses two offset values at two corresponding temperatures; this
changes the calibration linearly as the temperature increases or decreases.
Press scroll until the display shows CAL.P (Enter Calibration Code) Use the up
down keys to enter the password code. (Calibration Pass Code = 95). When the
correct password has been entered the display will show PNT.LO. If the wrong pass
code is entered the display will revert to zero pass code, until the correct pass code is
entered.
When the correct pass code is entered and PNT.LO (Adjust Low Point) is displayed. Use
the up and down keys to enter the Low Temperature Point, which you want to
apply an Offset.
Press scroll until the display shows OFS.LO (Adjust Low OFFset). Use the up and
down keys to enter the amount Offset you want to apply to the Low Temperature
Point.
Press scroll until the display shows PNT.HI (Adjust High Point). Use the up and
down keys to enter the High Temperature Point, which you want to apply an Offset.
Press scroll until the display shows OFS.HI (Adjust High OFFset). Use the up and
down keys to enter the amount Offset you want to apply the High Temperature
Point.
Once the calibration details have been entered, press scroll until the display shows
the next required parameter or return to the home list. The calibration data will now be
protected by the pass code. To edit the data the above procedure must be followed.
Single Offset
If a constant offset is required across the temperature range, set the required “High
Point” (PNT.HI) and “Low Point” (PNT.LO) to the required values (not the same), then
set the “low Offset” (OFS.LO) and “High Offset” (OFS.HI) to the same value.
Caution! - Do not make PNT.LO and PNT.HI the same value as the
controller will not work correctly and could cause the product to
overheat.
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1.6.7 Holdback
If the temperature ramp rate of the program is quicker than the product can achieve,
the program will wait until the temperature of the product catches up.
e.g. If a holdback value of 10 is set and the program is set to ramp to a setpoint of 600
°C, the program will reach 600 °C, then go into a hold state; the hold indicator will
light until the product temperature reaches 590 °C, the program will then continue to
control again.
The holdback will only apply once per segment, therefore when control has been re-
established, the holdback will not apply again to that segment, even if the product
temperature goes outside the holdback band.
Holdback can only be accessed in supervisor level (level 2) by scrolling with the scroll
until the display shows H.BACK <PROGRAM HOLDBACK>: Use the up and down
keys to select the required Holdback value.
If a multi programmer is used, each program can have its own holdback value assigned
to it.
Note: When a holdback is set, each segment used must have a Ramp Rate assigned
to it, in order for it to be recognised by the program.
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1.7 Programming
1.7.1 Creating a Program
Programs can be created in level 1 or level 2 of the 3216P1 and 3216P5. Each program
contains 8 Ramp/ Dwell pairs.
Note: A currently active program cannot be altered. Go into 'Reset' mode before
starting to create or modify a program
1.7.2 Program Number (3216P5 Only)
Press scroll until the display shows PROG <PROGRAM NUMBER.> Select the program
number.
1.7.3 Ramp Units
Press scroll until the display shows RAMP.U <Ramp Units>: Use the up down
to select the Ramp Units of Hour, Min or Seconds.
1.7.4 Dwell Units
Press scroll until the display shows DWEL.U <Dwell Units>: Use the up down
to select the Dwell Units of Hour or Min.
1.7.5 Holdback
See section 1.6. Press scroll until the display shows H.BACK <Program Holdback>:
If a holdback value is required, use the up down to enter the required value or
select “OFF” if no holdback is required.
1.7.6 Ramp Rate
Press scroll until the display shows RMP.1 <Ramp Rate 1>: Using the up down
enter the value for the first ramp rate depending on the Ramp Units selected. If the
Ramp segment is not required select “OFF”.
1.7.7 Target Setpoint
Press scroll until the display shows T.SP 1 <Target SP 1>: Enter the temperature
that you want the product to ramp up to using “Ramp rate 1”.
If “Ramp Rate 1” has been set to “OFF”. The product will Heat/ Cool directly to the
Target SP.
1.7.8 Dwell Time
Press scroll until the display shows DWELL. 1 <DWELL TIME 1>: Enter the time to
dwell at “Target SP 1”. If the dwell segment is not required, use the down to select
OFF, which is below the Zero value.
This Process is repeated for each of the 8 segments of the program.
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