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
2
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
4
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>
5
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
6
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.
7
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.
8
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.
9
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.
10
If not all the segments are used for a program, the Ramp & Dwell of each of the
subsequent segments should be set to OFF.
A program will end in one of two ways, either revert to the control setpoint or dwell at
the temperature set in the last segment used. When a program finishes on a dwell and
the dwell time expires the temperature will revert to the control setpoint.
Note: Before operating a program ensure that the control setpoint is set to Zero to
avoid unexpected heating at the end of the program.
1.7.9 Running a Program
If using the 3216P5 controller press scroll to display PROG <PROGRAM NUMBER>.
Select the required Program Number before operating a Program.
Table below shows the key presses to operate a program.
Operation Action Indication
To RUN a program Press and quickly release
+
Indicator – RUN = ON
Scrolling Display – Current
Program state
To HOLD a program Press and quickly release
+
Indicator – RUN = Flashing
Scrolling Display – Program Hold
To RESET a program Press and hold + for
more than 1 second
Indicator – RUN = OFF
Scrolling Display - None
Program Ended Indicator – RUN = OFF
Scrolling Text – Program End
To RESET a program
after it has
completed
Press and hold + for
more than 1 second or press
and quickly release Ack
Indicator – RUN = OFF
Scrolling Display - None
1.7.10 Program Status
While the program is operating in level 1 or level 2, the home display shows two values
at any one time:
1.7.11 Process Value
The upper display shows the current temperature of the product.
1.7.12 PSP, Segment Type and Number
The lower display continually alternates between the programs current set value
(Program SP = PSP) and scrolling text, indicating the current status of the program
whether RAMP or DWELLING followed by the segment number.
Additional information can be obtained using the scroll key while the program is
operating.
11
Working Output Power
From the home display, press scroll until the display shows WRK.OP <WORKING
OUTPUT POWER>. This shows the power being used as a percentage.
Time Remaining
Press scroll until the display shows T.REMN <TIME REMAINING>. This shows the
dwell time remaining for the current segment. There is no value for “Ramp Time
Remaining” therefore when the program is ramping the dwell time set will be shown
and will only begin to count down when the ramp has finished.
Program Review
Further presses of scroll will reveal the settings of the current program operating.
These parameters are locked, while the program is operating.
Program Hold with Holdback
If a holdback value has been set (see section 1.6) and the program goes into a hold
state, the red “HLD” indicator will light, until the current temperature catches up.
If while in this condition the program itself is put into “Hold” by pressing the up ,
down together, the “HLD” indicator will turn off and the “Run” indicator will flash,
indicating the program is on hold. When the program is started again by pressing the
up , down together, the “Run“ indicator will stop flashing and show continually and
the “HLD” indicator will light, if the current temperature has not caught up with the
program.
Power Failure
If there is a power failure while the program is operating and the power is subsequently
restored, the scrolling text will read <POWER FAIL - PROGRAM RESET>.
Press the “ACK” function to acknowledge this message, press the “ACK” function again
to reset the program.
Alarms
Alarms are used to alert the operator when a pre-set level has been exceeded or a
function error has occurred such as a sensor break. They are indicated by a scrolling
message on the display and a flashing red ALM (Alarm) indicator. The alarm may also
switch an output – usually a relay to allow external devices to be operated when an
alarm occurs. Alarms only operate if they have been configured and are dependent on
customer requirements.
How to acknowledge an alarm will depend on the type of latching which has been
configured. A non-latched alarm will reset itself when the alarm condition is removed. A
latched alarm requires acknowledgement with the “ACK” function before it is reset.
If an alarm has been activated the red “ALM” indicator will light and the scrolling text
will indicate the type of alarm.
To acknowledge an alarm and cancel the “ALM” indicator, press “ACK” function.
Note: The alarm indicator may seem to be permanently on when viewed from above.
When an alarm is active the indicator should only be flashing, to confirm this, the
controller must be viewed directly from the front.
12
Program Example
The following sequence of entries creates and runs the program shown graphically
below.
1. Press scroll until the display shows RAMP.U <SP RAMP UNITS>. Select MIN.
2. Press scroll until the display shows DWELL.U <DWELL UNITS>. Select MIN.
3. Press scroll until the display shows RMP.1 <RAMP RATE 1>. Select 5
4. Press scroll until the display shows T.SP1 <TARGET SP 1>. Select 600
5. Press scroll until the display shows DWEL.1 <DWELL TIME 1>. Select 30
6. Press scroll until the display shows RMP.2 <RAMP RATE 2>. Select 4
7. Press scroll until the display shows T.SP2 <TARGET SP 2>. Select 400
8. Press scroll until the display shows DWEL.2 <DWELL TIME 2>. Select 30
9. Press scroll until the display shows RMP.3 <RAMP RATE 3>. Select OFF
10. Press scroll until the display shows T.SP3 <TARGET SP 3>. Select 600
11. Press scroll until the display shows DWEL.3 <DWELL TIME 3>. Select 60
12. Press scroll until the display shows RMP.4 <RAMP RATE 4>. Select 3
13. Press scroll until the display shows T.SP4 <TARGET SP 4>. Select 800
14. Press scroll until the display shows DWEL.4 <DWELL TIME 4>. Select OFF
15. Press scroll until the display shows RMP.5 <RAMP RATE 5>. Select 5
16. Press scroll until the display shows T.SP5 <TARGET SP 5>. Select 400
17. Press scroll until the display shows DWEL.5 <DWELL TIME 5>. Select 480
18. Press the ACK function to return to the home display.
19. Press the up and down keys together, to operate the program.
Segment
13
1 2 3 4 5
RMP.1= 5°C/Min RMP.1= 4°C/Min RMP.1= OFF RMP.1= 3°C/Min RMP.1=5°C
T.SP1= 600°C T.SP1= 400°C T.SP1= 600°C T.SP1= 800°C T.SP1= 400°C
Dwel.1= 30 Min Dwel.1= 30 Min Dwel.1= 60 Min Dwel.1= OFF Dwel.1= 480 Min
1.8 Controller Options
As options can be ordered in a variety of combinations and for a variety of purposes,
exact instructions are not given here. The full Eurotherm manual may be required to
determine customer parameter settings. To reveal or hide parameters in the controllers
it is necessary to go into configuration mode, a security code is needed. Please consult
Carbolite Gero.
1.8.1 Digital Communications - RS232
If the RS232 option is supplied, the furnace is fitted with one sub-miniature D-
socket connected to the controller comms module. RS232 is suitable for direct
connection to a personal computer (PC) using a “straight through” cable as follows
(the linked pins at the computer end are recommended but may not be necessary).
The cable is usually 9-pin at the furnace end and 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
1.8.2 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
female (25-pin) 9-pin
RS485 Cable:
product to PC Computer end of cable
9-pin (25-pin) female
- (2) 3 3 (2) Tx
+ (3) 2 2 (3) Rx
Com (7) 5 _________________ 5 (7) Com
1.8.3 Comms Address
Typically the comms address is set to 1, but this can be changed. In the case of RS485
and multiple instruments it is necessary to set different addresses. To change the
14
address value, access the level 2 list. In level 2 press the page key until the COMMS
parameter is displayed. Press up down to select the address value.
1.8.4 Alarm Option
When an alarm board is fitted, which consists of a relay with voltage free contacts, for
operator use, the contacts are taken to a panel plug on the control panel, wired as
indicated:
Key
C Temperature Controller
F Fuse (2A)
S Supply
L Load
*Normally open relay
contacts
RO Relay Output 240V 2A
MAX
The purpose of the 2 amp fuse is to break the circuit to prevent overloading on the
circuit due to high voltage.
The instrument configuration and parameters available to the operator depend on the
customer requirements.
1.9 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 instrument and withdraw it from its
sleeve; push in the replacement.
1.10 3216 Controller Navigation Diagram
The following diagram details how to navigate to the various menu options within the
3216 Controller. At each option, values can be set using the arrow keys.
15
L1 Level 1 Press the Scroll Key Hold the Page key for 3
seconds
L2 Level 2 Press the Scroll Key mul-
tiple times
Locked - password
required
AAccess *If configured Unlocked
** Do not raise the power limit (if
accessible) above the design level
for the product
~Multiple Program Only
Black = Progress
Dashed = Through mul-
tiple menus
White = Return
16
Notes
Service Record
Engineer Name Date Record of Work
The products covered in this manual are only a small part of the wide range of ovens,
chamber furnaces and tube furnaces manufactured by Carbolite Gero for laboratory
and industrial use. For further details of our standard or custom built products please
contact 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: [email protected]
Carbolite Gero Ltd,
Parsons Lane, Hope, Hope Valley,
S33 6RB, England.
Telephone: + 44 (0) 1433 620011
Fax: + 44 (0) 1433 621198
Email: [email protected]
www.carbolite-gero.com
Copyright © 2021 Carbolite Gero Limited
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