VERDER CARBOLITE GERO AAF-BAL 11/17 Manual

Installation, Operation and Maintenance Instructions
1100°C Ashing Furnace - AAF-BAL Model: 17 Litres
3216CC Controller
AAF-BAL 11/17 + 3216CC Controller
MEN-AAF-BAL-1117-006_3216CC (01-08-2019)

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 7
2.4 Electrical Connections 8
2.5 Balance and Weighing Platform 10
3.0 3216CC Controller 12
3.1 3216CC 12
3.2 PID control 12
3.3 Operation 12
3.3.1 Controller Layout 12
3.3.2 Keys 13
3.4 Quick Start Guide 13
3.4.1 Operation as a simple controller 13
3.4.2 Changing the Setpoint 13
3.4.3 Using the Controller 13
3.4.4 Understanding User Levels 14
3.5 Setting up the Controller 15
3.5.1 Setpoint Ramp Rate 15
3.5.1.1 Setting Setpoint Ramp Rate 15
3.5.1.2 Running with Ramp Rate 15
3.5.2 Maximum Output Power 16
3.5.3 Customer ID 16
3.5.4 Units 16
3.5.5 Language 16
3.6 Timer 16
3.6.1 Setting the Timer 16
3.6.2 Dwell Timer 17
3.6.3 Delayed Switch On Timer 17
3.6.4 Soft Start Timer 18
2

3.7 Running a Timer 18
3.7.1 Dwell Timer 19
3.7.2 Power Failure While Using Dwell Timer 19
3.7.3 Running Dwell Timer with Ramp Rate 20
3.7.4 Running Dwell Timer with Ramp Rate & Threshold 20
3.7.5 Delayed Switch on Timer 20
3.7.6 Running Delay Timer with Ramp Rate 21
3.7.7 Delay timer with ramp rate functions 21
3.7.8 Power Failure While Using Delay Timer 22
3.7.9 Soft start Timer 22
3.7.10 Power Failure While Using Soft Start Timer 22
3.7.11 Ramp Rate with Soft Start Timer 22
3.7.12 Time Remaining 22
3.7.13 Alarms 23
3.8 Controller Options 23
3.8.1 Digital Communications - RS232 23
3.8.2 Digital Communications - RS485 24
3.8.3 Comms Address 24
3.8.4 Alarm Option 24
3.9 3216CC Navigation Diagram 25
4.0 2132 Over-Temperature Controller Description (if fitted) 26
4.1 Description 26
4.2 Operation 26
4.2.1 Controls 26
4.2.2 Operation 27
4.2.3 Over-Temperature Operation 27
4.2.4 Over-Temperature Alarm 27
4.2.5 Resetting the Over-Temperature Alarm 27
4.2.6 Sensor Break 27
4.3 Audible Alarm 28
4.4 Navigation Diagram 28
5.0 Operation 29
5.1 Operating Cycle 29
5.2 General Operating Notes 29
5.3 Use of Probes 30
5.4 Atmospheres 30
5.5 Operator Safety 30
5.6 Power Adjustment 31
3

6.0 Maintenance 32
6.1 General Maintenance 32
6.2 Maintenance Schedule 32
6.2.1 Cleaning 34
6.2.2 Safety Switch 34
6.3 Calibration 34
6.4 After-Sales Service 35
6.5 Recommended Spare Parts and Spare Parts Kit 35
7.0 Repairs and Replacements 36
7.1 Safety Warning - Disconnection from Power Supply 36
7.2 Safety Warning - Refractory Fibre Insulation 36
7.3 Temperature Controller Replacement 36
7.4 Solid-State Relay Replacement 37
7.5 Thermocouple Replacement 37
7.6 Panel Element Replacement 37
7.7 Door Plug Replacement 39
7.8 Fuse Replacement 39
8.0 Fault Analysis 41
A. Furnace Does Not Heat Up 41
B. Product Overheats 42
9.0 Wiring Diagrams 43
9.1 WA-U3-30 44
9.2 WA-U3-31 46
10.0 Fuses and Power Settings 48
10.1 Fuses 48
10.2 Power Settings 48
11.0 Specifications 49
11.1 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 7.2.
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.
Unless otherwise stated elsewhere in this manual, ensure that there is at least 150
mm of free space around the back and sides of the product. Clear space is required
above the product to dissipate heat.
6

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.
7
2.0 Installation

2.0 Installation
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 Electrical Connections
Connection by a qualified electrician is recommended.
This product requires a single-phase A.C. supply with earth (ground), which may be Live
to Neutral non-reversible (polarised), Live to Neutral reversible (non-polarised), or Live
to Live.
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
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. The 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
operator.
The supply MUST incorporate an earth (ground).
8

Supply Terminal Label Cable Colour
Supply Types
Live - Neutral Reversible or Live-
Live
1-phase L Brown to live
to either power
conductor
(For USA 200-240V,
connect L1)
N Blue to neutral
to the other power
conductor
(For USA 200-240V,
connect L2)
PE Green/ Yellow to earth
(ground) to earth (ground)
Electrical Connection Details:
9
2.0 Installation

2.0 Installation
2.5 Balance and Weighing Platform
1. Assemble the balance unit as shown below:
2. Ensure that the furnace is on a stable, level surface.
3. Place the balance on the support plate below the furnace chamber, ensuring the
front legs are located in the slots on the support plate.
4. Level the balance as detailed in the balance manufacturer’s instruction manual.
5. Open the furnace door.
6. One by one, insert the 3 ceramic tubes through the holes in the hearth, and locate
them over the three corresponding placement guides on the top of the balance.
Note: Due to the secure fit, you may need to twist the tubes down the guides in
order for them to make full contact with the weighing platform.
7. If required, loosen the bolts securing the bottom support plate, and adjust pos-
itioning to move the balance.
10

8. Carefully position the Silicon Carbide weighing platform onto the top of the ceramic
tubes.
9. Connect the DC power lead and RS-232 plug at the rear of the balance.
10. Before turning on the power supply, connect the earth cable to the earthing bolt on
the support plate.
Important Note: The balance will not stabilise if the ceramic tubes touch the sides
of the holes in the hearth.
11
2.0 Installation

3.0 3216CC Controller
3.0 3216CC Controller
3.1 3216CC
The 3216CC Controller is a digital temperature controller which uses PID algorithms to
give excellent temperature control when properly set. This controller can only be used
as a simple temperature controller, it cannot be programmed.
3.2 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.
3.3 Operation
3.3.1 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
12

3.3.2 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.
3.4 Quick Start Guide
3.4.1 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).
3.4.2 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.
3.4.3 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>
13
3.0 3216CC Controller

3.0 3216CC Controller
3.4.4 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
Program Status
Alarms (if configured)
Current Transformer Input (if configured)
Comms (if configured)
Controller set up (if configured)
Customer Calibration (if configured)
TIP
14

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.
3.5 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).
3.5.1 Setpoint Ramp Rate
To control the rate at which the temperature rises to setpoint, the SP.RATE function is
used.
Before setting the ramp rate, it is advisable to set the setpoint to a low value,
preferably 0 °C (see section 3.4). Once the ramp rate has been set, the required
setpoint can be entered from the home menu. Doing so will activate the ramp rate,
which can be identified with the run indicator showing on the bottom of the display.
While the ramp rate is active the working setpoint will be shown on the lower
temperature display (this is the setpoint, set by the ramp rate).
When the process temperature has reached the setpoint value at the given ramp rate,
the run indicator will turn off and the instrument will control at the required setpoint
temperature.
Any further modifications to setpoint will cause the ramp rate to be activated and the
instrument to control as described above.
NOTE: Ensure timer configuration is set to ‘none’ (see section 3.6) to use the setpoint
ramp rate feature without any timer functions.
3.5.1.1 Setting Setpoint Ramp Rate
In supervisor level (level 2).
Press scroll until the display shows SP.Rate <setpoint rate limit>. Using up and
down select the ramp rate required, in °C/ Min.
3.5.1.2 Running with Ramp Rate
Press the up and down keys at the same time to activate the ramp rate. The
"Run" indicator will illuminate and the scrolling text will read <RAMPING> to show the
ramp rate is active. The ramp rate will then start from the current process
temperature.
When the ramp reaches the setpoint temperature, the "Run" indicator will turn off and
the instrument will maintain control at the setpoint.
To put the ramp rate into a hold condition, press the up and down keys and
release. The "Run" indicator will flash and the scrolling text will read <HOLD> to show
the ramp rate is on hold.
15
3.0 3216CC Controller

3.0 3216CC Controller
To cancel the ramp rate, press and hold the up and down keys until the "Run"
indicator turns off.
3.5.2 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, see
section 10.0.
3.5.3 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.
3.5.4 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)
3.5.5 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.
3.6 Timer
3.6.1 Setting the Timer
A timer can be configured to operate in four different modes. These can be selected in
level 2 (supervisor level) using the TM.CFG parameter as:-
• None
• Dwell Timer
16

• Delayed switch on timer
• Soft start timer
None
The timer is turned off, no timer configurations are available, the instrument works as a
simple setpoint controller.
Press scroll until the display shows TM.CFG <TIMER CONFIGURATION>. Using the up
down select NONE.
3.6.2 Dwell Timer
A dwell timer is used to control a process at a fixed temperature for a defined period. At
the end of the time period the controller will switch off the output power to the
elements.
Press scroll until the display shows TM.CFG <TIMER CONFIGURATION>. Using the up
down select Dwell.
When Dwell parameter is selected, the Timer resolution (TM.RES), Time duration
(DWELL) and Timer Threshold (THRES) functions become available.
Press scroll until the display shows TM.RES < Time resolution >. Use the up down
to select the timer units in Min or Hours.
Press scroll until the display shows DWELL < SET TIME DURATION >. Use the up
down to enter the time duration required.
Press scroll until the display shows THres < TIMER THRESHOLD >. Use the up
down to select the temperature threshold that you require the timer to start at.
The threshold value is ±n around the setpoint (n=threshold value).
Example: If the setpoint is set to 800 °C and the timer threshold is set to 2, after the
timer is activated it will not start until the process value reaches 798 °C if ramping up or
802 °C if it is cooling.
Note: If the threshold is set to OFF, the timer will either; start to count down as soon
as it is activated with the mode keys or if a ramp rate has been set (see section 3.5.1
), the timer will start as soon as the ramp reaches the setpoint. (see section 3.7.1)
3.6.3 Delayed Switch On Timer
The delayed switch on timer is used to switch on the output power to the elements after
a set time period.
Press scroll until the display shows TM.CFG <TIMER CONFIGURATION>. Using the up
down select dELY.
When delay parameter is selected, the Timer Resolution (TM.RES) and Time Duration
(DWELL) functions become available.
Press scroll until the display shows TM.RES < Time Resolution >. Use the up down
to select the timer units in Min or Hours.
17
3.0 3216CC Controller

3.0 3216CC Controller
Press scroll until the display shows DWELL < SET TIME DURATION >. Use the up
down to enter the time duration required before the output power switches on.
3.6.4 Soft Start Timer
The Soft Start Timer is used to start a process at a reduced setpoint and power. The
Soft Start Setpoint is used as a threshold only and is not a control point.
Example: Main Setpoint = 800 °C
Max power limit = 75 % (This may be set at the factory)
Soft Start Setpoint = 600 °C (Threshold)
Soft Start Power Limit = 50% (Cannot be set above max power Limit)
When the timer is running, the maximum power is controlled by the Soft Start Setpoint
of 600 °C and the Soft Start Power limit of 50%. This will continue until the timer ends
or the current temperature exceeds the Soft Start Setpoint.
When the timer ends or the current temperature exceeds the Soft Start Setpoint, the
instrument will start to control using the main setpoint of 800 °C and the Max Power
Limit of 75%.
Press scroll until the display shows TM.CFG <TIMER CONFIGURATION>. Using the up
down select SF.st.
When Soft Start parameter is selected, the Timer Resolution (TM.RES), Time Duration
(DWELL), Soft Start Setpoint (SS.SP) and Soft Start Power Limit (SS.PWR) functions
become available.
Press scroll until the display shows TM.RES < Time resolution >. Use the up down
to select the timer units in minutes or hours.
Press scroll until the display shows DWELL < SET TIME DURATION >. Use the up
down to enter the time duration required, before the instrument starts to control
using the main setpoint and max power.
Press scroll until the display shows SS.SP < Soft Start Setpoint >. Use the up
down to enter the Soft Start Setpoint.
Press scroll until the display shows SS.PWR < Soft Start Power Limit >. Use the up
down to enter the Soft Start Power Limit.
3.7 Running a Timer
lRun. This starts the timer.
lHold. This stops the timer at the elapsed time. It will start again from the elapsed
time when Run is selected again.
lReset. This sets the timer back to zero. It can be operated again from this state.
lEnd cannot be set – it occurs automatically when the timer has counted down to
zero.
18

lAcknowledge any timer after a timer has timed out using ACK function (see section
3.3.2) by pressing the and simultaneously.
3.7.1 Dwell Timer
Operation Action Indication
To RUN Timer Press and quickly release
+
Indicator – RUN = ON
Scrolling Display – Timer
Running
To HOLD timer Press and quickly release
+
Indicator – RUN = Flashing
Scrolling Display – Timer
Hold
To switch off Timer / Cancel Press and hold +
for more than 1 second
Indicator – RUN = OFF
Scrolling Display – None
Static Text - OFF
To return to home after reset Press and hold +
for more than 1 second
Indicator – RUN = OFF
Display – A-M <LOOP
MODE- AUTO MANUAL
OFF>
Use the up or down
to select AUTO
Timer Ended
Indicator – RUN = OFF
Scrolling Text – Timer End
Static Text - OFF
To re-RUN Timer Press and quickly release
+
Indicator – RUN = ON
Scrolling Display – Timer
Running
To RESET timer and return to
home menu after timer end
Press and quickly release
Ack +
Indicator – RUN = OFF
Scrolling Display - None
Press and hold +
for more than 1 second
Indicator – RUN = OFF
Display – A-M <LOOP
MODE- AUTO MANUAL
OFF>
Use the up down to
select
3.7.2 Power Failure While Using Dwell Timer
If there is a power failure while the timer is operating and the power is subsequently
restored, the timer will reset and the static text will display “OFF“until the + keys
are pressed to re-run the timer.
19
3.0 3216CC Controller

3.0 3216CC Controller
3.7.3 Running Dwell Timer with Ramp Rate
Set the ramp rate as outlined in section 3.5.1
Set the dwell time as outlined in section 3.6.2.
When the timer is set to operate with a set ramp rate, the timer will not start to count
down until the setpoint has been reached with the ramp, at which time the timer will
begin time count down.
The scrolling display will indicate “timer running” and the run indicator will be illuminated
while the ramp rate is active and during the timer count down, after which the display
will indicate the instrument has switched off power to the elements (see section 3.7.7),
and the run indicator will switch off.
3.7.4 Running Dwell Timer with Ramp Rate & Threshold
Set the ramp rate as outlined in section 3.5.1.
Set the dwell time as outlined in section 3.6.2.
Set the threshold as outlined in section 3.6.3.
When the timer is set to operate with a set ramp rate and threshold, the timer will not
start to count down until the process temperature has reached the threshold value (see
example 3.6.3).
The scrolling display will indicate “timer running” and the run indicator will be illuminated
while the ramp rate is active, while the process value is reaching the threshold value and
during the timer count down, after which the display will indicate the instrument has
switched off power to the elements (see section 3.7.1).
3.7.5 Delayed Switch on Timer
Operation Action Indication
To RUN Timer
Press and quickly release + Indicator – RUN = ON
Scrolling Display – Timer
Running
Static Text - OFF
To HOLD timer Press and quickly release +
Indicator – RUN = Flashing
Scrolling Display – Timer
Hold
Static Text - OFF
To switch off Timer /
Cancel
Press and hold + for
more than 1 second Indicator –
RUN = Off
Scrolling Display – None
Static Text - OFF
To return to home
menu. After Resetting
timer
Press and hold + for
more than 1 second
Indicator – RUN = Off
Display – A-M <LOOP MODE-
AUTO MANUAL OFF>
Use the up or down to
select
20