VERDER CARBOLITE GERO ABF 8/28 Manual

Installation, Operation and Maintenance Instructions
800°C Afterburner Ashing Furnace - ABA Model: 28 Litres
2416 Controller
ABF 8/28 + 2416 Controller
MEN-ABF0828-002_2416 (08-10-2018)

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
1.3 Access to the Plenum Chamber 6
1.4 Maintenance or Dismantling 6
2.0 Supplied Items List 6
2.1 Parts Supplied 6
2.2 Tools Required 6
3.0 Installation 7
3.1 Unpacking & Handling 7
3.2 Siting and Setting Up 7
3.3 Fitting the Chimney 8
3.4 Ducting 9
3.5 Electrical Connections 10
4.0 2416 Controller 12
4.1 Description 12
4.2 Operation 14
4.3 Programming 16
4.3.1 Programming Tips 16
4.3.2 Multi-program model (2416P8) 17
4.3.3 Holdback 17
4.3.4 Program Cycling 17
4.3.5 Running a Program 17
4.3.6 Program example 18
4.4 Controller Options 19
4.4.1 Digital Communications - RS232 19
4.4.2 Digital Communications - RS485 19
4.4.3 Comms Address 19
4.4.4 Alarm Option 19
4.5 Temperature Controller Replacement 20
4.6 Navigation Diagram 21
5.0 Afterburner 2132 Controller 22
2

5.1 Description 22
5.2 2132 Controller Operation 22
5.2.1 Controls 22
5.2.2 2132 Controller Operation 23
5.2.3 Basic Operation 23
5.2.4 Altering the Setpoint 23
5.2.5 Stopping and Starting Control 24
5.2.6 Altering the Ramp Rate 24
5.3 Operating with the Timer 25
5.3.1 Setting the Timer Mode 27
5.3.2 Setting the Time Period 27
5.3.3 Running with the Timer 27
5.3.4 Stopping the Timer 28
5.3.5 End of Time Period 29
5.3.6 Cancelling the Alarm 29
5.3.7 Program Example 29
5.4 Altering Power Limit 29
5.5 Audible Alarm 32
5.6 Temperature Controller Replacement 32
5.7 Navigation Diagram 33
6.0 2132 Over-Temperature Controller Description (if fitted) 35
6.1 Description 35
6.2 Operation 35
6.2.1 Controls 35
6.2.2 Operation 36
6.2.3 Over-Temperature Operation 36
6.2.4 Over-Temperature Alarm 36
6.2.5 Resetting the Over-Temperature Alarm 36
6.2.6 Sensor Break 36
6.3 Audible Alarm 37
6.4 Navigation Diagram 37
7.0 Operation 38
7.1 Switches - Control Panel 38
7.2 General Operating Notes 38
7.3 Operator Safety 39
7.4 Temperature Control 39
8.0 Maintenance 41
8.1 General Maintenance 41
3

8.2 Maintenance Schedule 41
8.2.1 Cleaning 43
8.3 Cleaning the Plenum Chamber & Fan Impeller 43
8.4 Calibration 43
8.5 After-Sales Service 43
8.6 Recommended Spare Parts and Spare Parts Kit 44
9.0 Repairs and Replacements 45
9.1 Safety Warning - Disconnection from Power Supply 45
9.2 Safety Warning - Refractory Fibre Insulation 45
9.3 Solid-State Relay Replacement 45
9.4 Thermocouple Replacement 46
9.5 Element Replacement 46
9.6 Door Plug Replacement 46
10.0 Fault Analysis 47
A. Furnace Does Not Heat Up 47
B. Product Overheats 48
C. Furnace Slow to Heat Up 48
D. Chimney Emits Smoke 49
11.0 Wiring Diagrams 50
11.1 00348-1-5003-D 50
12.0 Fuses and Power Settings 51
12.1 Fuses 51
12.2 Customer Supply Fusing 51
12.3 Power Settings 51
13.0 Specifications 52
13.1 Environment 52
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 Supplied Items List
1.3 Access to the Plenum Chamber
Soot can accumulate in the airway following the after-burner, giving rise
to fire risk.
There is a plenum chamber with removable panels to give access to
cleaning; see section 8.3.
The operator is responsible for maintaining a clean plenum chamber and also for
regular cleaning of the chimney and the external flue or ducting system.
1.4 Maintenance or Dismantling
The operator should read the warning on refractory fibre insulation,
given in section 9.2, before undertaking any work involving exposure to
the internal insulation material.
The operator should disconnect the equipment from the electrical supply before
removing panels to access the electrical connections and control equipment.
2.0 Supplied Items List
2.1 Parts Supplied
The following items should be present. These should all be checked and identified as
soon as possible after receipt of the equipment.
quantity item
1Afterburner Ashing Furnace:
ABF 8/28
1 Chimney
1 Basket Set
1 Basket Set loading handle
(1) Stand (only if ordered)
In addition, any spare parts ordered should be separately identified and put aside in
safe storage.
2.2 Tools Required
10 mm spanner, 12 mm spanner, cross point screwdriver, flat blade screwdriver.
6

3.0 Installation
3.1 Unpacking & Handling
When unpacking or moving the product, always lift by its base; do not use the door or
any other projecting cover or component to support the equipment when moving it. Use
a fork lift or pallet truck to move the product; position the product on a level surface
and use an adequate number of personnel to safely move the product into position.
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 9.2.
3.2 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.
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3.0 Installation

3.0 Installation
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.
3.3 Fitting the Chimney
lRemove the chimney panel, (see Fig 10.)
lFasten the chimney to the top of the product using the screws provided, (see Fig 12.)
lReplace the chimney panel, (see Fig 11.)
8

Fig 10 - Remove the
chimney panel Fig 11 - Replace the
chimney panel
Fig 12 - Chimney
screws
3.4 Ducting
The chimney must either be placed under a powered exhaust hood, or connected
directly to a 76 mm duct (not supplied) to the outside of the building; any such duct
must NOT have powered extraction.
The fumes should be ducted by either of the above methods to at least 1 metre above
the level of the building.
Rules for ducting:
lDucting diameter must be 76 mm or more.
lDucting must be 76 mm where it connects to the chimney.
lDucting length must not exceed 3 metre for 76 mm diameter; for longer lengths con-
sult a ducting engineer.
lFlexible ducting, if used, must be suitable for exhaust gas extraction.
lIf an extraction fan is fitted an extraction hood is required with free flow of air
around the chimney.
lDo not connect more than one product to a single duct. (Exception: where a fanned
duct with hoods is used)
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3.0 Installation

3.0 Installation
Fig 13 - Ducting Schematic
3.5 Electrical Connections
Connection by a qualified electrician is recommended.
For electrical connection details of the ABF 8/28 refer to drawing 00348-1-5003
Look at the rating label before connection to check the electrical supply voltage and
frequency for which the product is configured. If there is a difference between the
actual supply and the rating label, please call Carbolite Gero.
Either wire directly to an isolator or fit with a line plug. An isolating switch should operate
on all live conductors (three phase); it should be within reach of the operator. A line plug
should be easily removable and should be within reach of the operator.
The electrical supply MUST incorporate an earth (ground).
Failure to wire to the appropriate diagram may damage the ABF.
10

Fig 14 - Schematic for Mains Electrical Connections
11
3.0 Installation

4.0 2416 Controller
4.0 2416 Controller
4.1 Description
This manual applies to the 2416, 2416CG and 2416P8 controllers.
Special customer requirements may result in changes to the available parameters and
the navigation diagram. It is not possible to list all the possibilities in this manual.
2416CG Controller
The Eurotherm model 2416CG is a digital instrument with PID control algorithms which
may be used as a simple controller or an 8-segment programmer. The 2416P8 is an
eight-program model in which the programs can be stored independently or can be
linked by a “call” parameter to form a single long program.
The 2416 Controller features:
lEasy use as a simple temperature controller, where 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.
lBy using one program segment, the control can be extended to include ramp-to-set-
point. Fig.2 shows the effect.
lAlternatively, the 2416 Controller may be used as an 8-segment programmer, with
each segment being a "Ramp", a "Step", a "Dwell", or "End". The program can be set
to cycle if required. See fig. 3.
lOptional “modules” are available, in particular:
lRS232 and RS432/485 digital communications modules;
lAnalogue communication modules;
l“PDSIO” modules for communication with other controllers of similar or higher spe-
cification, for example, to allow cascade control;
lAlarm modules, which can be used to drive visible or audible alarms, or to provide
volt-free contacts for customer use.
12

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
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4.0 2416 Controller

4.0 2416 Controller
4.2 Operation
Most Carbolite Gero products are fitted with an instrument switch which cuts off power
to the controller and other parts of the control circuit. See section 7.0 for operating
instructions.
To operate the 2416 Controller there must be power to the furnace or oven and the
instrument switch must be on. If a time switch is included in the furnace or oven circuit,
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 used for the following purposes:
Key
A Output Light
B Not Used
C Page
D Scroll
E Down
F Up
G Run/Hold
H Setpoint Temperature (SP)
I Measured Temperature
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Auto/
Manual Disabled. The unit is always in 'Auto' mode
RUN/HOLD -
Used to start, stop or pause a program. Short presses
cause it to alternate between 'Run' and 'Hold', but if it is
held for 2 seconds the programmer goes into 'Reset' mode
where it behaves as a simple controller.
Up + Down +
To adjust the value of a parameter. Used to change the
setpoint when the unit is being used as a simple controller
('Reset' mode). Holding down gives an accelerated
parameter change.
Page
Allows access to the parameters within the controller; most
lists and parameters are hidden from the operator as they
contain factory-set values which should not be altered. A
single press of the page key shows the temperature units,
normally °C; further presses reveal the lists indicated in the
Navigation Diagram.
Scroll
Allows access to the parameters within a 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 the program is paused
to allow the temperature to catch up with a heating or
cooling rate which is too fast).
Output
Indicator
OP1 indicates that the programmer is calling for heat to be
supplied.
OP2 is not used.
SP2 and REM Not generally used; indicate 'Second' or 'Remote' setpoint
in use.
Operation as a Simple Controller
Press RUN/HOLD for 2 seconds to go into 'Reset' mode. Use down or up from the
'Home List' (i.e. when the temperature is displayed) to adjust the setpoint. The unit
starts to control in the way indicated in Fig. 1.
Note that to use the Ramp Rate feature, as in Fig. 2, it is necessary to create a
program. See the following sections.
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4.0 2416 Controller

4.0 2416 Controller
4.3 Programming
Note that a currently active segment cannot be altered - put the programmer into 'Hold'
or 'Reset' whenever it is necessary to do so to alter a parameter. Go into 'Reset' mode
(i.e. press RUN/HOLD for 2 seconds) before starting to create or modify a program.
Press page until 'ProG LiSt' is displayed.
Press scroll to reveal the 'Holdback' and 'Loop Count' parameters. See sections 4.3.3
and 4.3.4 for a description of these.
Press scroll to display 'SEG.n' (segment number); use down or up to move to
the segment to be adjusted or created.
Press scroll to see the 'tYPE' (segment type); use down or up to change the
required segment type – see the table below.
Press scroll to access the parameters appropriate to the type of segment chosen –
see the following table – and use down or up to alter the values.
The final segment should be of type 'End', unless all program segments 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 previous target
temperature. 10ths of a minutes are allowed.
SteP tGt A new target temperature to be achieved as quickly as
possible.
CaLL PrG.n
cyc.n
Only applicable to 2416P8. Calls another stored program given
by 'PrG.n' as a subroutine, running it the number of times
given by 'cyc.n".
End End.t
'Dwel' holds the temperature at the last target value. 'RSET'
returns to simple controller operation; if the setpoint is set to
zero then this effectively turns the heating off. 'SoP' sets the
power to 0% – use of this is not recommended.
4.3.1 Programming Tips
Make sure the basic setpoint is set to zero to avoid unexpected heating at the end of a
program.
16

If all segments are used so that there is no 'End' segment, then on completion the
program automatically goes into 'Dwell'.
Dwell segments of length zero can be included. This is a way of allowing space for
future program changes.
For an example of program creation, see section 4.3.6.
4.3.2 Multi-program model (2416P8)
The 'Program Edit' list contains the extra parameter 'PrG.n' and the 'Run' list contains
the extra parameter 'PrG'. These features allow selection of the program to be edited
or to be operated.
The extra segment type 'cALL' allows one program to call another as a subroutine; use
this feature to create one or more long programs.
4.3.3 Holdback
"Holdback' can be used to prevent the program from operating ahead of the actual
heating or cooling.
In the program list, scroll to the 'Holdback' parameter and use down or up to
set the holdback type as follows:
Band Holdback applies to both heating and
cooling
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 program is held up until the
temperature comes within range again.
The standard setting for holdback is OFF.
4.3.4 Program Cycling
The 'Loop Count' parameter 'CYC.n' can be set to control the number of times the
program is run.
If 'CYC.n' = 1, the program stops at the end segment.
If 'CYC.n' = 5 (for example), the program runs 5 times: at the 'End' segment it returns
to segment 1, until the 5th time through when it stops.
If 'CYC.n' = cont, the program never ends: it cycles continuously.
4.3.5 Running a Program
Press Run/ Hold to light up the 'Run' light. The program starts to operate.
To view the progress of a program from the 'Home' list, press scroll to reveal the
current segment ('SEG') and the total program time remaining in hours ('PrG.t').
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4.0 2416 Controller

4.0 2416 Controller
For a more detailed view, press page to access the 'Run' list page and scroll to see
its contents as shown in the Navigation Diagram below. Provided the unit is first put into
'Hold' mode, temporary changes may be made to parameters; these apply only until
the program ends or is reset.
To pause a program, press Run/ Hold; the 'Hold' light comes on. To terminate a
program, press Run/ Hold for 2 seconds; the 'Run' and 'Hold' lights go out.
While the program is operating, the working setpoint is shown in the lower display.
4.3.6 Program example
The following sequence of entries creates and runs the program.
1. Press page key until 'ProG LiSt' is displayed.
2. Press scroll until 'CYC.n' is displayed and use the arrow key to select 1.
3. Press scroll until 'SEG.n' is displayed and use the arrow key to select 1.
4. Press scroll until 'tYPE' is displayed and use the arrow key to select rmP.r.
5. Press scroll until 'tGt' is displayed and use the arrow key to select 600.
6. Press scroll until 'rAtE' is displayed and use the arrow key to select 5.0.
7. Press scroll until 'SEG.n' is displayed and use the arrow key to select 2.
8. Press scroll until 'tYPE' is 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 the arrow key to select 60.0.
14. Press scroll until 'SEG.n' is displayed and use the arrow key to select 4.
15. Press scroll until 'tYPE' is displayed and use the arrow key to select 'dwEll'.
16. Press scroll until 'dur' is displayed and use the arrow key to select 30.
17. Press scroll until 'SEG.n' is displayed and use the arrow key to select 5.
18. Press scroll until 'tYPE' is displayed and use the arrow key to select rmP.r.
19. Press scroll until 'tGt' is displayed and use the arrow key to select 30.
20. Press scroll until 'rAtE' is displayed and use the arrow key to select 5.0.
21. Press scroll until 'SEG.n' is displayed and use the arrow key to select 6.
22. Press scroll until 'tYPE' is displayed and use the arrow key to select 'End'.
23. Press scroll until 'End.t' is displayed and use the arrow key to select 'dwEll'.
24. Press the page key until you return to the main display.
25. Press the 'Run' key. The program operates.
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4.4 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.
4.4.1 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
4.4.2 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
4.4.3 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
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.
4.4.4 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
19
4.0 2416 Controller

4.0 2416 Controller
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.
4.5 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 the replacement
controller.
Ease apart the two lugs at the side; grip the instrument and withdraw it from its sleeve;
push in the replacement.
20