VERDER CARBOLITE GERO E Series Manual

Installation, Operation and Maintenance Instructions
1200°C E-Range Tube Furnaces - EHA Model: 300mm
2416 Controller
EHA 12/300B + 2416 Controller
MEN-EHA12300B-003_2416 (09-07-2019)

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
1.3 Warning Labels 6
2.0 Installation 8
2.1 Unpacking and Handling 8
2.2 Siting 8
2.3 Setting Up 9
2.4 Electrical Connections 15
3.0 2416 Controller 16
3.1 Description 16
3.2 Operation 18
3.3 Programming 20
3.3.1 Programming Tips 20
3.3.2 Multi-program model (2416P8) 21
3.3.3 Holdback 21
3.3.4 Program Cycling 21
3.3.5 Running a Program 21
3.3.6 Program example 22
3.4 Controller Options 23
3.4.1 Digital Communications - RS232 23
3.4.2 Digital Communications - RS485 23
3.4.3 Comms Address 23
3.4.4 Alarm Option 23
3.5 Temperature Controller Replacement 24
3.6 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
2

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 Safe Operation of the Furnace 29
5.3 General Operating Advice 30
5.4 Operator Safety 30
5.5 Tube Life 31
5.6 Pressure 31
5.7 Gas Tightness 32
6.0 Operation 33
6.1 Operating Cycle 33
6.2 Control Method 33
6.3 Safe Operation of the Furnace 33
6.4 3-Zone Control Methods 34
A. Back-to-Back Thermocouples 35
B. Retransmission of Setpoint 35
C. Independent Control 36
6.5 General Operating Advice 36
6.6 Operator Safety 36
6.7 Tube Life 37
6.8 Pressure 37
6.9 Gas Tightness 37
7.0 Maintenance 39
7.1 General Maintenance 39
7.2 Maintenance Schedule 39
7.2.1 Cleaning 41
7.3 Calibration 41
7.4 After-Sales Service 41
7.5 Recommended Spare Parts and Spare Parts Kit 41
8.0 Maintenance 42
8.1 General Maintenance 42
8.2 Maintenance Schedule 42
8.2.1 Cleaning 44
8.3 Calibration 44
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8.4 After-Sales Service 44
8.5 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 Temperature Controller Replacement 45
9.4 Solid-state Relay Replacement 46
9.5 Thermocouple Replacement 46
9.6 Element Replacement 46
9.7 Fuse Replacement 47
10.0 Fault Analysis 48
A. Furnace Does Not Heat Up 48
B. Product Overheats 49
11.0 Wiring Diagrams 50
11.1 WA-11-30 50
11.2 WA-11-31 51
11.3 WA-12-30 52
11.4 WA-12-31 53
12.0 Wiring Diagrams 54
12.1 WC-13-30 54
12.2 WC-13-31 54
13.0 Fuses and Power Settings 55
13.1 Fuses 55
13.2 Power Settings 56
14.0 Specifications 57
14.1 Environment 57
Furnace drying out process 58
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.
Heat switch: the switch disconnects power to the heating elements;
unless this switch is OFF there is a danger of electric shock when
inserting objects into the product.
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.
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1.0 Symbols and Warnings

1.0 Symbols and Warnings
Caution – Double Pole/Neutral Fusing
1.3 Warning Labels
On the front control panel there are 2 warning labels as shown in figure 1.3.1; they are
numbered 7 and 8. These warnings must be followed for the safe operation of this
furnace.
7- Warning label - Do not operate without a work tube.
The furnace must not be operated without the correctly sized work tube
and correspond work tube adaptors or it could be possible for an
operator to access electrically live element coils that could cause serious
injury or death.
8- Warning label - Switch off the furnace before loading and
unloading.
The furnace heaters must be switched OFF using the heater switch, item
2 in figure 1.3.1, when the furnace is being loaded or unloaded. The
work tube can become electrically conductive at high temperatures,
presenting a possible hazard to the operator. If element failure is left
undetected the element could collapse onto the work tube.
6

Figure 1.3.1 - Control Box layout and warning
labels.
Figure 1.3.2- Back of control box showing
mains lead socket
Index to numbered items in Figure 1.3.1 and 1.3.2
1. Electrical supply switch - switches electrical power ON and OFF to the furnace.
2. Heater switch - switches electrical power ON and OFF to the furnace heating
elements.
3. Heater ON light - indicates that the furnace heating elements are energized.
4. Product rating label indicating the product serial number and electrical inform-
ation.
5. Access holes to front panel fixing screws.
6. Warning label - Disconnect the mains supply before removing this cover.
7. Warning label - Do not operate without a work tube.
8. Warning label - Switch OFF the furnace before loading and unloading.
9. Electrical power lead socket.
10. Back panel fixing screws.
7
1.0 Symbols and Warnings

2.0 Installation
2.0 Installation
If the product has been transported or stored in humid conditions it must
be dried out completely before operating the furnace. Contact Carbolite
Gero Service for instructions.
2.1 Unpacking and Handling
When unpacking or moving the product, always lift it by its base or both ends of the
main body. Never lift it by the end insulation or by a work tube. It may take 2 or 3
people to lift the furnace, depending on the size and configuration.
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.
2.2 Siting
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.
Work tubes:
It is recommended that the work tube has either insulation plugs or
radiation shields fitted to minimise heat loss from both ends of the work
tube. If the work tube has open ends, a significant amount of energy
could be radiated from the ends of the work tube. Adjacent surfaces
should always be made from a non-flammable material.
Ensure that the ends of the work tube are positioned at least 500 mm
away from any adjacent surface so that any energy radiated cannot heat
an adjacent surface to a dangerous temperature.
8

If the product is to be used in a process which could liberate hazardous gases, then it
should be installed together with a suitable fume extraction system.
Ensure that the product is placed in such a way that it can be quickly switched off or
disconnected from the electrical supply.
2.3 Setting Up
The horizontal models must have work tubes fitted before being used. The diameter of
the work tube is a customer order option and therefore varies between tube furnaces.
Note: If a metal work tube is being used in the furnace, ensure that it is
earthed. See 6.6.
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.
Fitting the standard length work tube to furnace
Tools required: 4 mm Allen key
Fitting work tube is as follows with reference to Figure 2.3.2. Please note that standard
length work tubes are also referred to as tubes suitable for working in air. They are 150
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2.0 Installation

2.0 Installation
mm longer than the heated length of the furnace (see the Specifications table at the
back of this manual). Read section 9.2 before fitting the work tube.
Figure 2.3.1 - Furnace model mounted on a
control box
Figure 2.3.2 - Exploded view showing how to fit
the work tube in the furnace
Index to numbered items in Figure 2.3.2
1. Tube furnace body
2. Work tube (diameter customer option)
3. Work tube adaptor (size dependent on work tube diameter)
4. Work tube adaptor fixing bracket
5. Work tube end stop (size dependent on work tube diameter)
6. Fixing screws M6 x 15
7. Washer M6
8. Tube furnace end guard
lRemove the work tube end guard (8) then remove the work tube adaptor fixing
bracket (4) that holds in place the work tube end stop (5) and the end adaptor (3)
from one side only. Note that if a different work tube with a different outer diameter
is being fitted it will be necessary to fit new correctly sized work tube adaptors (3) in
which case both end guards and work tube adaptor fixing brackets (4) will need
removing.
lSlide the work tube into the furnace through the work tube adaptor (3) until it
reaches the opposite work tube end stop (5). Note that the work might be a tight fit
when it is new and may need to be twisted backwards and forwards slightly as it
slides in. For long work tubes it may be necessary to use a long wooden pole to sup-
port and line up the work tube as it pushed through. It may also take 2 people to per-
form this operation.
lReassemble the work tube end stop (5), work tube adaptor bracket (4) and tube end
guard (8).
Fitting the extended work tube in the furnace
Tools required 4 mm Allen key.
10

Fitting of the work tube is as follows with reference to Figure 2.3.2 to 2.3.8.
lBefore the extended work tube can be fitted, the work tube end stops for the stand-
ard length work tube (item 5 in figure 2.3.2 ) must be removed from both ends of
the furnace. This is done by removing the furnace end guard (8) and the work tube
adaptor brackets (4) to release the work tube end stop (5). The brackets should
then be refitted.
lFit the tube support bracket, (5), figure 2.3.4. Use the M6 button head screws and
washers supplied.
lFit the extended work tube guard, (4), figure 2.3.5. Use the M6 button head screws
and washers supplied.
lRe-fit furnace end guard, (3), figure 2.3.6. Use the M6 button head screws and wash-
ers supplied.
lIf supplied, fit the optional tube end seal assembly as shown in figures 2.3.9. and
2.3.10. Refer to manual MEN-ENDSEALS-01 for detailed fitting instructions.
lFit the tube support bracket, (1), figure 2.3.7. Use the M6 button head screws and
washers supplied.
lFinally, fit tube support collar, (2) and secure figure tight using (6) until the tube is
secure to be used in a vertical arrangement. The fitting arrangement is shown in fig-
ure 2.3.8.
lFigure 2.3.3 - shows an exploded view of all the required parts.
lFigure 2.3.8 - shows the assembled parts as they would be used.
Figure 2.3.3
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2.0 Installation

2.0 Installation
Figure 2.3.4 Figure 2.3.5 Figure 2.3.6
Figure 2.3.7 Figure 2.3.8
12

Figure 2.3.9 - Tube support and end seal assembly
Figure 2.3.10 - Tube support and end seal assembly
Index to numbered items in figure 2.3.3 - 2.3.10
1. Tube support bracket
2. Tube support collar
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2.0 Installation

2.0 Installation
3. End guards
4. Extended work tube guard
5. End adaptor
6. Fluted grip knob
Fitting the Optional Insulation Plugs and Radiation Shield
For optimum temperature uniformity, insulation plugs or radiation shields should be
placed in the work tube ends as shown below. With a standard work tube, the insulation
plug must be fitted as shown in figure A.
If a gas/vacuum end seal is fitted, either horizontally or vertically, the insulation plug
hooks onto the end seal hook; see figure B.
Alignment of radiation shields is similar to that of insulation plugs, see figure C.
If a metal work tube is being used in the furnace, ensure that it is earthed. See the
safety warning in section 6.6.
Figure A- Cross-section view showing standard
length work tube insulation plug fitted
Figure B- Cross-section view showing extended
work tube insulation plug fitted
Figure C- Cross-section view showing an extended length work tube with a radiation shield fitted
14

2.4 Electrical Connections
Connection by a qualified electrician is recommended.
All furnaces in the range are single-phase and operate over the voltage ranges 100 to
110 volts or 200 - 240 volts. Check the rating label before connection, see "Warning
Labels" for location of rating label. To check that the OP.Hi setting is correct for the
appropriate voltage, or to change to another setting, follow the instructions in section
13.2.
The electrical supply should be fused at the next standard size equal to or higher than
the design current. Where a supply cable is supplied there are internal supply fuses, in
which case customer fusing is preferred but not essential. See section 13.0 for furnace
rating power, current and fusing information.
The external connection should be either a permanent connection to a fused isolator
supply or to a socket on a fused isolator supply; the isolating switch must operate on
both conductors. Make sure that the isolator switch is within easy reach of the furnace
operator.
Supply Terminal
Label
UK/ Europe
Cable Colour
USA/
Canada
Common
Cable
Colours
Supply Type
Live -
Neutral
Reversible or
Live - Live
1-phase
L Brown Red or
Black To live to either power conductor
N Blue White To neutral to the other power
conductor
PE Green/ Yellow
Green or
Green/
Yellow
To earth
(ground) to earth (ground)
Terminal Connection Details
15
2.0 Installation

3.0 2416 Controller
3.0 2416 Controller
3.1 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.
16

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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3.0 2416 Controller

3.0 2416 Controller
3.2 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 6.0 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
18

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.
19
3.0 2416 Controller

3.0 2416 Controller
3.3 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 3.3.3
and 3.3.4 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.
3.3.1 Programming Tips
Make sure the basic setpoint is set to zero to avoid unexpected heating at the end of a
program.
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