VERDER CARBOLITE GERO E Series Manual

Installation, Operation and Maintenance Instructions
1200°C E-Range Tube Furnaces - EST Model: 450mm
2416 Controller
EST 12/450B + 2416 Controller
MEN-EST12450B-003_2416 (02-08-2019)

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
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 16
3.0 2416 Controller 17
3.1 Description 17
3.2 Operation 19
3.3 Programming 21
3.3.1 Programming Tips 21
3.3.2 Multi-program model (2416P8) 22
3.3.3 Holdback 22
3.3.4 Program Cycling 22
3.3.5 Running a Program 22
3.3.6 Program example 23
3.4 Controller Options 24
3.4.1 Digital Communications - RS232 24
3.4.2 Digital Communications - RS485 24
3.4.3 Comms Address 24
3.4.4 Alarm Option 25
3.5 Temperature Controller Replacement 25
3.6 Navigation Diagram 26
4.0 2132 Over-Temperature Controller Description (if fitted) 27
4.1 Description 27
4.2 Operation 27
4.2.1 Controls 27
4.2.2 Operation 28
4.2.3 Over-Temperature Operation 28
4.2.4 Over-Temperature Alarm 28
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4.2.5 Resetting the Over-Temperature Alarm 28
4.2.6 Sensor Break 28
4.3 Audible Alarm 29
4.4 Navigation Diagram 29
5.0 Operation 30
5.1 Operating Cycle 30
5.2 Safe Operation of the Furnace 30
5.3 General Operating Advice 31
5.4 Operator Safety 31
5.5 Tube Life 32
5.6 Pressure 32
5.7 Gas Tightness 33
6.0 Maintenance 34
6.1 General Maintenance 34
6.2 Maintenance Schedule 34
6.2.1 Cleaning 36
6.2.2 Safety Switch 36
6.3 Calibration 36
6.4 After-Sales Service 37
6.5 Recommended Spare Parts and Spare Parts Kit 37
7.0 Repairs and Replacements 38
7.1 Safety Warning - Disconnection from Power Supply 38
7.2 Safety Warning - Refractory Fibre Insulation 38
7.3 Temperature Controller Replacement 38
7.4 Solid-state Relay Replacement 39
7.5 Thermocouple Replacement 39
7.6 Element Replacement 39
7.7 Fuse Replacement 40
8.0 Fault Analysis 41
A. Furnace Does Not Heat Up 41
B. Product Overheats 42
9.0 Wiring Diagrams 43
9.1 WA-11-30 43
9.2 WA-11-70 44
10.0 Fuses and Power Settings 45
10.1 Fuses 45
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10.2 Power Settings 46
11.0 Specifications 47
11.1 Environment 47
Furnace drying out process 48
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 7.2.
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 furnace models must have a work tube 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 5.4.
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 in a split tube furnace
No tools required.
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2.0 Installation

2.0 Installation
The fitting of the work tube is as follows with reference to figure 2.3.1. Please note that
standard length work tubes are also referred to as tubes suitable for working in air.
They are 150 mm longer than the heated length of the furnace (see the table in section
11.0). Read section 7.2 before fitting the work tube.
Figure 2.3.1 - view showing how to fit the standard length work tube in the split tube furnace. Note
that the right hand furnace end guard (8) has been removed from the view for clarity to show the
end adaptor and tube end stop.
lRelease the fixing clips (9 in figure 2.3.1), lift the lid by the handle (1).
lPlace the work tube into the bottom half of the furnace in the tube adaptors,
between the work tube end stops (5). Note that the work tube might be a tight fit
when it is new and may need to be twisted backwards and forwards slightly as it
is placed.
lLower the lid by the handle and refasten the clips.
lNote in Figure 2.3.1 the right hand furnace end guard (8) is not shown so that
the end adaptor (3) and tube end stop (5) can be seen. It is not necessary to
remove the guards to fit the work tube.
Index to numbered items in Figure 2.3.1 and 2.3.2
1. Top lifting handle
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
9. Fixing clip
10

Figure 2.3.2 - Close-up view of the tube end stop for a standard length work tube on the split tube
furnace. Note that the right hand furnace end guard (8) has been removed from the view for clarity
to show the end adaptor and tube end stop.
Fitting the extended work tube in the furnace
Tools required: 4 mm Allen key.
Fitting of the work tube is as follows, with reference to figures 2.3.1 to 2.3.10.
Before the extended work tube can be fitted, the work tube end stops for the standard
length work tube (item 5 in figure 2.3.1 and 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. The guards and brackets
should then be refitted.
lFit the tube support bracket, see (5) figure 2.3.5. Use the M6 button head screws
and washers supplied.
lFit the extended work tube guard, see (4) figure 2.3.6. Use the M6 button head
screws and washers supplied.
lRe-fit furnace end guards, see (3) figure 2.3.7. Use the M6 button head screws and
supplied washers.
lIf supplied, fit the optional tube end seal assembly as shown in figures 2.3.11 and
2.3.12. Refer to manual MEN-ENDSEALS-01 for detailed fitting instructions.
lFit the tube support bracket, see (1) figure 2.3.8. Use the M6 button head screws
and washers supplied.
lFinally, fit the tube support collar, (2) and secure tightly using (6), until the tube is
secure to be used in a vertical arrangement. The fitting arrangement is shown in fig-
ure 2.3.9.
lFigure 2.3.3 shows an exploded view of all the required parts.
lFigure 2.3.9 shows the assembled parts as they would be used.
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2.0 Installation

2.0 Installation
Figure 2.3.3
Figure 2.3.4 Figure 2.3.5 Figure 2.3.6
12

Figure 2.3.7 Figure 2.3.8 Figure 2.3.9
Figure 2.3.10- Tube support assembled
13
2.0 Installation

2.0 Installation
Figure 2.3.11- Tube support and end seal
Figure 2.3.12- Tube support and end seal assembly
Index to numbered items in Figure 2.3.3 - 2.3.12
1. Tube support bracket
2. Tube support collar
3. End guard
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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 5.4.
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
15
2.0 Installation

2.0 Installation
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
0.1.
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 10.0 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
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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.
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3.0 2416 Controller

3.0 2416 Controller
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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3.2 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 5.0 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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3.0 2416 Controller

3.0 2416 Controller
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.
20