VERDER CARBOLITE GERO E Series Manual

Installation, Operation and Maintenance Instructions
1200°C E-Range Tube Furnace - EVA Model: 450mm
3216 Controller
EVA 12/450B + 3216 Controller
MEN-EVA12450B-004_3216 (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 6
1.1 Switches and Lights 6
1.2 General Warnings 6
1.3 Warning Labels 7
2.0 Installation 9
2.1 Unpacking and Handling 9
2.2 Siting 9
2.3 Setting Up 10
2.3.1 Figure - Vertical tube furnace model mounted on its stand. 11
2.3.2 Figure - Assembling the stand. 11
2.3.3 Figure - Mounting the furnace onto the vertical stand. 11
2.3.4 Figure -Tube furnace positioned horizontally on the stand. 12
2.3.5 Figure - Exploded view showing how to fit the work tube in the EVA 13
2.3.6 Figure - Tube support 14
2.3.7 Figure - Tube support assembly 14
2.3.8 Figure - Tube support and end seal assembly 15
2.3.9 Figure - Tube support and end seal assembly 15
2.3.10 Figure - View showing how to support the work tube in a vertical ori-
entation. 16
2.4 Setting Up - Without a Stand 16
2.4.1 Figure - Tube furnace shown without a stand for customers own mount-
ing as an example. 16
2.5 Electrical Connections 18
3.0 3216 Controller 19
3.1 PID control 19
3.2 3216P1 19
3.3 3216P5 19
3.4 Operation 19
3.4.1 Controller Layout 19
3.4.2 Keys 20
3.5 Quick Start Guide 20
3.5.1 Operation as a simple controller 20
3.5.2 Changing the Setpoint 20
3.5.3 Using the Controller 20
2

3.5.4 Understanding User Levels 21
3.6 Setting up the Controller 22
3.6.1 Maximum Output Power 22
3.6.2 Customer ID 22
3.6.3 Units 22
3.6.4 Language 22
3.6.5 Scrolling Text 23
3.6.6 Customer Calibration 23
3.6.7 Holdback 24
3.7 Programming 25
3.7.1 Creating a Program 25
3.7.2 Program Number (3216P5 Only) 25
3.7.3 Ramp Units 25
3.7.4 Dwell Units 25
3.7.5 Holdback 25
3.7.6 Ramp Rate 25
3.7.7 Target Setpoint 25
3.7.8 Dwell Time 25
3.7.9 Running a Program 26
3.7.10 Program Status 26
3.7.11 Process Value 26
3.7.12 PSP, Segment Type and Number 26
3.8 Controller Options 29
3.8.1 Digital Communications - RS232 29
3.8.2 Digital Communications - RS485 29
3.8.3 Comms Address 29
3.8.4 Alarm Option 30
3.9 Temperature Controller Replacement 30
3.10 3216 Controller Navigation Diagram 30
4.0 2132 Over-Temperature Controller Description (if fitted) 32
4.1 Description 32
4.2 Operation 32
4.2.1 Controls 32
4.2.2 Operation 33
4.2.3 Over-Temperature Operation 33
4.2.4 Over-Temperature Alarm 33
4.2.5 Resetting the Over-Temperature Alarm 33
4.2.6 Sensor Break 33
4.3 Audible Alarm 34
3

4.4 Navigation Diagram 34
5.0 Operation 35
5.1 Operating Cycle 35
5.2 Safe Operation of the Furnace 35
5.3 General Operating Advice 36
5.4 Operator Safety 36
5.5 Tube Life 37
5.6 Pressure 37
5.7 Gas Tightness 38
6.0 Maintenance 39
6.1 General Maintenance 39
6.2 Maintenance Schedule 39
6.2.1 Cleaning 41
6.3 Calibration 41
6.4 After-Sales Service 41
6.5 Recommended Spare Parts and Spare Parts Kit 41
7.0 Repairs and Replacements 42
7.1 Safety Warning - Disconnection from Power Supply 42
7.2 Safety Warning - Refractory Fibre Insulation 42
7.3 Temperature Controller Replacement 42
7.4 Solid-state Relay Replacement 43
7.5 Thermocouple Replacement 43
7.6 Element Replacement 43
7.7 Fuse Replacement 44
8.0 Fault Analysis 45
A. Furnace Does Not Heat Up 45
B. Product Overheats 46
9.0 Wiring Diagrams 47
9.1 WA-11-30 47
9.2 WA-11-31 48
9.3 WA-12-30 49
9.4 WA-12-31 49
10.0 Fuses and Power Settings 50
10.1 Fuses 50
10.2 Power Settings 51
4

11.0 Specifications 52
11.1 Environment 52
Furnace drying out process 53
5

1.0 Symbols and Warnings
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.
6

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.
7
1.0 Symbols and Warnings

1.0 Symbols and Warnings
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 ele-
ments.
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.
8

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.
9
2.0 Installation

2.0 Installation
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 vertical tube furnace models must have their stands assembled, the furnace
mounted on the stand and their work tubes fitted before they can be used.
Assembling the stand and mounting the furnace
Tools required: 4 mm Allen key.
The assembly of the vertical stand is as follows with reference to 2.3.1, 2.3.2 and 2.3.3.
Place the vertical stand base item (1) on the floor or bench on which it is to be
assembled.
lPosition the vertical stand upright (2) on the stand base in line with the fixing holder.
lSecure the stand upright to the base using the 6 x M6 dome cap screws (4) and wash-
ers (3) supplied.
lPartially screw in the top M6 screw knobs, 2 x (6) into the frame upright as shown in
2.3.3.
lHook the furnace onto the top screw knobs. This may take 2 people to lift the fur-
nace.
lFit the bottom screw knobs x 2 and tighten all four.
10

2.3.1 Figure - Vertical tube furnace model
mounted on its stand.
2.3.2 Figure - Assembling the
stand.
Index to numbered items in Figure 2.3.2 and
Figure 2.3.3
1. Vertical stand base
2. Vertical stand upright
3. Fixing screws M6 x 16 dome cap screw
4. Washer M6
5. Tube furnace
6. M6 screw knob
2.3.3 Figure - Mounting the fur-
nace onto the vertical stand.
11
2.0 Installation

2.0 Installation
Using the tube furnace horizontally
The furnace can be used either with the stand
vertically as shown in 2.3.3 or horizontally as
shown in 2.3.4.
To use horizontally simply tip the stand over
into the horizontal position making sure that
the flexible conduits are not trapped beneath
the frame. This may take 2 people to do on
the largest models.
The position of the furnace on the stand can
be adjusted if necessary.
Note: To prevent injury to the operator and
damage to the furnace this must only be
done when the furnace is switched OFF and is
cold. 2.3.4 Figure -Tube furnace posi-
tioned horizontally on the stand.
Fitting the standard length work tube in the furnace.
Tools required: 4 mm Allen key.
Note that the split tube furnace can only be used with the extended length work tube.
This is to allow the work tube to be held in place when the furnace is opened in the
vertical position. The diameter of the work tube is a customer order option and
therefore varies between tube furnaces. The fitting of the work tube is as follows with
reference to 2.3.5. 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.
lRemove the top work tube end guard (item 8) hen remove the work tube adaptor fix-
ing bracket (4) that holds the work tube end stop (7) and the work tube adaptor (3)
in place.
Note (1) it might be easier to do this with the furnace in the horizontal position as
shown in 2.3.4.
Note (2) 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 bottom stop (7). 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 slides in. For long work tubes it is important to support and line up the work tube
as it is pushed through the furnace. It may also take 2 people to perform this oper-
ation.
lReassemble the work tube end stop (7), work tube adaptor bracket (4) and the tube
end guard (8).
12

Index to numbered items in Figure 2.3.5
1. Tube furnace
2. Work tube adaptor (size dependent on work
tube diameter)
3. Work tube (size diameter customer option)
4. Work tube adaptor fixing bracket
5. Fixing screws M6 x 15
6. Washer M6
7. Work tube end stop (dependent on work tube
diameter)
8. Tube furnace end guard 2.3.5 Figure - Exploded
view showing how to fit the
work tube in the EVA
Fitting the extended work tube in a furnace
Tools required: 4 mm Allen key
The fitting of the work tube is as follows with reference to Figure 2.3.5. Extended work
tubes are 450 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.
Note it is easier to fit the work tube with the furnace in the horizontal position as shown
in figure 2.3.4.
To fit the work tube in a vertical orientation follow the steps below. Omit the use of the
end seal if not required. The same tube support design will work with or without the
tube end seal in place.
WARNING - If clamps are used without an end seal, care should be
taken not to over tighten on to a bare tube, especially if the tube is
either quartz or thin wall section.
lBefore the extended work tube can be fitted, the work tube end stops for the stand-
ard length work tube 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, item 15, figure 2.2. Use supplied M6 button head
screws and supplied washers.
lFit the extended work tube guard, item 14, figure 2.2. Use supplied M6 button head
screws and supplied washers.
lRe-fit furnace end guard, item 13, figure 2.2. Use supplied M6 button head screws
and supplied washers.
lFit tube end seal assembly as shown in figure 2.2. refer to manual that was provided
with the replacement end seals or detailed fitting instructions.
lFit tube support bracket, item 7, figure 2.2. Use supplied M6 button head screws and
supplied washers.
lFinally, fit tube support collar, (5) using item (6) until the tube is secure enough for
use in a vertical arrangement. Fitting arrangement is shown in figure 2.2.
13
2.0 Installation

2.0 Installation
lFigure 2.2 - shows an exploded view of all the required parts.
lFigure 2.2 - shows the assembled parts as they would be used.
2.3.6 Figure - Tube support
2.3.7 Figure - Tube support assembly
14

2.3.8 Figure - Tube support and end seal assembly
2.3.9 Figure - Tube support and end seal assembly
For extra stability of the tube, repeat the assembly instructions above (as shown in
figure 2.3.10
15
2.0 Installation

2.0 Installation
2.3.10 Figure - View showing how to support the work tube in a vertical orientation.
2.4 Setting Up - Without a Stand
Any of the E-range vertical furnaces can be supplied without a stand for either wall
mounting (using wall bracket order option) or installation in customer's test
rig/mounting frame.
It is the customer’s responsibility to carry out a risk assessment on the
siting and mounting of the furnace and to ensure that it is operated in a
safe manner, see section 2.2 for the recommended siting instructions.
The fitting of the work tube is covered in the previous section.
2.4.1 Figure - Tube furnace shown without a stand for customers own mounting as
an example.
16

Index to numbered items in Figure 2.4.1
1. Control Box
2. Furnace Body
3. Connecting conduit between furnace and control box
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
17
2.0 Installation

2.0 Installation
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.
2.5 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
10.2.
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 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
18

3.0 3216 Controller
3.1 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.
3.2 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.
3.3 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.
3.4 Operation
3.4.1 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
19
3.0 3216 Controller

3.0 3216 Controller
3.4.2 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.
3.5 Quick Start Guide
3.5.1 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).
3.5.2 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.
3.5.3 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.
20