VERDER CARBOLITE GERO G Series Manual

Installation, Operation and Maintenance Instructions
1200°C G-Range Tube Furnace - GHA Model: 900mm
2416 Controller
GHA 12/900 + 2416 Controller
MEN-GHA120900-003_2416 (09-01-2019)

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 Work Tubes and Fittings 8
2.4 Electrical Connections 10
2.5 Reconfiguring and Adjusting for Voltage 12
3.0 2416 Controller 13
3.1 Description 13
3.2 Operation 15
3.3 Programming 17
3.3.1 Programming Tips 17
3.3.2 Multi-program model (2416P8) 18
3.3.3 Holdback 18
3.3.4 Program Cycling 18
3.3.5 Running a Program 18
3.3.6 Program example 19
3.4 Controller Options 20
3.4.1 Digital Communications - RS232 20
3.4.2 Digital Communications - RS485 20
3.4.3 Comms Address 20
3.4.4 Alarm Option 21
3.5 Temperature Controller Replacement 21
3.6 Navigation Diagram 22
4.0 2132 Over-Temperature Controller Description (if fitted) 23
4.1 Description 23
4.2 Operation 23
4.2.1 Controls 23
4.2.2 Operation 24
4.2.3 Over-Temperature Operation 24
4.2.4 Over-Temperature Alarm 24
2

4.2.5 Resetting the Over-Temperature Alarm 24
4.2.6 Sensor Break 24
4.3 Audible Alarm 25
4.4 Navigation Diagram 25
5.0 Operation 26
5.1 Operating Cycle 26
5.2 General Operating Advice 26
5.3 Operator Safety 27
5.4 Tube Life 27
5.5 Pressure 27
5.6 Gas Tightness 28
5.7 Running at Low Temperatures 28
6.0 Maintenance 29
6.1 General Maintenance 29
6.2 Maintenance Schedule 29
6.2.1 Cleaning 31
6.3 Calibration 31
6.4 After-Sales Service 31
6.5 Recommended Spare Parts and Spare Parts Kit 31
7.0 Repairs and Replacements 32
7.1 Safety Warning - Disconnection from Power Supply 32
7.2 Safety Warning - Refractory Fibre Insulation 32
7.3 Temperature Controller Replacement 32
7.4 Solid-state Relay Replacement 33
7.5 Thermocouple Replacement 33
7.6 Element Replacement 34
7.7 Fuse Replacement 35
8.0 Fault Analysis 36
A. Furnace Does Not Heat Up 36
B. Product Overheats 37
9.0 Wiring Diagrams 38
9.1 WA-11-31 38
9.2 WA-U3-31 39
10.0 Fuses and Power Settings 41
10.1 Fuses 41
10.2 Power Settings 42
3

11.0 Specifications 43
11.1 Environment 43
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 or moving the product always lift it by its base or by both ends of the
main body. Never lift it by its work tube or the surrounding insulation. Use two or more
people to carry the product and control box. Remove any packing material from inside
the product before use.
If an optional or special stand is separately supplied, assemble the product on to it.
Some models may be supplied for customer mounting and may require customer
preparation of mounting components before installation.
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.
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.
6

Ensure that the product is placed in such a way that it can be quickly switched off or
disconnected from the electrical supply.
This horizontal tube product is supplied with the controls in an integral base (or, to
order, with the base control panel blanked off and the controls in a separate box). A
horizontal tube support kit.
All G-range tube furnaces have “modular” heating elements in which resistance wire is
partially embedded in vacuum formed light-weight refractory fibre. The modules are
150 mm long. In all standard models the two end elements (one at each end) are rated
at 1170 W maximum, while the other (centre) elements are rated at 780 W.
All models are supplied with a pair of “tube adaptors”, which can be made to suit any
work tube size up to 170 mm outside diameter. Spare or replacement adaptors can be
ordered.
The horizontal models generally require no special setting up. Observe the above
paragraph on siting. See section 2.3 for work tube and end adaptor considerations.
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.
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2.0 Installation

2.0 Installation
2.3 Work Tubes and Fittings
Tubes of various diameters and
lengths may be fitted.
Type C: minimum length for the
product.
Type D: 400 mm longer than C, to
allow for the fitting of end seals.
A pair of removable 'end adaptors' form part of the end insulation. These may be blank
(no hole) or may have a hole to suit a work tube, depending on the customer order.
Additional adaptors may be ordered to suit different work tube sizes. Check that the end
adaptors are correct for the tube: if not, seek advice from Carbolite Gero. Small
alterations to the hole in the adaptors may be made with a file, but first read the section
on ceramic fibre safety 7.2. To insert a work tube it is often convenient to use a long
pole (such as a broom handle) to guide it into the far end of the product.
For optimum temperature uniformity, insulating plugs should be placed in the tube ends
as shown in fig.1. With a long work tube, the stem of the plug assembly should line up
with the end of the tube as in fig.2. Alignment of radiation shields is similar to that of
plugs.
If stainless steel seals with gas inlets are supplied, they are to be fitted as shown in
fig.3; the stem of any insulating plug should touch the seal.
Horizontal use: if heavy fittings are to be clamped to the end of an extended work tube
they can increase the bending stress at the centre of the tube. Support such fittings in
such a way that expansion of the tube is allowed. A horizontal tube support kit can be
supplied for this purpose.
If a metal work tube is being used in the product, ensure that it is earthed. See the
"Safety Warning" under "Operator Safety".
8

Fig 1 - Insulating Plug
(standard length tube) Key
A Tube
B Insulating Plug
C Stem
Fig 2 - Insulating Plug
(long work tube)
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2.0 Installation

2.0 Installation
Key
A Clamp
B Seal plate
C 'O' Ring seal
D Seal sleeve
E Clamp seal
F End plate
Key
A Clamp
B End plate
CClamp seal (between Seal
sleeve and Clamp
D Seal sleeve
ESeal plate & 'O' Ring seal
(underneath clamp)
F Tube
Fig 3 'Twin Clamp' End Seal
For assembly details refer to the separate work tube end seal manual.
2.4 Electrical Connections
Connection by a qualified electrician is recommended.
All models covered by this manual may be ordered for single phase A.C. supply, which
may be Live to Neutral non-reversible, Live to Neutral reversible or Live to Live.
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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).
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:
2- or
3-phase L1 Black to phase 1
L2 Black to phase 2
L3 Black to phase 3 (except 2-phase)
N Light Blue to neutral (except delta)
PE Green/ Yellow to earth (ground)
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2.0 Installation

2.0 Installation
2.5 Reconfiguring and Adjusting for Voltage
The standard single-phase models can operate over the voltage range 200 - 240 V. The
2-phase models can operate over the range 380/220 V to 415/240 V. The 3-phase
models can operate over the range 380/220 V to 415/240 V.
The product is wired according to the original order and conversion from 1-phase to 2-
phase or 1-phase to 3-phase is not possible. To check for voltage setting within the
appropriate range, or to change to another setting, follow the instructions in section
10.0.
Special Voltages
The products can be specially made to suit certain special voltages, such as 440/254 or
480/277.
Due to unbalanced phases, the furnaces cannot be made to suit 3-phase without neutral
of 380 V or above.
Products made for special voltages are generally not convertible between configurations
and voltages.
12

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.
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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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3.0 2416 Controller

3.0 2416 Controller
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 3.3.6.
3.3.2 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.
3.3.3 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.
3.3.4 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.
3.3.5 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').
18

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.
3.3.6 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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3.0 2416 Controller

3.0 2416 Controller
3.4 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.
3.4.1 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
3.4.2 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
3.4.3 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.
20