VERDER CARBOLITE GERO GHA 12/1050 Manual

Installation, Operation and Maintenance Instructions
1200°C G-Range Tube Furnace - GHA Model: 1050mm
3508 Controller
GHA 12/1050 + 3508 Controller
MEN-GHA121050-002_3508 (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 3508 Controller 13
3.1 PID control 13
3.2 3508P1 13
3.3 3508P10 13
3.4 3508P25 13
3.5 Basic Operation 14
3.5.1 Controller Layout 15
3.5.2 Keys 15
3.6 Quick Start Guide 15
3.6.1 Operation as a simple controller 15
3.6.2 Changing the Setpoint 15
3.6.3 Resetting the programmer 16
3.6.4 Understanding User Levels 16
3.7 Setting Up Controller 17
3.7.1 Maximum output power setting 17
3.7.2 Customer ID. 17
3.7.3 Units 18
3.7.4 Language 18
3.8 Programming 18
3.8.1 Programming Notes 18
3.8.2 Holdback 19
3.8.3 Wait Segments 19
3.8.4 Program Cycling 20
3.8.5 Creating a Program 20
3.8.6 Running a Program 21
2

3.8.7 To pause (hold) a program 22
3.8.8 To stop and reset a program 22
3.8.9 To run a different program (P10 and P25) 22
3.8.10 Program Status 22
3.8.11 Program Hold with Holdback 23
3.8.12 Power Failure Recovery 23
3.8.13 Alarms 23
3.8.14 Program Example 1 24
3.8.15 Program Example 2 26
3.9 Controller Options 28
3.9.1 Digital Communications - RS232 29
3.9.2 Digital Communications - RS485 29
3.9.3 Comms Address 29
3.9.4 Alarm Option 29
3.9.5 Remote Input and Output (Analogue Communications) 30
3.9.6 Program segment output 30
3.10 Temperature Controller Replacement 31
3.11 Controller Navigation Diagrams 31
3.11.1 Operator Level 1 - No Program Running 32
3.11.2 Operator Level 1 - Program Running 33
3.11.3 Supervisor Level 2 34
4.0 3508 Dual Loop Cascade Control (if fitted) 35
4.1 Principle of Cascade Control 35
4.2 Operation of Cascade Control 35
4.3 Bypassing Cascade Control 39
4.4 3508P1 Element Loop (Loop 2) 39
4.5 Caution 39
4.6 Over-Temperature Control 39
5.0 2132 Over-Temperature Controller Description (if fitted) 40
5.1 Description 40
5.2 Operation 40
5.2.1 Controls 40
5.2.2 Operation 41
5.2.3 Over-Temperature Operation 41
5.2.4 Over-Temperature Alarm 41
5.2.5 Resetting the Over-Temperature Alarm 41
5.2.6 Sensor Break 41
5.3 Audible Alarm 42
3

5.4 Navigation Diagram 42
6.0 Operation 43
6.1 Operating Cycle 43
6.2 General Operating Advice 43
6.3 Operator Safety 43
6.4 Tube Life 44
6.5 Pressure 44
6.6 Gas Tightness 45
6.7 Running at Low Temperatures 45
7.0 Maintenance 46
7.1 General Maintenance 46
7.2 Maintenance Schedule 46
7.2.1 Cleaning 48
7.3 Calibration 48
7.4 After-Sales Service 48
7.5 Recommended Spare Parts and Spare Parts Kit 48
8.0 Repairs and Replacements 49
8.1 Safety Warning - Disconnection from Power Supply 49
8.2 Safety Warning - Refractory Fibre Insulation 49
8.3 Temperature Controller Replacement 49
8.4 Solid-state Relay Replacement 50
8.5 Thermocouple Replacement 50
8.6 Element Replacement 51
8.7 Fuse Replacement 52
9.0 Fault Analysis 53
A. Furnace Does Not Heat Up 53
B. Product Overheats 54
10.0 Wiring Diagrams 55
10.1 WA-11-31 55
10.2 WA-U3-31 56
11.0 Fuses and Power Settings 58
11.1 Fuses 58
11.2 Power Settings 59
12.0 Specifications 60
12.1 Environment 60
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 8.2.
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.
7
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 8.2. 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)
9
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.
10

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)
11
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
11.0.
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 3508 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 3508P1
The 3508P1 is a digital temperature controller which uses PID algorithm to give
excellent temperature control when properly set. This controller can store and operate
a single program of up to 20 segments. The 3508P1 can also be used as a simple
temperature controller.
3.3 3508P10
The 3508P10 is a digital controller which uses PID algorithms to give excellent
temperature control when properly set. This controller can store 10 programs of up to
50 segments each. Programs can be operated individually or linked by a Call parameter
as sub-programs or to form single long programs. The 3508P10 can also be used as a
simple temperature controller.
3.4 3508P25
The 3508P25 is a digital temperature controller which uses PID algorithms to give
excellent temperature control when properly set. This controller has a maximum of 500
segments or 25 programs; each program has a maximum of 50 segments. For
example 3508P25 could store 10 programs with 50 segments or 25 programs with 20
segments. Programs can be operated individually or linked by a Call parameter as sub-
programs or to form single long programs. The 3508P25 can also be used as a simple
temperature controller.
13
3.0 3508 Controller

3.0 3508 Controller
3.5 Basic Operation
Key
A Alarm Indicator
B Power Output Indicator
C Not Used
D Runs, Holds, Resets the current program
E Page
F Scroll
G Down
H Up
I Power Output Percentage
JProgram Setpoint Temperature (PSP) when a program is
running
K Setpoint Temperature (SP) when basic controlling
14

L Measurement Temperature
M Measurement Units
3.5.1 Controller Layout
3.5.2 Keys
A/ Man - Disabled
RUN/ HOLD - Runs, Holds or Resets the current program. Hold down for 3
seconds to Reset.
Page Key Scrolls through the page headings. Hold down for 3 seconds
to access further levels, pass codes are required.
Scroll Key Scrolls through parameters listed on pages.
Arrow Keys +Adjust parameter values.
Page and
Scroll
together +Press together to return to the home display or to
acknowledge an alarm.
Page and Up
together +Press together quickly to scroll back up the page headings.
Scroll and Up
together +Press together quickly to scroll back up a parameter list.
Pressing any other combination of keys together has no effect.
Note: If no keys are pressed for 1 minute, the display returns to Home.
3.6 Quick Start Guide
3.6.1 Operation as a simple controller
When switched on the controller goes through a short test routine and then shows the
measured temperature. Below it, the setpoint temperature (SP) and percentage of
power output.
The controller will immediately attempt to reach the set temperature and 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.
3.6.2 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 at the top of the display, indicating that
the product is heating.
15
3.0 3508 Controller

3.0 3508 Controller
The controller will immediately attempt to reach the set temperature and 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.
3.6.3 Resetting the programmer
To reset the programmer to simple controller mode, press RUN/HOLD for 2 seconds.
Operating the current program
• To avoid unwanted heating at the end of a program, set the SP temperature to zero
before operating a program.
• Ensure the programmer is reset to simple controller mode before starting a program
by pressing RUN/HOLD for 2 seconds.
• To start the program, press RUN/HOLD twice, RUN will light up on the display.
The displayed Program Setpoint (PSP) follows ramps, dwells and steps as the program
runs. The SP temperature of the controller does not apply when a program is operating.
• To pause the program, press RUN/HOLD.
• To stop the program and return to simple controlling (reset), press RUN/HOLD for 2
seconds.
When the program ends, the programmer will either:
• Automatically reset to operation as a simple controller.
• Dwell at the last temperature of the program (with the RUN indicator flashing), until
the operator presses RUN/HOLD for 2 seconds to manually reset, or presses RUN/HOLD
once to restart the program.
• Turn power to the elements down to zero.
3.6.4 Understanding User Levels
There are two levels in the controller; Level 1(Operator) and Level 2 (Supervisor).
Level 1 (Operator) is for the day-to-day operation of the controller is not protected by a
security code. There are 3 pages at this level. Page 1, Customer Identity, can only be
altered in level 2. Page 2 shows the current program status. Page 3 is for writing and
viewing programs.
Level 2 (Supervisor) requires a security code to enter, but once enable, provides access
to additional parameters. A further 4 pages are accessible in this level as follows; Home
, Customer identity, Control Output Hi percentage, Units.
16

To Enter Level 2:
1. Press and hold page for 3 seconds. The display will show “Access Goto Level
1”
2. Press up to select level 2. After a short pause the display will show “Access
Pass code”.
3. Press up or down to enter the pass code. Pass is momentarily displayed.
After a short pause the display will return to home, the controller is now in level 2.
When Level 2 operations have been completed the supervisor must return to Level
1 manually. It is not necessary to enter a code when going from a higher level to a
lower level.
To Return to Level 1:
1. Press and hold page for 3 seconds. The display will show “Access Goto Level 2.
2. Press down to go to level 1. After a short pause the display will revert to
home, the controller is now in level 1.
3.7 Setting Up Controller
Before using the controller (or during its lifetime) certain parameters may have to be
set, depending on specific requirements. To do this the controller must be set to
Supervisor Level 2, see "Controller Navigation Diagrams".
3.7.1 Maximum output power setting
Press page until "Control Output Hi" is displayed. Press up or down to adjust
the value.
Depending on the product model, the maximum power output setting may be
accessible or locked.
For silicon carbide heated products the parameter is accessible to allow compensation
for element ageing.
In many models the maximum power output setting depends on the electrical supply
voltage, refer to section 11.0.
3.7.2 Customer ID.
A product identity number can be entered if required. This may be used to identify one
of many units, for production or quality control systems.
Press page until "Customer Identity" is displayed. Press up or down to select a
number.
17
3.0 3508 Controller

3.0 3508 Controller
3.7.3 Units
Press page until "Units" is displayed. Press up or down to select:
C Celsius
F Fahrenheit
K Kelvin
3.7.4 Language
The text on the 3508 Controller can be shown in different languages, this can only be set
at the factory and therefore must be specified at the time of placing an order.
3.8 Programming
3.8.1 Programming Notes
Programs can be created in Level 1 or Level 2 of the 3508 Controller.
For the P10 and P25, new programs can be created while the current program is
operating.
To avoid unwanted heating at the end of a program, set the controller setpoint
temperature to zero before operating a program.
All new unused programs show only 1 segment of type 'End'.
The minimum number of segments for a program is 2. The second being an 'End' type.
Ramp-to-setpoint control. To achieve this, create a two segment program. Set the first
segment type as 'Rate' or 'Time'. Set the second segment type 'End' type' Dwell'.
For the P10 and P25, programs can be linked together using a 'Call' segment. However,
a lower number program can not be called and a program can not be ended with a call
segment.
A program can be ended in four ways:
1. With 'End' segment set to S.OP the power to the elements is turned down to 0%,
no matter what the 'Setpoint' temperature is.
2. With 'End' segment set to 'Reset' and the 'Setpoint' temperature turned down to
zero, power to the elements will be 0%. To do this set the 'Setpoint' temperature
to the minimum possible. For type B thermocouples this will be below zero.
3. With the 'End' segment set to 'Reset'. The controller will try to reach and maintain
the 'Setpoint' temperature in place before the program started.
4. With the 'End' segment set to 'Dwell'. The controller will dwell at the 'PSP' of the
last segment ("RUN" indicator flashes), until it is reset.
To reduce the number of segments in a program, change the last required segment to
an 'End' type.
You will be asked to press to cancel or for OK.
To cancel all segments in a program, change the first segment to an 'End' type.
18

To alter parameters or segments of an operating program, this program must be held
or reset. Press RUN/ HOLD to pause the program, or press RUN/ HOLD for 2 seconds to
reset.
3.8.2 Holdback
Holdback can be used to prevent the program from operating ahead of the actual
heating or cooling.
The holdback value is the amount, in degrees, by which the program setpoint can run
ahead of the measured temperature before holdback operates. The value applies to a
whole program.
To set the value press page twice, press scroll until 'Holdback Value' appears and
press up or down to set.
Holdback can be used in 'Rate', 'Time' and 'Step' segments.
• For 'Rate' and 'Time' segments holdback will operate during the segment.
• For a 'Step' segment holdback delays continuation to the next segment until the step
target is reached.
The 'Holdback Type' can be set as follows:
• Low Applies to heating only
• High Applies to cooling only
• Band Applies to both heating and cooling
• Off Holdback is switched off
To set the holdback type, press page twice, then press scroll until the display
shows 'Holdback Type' for each segment and press up or down to set.
The default setting for holdback is 'OFF'.
3.8.3 Wait Segments
Wait prevents the program proceeding to the next segment, in a similar way to
holdback, until the selected ‘Wait-For’ parameter has been met. There are 5 ‘Wait For’
parameters. The first 4 only work if there are configured inputs to the controller.
1. PrgIn1 Wait until Input 1 is true
2. PrgIn2 Wait until Input 2 is true
3. PrgIn 1&2 Wait until Inputs 1 AND 2 are true
4. PrgIn 1or2 Wait until Inputs 1 OR 2 is true
5. PVWaitIP Wait until the measured temperature reaches a threshold value before
continuing. It can operate in one of 4 ways:
1. 'Abs Hi' Wait until the measured temperature is greater than or equal to a
value 'WaitVal' set for that segment.
2. 'Abs Lo' Wait until the measured temperature is less than or equal to a value
'WaitVal' set for that segment.
3. 'Dev Hi’ Wait until the measured temperature exceeds a fixed* threshold by
an amount ‘WaitVal’ set for that segment.
19
3.0 3508 Controller

3.0 3508 Controller
4. ‘Dev Lo’ Wait until the measured temperature drops below a fixed* threshold
by an amount ‘WaitVal’ set for that segment.
* The fixed threshold used by deviation parameters is set in the configuration level of
the programmer and if required should be requested when purchasing a product from
Carbolite Gero.
3.8.4 Program Cycling
The 'Cycles' parameter sets the number of times the program will operate.
The default setting is 1 cycle.
To change the number of cycles, press page twice, then press scroll until the
display shows 'Prog Cycles', then press up to set a finite number of cycles up to 999.
Or press down to set cycling to continuous.
3.8.5 Creating a Program
From the home display, press page three times to get to the programming page, the
display will show “ProgEdit 1”.
Program number
On P10 or P25 models press up or down to select a new program number. The
display will show that new programs have only one segment.
Holdback Value
Press scroll until the display shows 'Holdback Value". If required: Press up or
down to set a value. This value will be used in any segment where a 'Holdback Type'
is set.
Ramp Units
These apply to Rate segments only. Press scroll until the display shows 'Ramp Units'.
Press up or down to select the ramp units of degrees per Hour, Min or Sec.
Number of program cycles
Press scroll until the display shows 'Cycles'. Press up or down to select more
than one cycle.
Now create all the segments for your program, finishing with an 'End' segment. When
parameters for each segment have been entered the display goes to the next segment
number.
Segment Type
Press scroll until the display shows 'Segment Type'. Press up or down to select
'Rate', 'Time', 'Dwell', 'Step', 'Wait', 'GoBack', 'Call' or 'End'.
20