VERDER CARBOLITE GERO PTC 12 Manual

Installation, Operation and Maintenance Instructions
1200 °C Thermocouple Calibration Furnace - PTC Model: 12/20
2132 Controller
PTC 12/20/150 + 2132 Controller
MEN-PTC1220-01_2132 (09-10-2018)

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 4
1.1 Switches and Lights 4
1.2 General Warnings 4
2.0 Installation 5
2.1 Unpacking and Handling 5
2.2 Siting and Setting Up 5
2.3 Electrical Connections 6
3.0 2132 Controller 8
3.1 Description 8
3.2 2132 Controller Operation 8
3.2.1 Controls 8
3.2.2 2132 Controller Operation 9
3.2.3 Basic Operation 9
3.2.4 Altering the Setpoint 9
3.2.5 Stopping and Starting Control 10
3.2.6 Altering the Ramp Rate 10
3.3 Operating with the Timer 11
3.3.1 Setting the Timer Mode 13
3.3.2 Setting the Time Period 13
3.3.3 Running with the Timer 13
3.3.4 Stopping the Timer 14
3.3.5 End of Time Period 15
3.3.6 Cancelling the Alarm 15
3.3.7 Program Example 15
3.4 Altering Power Limit 15
3.5 Audible Alarm 18
3.6 Temperature Controller Replacement 18
3.7 Navigation Diagram 19
4.0 Operation 21
4.1 Operating Cycle 21
4.2 General Operating Advice 21
4.3 Operator Safety 21
4.4 Instructions for Use as a Calibration Furnace 22
2

5.0 Maintenance 23
5.1 General Maintenance 23
5.2 Maintenance Schedule 23
5.2.1 Cleaning 25
5.3 Calibration 25
5.4 After-Sales Service 25
5.5 Recommended Spare Parts and Spare Parts Kit 25
5.6 Power Adjustment 25
6.0 Repairs and Replacements 27
6.1 Safety Warning - Disconnection from Power Supply 27
6.2 Safety Warning - Refractory Fibre Insulation 27
6.3 Temperature Controller Replacement 27
6.4 Solid-State Relay Replacement 28
6.5 Thermocouple Replacement 28
6.6 Element Replacement 28
7.0 Fault Analysis 29
A. Furnace Does Not Heat Up 29
B. Product Overheats 30
8.0 Wiring Diagrams 31
8.1 183/4/1006 31
9.0 Fuses and Power Settings 32
9.1 Fuses 32
9.2 Power Settings 32
10.0 Specifications 33
10.1 Environment 33
3

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.
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
4

2.0 Installation
2.1 Unpacking and Handling
Unpack the product and remove the transit clamp from the working end of the product
as follows:
lloosen the locking nut on the central clamp bolt;
lturn the bolt clockwise with a screwdriver to release the force on the clamping
device;
lremove the two screws which hold the transit clamp to the product;
lcarefully withdraw the transit clamp;
lretain the clamp.
If at any time the product is returned for repair or otherwise subject to arduous travel,
refit the transit clamp. The product must be cold before the clamp is fitted.
Underneath the product is a dual voltage switch. Set this correctly for the electrical
supply to be used: 115 V for 110 - 120 V, 230 V for 220 - 240 V.
NOTE: This product contains Refractory Ceramic Fibre (also known as
Alumino Silicate Wool - ASW). For precautions and advice on handling
this material see section 6.2.
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.
5
2.0 Installation

2.0 Installation
Depending on the application of the product, it may be appropriate to position it under
an extraction hood. Ensure the extraction hood is switched on during use.
Ensure that the product is placed in such a way that it can be quickly switched off or
disconnected from the electrical supply.
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.
2.3 Electrical Connections
Connection by a qualified electrician is recommended.
This product requires a single-phase A.C. supply with earth (ground), which may be Live
to Neutral non-reversible (polarised), Live to Neutral reversible (non-polarised), or Live
to Live.
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. For further information, please see wiring diagram 02047-5001.
6

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:
7
2.0 Installation

3.0 2132 Controller
3.0 2132 Controller
3.1 Description
The 2132 Controller is made by Eurotherm, and is fitted and configured by Carbolite
Gero for immediate use. It is a digital instrument with PID control algorithms.
The 2132 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.
lA ramp-to-setpoint feature, which may be used to limit the heating (or cooling).
lA timer function which allows for heating for a predetermined time, either from start
or from reaching temperature; or alternatively for delaying the start of heating.
lAn alarm output which may be used in conjunction with the timer, for example to
give an audible alarm at the end of the timing period.
3.2 2132 Controller Operation
3.2.1 Controls
Most Carbolite Gero products are fitted with an instrument switch which cuts off power
to the controller and other parts of the control circuit.
To operate the controller, power must be supplied to the product and the instrument
switch must be on. If a time switch is included in the product circuit, this must be in the
'ON' position.
When an over-temperature condition occurs, the controller cuts the power to a
contactor, which in turn cuts power to the heating elements. Power is not restored until
the controller is 'reset'.
Some components will operate after the over-temperature feature isolates the power
supply e.g. cooling fans will continue to operate, provided that there is a power supply
to the product. In some cases the product may not do so, if other options (such as a
door switch) are fitted.
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3.2.2 2132 Controller Operation
Key
A Alarm Light
B Page
C Scroll
D Down
E Up
F Display
When switched on, the controller lights up, goes through a short test routine and then
displays the measured temperature or the over-temperature setpoint.
The page key allows access to parameter lists within the controller.
A single press of the page key displays the temperature units, normally set to °C;
further presses reveal the lists indicated in the navigation diagram. See section 0.1.
The scroll key allows access to the parameters within a list. Some parameters are
display-only; others may be altered by the operator.
A single press of the scroll key in the 'Home' list displays the temperature units;
further presses reveal the parameters in the current list indicated in the navigation
diagram.
To return to the 'Home' list at any time, press page and scroll together, or wait
for 45 seconds.
The down and up keys are used to alter the setpoint or other parameter values.
3.2.3 Basic Operation
Normally no operator action is required other than entering the setpoint, as the
controller starts to control on being switched on, as described above.
3.2.4 Altering the Setpoint
With the display at 'Home', showing the measured temperature, press down or up
once to display the setpoint; press again or hold down to adjust it. The display returns
to the measured temperature when no key is pressed for 30 seconds.
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3.0 2132 Controller

3.0 2132 Controller
3.2.5 Stopping and Starting Control
It is possible to stop and start the controller without altering the setpoint. Press scroll
until the legend 'm-A' (manual/ auto) appears. In this controller, manual means OFF
and auto means ON. Press down or up once to show the current on/ off state:
'mAn' for OFF and 'Auto' for ON. Press down or up to change between manual and
auto (off and on) as required.
Note that timer modes 1 & 3 set the controller to 'mAn' at the end of the timing
period. If the controller unexpectedly does not control it may be in manual, possibly
as the result of previous use of the timer function.
3.2.6 Altering the Ramp Rate
It is only possible to limit the rate of heating by setting a ramp rate if the timer feature
is not in use.
To enable direct setting of the ramp rate, first ensure that the 'StAt' parameter and
'dwEll' parameter are both set to OFF (see sections 3.3.1 and 3.3.2).
Press scroll until 'SPrr' (setpoint ramp rate) is displayed. Use down or up to
display and adjust the value.
The ramp rate sets the maximum rate of heating or cooling in degrees per minute. A
value of OFF cancels the ramp rate, allowing heating and cooling at the maximum rate.
When this feature is in use, there is a “working setpoint” which can be viewed at any
time by scrolling to 'w.SP' and pressing or .
Fig 1 and fig 2 indicate the possible difference between operating without and with a
ramp-to-setpoint value (depending on the load and the value used).
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Fig 1 - Control without Ramp-to-Setpoint Fig 2 - Control with Ramp-to-Setpoint
Key
T1 Temperature
T2 Time
SP Setpoint
WSP Working Setpoint
AT Actual Temperature
3.3 Operating with the Timer
This controller can be used as a process timer allowing timed heating or timed delay,
according to the options in the table. There are 5 timer modes, but 2 of them are
affected by whether the setpoint ramp rate feature is being used, making 7 entries in
the table. The table also shows the status of the timer light on the controller. A visual
impression of the different modes is given in fig 3.
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3.0 2132 Controller

3.0 2132 Controller
Timer Mode Description Timer Light
mode 1
Timed dwell and
switch off
The timer starts timing when the
actual temperature is within 1 °C
of the setpoint. At the end of the
timing period, control switches
off (i.e. goes into Manual) to
allow cooling and 'End' flashes on
the display.
On while temperature is
reaching setpoint. On during
the timing period. Off from
the end of the timing period.
mode 2
Timed dwell and stay
on
The timer starts timing when the
actual temperature is within 1 °C
of the setpoint. At the end of the
timing period, control remains
on, maintaining the setpoint
temperature and 'End' flashes on
the display
On while temperature is
reaching setpoint. On during
the timing period. Off from
the end of the timing period.
mode 3, with SPrr off
Time from cold and
switch off
The timer starts timing
immediately. At the end of the
timing period, control switches
off (i.e. goes into Manual) to
allow cooling and 'End' flashes on
the display.
On during the timing period.
Off from the end of the timing
period.
mode 3, with SPrr
active
Dwell from working
setpoint and switch
off
The timer starts timing when the
working setpoint is within 1 °C of
the setpoint. At the end of the
timing period, control switches
off (i.e. goes into Manual) to
allow cooling and 'End' flashes on
the display.
On during the timing period.
Off from the end of the timing
period.
mode 4, with SPrr off
Time from cold and
stay on
The timer starts timing
immediately. At the end of the
timing period, control remains
on, maintaining the setpoint
temperature and 'End' flashes on
the display.
On during the timing period.
Off from the end of the timing
period.
mode 4, with SPrr
active
Dwell from working
setpoint and stay on
The timer starts timing when the
working setpoint is within 1 °C of
the setpoint. At the end of the
timing period, control remains
on, maintaining the setpoint
temperature and 'End' flashes on
the display.
On during the timing period.
Off from the end of the timing
period.
mode 5
Delayed switch on
The timer starts timing
immediately and control starts at
the end of the timing period.
There is no 'End' condition in this
mode.
On during the timing period.
Off from the end of the timing
period.
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3.3.1 Setting the Timer Mode
Scroll to 'tm.OP'; use or to view and alter the mode. The mode shows as 'OPt.1'
to 'OPt.5'.
It is not possible to alter the mode while the timer is operating; if the mode cannot be
altered, scroll to the 'StAt' parameter and set its value to OFF.
3.3.2 Setting the Time Period
Method 1
Scroll to 'tmr' (time remaining). Use or to view the remaining time; the units are
always in minutes. Use or to set or alter the time. Setting 'tmr' automatically
activates the timer; the 'm-A' parameter changes to 'Auto' and the 'StAt' parameter
changes to run.
Note that the 'tmr' display shows 0 (zero) during the last minute of timing and also
shows 0 when the time has expired. The timer light indicates whether timing is still in
progress.
Method 2
Scroll to 'dwEll' and use or to set the timing duration. The advantage of method 2
is that 'dwEll' need only be set once if repeated use of the same time period is required.
Scroll to 'StAt' and use or to set the parameter value to run. This copies the dwell
time into 'tmr' and activates the timer as in method 1.
3.3.3 Running with the Timer
Once the timer is activated by method 1 or 2 above, the control sequence depends on
the 'Timer' mode, as previously given in the table. Fig 3 gives another representation of
the timer action.
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3.0 2132 Controller

3.0 2132 Controller
Fig 3 - Timer Modes
Key
T1 Temperature
T2 Time
SP Setpoint
WSP Working Setpoint (if setpoint ramp rate active)
AT Actual Temperature
M245 Modes 2, 4 & 5
M13 Modes 1 & 3
TM Timing
E End
1 Mode 5
2 Reaching Temperature Modes 1 & 2
3 Modes 1 & 2
4 Modes 3 & 4 with setpoint ramp rate
5 Modes 3 & 4 with setpoint ramp rate off
6 Reaching temperature and continuing temperature Mode 5
7 Continuing at temperature modes 2 & 4, or cooling down modes 1 & 3
3.3.4 Stopping the Timer
To stop the timer at any time while it is operating, change the 'StAt User Calibration'
parameter to OFF. This is the same as reducing 'tmr' to zero. The controller then acts as
14

though it has reached the end of the time period.
3.3.5 End of Time Period
Modes 1 and 3: heating stops at the end of timing; the 'm-A' parameter changes to
'mAn'.
Modes 2 and 4: heating continues at the end of timing; the 'm-A' parameter remains at
'Auto'.
Mode 5: heating starts at the end of the timing period; the 'm-A' parameter remains at
'Auto'.
In modes 1 to 4 the alarm message 'End' flashes on the display at the end of timing;
the 'StAt' parameter remains at run.
In mode 5 there is no 'End' message; the 'StAt' parameter changes to OFF at the end of
timing.
3.3.6 Cancelling the Alarm
To acknowledge (cancel) the 'End' alarm, press page and scroll together; the 'StAt'
parameter changes to OFF.
Alternatively cancel the alarm by directly changing the 'StAt' parameter from run to
OFF.
3.3.7 Program Example
To heat up at 10 °C per minute to 500 °C; to hold at 500 °C for 1 hour; then to allow to
cool down.
(This example uses timing mode 1, as on the first row of the timer table, but also
includes the use of ramp rate).
To create this program
1. Start with display at home; use arrow keys to alter the setpoint to 500.
2. Press scroll until 'sp.rr' shows; use arrow key to set value to 10 (if you do not want
to limit the ramp rate, ignore this step or set the value to OFF)
3. Press scroll until 'tm.op' shows; use arrow key to set value to opt.1
4. Press scroll until 'dwell' shows; use arrow key to set value to 60
To operate this program
5. Press scroll until 'stat' shows; use arrow key to set value to run
lheating starts when run is set;
ltiming starts when the working setpoint reaches 499 °C;
lheating stops 61* minutes later and 'End' flashes on the display.
6. Cancel 'End' by pressing page and scroll together.
* note that the timer runs for an extra minute, when tmr has counted down to zero;
allow for this when testing the system with short durations such as 1 or 2 minutes.
3.4 Altering Power Limit
Overview
15
3.0 2132 Controller

3.0 2132 Controller
Depending on the furnace or oven model the power limit parameter OP.Hi (Output
High) may be accessible or hidden.
For silicon carbide heated furnaces the parameter is accessible to allow for
compensation for element ageing. In wire-heated chamber or tube furnaces, reducing
the power limit is a convenient method of improving control at low temperatures, as
outlined below.
The power limit may be set to zero to permit demonstration of the controls without
heating.
In many models the power limit setting depends on the supply voltage; usually the
furnace or oven manual contains details: if in doubt, contact Carbolite Gero for advice.
The power limit parameter does not apply to the over-temperature controller, if fitted.
Altering the value
Press page until oP (output list) is displayed. Press scroll until OP.Hi (Output High) is
displayed. Press down or up once to display the value of OP.Hi and write down the
value. To alter the value, use down or up .
Note: setting the value to zero prevents the furnace or oven from heating.
Caution: Do not increase the power limit value to a value above the
design level for the oven or furnace model, or to a value above that
correctly calculated for silicon carbide elements. The heating elements
could burn out, or other damage could be caused.
Control at Low Temperatures
If a product is to be used at temperatures much lower than its design maximum, control
stability can often be improved by reducing the power limit. Remember to make a
record of the original setting before altering the power limit.
Example: It is desired to operate a 1200 °C furnace at 300 °C. The normal control
settings can be expected to cause excessive overshoot as the furnace reaches
temperature. If the power limit OP.Hi is normally set to 100%, try a setting of 40%. This
should greatly reduce the overshoot. (There is no firm calculation rule to get this
example setting of 40% – experimentation may be required to achieve a good result.
Avoid power limits below approximately 30% – control accuracy is reduced at such
levels.)
Depending on the furnace or oven model the power limit parameter OP.Hi (Output
High) may be accessible or hidden.
For silicon carbide heated furnaces the parameter is accessible to allow for
compensation for element ageing. In wire-heated chamber or tube furnaces, reducing
the power limit is a convenient method of improving control at low temperatures, as
outlined above.
The power limit may be set to zero to permit demonstration of the controls without
heating.
In many models the power limit setting depends on the supply voltage; usually the
furnace or oven manual contains details: if in doubt, contact Carbolite Gero for advice.
16

User Calibration
The controller is calibrated for life at manufacture against known reference sources, but
there may be sensor errors or other system errors. User calibration allows
compensation for such errors and this controller allows for a user 2-point calibration.
This setting is password protected to avoid accidental alteration.
Page to iP, scroll to CAL.P and use up to alter the password. The password is 3. If
the correct password is entered, the display shows PASS. Scroll to CAL and use up or
down to observe the setting FACt (factory values, as manufactured) or USEr (user
values). Change to USEr.
NOTE: before checking the calibration of the controller, or of the complete system,
remember to reset the controller to factory calibration values by setting the CAL.P
parameter to FACt.
To enter a user calibration, scroll to each of the following parameters in turn and set the
desired values.
Pnt.L low temperature for which an offset is to be entered
OFS.L offset value for the low temperature
Pnt.H high temperature for which an offset is to be entered
OFS.H offset value for the high temperature
Example: the controller reads 3 °C low at 400 °C and 5 °C low at 1000 °C. The
parameter values should be Pnt.L=400, OFS.L=3, Pnt.H=1000, OFS.H=5.
Negative or positive values can be entered: if the controller is reading high, negative
offsets would be appropriate.
Fig 4 gives a graphical representation of the 2-point calibration.
Fig 4 - 2-Point Calibration
17
3.0 2132 Controller

3.0 2132 Controller
Key
A User Temperature Reading
B Factory Temperature Reading
UC User Calibration
UF Factory Calibration
3.5 Audible Alarm
If an audible alarm is supplied for use with the timer function, then it is normally
configured to sound at the 'End' condition and to go off when the alarm is acknowledged
as given in section 3.3.6.
It is not feasible to cover all possible alarm features which may be included by customer
special order, within this manual.
3.6 Temperature Controller Replacement
Before handling the controller: wear an anti-static wrist strap or
otherwise avoid any possibility of damage to the unit by static electricity.
Refer to the detailed instructions supplied with the replacement
controller.
Ease apart the two lugs at the side; grip the instrument and withdraw it from its sleeve;
push in the replacement.
18

3.7 Navigation Diagram
19
3.0 2132 Controller

3.0 2132 Controller
Key
HL Home List
IL Input List
OL Output List
AL Access List
1 Measured temperature; use arrow keys to access setpoint
2 Output power (read only)
3 Present only if SPrr in use
4 Manual/Auto (mAn = off, Auto = on)
5 Setpoint ramp rate OFF or value
6 Timer mode
7 Time remaining
8 Dwell time for timer
9 Timer status run or OFF
10 Enter password
11 If User Calibration
12 User 2-Point Calibration
13 Power limit setting, if present
14 For factory acess to lists and parameters not available to the operator
20