VERDER CARBOLITE GERO 2416 Series Handbuch

Installation, Operation and Maintenance Instructions

1200°C E-Range Tube Furnace - EVA Model: 600mm

2416 Controller

EVA 12/600B + 2416 Controller

MEN-EVA12600B-003_2416 (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 5

1.1 Switches and Lights 5

1.2 General Warnings 5

1.3 Warning Labels 6

2.0 Installation 8

2.1 Unpacking and Handling 8

2.2 Siting 8

2.3 Setting Up 9

2.3.1 Figure - Vertical tube furnace model mounted on its stand. 10

2.3.2 Figure - Assembling the stand. 10

2.3.3 Figure - Mounting the furnace onto the vertical stand. 10

2.3.4 Figure -Tube furnace positioned horizontally on the stand. 11

2.3.5 Figure - Exploded view showing how to fit the work tube in the EVA 12

2.3.6 Figure - Tube support 13

2.3.7 Figure - Tube support assembly 13

2.3.8 Figure - Tube support and end seal assembly 14

2.3.9 Figure - Tube support and end seal assembly 14

2.3.10 Figure - View showing how to support the work tube in a vertical ori-

entation. 15

2.4 Setting Up - Without a Stand 15

2.4.1 Figure - Tube furnace shown without a stand for customers own mount-

ing as an example. 15

2.5 Electrical Connections 17

3.0 2416 Controller 18

3.1 Description 18

3.2 Operation 20

3.3 Programming 22

3.3.1 Programming Tips 22

3.3.2 Multi-program model (2416P8) 23

3.3.3 Holdback 23

3.3.4 Program Cycling 23

3.3.5 Running a Program 23

3.3.6 Program example 24

3.4 Controller Options 25

3.4.1 Digital Communications - RS232 25

3.4.2 Digital Communications - RS485 25

3.4.3 Comms Address 25

3.4.4 Alarm Option 25

3.5 Temperature Controller Replacement 26

3.6 Navigation Diagram 27

4.0 2132 Over-Temperature Controller Description (if fitted) 28

4.1 Description 28

4.2 Operation 28

4.2.1 Controls 28

4.2.2 Operation 29

4.2.3 Over-Temperature Operation 29

4.2.4 Over-Temperature Alarm 29

4.2.5 Resetting the Over-Temperature Alarm 29

4.2.6 Sensor Break 29

4.3 Audible Alarm 30

4.4 Navigation Diagram 30

5.0 Operation 31

5.1 Operating Cycle 31

5.2 Safe Operation of the Furnace 31

5.3 General Operating Advice 32

5.4 Operator Safety 32

5.5 Tube Life 33

5.6 Pressure 33

5.7 Gas Tightness 34

6.0 Maintenance 35

6.1 General Maintenance 35

6.2 Maintenance Schedule 35

6.2.1 Cleaning 37

6.3 Calibration 37

6.4 After-Sales Service 37

6.5 Recommended Spare Parts and Spare Parts Kit 37

7.0 Repairs and Replacements 38

7.1 Safety Warning - Disconnection from Power Supply 38

7.2 Safety Warning - Refractory Fibre Insulation 38

7.3 Temperature Controller Replacement 38

7.4 Solid-state Relay Replacement 39

7.5 Thermocouple Replacement 39

7.6 Element Replacement 39

7.7 Fuse Replacement 40

8.0 Fault Analysis 41

A. Furnace Does Not Heat Up 41

B. Product Overheats 42

9.0 Wiring Diagrams 43

9.1 WA-11-30 43

9.2 WA-11-31 44

9.3 WA-12-30 45

9.4 WA-12-31 45

10.0 Fuses and Power Settings 46

10.1 Fuses 46

10.2 Power Settings 47

11.0 Specifications 48

11.1 Environment 48

Furnace drying out process 49

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.

1.0 Symbols and Warnings

Caution – Double Pole/Neutral Fusing

1.3 Warning Labels

On the front control panel there are 2 warning labels as shown in figure 1.3.1; they are

numbered 7 and 8. These warnings must be followed for the safe operation of this

furnace.

7- Warning label - Do not operate without a work tube.

The furnace must not be operated without the correctly sized work tube

and correspond work tube adaptors or it could be possible for an

operator to access electrically live element coils that could cause serious

injury or death.

8- Warning label - Switch off the furnace before loading and

unloading.

The furnace heaters must be switched OFF using the heater switch, item

2 in figure 1.3.1, when the furnace is being loaded or unloaded. The

work tube can become electrically conductive at high temperatures,

presenting a possible hazard to the operator. If element failure is left

undetected the element could collapse onto the work tube.

Figure 1.3.1 - Control Box layout and warning

labels.

Figure 1.3.2- Back of control box showing

mains lead socket

Index to numbered items in Figure 1.3.1 and 1.3.2

1. Electrical supply switch - switches electrical power ON and OFF to the furnace.

2. Heater switch - switches electrical power ON and OFF to the furnace heating

elements.

3. Heater ON light - indicates that the furnace heating elements are energized.

4. Product rating label indicating the product serial number and electrical inform-

ation.

5. Access holes to front panel fixing screws.

6. Warning label - Disconnect the mains supply before removing this cover.

7. Warning label - Do not operate without a work tube.

8. Warning label - Switch OFF the furnace before loading and unloading.

9. Electrical power lead socket.

10. Back panel fixing screws.

1.0 Symbols and Warnings

2.0 Installation

2.0 Installation

If the product has been transported or stored in humid conditions it must

be dried out completely before operating the furnace. Contact Carbolite

Gero Service for instructions.

2.1 Unpacking and Handling

When unpacking or moving the product, always lift it by its base or both ends of the

main body. Never lift it by the end insulation or by a work tube. It may take 2 or 3

people to lift the furnace, depending on the size and configuration.

NOTE: This product contains Refractory Ceramic Fibre (also known as

Alumino Silicate Wool - ASW). For precautions and advice on handling

this material see section 7.2.

2.2 Siting

Place the product on a level surface in a well ventilated area.

Site away from other sources of heat and on a non-flammable surface that is resistant

to accidental spillage or hot materials.

The surface on which the equipment is mounted should be stable and not subject to

movement or vibrations.

The height of the mounting surface is important to avoid operator strain when loading

and unloading samples.

Unless otherwise stated elsewhere in this manual, ensure that there is at least 150

mm of free space around the back and sides of the product. Clear space is required

above the product to dissipate heat.

Work tubes:

It is recommended that the work tube has either insulation plugs or

radiation shields fitted to minimise heat loss from both ends of the work

tube. If the work tube has open ends, a significant amount of energy

could be radiated from the ends of the work tube. Adjacent surfaces

should always be made from a non-flammable material.

Ensure that the ends of the work tube are positioned at least 500 mm

away from any adjacent surface so that any energy radiated cannot heat

an adjacent surface to a dangerous temperature.

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.

2.0 Installation

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.

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