VERDER CARBOLITE GERO AAF-BAL 11/17 Handbuch

Installation, Operation and Maintenance Instructions

1100°C Ashing Furnace - AAF-BAL Model: 17 Litres

3216CC Controller

AAF-BAL 11/17 + 3216CC Controller

MEN-AAF-BAL-1117-006_3216CC (01-08-2019)

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 Chimney 7

2.4 Electrical Connections 8

2.5 Balance and Weighing Platform 10

3.0 3216CC Controller 12

3.1 3216CC 12

3.2 PID control 12

3.3 Operation 12

3.3.1 Controller Layout 12

3.3.2 Keys 13

3.4 Quick Start Guide 13

3.4.1 Operation as a simple controller 13

3.4.2 Changing the Setpoint 13

3.4.3 Using the Controller 13

3.4.4 Understanding User Levels 14

3.5 Setting up the Controller 15

3.5.1 Setpoint Ramp Rate 15

3.5.1.1 Setting Setpoint Ramp Rate 15

3.5.1.2 Running with Ramp Rate 15

3.5.2 Maximum Output Power 16

3.5.3 Customer ID 16

3.5.4 Units 16

3.5.5 Language 16

3.6 Timer 16

3.6.1 Setting the Timer 16

3.6.2 Dwell Timer 17

3.6.3 Delayed Switch On Timer 17

3.6.4 Soft Start Timer 18

3.7 Running a Timer 18

3.7.1 Dwell Timer 19

3.7.2 Power Failure While Using Dwell Timer 19

3.7.3 Running Dwell Timer with Ramp Rate 20

3.7.4 Running Dwell Timer with Ramp Rate & Threshold 20

3.7.5 Delayed Switch on Timer 20

3.7.6 Running Delay Timer with Ramp Rate 21

3.7.7 Delay timer with ramp rate functions 21

3.7.8 Power Failure While Using Delay Timer 22

3.7.9 Soft start Timer 22

3.7.10 Power Failure While Using Soft Start Timer 22

3.7.11 Ramp Rate with Soft Start Timer 22

3.7.12 Time Remaining 22

3.7.13 Alarms 23

3.8 Controller Options 23

3.8.1 Digital Communications - RS232 23

3.8.2 Digital Communications - RS485 24

3.8.3 Comms Address 24

3.8.4 Alarm Option 24

3.9 3216CC Navigation Diagram 25

4.0 2132 Over-Temperature Controller Description (if fitted) 26

4.1 Description 26

4.2 Operation 26

4.2.1 Controls 26

4.2.2 Operation 27

4.2.3 Over-Temperature Operation 27

4.2.4 Over-Temperature Alarm 27

4.2.5 Resetting the Over-Temperature Alarm 27

4.2.6 Sensor Break 27

4.3 Audible Alarm 28

4.4 Navigation Diagram 28

5.0 Operation 29

5.1 Operating Cycle 29

5.2 General Operating Notes 29

5.3 Use of Probes 30

5.4 Atmospheres 30

5.5 Operator Safety 30

5.6 Power Adjustment 31

6.0 Maintenance 32

6.1 General Maintenance 32

6.2 Maintenance Schedule 32

6.2.1 Cleaning 34

6.2.2 Safety Switch 34

6.3 Calibration 34

6.4 After-Sales Service 35

6.5 Recommended Spare Parts and Spare Parts Kit 35

7.0 Repairs and Replacements 36

7.1 Safety Warning - Disconnection from Power Supply 36

7.2 Safety Warning - Refractory Fibre Insulation 36

7.3 Temperature Controller Replacement 36

7.4 Solid-State Relay Replacement 37

7.5 Thermocouple Replacement 37

7.6 Panel Element Replacement 37

7.7 Door Plug Replacement 39

7.8 Fuse Replacement 39

8.0 Fault Analysis 41

A. Furnace Does Not Heat Up 41

B. Product Overheats 42

9.0 Wiring Diagrams 43

9.1 WA-U3-30 44

9.2 WA-U3-31 46

10.0 Fuses and Power Settings 48

10.1 Fuses 48

10.2 Power Settings 48

11.0 Specifications 49

11.1 Environment 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.

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

1.0 Symbols and Warnings

2.0 Installation

2.0 Installation

2.1 Unpacking and Handling

When unpacking and handling the product, always lift it by its base. Do not use the door

or any other projecting cover or component to support the equipment when moving it.

Use two or more people to carry the product where possible.

Carefully remove any packing material from inside and around the product before use.

Avoid damaging the surrounding insulation when removing packing materials.

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.

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 Chimney

The chimney is a length of tubing. If it is supplied unfitted, then fit it through the hole in

the top of the case.

If the product is to be used to heat substances that emit fumes, a fume extraction duct

of approximately 75 mm - 150 mm inlet diameter may be placed directly above the

chimney outlet.

Do not make a sealed connection to the product chimney as this causes excessive

airflow through the chamber and results in poor temperature uniformity.

2.0 Installation

Key

A Duct (75mm-150mm diameter)

B Ambient air is drawn into duct

C Chimney

D 25mm vertical gap between chimney and duct

2.4 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.

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:

2.0 Installation

2.5 Balance and Weighing Platform

1. Assemble the balance unit as shown below:

2. Ensure that the furnace is on a stable, level surface.

3. Place the balance on the support plate below the furnace chamber, ensuring the

front legs are located in the slots on the support plate.

4. Level the balance as detailed in the balance manufacturer’s instruction manual.

5. Open the furnace door.

6. One by one, insert the 3 ceramic tubes through the holes in the hearth, and locate

them over the three corresponding placement guides on the top of the balance.

Note: Due to the secure fit, you may need to twist the tubes down the guides in

order for them to make full contact with the weighing platform.

7. If required, loosen the bolts securing the bottom support plate, and adjust pos-

itioning to move the balance.

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