VERDER CARBOLITE GERO E Series Handbuch

Installation, Operation and Maintenance Instructions

1200°C E-Range Tube Furnaces - EHA Model: 300mm

2416 Controller

EHA 12/300B + 2416 Controller

MEN-EHA12300B-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

2.4 Electrical Connections 15

3.0 2416 Controller 16

3.1 Description 16

3.2 Operation 18

3.3 Programming 20

3.3.1 Programming Tips 20

3.3.2 Multi-program model (2416P8) 21

3.3.3 Holdback 21

3.3.4 Program Cycling 21

3.3.5 Running a Program 21

3.3.6 Program example 22

3.4 Controller Options 23

3.4.1 Digital Communications - RS232 23

3.4.2 Digital Communications - RS485 23

3.4.3 Comms Address 23

3.4.4 Alarm Option 23

3.5 Temperature Controller Replacement 24

3.6 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 Safe Operation of the Furnace 29

5.3 General Operating Advice 30

5.4 Operator Safety 30

5.5 Tube Life 31

5.6 Pressure 31

5.7 Gas Tightness 32

6.0 Operation 33

6.1 Operating Cycle 33

6.2 Control Method 33

6.3 Safe Operation of the Furnace 33

6.4 3-Zone Control Methods 34

A. Back-to-Back Thermocouples 35

B. Retransmission of Setpoint 35

C. Independent Control 36

6.5 General Operating Advice 36

6.6 Operator Safety 36

6.7 Tube Life 37

6.8 Pressure 37

6.9 Gas Tightness 37

7.0 Maintenance 39

7.1 General Maintenance 39

7.2 Maintenance Schedule 39

7.2.1 Cleaning 41

7.3 Calibration 41

7.4 After-Sales Service 41

7.5 Recommended Spare Parts and Spare Parts Kit 41

8.0 Maintenance 42

8.1 General Maintenance 42

8.2 Maintenance Schedule 42

8.2.1 Cleaning 44

8.3 Calibration 44

8.4 After-Sales Service 44

8.5 Recommended Spare Parts and Spare Parts Kit 44

9.0 Repairs and Replacements 45

9.1 Safety Warning - Disconnection from Power Supply 45

9.2 Safety Warning - Refractory Fibre Insulation 45

9.3 Temperature Controller Replacement 45

9.4 Solid-state Relay Replacement 46

9.5 Thermocouple Replacement 46

9.6 Element Replacement 46

9.7 Fuse Replacement 47

10.0 Fault Analysis 48

A. Furnace Does Not Heat Up 48

B. Product Overheats 49

11.0 Wiring Diagrams 50

11.1 WA-11-30 50

11.2 WA-11-31 51

11.3 WA-12-30 52

11.4 WA-12-31 53

12.0 Wiring Diagrams 54

12.1 WC-13-30 54

12.2 WC-13-31 54

13.0 Fuses and Power Settings 55

13.1 Fuses 55

13.2 Power Settings 56

14.0 Specifications 57

14.1 Environment 57

Furnace drying out process 58

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 9.2.

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 horizontal models must have work tubes fitted before being used. The diameter of

the work tube is a customer order option and therefore varies between tube furnaces.

Note: If a metal work tube is being used in the furnace, ensure that it is

earthed. See 6.6.

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.

Fitting the standard length work tube to furnace

Tools required: 4 mm Allen key

Fitting work tube is as follows with reference to Figure 2.3.2. Please note that standard

length work tubes are also referred to as tubes suitable for working in air. They are 150

2.0 Installation

mm longer than the heated length of the furnace (see the Specifications table at the

back of this manual). Read section 9.2 before fitting the work tube.

Figure 2.3.1 - Furnace model mounted on a

control box

Figure 2.3.2 - Exploded view showing how to fit

the work tube in the furnace

Index to numbered items in Figure 2.3.2

1. Tube furnace body

2. Work tube (diameter customer option)

3. Work tube adaptor (size dependent on work tube diameter)

4. Work tube adaptor fixing bracket

5. Work tube end stop (size dependent on work tube diameter)

6. Fixing screws M6 x 15

7. Washer M6

8. Tube furnace end guard

lRemove the work tube end guard (8) then remove the work tube adaptor fixing

bracket (4) that holds in place the work tube end stop (5) and the end adaptor (3)

from one side only. Note that if a different work tube with a different outer diameter

is being fitted it will be necessary to fit new correctly sized work tube adaptors (3) in

which case both end guards and work tube adaptor fixing brackets (4) will need

removing.

lSlide the work tube into the furnace through the work tube adaptor (3) until it

reaches the opposite work tube end stop (5). Note that the work might be a tight fit

when it is new and may need to be twisted backwards and forwards slightly as it

slides in. For long work tubes it may be necessary to use a long wooden pole to sup-

port and line up the work tube as it pushed through. It may also take 2 people to per-

form this operation.

lReassemble the work tube end stop (5), work tube adaptor bracket (4) and tube end

guard (8).

Fitting the extended work tube in the furnace

Tools required 4 mm Allen key.

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