VERDER CARBOLITE GERO E Series Handbuch

Installation, Operation and Maintenance Instructions

1200°C E-Range Tube Furnaces - EST Model: 450mm

2416 Controller

EST 12/450B + 2416 Controller

MEN-EST12450B-003_2416 (02-08-2019)

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

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 16

3.0 2416 Controller 17

3.1 Description 17

3.2 Operation 19

3.3 Programming 21

3.3.1 Programming Tips 21

3.3.2 Multi-program model (2416P8) 22

3.3.3 Holdback 22

3.3.4 Program Cycling 22

3.3.5 Running a Program 22

3.3.6 Program example 23

3.4 Controller Options 24

3.4.1 Digital Communications - RS232 24

3.4.2 Digital Communications - RS485 24

3.4.3 Comms Address 24

3.4.4 Alarm Option 25

3.5 Temperature Controller Replacement 25

3.6 Navigation Diagram 26

4.0 2132 Over-Temperature Controller Description (if fitted) 27

4.1 Description 27

4.2 Operation 27

4.2.1 Controls 27

4.2.2 Operation 28

4.2.3 Over-Temperature Operation 28

4.2.4 Over-Temperature Alarm 28

4.2.5 Resetting the Over-Temperature Alarm 28

4.2.6 Sensor Break 28

4.3 Audible Alarm 29

4.4 Navigation Diagram 29

5.0 Operation 30

5.1 Operating Cycle 30

5.2 Safe Operation of the Furnace 30

5.3 General Operating Advice 31

5.4 Operator Safety 31

5.5 Tube Life 32

5.6 Pressure 32

5.7 Gas Tightness 33

6.0 Maintenance 34

6.1 General Maintenance 34

6.2 Maintenance Schedule 34

6.2.1 Cleaning 36

6.2.2 Safety Switch 36

6.3 Calibration 36

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-11-70 44

10.0 Fuses and Power Settings 45

10.1 Fuses 45

10.2 Power Settings 46

11.0 Specifications 47

11.1 Environment 47

Furnace drying out process 48

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 horizontal furnace models must have a work tube 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 5.4.

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 in a split tube furnace

No tools required.

2.0 Installation

The fitting of the work tube is as follows with reference to figure 2.3.1. Please note that

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

They are 150 mm longer than the heated length of the furnace (see the table in section

11.0). Read section 7.2 before fitting the work tube.

Figure 2.3.1 - view showing how to fit the standard length work tube in the split tube furnace. Note

that the right hand furnace end guard (8) has been removed from the view for clarity to show the

end adaptor and tube end stop.

lRelease the fixing clips (9 in figure 2.3.1), lift the lid by the handle (1).

lPlace the work tube into the bottom half of the furnace in the tube adaptors,

between the work tube end stops (5). Note that the work tube might be a tight fit

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

is placed.

lLower the lid by the handle and refasten the clips.

lNote in Figure 2.3.1 the right hand furnace end guard (8) is not shown so that

the end adaptor (3) and tube end stop (5) can be seen. It is not necessary to

remove the guards to fit the work tube.

Index to numbered items in Figure 2.3.1 and 2.3.2

1. Top lifting handle

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

9. Fixing clip

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