VERDER CARBOLITE GERO E Series Handbuch

Installation, Operation and Maintenance Instructions

1200°C E-Range Tube Furnace - EVA Model: 450mm

3216 Controller

EVA 12/450B + 3216 Controller

MEN-EVA12450B-004_3216 (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 6

1.1 Switches and Lights 6

1.2 General Warnings 6

1.3 Warning Labels 7

2.0 Installation 9

2.1 Unpacking and Handling 9

2.2 Siting 9

2.3 Setting Up 10

2.3.1 Figure - Vertical tube furnace model mounted on its stand. 11

2.3.2 Figure - Assembling the stand. 11

2.3.3 Figure - Mounting the furnace onto the vertical stand. 11

2.3.4 Figure -Tube furnace positioned horizontally on the stand. 12

2.3.5 Figure - Exploded view showing how to fit the work tube in the EVA 13

2.3.6 Figure - Tube support 14

2.3.7 Figure - Tube support assembly 14

2.3.8 Figure - Tube support and end seal assembly 15

2.3.9 Figure - Tube support and end seal assembly 15

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

entation. 16

2.4 Setting Up - Without a Stand 16

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

ing as an example. 16

2.5 Electrical Connections 18

3.0 3216 Controller 19

3.1 PID control 19

3.2 3216P1 19

3.3 3216P5 19

3.4 Operation 19

3.4.1 Controller Layout 19

3.4.2 Keys 20

3.5 Quick Start Guide 20

3.5.1 Operation as a simple controller 20

3.5.2 Changing the Setpoint 20

3.5.3 Using the Controller 20

3.5.4 Understanding User Levels 21

3.6 Setting up the Controller 22

3.6.1 Maximum Output Power 22

3.6.2 Customer ID 22

3.6.3 Units 22

3.6.4 Language 22

3.6.5 Scrolling Text 23

3.6.6 Customer Calibration 23

3.6.7 Holdback 24

3.7 Programming 25

3.7.1 Creating a Program 25

3.7.2 Program Number (3216P5 Only) 25

3.7.3 Ramp Units 25

3.7.4 Dwell Units 25

3.7.5 Holdback 25

3.7.6 Ramp Rate 25

3.7.7 Target Setpoint 25

3.7.8 Dwell Time 25

3.7.9 Running a Program 26

3.7.10 Program Status 26

3.7.11 Process Value 26

3.7.12 PSP, Segment Type and Number 26

3.8 Controller Options 29

3.8.1 Digital Communications - RS232 29

3.8.2 Digital Communications - RS485 29

3.8.3 Comms Address 29

3.8.4 Alarm Option 30

3.9 Temperature Controller Replacement 30

3.10 3216 Controller Navigation Diagram 30

4.0 2132 Over-Temperature Controller Description (if fitted) 32

4.1 Description 32

4.2 Operation 32

4.2.1 Controls 32

4.2.2 Operation 33

4.2.3 Over-Temperature Operation 33

4.2.4 Over-Temperature Alarm 33

4.2.5 Resetting the Over-Temperature Alarm 33

4.2.6 Sensor Break 33

4.3 Audible Alarm 34

4.4 Navigation Diagram 34

5.0 Operation 35

5.1 Operating Cycle 35

5.2 Safe Operation of the Furnace 35

5.3 General Operating Advice 36

5.4 Operator Safety 36

5.5 Tube Life 37

5.6 Pressure 37

5.7 Gas Tightness 38

6.0 Maintenance 39

6.1 General Maintenance 39

6.2 Maintenance Schedule 39

6.2.1 Cleaning 41

6.3 Calibration 41

6.4 After-Sales Service 41

6.5 Recommended Spare Parts and Spare Parts Kit 41

7.0 Repairs and Replacements 42

7.1 Safety Warning - Disconnection from Power Supply 42

7.2 Safety Warning - Refractory Fibre Insulation 42

7.3 Temperature Controller Replacement 42

7.4 Solid-state Relay Replacement 43

7.5 Thermocouple Replacement 43

7.6 Element Replacement 43

7.7 Fuse Replacement 44

8.0 Fault Analysis 45

A. Furnace Does Not Heat Up 45

B. Product Overheats 46

9.0 Wiring Diagrams 47

9.1 WA-11-30 47

9.2 WA-11-31 48

9.3 WA-12-30 49

9.4 WA-12-31 49

10.0 Fuses and Power Settings 50

10.1 Fuses 50

10.2 Power Settings 51

11.0 Specifications 52

11.1 Environment 52

Furnace drying out process 53

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.

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.

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.

1.0 Symbols and Warnings

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 ele-

ments.

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.

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.

2.0 Installation

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.

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