VERDER CARBOLITE GERO G Series Handbuch

Installation, Operation and Maintenance Instructions

1200°C G-Range Tube Furnace - GHA Model: 450mm

2416 Controller

GHA 12/450 + 2416 Controller

MEN-GHA120450-003_2416 (09-01-2019)

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 Work Tubes and Fittings 8

2.4 Electrical Connections 10

2.5 Reconfiguring and Adjusting for Voltage 12

3.0 2416 Controller 13

3.1 Description 13

3.2 Operation 15

3.3 Programming 17

3.3.1 Programming Tips 17

3.3.2 Multi-program model (2416P8) 18

3.3.3 Holdback 18

3.3.4 Program Cycling 18

3.3.5 Running a Program 18

3.3.6 Program example 19

3.4 Controller Options 20

3.4.1 Digital Communications - RS232 20

3.4.2 Digital Communications - RS485 20

3.4.3 Comms Address 20

3.4.4 Alarm Option 21

3.5 Temperature Controller Replacement 21

3.6 Navigation Diagram 22

4.0 2132 Over-Temperature Controller Description (if fitted) 23

4.1 Description 23

4.2 Operation 23

4.2.1 Controls 23

4.2.2 Operation 24

4.2.3 Over-Temperature Operation 24

4.2.4 Over-Temperature Alarm 24

4.2.5 Resetting the Over-Temperature Alarm 24

4.2.6 Sensor Break 24

4.3 Audible Alarm 25

4.4 Navigation Diagram 25

5.0 Operation 26

5.1 Operating Cycle 26

5.2 General Operating Advice 26

5.3 Operator Safety 27

5.4 Tube Life 27

5.5 Pressure 27

5.6 Gas Tightness 28

5.7 Running at Low Temperatures 28

6.0 Maintenance 29

6.1 General Maintenance 29

6.2 Maintenance Schedule 29

6.2.1 Cleaning 31

6.3 Calibration 31

6.4 After-Sales Service 31

6.5 Recommended Spare Parts and Spare Parts Kit 31

7.0 Repairs and Replacements 32

7.1 Safety Warning - Disconnection from Power Supply 32

7.2 Safety Warning - Refractory Fibre Insulation 32

7.3 Temperature Controller Replacement 32

7.4 Solid-state Relay Replacement 33

7.5 Thermocouple Replacement 33

7.6 Element Replacement 34

7.7 Fuse Replacement 35

8.0 Fault Analysis 36

A. Furnace Does Not Heat Up 36

B. Product Overheats 37

9.0 Wiring Diagrams 38

9.1 WA-11-31 38

9.2 WA-U3-31 39

10.0 Fuses and Power Settings 41

10.1 Fuses 41

10.2 Power Settings 42

11.0 Specifications 43

11.1 Environment 43

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

main body. Never lift it by its work tube or the surrounding insulation. Use two or more

people to carry the product and control box. Remove any packing material from inside

the product before use.

If an optional or special stand is separately supplied, assemble the product on to it.

Some models may be supplied for customer mounting and may require customer

preparation of mounting components before installation.

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.

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.

Ensure that the product is placed in such a way that it can be quickly switched off or

disconnected from the electrical supply.

This horizontal tube product is supplied with the controls in an integral base (or, to

order, with the base control panel blanked off and the controls in a separate box). A

horizontal tube support kit.

All G-range tube furnaces have “modular” heating elements in which resistance wire is

partially embedded in vacuum formed light-weight refractory fibre. The modules are

150 mm long. In all standard models the two end elements (one at each end) are rated

at 1170 W maximum, while the other (centre) elements are rated at 780 W.

All models are supplied with a pair of “tube adaptors”, which can be made to suit any

work tube size up to 170 mm outside diameter. Spare or replacement adaptors can be

ordered.

The horizontal models generally require no special setting up. Observe the above

paragraph on siting. See section 2.3 for work tube and end adaptor considerations.

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.

2.0 Installation

2.3 Work Tubes and Fittings

Tubes of various diameters and

lengths may be fitted.

Type C: minimum length for the

product.

Type D: 400 mm longer than C, to

allow for the fitting of end seals.

A pair of removable 'end adaptors' form part of the end insulation. These may be blank

(no hole) or may have a hole to suit a work tube, depending on the customer order.

Additional adaptors may be ordered to suit different work tube sizes. Check that the end

adaptors are correct for the tube: if not, seek advice from Carbolite Gero. Small

alterations to the hole in the adaptors may be made with a file, but first read the section

on ceramic fibre safety 7.2. To insert a work tube it is often convenient to use a long

pole (such as a broom handle) to guide it into the far end of the product.

For optimum temperature uniformity, insulating plugs should be placed in the tube ends

as shown in fig.1. With a long work tube, the stem of the plug assembly should line up

with the end of the tube as in fig.2. Alignment of radiation shields is similar to that of

plugs.

If stainless steel seals with gas inlets are supplied, they are to be fitted as shown in

fig.3; the stem of any insulating plug should touch the seal.

Horizontal use: if heavy fittings are to be clamped to the end of an extended work tube

they can increase the bending stress at the centre of the tube. Support such fittings in

such a way that expansion of the tube is allowed. A horizontal tube support kit can be

supplied for this purpose.

If a metal work tube is being used in the product, ensure that it is earthed. See the

"Safety Warning" under "Operator Safety".

Fig 1 - Insulating Plug

(standard length tube) Key

A Tube

B Insulating Plug

C Stem

Fig 2 - Insulating Plug

(long work tube)

2.0 Installation

Key

A Clamp

B Seal plate

C 'O' Ring seal

D Seal sleeve

E Clamp seal

F End plate

Key

A Clamp

B End plate

CClamp seal (between Seal

sleeve and Clamp

D Seal sleeve

ESeal plate & 'O' Ring seal

(underneath clamp)

F Tube

Fig 3 'Twin Clamp' End Seal

For assembly details refer to the separate work tube end seal manual.

2.4 Electrical Connections

Connection by a qualified electrician is recommended.

All models covered by this manual may be ordered for single phase A.C. supply, which

may be Live to Neutral non-reversible, Live to Neutral reversible or Live to Live.

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