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Installation, Operation and Maintenance Instructions
250°C Clean Room Oven - CR Model: 330 Litres
3216 Controller
CR/330 + 3216 Controller
MEN-CR330-004_3216 ( 28-01-2019 )
2
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.
Operation as a simple controller
Digital Communications - RS232
Digital Communications - RS485
Temperature Controller Replacement
3216 Controller Navigation Diagram
4.0 2132 Over-Temperature Controller Description (if fitted)
Resetting the Over-Temperature Alarm
Over-Temperature Control (if fitted)
Solenoid Valve with Manual Switch (if fitted)
Variable Speed Fan (if fitted)
Stoving and Curing (if fitted)
3
4
Recommended Spare Parts and Spare Parts Kit
Safety Warning - Disconnection from Power Supply
Safety Warning - Refractory Fibre Insulation
Temperature Controller Replacement
WS-10-01 - Isolating for 208 V version only
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.
Interior light: when the interior light switch is operated the interior light illuminates.
Solenoid valve (if fitted): see section 5.8 for full details
Variable speed fan (if fitted): see section 5.9 for full details
Exhaust fan (if fitted): see section 5.10 for full details
Stoving and curing (if fitted): see section 5.11 for full details
1.2
General Warnings
DANGER – Electric shock. Read any warning printed next to this symbol.
WARNING: Risk of fatal injury.
5
6
1.0 Symbols and Warnings
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
2.0 Installation
2.0
Installation
2.1
Unpacking and Handling
When unpacking or moving the product, always lift by its base; do not use the door or any other projecting cover or component to support the equipment when moving it. Use a fork lift or pallet truck to move the product; position the product on a level surface and use an adequate number of personnel to safely move the product into position.
Carefully remove any packing material from inside and around the product before use.
Avoid damaging the surrounding insulation when removing packing materials.
Locate the shelves as required.
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.
7
2.0 Installation
8
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
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.
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
2.0 Installation 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).
Electrical Connection Details:
Supply Types
Supply Terminal Label Cable Colour
Live - Neutral
Reversible or Live-
Live
1-phase L
N
Brown
Blue to live to neutral to either power conductor
(For USA 200-240V, connect L1) to the other power conductor
(For USA 200-240V, connect L2)
PE Green/ Yellow to earth
(ground) to earth (ground)
2- or
3-phase
L1
L2
L3
N
PE
Black
Black
Black
Light Blue to phase 1 to phase 2 to phase 3 ( to neutral ( except 2-phase except delta
Green/ Yellow to earth ( ground )
)
)
9
3.0 3216 Controller
3.0
3216 Controller
3.1
PID control
This controller uses PID (Proportional Integral Derivative) temperature control. This type of control uses a complex mathematical control system to adjust the heating power and achieve the desired temperature.
3.2
3216P1
The 3216P1 is a digital temperature controller which uses PID algorithms to give excellent temperature control. This controller can store and operate a single program of
8 ramp/ dwell segments. The 3216P1 can also be used as a simple temperature controller.
3.3
3216P5
The 3216P5 is a digital temperature controller which uses PID algorithms to give excellent temperature control. This controller can store up to 5 programs of 8 ramp/ dwell segments. The 3216P5 can also be used as a simple temperature controller.
3.4
Operation
3.4.1
Controller Layout
Key
A Power Output Indicator
B Alarm Indicator
C
Remote Indicator
(when configured)
D Page
E Scroll
F Down
G Up
H Run Indicator
I Hold Indicator
J
Setpoint Temperature
(SP)
K
Measurement Temperature
10
3.0 3216 Controller
3.4.2
Keys
Page Key
Scroll Key
Ack
Page and
Scroll
Arrow Keys
+
+
The page key is used to access level 2 when held down for 3 seconds.
The scroll key is used to scroll through parameters.
When pressed simultaneously the ACK function is used to: l l l
Return to the Home Menu
Acknowledge an alarm if activated.
Reset a program after the program has ended.
The arrow keys are used individually to adjust the selected parameters and in combinations to operate a program.
Note: If a parameter is selected and no further action is taken, the display will time out and revert back to the home display in its working level after approximately 1 minute.
3.5
Quick Start Guide
3.5.1
Operation as a simple controller
When switched on, the controller goes through a short test routine and then shows the measured temperature (PV = Process Value) in the upper part of the display and below it, the desired temperature (Setpoint).
3.5.2
Changing the Setpoint
Press Up or Down to select the required SP. If the SP is higher than the measured temperature, the OP1 indicator will illuminate in the top left corner of the display, indicating that the controller is calling for power (giving an output).
The controller will immediately attempt to reach the setpoint and then maintain it.
This will cause the product to heat as quickly as possible which may not be appropriate where the product contains sensitive ceramic components. For products with ceramic components, e.g. a tube furnaces fitted with a long ceramic work tube, use the ramp rate feature set with a low heating rate such as 5°C per minute (300°C per hour), to prevent damage.
3.5.3
Using the Controller
The parameters in the controller are first shown by a short code (mnemonic). After 5
Seconds a description of the parameter will scroll once along the display and then revert back to the mnemonic. The scrolling text can be interrupted at any time by a single press of any of the buttons, but will not scroll again until the parameter is returned to.
In this manual the mnemonic will be shown first, followed by the scrolling text in brackets; e.g. PROG <PROGRAM NUMBER>
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3.0 3216 Controller
3.5.4
Understanding User Levels
There are two user levels in the controller; Level 1 (Operator) and Level 2 (Supervisor).
Level 1 (Operator) is for the day to day operation of the controller. These parameters are not protected by a security code.
Level 2 (Supervisor) provides access to additional parameters. Access to this level protected by a security code
To Enter Level 2
1. Press and hold the page key for 3 seconds.
2. The display will show LEu 1 GOTO
3. Release the page Key
4. Press the up or down to choose LEu 2 (level 2)
5. Press the up or down to enter the code (Level 2 Code = 9).
If the correct code is entered, PASS should momentarily be displayed and then revert to the level 2 home display.
If an incorrect code is entered the display reverts back to Level 1 home display.
When level 2 operations have been completed, the supervisor must return to Level 1 either manually or by switching the instrument off and back on. There is no time out function.
To Return to Level 1
1. Press and hold the page Key
2. Press down to select LEu 1
It is not necessary to enter a code when going from a higher level to a lower level.
When level 1 is selected, the display reverts to the home display (See Controller Layout)
Table showing parameters accessible in level 1 and Level 2
Operator LEVEL 1 home display
Programming
Program Status
Supervisor LEVEL 2 home display
Programming
Program Status
Alarms (if configured)
Current Transformer Input (if configured)
Comms (if configured)
Controller Setup
Customer Calibration
TIP
If while navigating the controller, a parameter has been passed or you need to access parameters which would be at the end of a scroll list, press and hold scroll and use up to return to a previous parameter.
12
3.0 3216 Controller
3.6
Setting up the Controller
Before using the controller (or during its lifetime) certain parameters may have to be set, depending on specific requirements. To do this the controller must be set to supervisor level (Level 2).
3.6.1
Maximum Output Power
Press scroll until the display shows OP.HI <OUTPUT HIGH>. Use the up and down keys to select the output power required as a percentage. Once the setting is made, turn the instrument switch off and on to power cycle the temperature controller.
Depending on the furnace or oven model, the maximum output power setting OP.Hi
may be accessible or locked.
For silicon carbide heated furnaces, the parameter is accessible to allow compensation for element ageing.
In many models the maximum output power setting depends on the supply voltage, see
3.6.2
Customer ID
A furnace or oven identification number can be entered if required. This maybe used to identify one of many units for production or quality control systems.
Press scroll until the display shows ID <CUSTOMER ID>. Use the up keys to enter your own identification number. This can range from 1-9999.
and down
3.6.3
Units or Press scroll until the display shows UNITS <DISPLAY UNITS>. Use the up down keys to select the required units.
Mnemonic
NONE
°C
°F
°K
PERC
Celsius
Kelvin
Description
No units (Default °C)
Fahrenheit
% (shows °C value)
3.6.4
Language
The scrolling text on the 3216 can be shown in different languages, this can only be set at the factory and therefore must be specified at the time of placing an order.
3.6.5
Scrolling Text
If at any time the scrolling text is not required.
Press and hold the page for three seconds until “GOTO” is displayed.
Press scroll until the display shows. TEXT <ENABLE/ DISABLE SCROLLING TEXT>
Use the up and down keys to select ON or OFF.
13
3.0 3216 Controller
3.6.6
Customer Calibration
The 3216 Controller series are calibrated for life at manufacture, there may however be sensor or other system errors, which affect the accuracy of the measured temperature.
Customer calibration can be used to compensate for these errors.
Dual Offset
Dual point calibration uses two offset values at two corresponding temperatures; this changes the calibration linearly as the temperature increases or decreases.
Press scroll until the display shows CAL.P (Enter Calibration Code) Use the up down keys to enter the password code. (Calibration Pass Code = 95). When the correct password has been entered the display will show PNT.LO. If the wrong pass code is entered the display will revert to zero pass code, until the correct pass code is entered.
When the correct pass code is entered and PNT.LO (Adjust Low Point) is displayed. Use the up and down keys to enter the Low Temperature Point, which you want to apply an Offset.
Press scroll until the display shows OFS.LO (Adjust Low OFFset). Use the up and down keys to enter the amount Offset you want to apply to the Low Temperature
Point.
Press scroll until the display shows PNT.HI (Adjust High Point). Use the up down and keys to enter the High Temperature Point, which you want to apply an Offset.
Press scroll until the display shows OFS.HI (Adjust High OFFset). Use the up down and keys to enter the amount Offset you want to apply the High Temperature
Point.
Once the calibration details have been entered, press scroll until the display shows the next required parameter or return to the home list. The calibration data will now be protected by the pass code. To edit the data the above procedure must be followed.
Single Offset
If a constant offset is required across the temperature range, set the required “High
Point” (PNT.HI) and “Low Point” (PNT.LO) to the required values (not the same), then set the “low Offset” (OFS.LO) and “High Offset” (OFS.HI) to the same value.
Caution! - Do not make PNT.LO and PNT.HI the same value as the controller will not work correctly and could cause the product to overheat.
3.6.7
Holdback
If the temperature ramp rate of the program is quicker than the product can achieve, the program will wait until the temperature of the product catches up.
14
3.0 3216 Controller e.g. If a holdback value of 10 is set and the program is set to ramp to a setpoint of 600
°C, the program will reach 600 °C, then go into a hold state; the hold indicator will light until the product temperature reaches 590 °C, the program will then continue to control again.
The holdback will only apply once per segment, therefore when control has been reestablished, the holdback will not apply again to that segment, even if the product temperature goes outside the holdback band.
Holdback can only be accessed in supervisor level (level 2) by scrolling with the scroll until the display shows H.BACK <PROGRAM HOLDBACK>: Use the up keys to select the required Holdback value.
and down
If a multi programmer is used, each program can have its own holdback value assigned to it.
Note: When a holdback is set, each segment used must have a Ramp Rate assigned to it, in order for it to be recognised by the program.
15
3.0 3216 Controller
3.7
Programming
3.7.1
Creating a Program
Programs can be created in level 1 or level 2 of the 3216P1 and 3216P5. Each program contains 8 Ramp/ Dwell pairs.
Note: A currently active program cannot be altered. Go into 'Reset' mode before starting to create or modify a program
3.7.2
Program Number (3216P5 Only)
Press scroll until the display shows PROG <PROGRAM NUMBER.> Select the program number.
3.7.3
Ramp Units
Press scroll until the display shows RAMP.U <Ramp Units>: Use the up select the Ramp Units of Hour, Min or Seconds.
3.7.4
Dwell Units down to
Press scroll until the display shows DWEL.U <Dwell Units>: Use the up select the Dwell Units of Hour or Min.
3.7.5
Holdback down to
until the display shows H.BACK <Program Holdback>: If a holdback value is required, use the up select “OFF” if no holdback is required.
down to enter the required value or
3.7.6
Ramp Rate
Press scroll until the display shows RMP.1 <Ramp Rate 1>: Using the up down enter the value for the first ramp rate depending on the Ramp Units selected. If the
Ramp segment is not required select “OFF”.
3.7.7
Target Setpoint
Press scroll until the display shows T.SP 1 <Target SP 1>: Enter the temperature that you want the product to ramp up to using “Ramp rate 1”.
If “Ramp Rate 1” has been set to “OFF”. The product will Heat/ Cool directly to the
Target SP.
3.7.8
Dwell Time
Press scroll until the display shows DWELL. 1 <DWELL TIME 1>: Enter the time to dwell at “Target SP 1”. If the dwell segment is not required, use the down to select
OFF, which is below the Zero value.
This Process is repeated for each of the 8 segments of the program.
16
3.0 3216 Controller
If not all the segments are used for a program, the Ramp & Dwell of each of the subsequent segments should be set to OFF.
A program will end in one of two ways, either revert to the control setpoint or dwell at the temperature set in the last segment used. When a program finishes on a dwell and the dwell time expires the temperature will revert to the control setpoint.
Note: Before operating a program ensure that the control setpoint is set to Zero to avoid unexpected heating at the end of the program.
3.7.9
Running a Program
If using the 3216P5 controller press scroll to display PROG <PROGRAM NUMBER>.
Select the required Program Number before operating a Program.
Table below shows the key presses to operate a program.
Operation Action
To RUN a program
Press and quickly release
+
Indication
Indicator – RUN = ON
Scrolling Display – Current
Program state
To HOLD a program
Press and quickly release
+
To RESET a program Press and hold
Program Ended
+ more than 1 second for
Indicator – RUN = Flashing
Scrolling Display – Program Hold
Indicator – RUN = OFF
Scrolling Display - None
Indicator – RUN = OFF
Scrolling Text – Program End
To RESET a program after it has completed
Press and hold + for more than 1 second or press and quickly release Ack
Indicator – RUN = OFF
Scrolling Display - None
3.7.10
Program Status
While the program is operating in level 1 or level 2, the home display shows two values at any one time:
3.7.11
Process Value
The upper display shows the current temperature of the product.
3.7.12
PSP, Segment Type and Number
The lower display continually alternates between the programs current set value
(Program SP = PSP) and scrolling text, indicating the current status of the program whether RAMP or DWELLING followed by the segment number.
Additional information can be obtained using the scroll key while the program is operating.
17
3.0 3216 Controller
Working Output Power
From the home display, press scroll until the display shows WRK.OP <WORKING
OUTPUT POWER>. This shows the power being used as a percentage.
Time Remaining
Press scroll until the display shows T.REMN <TIME REMAINING>. This shows the dwell time remaining for the current segment. There is no value for “Ramp Time Remaining” therefore when the program is ramping the dwell time set will be shown and will only begin to count down when the ramp has finished.
Program Review
Further presses of scroll will reveal the settings of the current program operating.
These parameters are locked, while the program is operating.
Program Hold with Holdback
If a holdback value has been set (see section 3.6) and the program goes into a hold
state, the red “HLD” indicator will light, until the current temperature catches up.
If while in this condition the program itself is put into “Hold” by pressing the up , down together, the “HLD” indicator will turn off and the “Run” indicator will flash, indicating the program is on hold. When the program is started again by pressing the up , down together, the “Run“ indicator will stop flashing and show continually and the “HLD” indicator will light, if the current temperature has not caught up with the program.
Power Failure
If there is a power failure while the program is operating and the power is subsequently restored, the scrolling text will read <POWER FAIL - PROGRAM RESET>.
Press the “ACK” function to acknowledge this message, press the “ACK” function again to reset the program.
Alarms
Alarms are used to alert the operator when a pre-set level has been exceeded or a function error has occurred such as a sensor break. They are indicated by a scrolling message on the display and a flashing red ALM (Alarm) indicator. The alarm may also switch an output – usually a relay to allow external devices to be operated when an alarm occurs. Alarms only operate if they have been configured and are dependent on customer requirements.
How to acknowledge an alarm will depend on the type of latching which has been configured. A non-latched alarm will reset itself when the alarm condition is removed. A latched alarm requires acknowledgement with the “ACK” function before it is reset.
If an alarm has been activated the red “ALM” indicator will light and the scrolling text will indicate the type of alarm.
To acknowledge an alarm and cancel the “ALM” indicator, press “ACK” function.
Note: The alarm indicator may seem to be permanently on when viewed from above.
When an alarm is active the indicator should only be flashing, to confirm this, the controller must be viewed directly from the front.
18
3.0 3216 Controller
Program Example
The following sequence of entries creates and runs the program shown graphically below.
1. Press scroll until the display shows RAMP.U <SP RAMP UNITS>. Select MIN.
2. Press scroll until the display shows DWELL.U <DWELL UNITS>. Select MIN.
3. Press scroll until the display shows RMP.1 <RAMP RATE 1>. Select 5
4. Press scroll until the display shows T.SP1 <TARGET SP 1>. Select 600
5. Press scroll until the display shows DWEL.1 <DWELL TIME 1>. Select 30
6. Press scroll until the display shows RMP.2 <RAMP RATE 2>. Select 4
7. Press scroll until the display shows T.SP2 <TARGET SP 2>. Select 400
8. Press scroll until the display shows DWEL.2 <DWELL TIME 2>. Select 30
9. Press scroll until the display shows RMP.3 <RAMP RATE 3>. Select OFF
10. Press scroll until the display shows T.SP3 <TARGET SP 3>. Select 600
11. Press scroll until the display shows DWEL.3 <DWELL TIME 3>. Select 60
12. Press scroll until the display shows RMP.4 <RAMP RATE 4>. Select 3
13. Press scroll until the display shows T.SP4 <TARGET SP 4>. Select 800
14. Press scroll until the display shows DWEL.4 <DWELL TIME 4>. Select OFF
15. Press scroll until the display shows RMP.5 <RAMP RATE 5>. Select 5
16. Press scroll until the display shows T.SP5 <TARGET SP 5>. Select 400
17. Press scroll until the display shows DWEL.5 <DWELL TIME 5>. Select 480
18. Press the ACK function to return to the home display.
19. Press the up and down keys together, to operate the program.
Segment
19
3.0 3216 Controller
1
RMP.1= 5°C/Min
T.SP1= 600°C
Dwel.1= 30 Min
2
RMP.1= 4°C/Min
T.SP1= 400°C
Dwel.1= 30 Min
3
RMP.1= OFF
T.SP1= 600°C
Dwel.1= 60 Min
4
RMP.1= 3°C/Min
T.SP1= 800°C
Dwel.1= OFF
5
RMP.1=5°C
T.SP1= 400°C
Dwel.1= 480 Min
3.8
Controller Options
As options can be ordered in a variety of combinations and for a variety of purposes, exact instructions are not given here. The full Eurotherm manual may be required to determine customer parameter settings. To reveal or hide parameters in the controllers it is necessary to go into configuration mode, a security code is needed. Please consult
Carbolite Gero.
3.8.1
Digital Communications - RS232
If the RS232 option is supplied, the furnace is fitted with one sub-miniature D-socket connected to the controller comms module. RS232 is suitable for direct connection to a personal computer (PC) using a “straight through” cable as follows (the linked pins at the computer end are recommended but may not be necessary). The cable is usually 9-pin at the furnace end and 9-pin at the computer, but other alternatives are shown in parentheses.
Product end of cable female (25-pin) 9-pin
RS232 Cable: product to PC
Computer end of cable
9-pin (25-pin) male
Rx
Tx
Com
(2)
(3)
(7)
3
2
5
_________________
_________________
_________________
3
2
(2)
(3)
Tx
Rx
5 (7) Com
7,8 (4,5) Link together
1,4,6 (6,8,20) Link together
3.8.2
Digital Communications - RS485
If an RS485 option is supplied, the furnace is fitted with two D-sockets. Connection between products is by “straight” cable as follows:
Product end of cable female (25-pin) 9-pin
-
+
Com
(2)
(3)
(7)
3
2
5
RS485 Cable: product to PC
_________________
Computer end of cable
9-pin (25-pin) female
3
2
5
(2)
(3)
(7)
Tx
Rx
Com
3.8.3
Comms Address
Typically the comms address is set to 1, but this can be changed. In the case of RS485 and multiple instruments it is necessary to set different addresses. To change the
20
3.0 3216 Controller address value, access the level 2 list. In level 2 press the page key until the COMMS parameter is displayed. Press up down to select the address value.
3.8.4
Alarm Option
When an alarm board is fitted, which consists of a relay with voltage free contacts, for operator use, the contacts are taken to a panel plug on the control panel, wired as indicated:
Key
C Temperature Controller
F Fuse (2A)
S Supply
L Load
*
Normally open relay contacts
RO
Relay Output 240V 2A
MAX
The purpose of the 2 amp fuse is to break the circuit to prevent overloading on the circuit due to high voltage.
The instrument configuration and parameters available to the operator depend on the customer requirements.
3.9
Temperature Controller Replacement
Before handling the controller: wear an anti-static wrist strap or otherwise avoid any possibility of damage to the unit by static electricity.
Refer to the detailed instructions supplied with the replacement controller.
Ease apart the two lugs at the side; grip the instrument and withdraw it from its sleeve; push in the replacement.
3.10
3216 Controller Navigation Diagram
The following diagram details how to navigate to the various menu options within the
3216 Controller. At each option, values can be set using the arrow keys.
21
3.0 3216 Controller
22
L1 Level 1 Press the Scroll Key
L2 Level 2
Press the Scroll Key multiple times
*
If configured A Access
**
Do not raise the power limit (if accessible) above the design level for the product
~
Multiple Program Only
Hold the Page key for 3 seconds
Locked - password required
Unlocked
Black = Progress
Dashed = Through multiple menus
White = Return
4.0 2132 Over-Temperature
4.0
2132 Over-Temperature Controller Description (if fitted)
4.1
Description
Key
A Alarm Light
B Page
C Scroll
D Down
E Up
F Display
This over-temperature controller is fitted and supplied ready to use by Carbolite Gero.
It is a digital instrument with a latching alarm, requiring no additional panel controls.
The controller features easy setting of over-temperature setpoint and reading of current temperature by the over-temperature sensor.
4.2
Operation
4.2.1
Controls
Most Carbolite Gero products are fitted with an instrument switch which cuts off power to the controller and other parts of the control circuit.
To operate the controller, power must be supplied to the product and the instrument switch must be on. If a time switch is included in the product circuit, this must be in the
'ON' position.
When an over-temperature condition occurs, the controller cuts the power to a contactor, which in turn cuts power to the heating elements. Power is not restored until the controller is 'reset'.
Some components will operate after the over-temperature feature isolates the power supply e.g. cooling fans will continue to operate, provided that there is a power supply to the product. In some cases the product may not do so, if other options (such as a door switch) are fitted.
23
4.0 2132 Over-Temperature
4.2.2
Operation
When switched on, the controller lights up, goes through a short test routine and then displays the measured temperature or the over-temperature setpoint.
The page key allows access to parameter lists within the controller.
A single press of the page key displays the temperature units, normally set to °C;
further presses reveal the lists indicated in the navigation diagram. See section 4.4.
The scroll key allows access to the parameters within a list. Some parameters are display-only; others may be altered by the operator.
A single press of the scroll key in the 'Home' list displays the temperature units; further presses reveal the parameters in the current list indicated in the navigation diagram.
To return to the 'Home' list at any time, press page and scroll together, or wait for 45 seconds.
The down and up keys are used to alter the setpoint or other parameter values.
4.2.3
Over-Temperature Operation
Use down and up to alter the over-temperature setpoint. This should normally be set a little above the working temperature (for example 15 °C above). The product is supplied with the over-temperature set at 15 °C above the furnace or oven maximum working temperature.
Press scroll twice view the present temperature as measured by the overtemperature controller. Press it twice, the first press shows the temperature units (°C).
4.2.4
Over-Temperature Alarm
If an over-temperature condition occurs, the OP2 indicator flashes and an alarm message 2FSH also flashes, alternating with the setpoint. Power to the heating elements is disconnected.
4.2.5
Resetting the Over-Temperature Alarm
To acknowledge the alarm press scroll and page together.
If the alarm is acknowledged while there is still an over-temperature condition, the OP2 indicator stops flashing but continues to glow. The 2FSH alarm continues to flash until the over-temperature condition is cleared (by the temperature falling), when normal operation resumes.
If the alarm is acknowledged when the temperature has dropped (or after the overtemperature setpoint has been raised) so that the over-temperature condition no longer exists, then the furnace or oven immediately resumes normal operation.
4.2.6
Sensor Break
The over-temperature cut-out system also operates if the over-temperature control thermocouple breaks or becomes disconnected. The message S.br flashes where the measured temperature is normally displayed.
24
4.0 2132 Over-Temperature
4.3
Audible Alarm
If an audible alarm is supplied for use with the over-temperature controller, it is normally configured to sound on over-temperature condition and to stop sounding when
the alarm is acknowledged as given in section 4.2.
Note: the alarm may sound during controller start-up.
4.4
Navigation Diagram
HL Home List
OTSP
Over-Temperature
Setpoint
AL Access List
Page Key
Scroll Key
For factory access to list and parameters not available to the operator.
Black = Progress
Dashed = Through to other options
25
5.0 Operation
5.0
Operation
5.1
Operating Cycle
The product is fitted with an instrument switch. The switch cuts off power to the controllers and elements. The circulation fan will operate when the instrument switch is on. An optional door switch may be fitted. If so, ensure that the door is closed to operate the fans and heating elements.
Turn on the instrument switch to activate the temperature controllers. The controllers illuminate and go through a short test cycle.
Over-Temperature option only . If the digital over-temperature option has not yet been set as required, set and activate it according to the over-temperature controller instructions.
The product will heat up according to the controller setpoint or program, unless a time switch is fitted and switched off.
Over-Temperature option only.
If the over-temperature circuit has tripped, an indicator on the over-temperature controller flashes and the heating elements are isolated. Find and correct the cause before resetting the over-temperature controller according to the instructions supplied.
To switch the product off, turn off the instrument switch. If the product is to be left unattended, isolate the electricity supply.
DO NOT switch off if the temperature is above 100 °C - damage could be caused to the fan and motor. Adjust the controller to allow the temperature to fall.
5.2
Over-Temperature Control (if fitted)
The over-temperature controller should typically be set at 15 °C above the main controller. If an over-temperature condition occurs, check the main controller is functioning correctly.
An over-temperature condition cuts off power to the heating elements. A light in the over-temperature controller flashes. To reset this, refer to the over-temperature control section of this manual.
5.3
Vents
On the back of this product are two vents: inlet and exhaust. The inlet vent is covered by a baffle that should be left in place.
The exhaust vent is closed by a butterfly valve that can be controlled from the front panel. Rotate the knob clockwise to open the vent, anticlockwise to close.
In non-fan models there is only a small flow of air through the chamber. With fan versions, fumes are pushed out through the exhaust vent by fan action and fresh air is drawn in through the inlet vent.
26
5.0 Operation
5.4
Temperature Uniformity
Where accurate temperature control of the load is important, use the central part of the chamber and place or distribute the load to allow free air circulation. Do not place loads on the chamber floor: use the bottom shelf.
5.5
Explosive Vapours
Unless your product includes the stoving and curing option, this model is not suitable for drying or heat treatment applications where vapours are released that are combustible or which can form explosive mixtures with air. Carbolite Gero manufactures other products suitable for these applications.
5.6
Atmospheres
When an optional gas inlet is fitted, there is a label near the inlet saying "INERT GAS
ONLY". In practice, inert or oxidising gases may be used, but not combustible or toxic gases.
The chamber is not gas tight, the gas usage may be high and the chamber is always likely to contain some air. Residual oxygen of approximately 1% to 2% is to be expected.
5.7
Interior Light (if fitted)
If fitted, the interior light is operated using the panel mounted switch.
It will only operate when the instrument switch is on.
5.8
Solenoid Valve with Manual Switch (if fitted)
If ordered the solenoid valve is operated using the panel mounted switch. When the switch is in the 'ON' position the solenoid valve will allow gas to flow. Ensure the installation and use of the product does not create a hazardous atmosphere. The workspace must have sufficient ventilation.
27
5.0 Operation
5.9
Variable Speed Fan (if fitted)
If fitted, the variable speed control is fitted in the air circulation fan circuit. A panel mounted rotary dial is used to control the speed.
Please note that there is a minimum setting at which the fan motor starts up when the product is switched on. It is recommended that the speed of the fan is not set below
50%, as there would be very little air flow around the chamber and also risk overheating the fan motor.
5.10
Exhaust Fan (if fitted)
To operate the exhaust fan use the fan switch on the control panel; this is only functional when the instrument switch is on.
The level of air exhaust can be controlled by adjusting the slider under the exhaust box.
When the exhaust fan is turned on, there may be a drop in internal temperature before the product recovers to the setpoint value.
The airflow should be adjusted to the minimum required by the process to reduce the amount of energy wasted in heating air.
5.11
Stoving and Curing (if fitted)
The stoving and curing option adds an explosion relief panel and a powered exhaust fan. With this option the exhaust fan operates continuously when the product is switched on.
A pressure switch detects that there is sufficient air flow through the chamber. If the pressure switch does not detect sufficient air flow, a fault light illuminates and heating is disabled.
At least 610 mm free space must be left around the explosion relief panel to allow this to break out if there is a rapid build up of pressure inside the chamber.
Please note that if the stoving and curing option is fitted, there may be an increase in the power rating of the product. See the product rating label located on the side panel of the product for correct power rating.
5.11.1
Pre-heater (if fitted)
Products with the stoving and curing option may also be fitted with a pre-heater that pre-heats the incoming air to the same temperature set on the main controller.
The temperature of the pre-heater is controlled by the main controller, but measured by a separate thermocouple.
28
5.0 Operation
5.12
Door Switch (if fitted)
If ordered, the door switch will isolate the heating elements and circulation fan. The door switch is operated when the door is opened causing the heating elements and air circulation fan to be switched off.
29
6.0 Maintenance
6.0
Maintenance
6.1
General Maintenance
Preventive rather than reactive maintenance is recommended. The type and frequency depends on the product use; the following are recommended.
6.2
Maintenance Schedule
CUSTOMER
QUALIFIED PERSONNEL
DANGER! ELECTRIC SHOCK . Risk of fatal injury. Only electrically qualified personnel should attempt these maintenance procedures.
Safety
Maintenance
Procedure
Over-Temperature Safety Circuit
(if fitted)
Method
Set an over-temperature setpoint lower than the displayed temperature and check for an over-temperature alarm as detailed in this manual
Over-Temperature Safety Circuit
(if fitted)
Door Seal
Door Seal
Air Vent
Electrical Safety (external)
Electrical Safety (internal)
Electrical measurement
Visual inspection - check for splits or fraying
Replacement
Check and clean if necessary
Visual check of external cables and plugs
Physically check all connections and cleaning of the power plate area
Frequency
Daily Weekly Monthly
Bi-
Annually
Annually
Function
Temperature Calibration
Operational Check
Operational Check
Tested using certified equipment, frequency dependent on the standard required
Check that all functions are working normally
Thorough inspection and report incorporating a test of all functions
Performance
30
Cooling Fans (if fitted)
Circulating Fan
(if fitted)
Circulating Fan
(if fitted)
Element Circuit
Power Consumption
Shelves
Check whether the cooling fans are working
Visual check to see if it is running
Check bearings and replace if necessary
Electrical measurement
Measure the current drawn on each phase / circuit
Visual check for fit and damage
6.0 Maintenance
31
6.0 Maintenance
6.2.1
Cleaning
The product's outer surface may be cleaned with a damp cloth. Do not allow water to enter the interior of the case or chamber. Do not clean with organic solvents.
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.
6.3
Calibration
After prolonged use, the controller and/or thermocouple may require recalibration. This is important for processes that require accurate temperature readings or for those that use the product close to its maximum temperature. A quick check using an independent thermocouple and temperature indicator should be made from time to time to determine whether full calibration is required. Carbolite Gero can supply these items.
Depending on the controller fitted, the controller instructions may contain calibration instructions.
6.4
After-Sales Service
Carbolite Gero Service has a team of Service Engineers who can offer repair, calibration and preventive maintenance of furnace and oven products both at the Carbolite Gero factory and at customers’ premises throughout the world. A telephone call or email often enables a fault to be diagnosed and the necessary parts to be despatched.
In all correspondence please quote the serial number and model type given on the rating label of the product. The serial number and model type are also given on the back of this manual when supplied with the product.
Carbolite Gero Service and Carbolite Gero contact information can be found on the back page of this manual.
6.5
Recommended Spare Parts and Spare Parts Kit
Carbolite Gero can supply individual spare parts or a kit of the items most likely to be required. Ordering a kit in advance can save time in the event of a breakdown.
Each kit consists of a fan and motor assembly, a thermocouple, a solid state relay, an element (or set of elements) and a door seal. Individual spare parts are also available.
When ordering spare parts please quote the model details as requested above.
6.6
Power Adjustment
The control system incorporates electronic power limiting, but for the model listed in this manual the power limit is set to 100%. The power limit parameter OP.Hi may be accessible to the operator, but should not generally be altered.
32
6.0 Maintenance
In some cases the supply voltage may be outside the range 220-240 V or the 3-phase equivalent, the power limit parameter may be set to a value other than 100%. Do not
increase the value to 100%, see section 10.0 for details of power limit settings.
33
7.0 Repairs and Replacements
7.0
Repairs and Replacements
7.1
Safety Warning - Disconnection from Power Supply
Immediately switch the product off in the event of unforeseen circumstances (e.g. large amount of smoke). Allow the product to return to room temperature before inspection.
Always ensure that the product is disconnected from the electrical supply before repair work is carried out.
Caution : Double pole/neutral fusing may be used in this product.
7.2
Safety Warning - Refractory Fibre Insulation
Insulation made from High Temperature Insulation Wool
Refractory Ceramic Fibre, better known as (Alumina silicate wool - ASW).
This product contains alumino silicate wool products in its thermal insulation. These materials may be in the form of blanket or felt, formed board or shapes, slab or loose fill wool.
Typical use does not result in any significant level of airborne dust from these materials, but much higher levels may be encountered during maintenance or repair.
Whilst there is no evidence of any long term health hazards, it is strongly recommended that safety precautions are taken whenever the materials are handled.
Exposure to fibre dust may cause respiratory disease.
When handling the material, always use approved respiratory protection equipment (RPE-eg. FFP3), eye protection, gloves and long sleeved clothing.
Avoid breaking up waste material. Dispose of waste in sealed containers.
After handling, rinse exposed skin with water before washing gently with soap
(not detergent). Wash work clothing separately.
Before commencing any major repairs it is recommended to make reference to the
European Association representing the High Temperature Insulation Wool industry
(www.ecfia.eu).
Further information can be provided on request. Alternatively, Carbolite Gero Service can quote for any repairs to be carried out either on site or at the Carbolite Gero factory.
7.3
Panel Removal
Disconnect the product from the electrical supply.
34
7.0 Repairs and Replacements
Control panel: l
Remove the 6 screws holding the control panel to the case.
Internal element cover: l l l l
Open the door.
Thermocouples may be clipped to the fan cover. Note the location of the thermocouples.
Unclip, and gently bend the thermocouples out of the way.
Remove the screws holding the element cover at the back of the chamber, and carfully remove the panel.
Fan cover (air guide): l l
Whilst supporting the fan cover from below, remove the screws securing it in place.
Gently remove it from the oven chamber, taking care not to damage the thermocouples
7.4
Temperature Controller Replacement
Refer to the controller instructions for more information on how to replace the temperature controller.
7.5
Solid-State Relay Replacement
Disconnect the product from the power supply and remove the appropriate cover as given above.
Make a note of the wire connections to the solid state relay and disconnect them.
Remove the solid state relay from the base panel or aluminium plate.
Replace and reconnect the solid state relay ensuring that the bottom of it has good thermal contact with the base panel or aluminium plate.
Replace the access panel.
7.6
Thermocouple Replacement
Disconnect the product from the power supply. Remove terminal cover to gain access to the thermocouple connections. Make a note of the thermocouple connections.
Thermocouple cable colour codings are:
Thermocouple leg Colour positive (type K) negative green white
35
7.0 Repairs and Replacements
Undo any clips holding the thermocouple. Remove the air guide from the oven chamber.
Disconnect the thermocouple from its terminal block. Unscrew the compression fitting inside the chamber and pull the thermocouple into the chamber. Cut through the thermocouple behind the olive and remove the two parts. Loosely assemble compression fitting with a new ferrule. Feed in new thermocouple through from the back. Tighten the compression fitting. Refit the air guide. Bend the thermocouple to match the shape of the previous part and refit any clips.
Refit the element access panel.
Compression fittings are only fitted to moisture extraction and stoving and curing products. If fitted, ferrules need replacing.
7.7
Element Replacement
To find out whether the element failure was caused by a fault in the control circuit, operate the oven at a low temperature and check that it is functioning correctly.
to replace the element, remove the rear panel and internal air guides. The element terminals are accessed from the back.
Disconnect the wires from the element terminals. Ferrules in the compression fitting are designed for single usage and need to be replaced with the element. Remove the element by undoing the element fitting. Slightly withdraw the element. Cut through the ferrules and the element. Remove the three parts of the element.
Install a new element from inside the chamber. Install the new ferrules and replace the compression fitting. Tighten the compression fitting to ensure the chamber is gas tight.
7.8
Fuse Replacement
Fuses are accessed by removal of the panel as explained in 'Panel Removal' section.
Depending on the model, supply fuses and control circuit fuses may be mounted in their own holders, or may be on a circuit board that contains an EMC filter. The fuses are marked with their ratings.
Take care not to disconnect the wires leading from the EMC filter without first recording their positions: they must be reconnected to the correct terminals.
36
8.0 Fault Analysis
8.0
Fault Analysis
A.
Oven Does Not Heat Up
1.
The temperature controller is
OFF
No power from supply
2.
The temperature controller is
ON
The controller shows a very high temperature or a code such as EEE or --- or S.br
The controller shows a low temperature
There are no lights glowing on the controller
B.
Oven Overheats
1.
Oven only heats up when the instrument switch is ON
The controller shows a very high temperature
The controller shows a low temperature
Check the fuses in the supply line
The temperature sensor has broken or has a wiring fault
The SSR could be failing to switch on due to internal failure, faulty logic wiring from the controller, or faulty controller
The controller may be faulty or not receiving a supply due to a faulty switch or a wiring fault
The controller is faulty
2.
Oven heats up when the instrument switch is OFF
The SSR has failed
"ON"
The thermocouple may have been shorted out or may have been moved out of the oven
The thermocouple may be connected the wrong way round
The controller may be faulty
Replace the SSR. Check for an accidental wiring fault which could have overloaded the SSR
37
9.0 Wiring Diagrams
9.0
Wiring Diagrams
9.1
WV-11-01
OT
TC
SSR
EL
*
L
N
Key
F1, F2
FIL
SW
R1
Fuses
Filter
Instrument Switch
Relay (Coil)
R1/1, R1/2 Relay Contactor
C
Temperature
Controller
Over-Temperature Controller
Thermocouple
Solid State Relay
Element(s)
If Fitted
PE (GR/Y)
Live
Neutral
Earth
(Green+Yellow)
38
9.0 Wiring Diagrams
9.2
WS-10-01 - Isolating for 208 V version only
The transformer changes the supply voltage of the control circuit into the desired operating range for the controller and other components.
The supply voltage as shown is taken from a single phase supply or from the phase-tophase voltage of a 3-phase supply.
The instrument circuit is modified as follows.
SW
N
L1
PE
Key
F1, F2 Fuses
FIL
TX
Filter (if fitted)
Transformer
Instrument Switch
Neutral
Live
Earth
39
10.0 Fuses and Power Settings
10.0
Fuses and Power Settings
10.1
Fuses
F1 - F3: Refer to the circuit diagrams.
F1
Internal
Supply
Fuses
Fitted if supply cable fitted.
Fitted on board to some types of EMC filter.
GEC Safeclip of the type shown
(glass type F up to 16 A)
38 mm x 10 mm type F fitted on
EMC filter circuit board(s)
F2
Auxiliary
Circuit Fuses
Customer
Fuses
Model
CR/330
Phases
1-phase
Fitted on board to some types of EMC filter.
May be omitted up to 25 Amp/ phase supply rating.
Required if no supply cable fitted.
Recommended if cable fitted.
2 Amps glass type F
On board: 20 mm x 5 mm
Other: 32 mm x 6 mm
See rating label for current;
See table below for fuse rating.
Volts Supply Fuse Rating
220 - 240 V 20 A
Control Fuse
5 A
10.2
Power Settings
The power limit settings (parameter OP.Hi) for this model are voltage dependant. The figures represent the maximum percentage of time that controlled power is supplied to the elements. Do not attempt to “improve performance” by setting a value higher than the recommended values. To adjust the parameter refer to the "Changing the
Maximum Output Power" of the control section of the manual.
Volts (V)
Power (%)
200
100
208
100
220
100
230
100
240
100
Please refer to the rating label for product specific information.
40
11.0 Specifications
11.0
Specifications
Carbolite Gero reserves the right to change the specification without notice.
Model
Max
Temp
(°C)
Max
Power
(kW)
Chamber Size (mm)
H W D
Approx.
Capacity
(l)
Net Weight
(kg)
CR/330 250 4.5
Clean Room Ovens
915 610 610 340 -
11.1
Environment
The models listed in this manual contains electrical parts and should be stored and used in indoor conditions as follows:
Temperature: 5 °C - 40 °C
Relative humidity:
Maximum 80 % up to 31 °C decreasing linearly to 50 % at 40
°C
41
Notes
Engineer Name Date
Service Record
Record of Work
The products covered in this manual are only a small part of the wide range of ovens, chamber furnaces and tube furnaces manufactured by Carbolite Gero for laboratory and industrial use. For further details of our standard or custom built products please contact us at the address below, or ask your nearest stockist.
For preventive maintenance, repair and calibration of all furnace and oven products, please contact:
Carbolite Gero Service
Telephone: + 44 (0) 1433 624242
Fax: +44 (0) 1433 624243
Email: [email protected]
Carbolite Gero Ltd,
Parsons Lane, Hope, Hope Valley,
S33 6RB, England.
Telephone: + 44 (0) 1433 620011
Fax: + 44 (0) 1433 621198
Email: [email protected]
www.carbolite-gero.com
Copyright © 2018 Carbolite Gero Limited
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