Installation, Operation and Maintenance Instructions

Controller Manual
2416 Controller

2416 Controller

MEN-2416_CTRL (02-01-2018)
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 2416 Controller 3

1.1 Description 3
1.2 Operation 4
1.3 Programming 5
1.3.1 Programming Tips 6
1.3.2 Multi-program model (2416P8) 6
1.3.3 Holdback 6
1.3.4 Program Cycling 7
1.3.5 Running a Program 7
1.3.6 Program example 7
1.4 Controller Options 8
1.4.1 Digital Communications - RS232 8
1.4.2 Digital Communications - RS485 9
1.4.3 Comms Address 9
1.4.4 Alarm Option 9
1.5 Temperature Controller Replacement 10
1.6 Navigation Diagram 11

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 1.0 2416 Controller

1.0 2416 Controller

1.1 Description
This manual applies to the 2416, 2416CG and 2416P8 controllers.
Special customer requirements may result in changes to the available parameters and
the navigation diagram. It is not possible to list all the possibilities in this manual.
2416CG Controller
The Eurotherm model 2416CG is a digital instrument with PID control algorithms which
may be used as a simple controller or an 8-segment programmer. The 2416P8 is an
eight-program model in which the programs can be stored independently or can be
linked by a “call” parameter to form a single long program.
The 2416 Controller features:
l Easy use as a simple temperature controller, where on setting the required tem-
perature the controller immediately attempts to reach and maintain it. Fig.1 indic-
ates the type of temperature response when used in this way.
l By using one program segment, the control can be extended to include ramp-to-set-
point. Fig.2 shows the effect.
l Alternatively, the 2416 Controller may be used as an 8-segment programmer, with
each segment being a "Ramp", a "Step", a "Dwell", or "End". The program can be
set to cycle if required. See fig. 3.
l Optional “modules” are available, in particular:
l RS232 and RS432/485 digital communications modules;
l Analogue communication modules;
l “PDSIO” modules for communication with other controllers of similar or higher spe-
cification, for example, to allow cascade control;
l Alarm modules, which can be used to drive visible or audible alarms, or to provide
volt-free contacts for customer use.

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 1.0 2416 Controller

1.2 Operation
Most Carbolite Gero products are fitted with an instrument switch which cuts off power
to the controller and other parts of the control circuit. See section 1.0 for operating
instructions.
To operate the 2416 Controller there must be power to the furnace or oven and the
instrument switch must be on. If a time switch is included in the furnace or oven circuit,
this must be in an ON position.
2416CG - Operation
When switched on, the controller lights up, goes through a short test routine and then
displays the measured temperature and setpoint. Depending on its state when it was
last switched off, it may start to control to the current setpoint of program. The output
light glows or flashes to indicate that the control is occurring.
The buttons and indicators are used for the following purposes:

Auto/
Disabled. The unit is always in 'Auto' mode
Manual
Used to start, stop or pause a program. Short presses
cause it to alternate between 'Run' and 'Hold', but if it is
RUN/HOLD -
held for 2 seconds the programmer goes into 'Reset' mode
where it behaves as a simple controller.
To adjust the value of a parameter. Used to change the
setpoint when the unit is being used as a simple controller
Up + Down + ('Reset' mode). Holding down gives an accelerated
parameter change.
Allows access to the parameters within the controller; most
lists and parameters are hidden from the operator as they
Page
contain factory-set values which should not be altered. A
single press of the page key shows the temperature units,

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normally °C; further presses reveal the lists indicated in the

Navigation Diagram.
Allows access to the parameters within a list. A single press
displays the temperature units; further presses reveal the
Scroll
parameters in the current list. Some parameters are
display-only, others may be altered by the operator.
Press together to cause an immediate return to the 'Home
Page + Scroll + List'
Indicate the current mode: 'Run', 'Hold', or 'Reset' (Reset:
both lights off).
'Run' flashes at the end of a program.
Run & Hold
'Hold' flashes during holdback (when the program is paused
to allow the temperature to catch up with a heating or
cooling rate which is too fast).
OP1 indicates that the programmer is calling for heat to be
Output supplied.
Indicator
OP2 is not used.
Not generally used; indicate 'Second' or 'Remote' setpoint in
SP2 and REM
use.
Operation as a Simple Controller

Press RUN/HOLD for 2 seconds to go into 'Reset' mode. Use down or up from the
'Home List' (i.e. when the temperature is displayed) to adjust the setpoint. The unit
starts to control in the way indicated in Fig. 1.

Note that to use the Ramp Rate feature, as in Fig. 2, it is necessary to create a
program. See the following sections.

1.3 Programming
Note that a currently active segment cannot be altered - put the programmer into 'Hold'
or 'Reset' whenever it is necessary to do so to alter a parameter. Go into 'Reset' mode
(i.e. press RUN/HOLD for 2 seconds) before starting to create or modify a program.

Press page until 'ProG LiSt' is displayed.

Press scroll to reveal the 'Holdback' and 'Loop Count' parameters. See sections 1.3.3
and 1.3.4 for a description of these.

Press scroll to display 'SEG.n' (segment number); use down or up to move to

the segment to be adjusted or created.

Press scroll to see the 'tYPE' (segment type); use down or up to change the
required segment type – see the table below.

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 1.0 2416 Controller

Press scroll to access the parameters appropriate to the type of segment chosen –
see the following table – and use down or up to alter the values.
The final segment should be of type 'End', unless all program segments are used.
Segments after 'End' are ignored.
Segment
Parameter Function
Type
TGt The target setpoint for this segment
RmP.r
rATE The ramp rate (rate of temperature change) in °/ minute
The target setpoint for this segment
TGt
RmP.t The duration of the segment. The controller calculates the rate
dur
of temperature rise necessary to achieve this duration.
The time in minutes to remain at the previous target
Dwel dur
temperature. 10ths of a minutes are allowed.
A new target temperature to be achieved as quickly as
SteP tGt
possible.

PrG.n Only applicable to 2416P8. Calls another stored program given

CaLL by 'PrG.n' as a subroutine, running it the number of times
cyc.n given by 'cyc.n".
'Dwel' holds the temperature at the last target value. 'RSET'
returns to simple controller operation; if the setpoint is set to
End End.t
zero then this effectively turns the heating off. 'SoP' sets the
power to 0% – use of this is not recommended.

1.3.1 Programming Tips

Make sure the basic setpoint is set to zero to avoid unexpected heating at the end of a
program.
If all segments are used so that there is no 'End' segment, then on completion the
program automatically goes into 'Dwell'.
Dwell segments of length zero can be included. This is a way of allowing space for future
program changes.
For an example of program creation, see section 1.3.6.
1.3.2 Multi-program model (2416P8)
The 'Program Edit' list contains the extra parameter 'PrG.n' and the 'Run' list contains
the extra parameter 'PrG'. These features allow selection of the program to be edited or
to be operated.
The extra segment type 'cALL' allows one program to call another as a subroutine; use
this feature to create one or more long programs.
1.3.3 Holdback
"Holdback' can be used to prevent the program from operating ahead of the actual
heating or cooling.

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 1.0 2416 Controller

In the program list, scroll to the 'Holdback' parameter and use down or up to
set the holdback type as follows:
Holdback applies to both heating and
Band
cooling
Lo Holdback applies to heating only
Hi Holdback applies to cooling only
Off Holdback is off
Set 'Hb.V' to the value in °C beyond which holdback is to operate. Type 'BAnd' and a
value of 10 °C is often a suitable combination, if holdback is required. In this case, if the
actual temperature deviates outside ±10 °C from the working setpoint, the holdback
lamp of the front of the controller flashes and the program is held up until the
temperature comes within range again.
The standard setting for holdback is OFF.
1.3.4 Program Cycling
The 'Loop Count' parameter 'CYC.n' can be set to control the number of times the
program is run.
If 'CYC.n' = 1, the program stops at the end segment.
If 'CYC.n' = 5 (for example), the program runs 5 times: at the 'End' segment it returns
to segment 1, until the 5th time through when it stops.
If 'CYC.n' = cont, the program never ends: it cycles continuously.
1.3.5 Running a Program
Press Run/ Hold to light up the 'Run' light. The program starts to operate.
To view the progress of a program from the 'Home' list, press scroll to reveal the
current segment ('SEG') and the total program time remaining in hours ('PrG.t').
For a more detailed view, press page to access the 'Run' list page and scroll to see
its contents as shown in the Navigation Diagram below. Provided the unit is first put into
'Hold' mode, temporary changes may be made to parameters; these apply only until
the program ends or is reset.
To pause a program, press Run/ Hold; the 'Hold' light comes on. To terminate a
program, press Run/ Hold for 2 seconds; the 'Run' and 'Hold' lights go out.
While the program is operating, the working setpoint is shown in the lower display.
1.3.6 Program example
The following sequence of entries creates and runs the program.

1. Press page key until 'ProG LiSt' is displayed.

2. Press scroll until 'CYC.n' is displayed and use the arrow key to select 1.
3. Press scroll until 'SEG.n' is displayed and use the arrow key to select 1.
4. Press scroll until 'tYPE' is displayed and use the arrow key to select rmP.r.

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 1.0 2416 Controller

5. Press scroll until 'tGt' is displayed and use the arrow key to select 600.
6. Press scroll until 'rAtE' is displayed and use the arrow key to select 5.0.
7. Press scroll until 'SEG.n' is displayed and use the arrow key to select 2.
8. Press scroll until 'tYPE' is displayed and use the arrow key to select dwEl.
9. Press scroll until 'dur' is displayed and use the arrow key to select 60.0.
10. Press scroll until 'SEG.n' is displayed and use the arrow key to select 3.
11. Press scroll until 'tYPE' is displayed and use the arrow key to select rmP.t.
12. Press scroll until 'tGt' is displayed and use the arrow key to select 400.
13. Press scroll until 'dur' is displayed and use the arrow key to select 60.0.
14. Press scroll until 'SEG.n' is displayed and use the arrow key to select 4.
15. Press scroll until 'tYPE' is displayed and use the arrow key to select 'dwEll'.
16. Press scroll until 'dur' is displayed and use the arrow key to select 30.
17. Press scroll until 'SEG.n' is displayed and use the arrow key to select 5.
18. Press scroll until 'tYPE' is displayed and use the arrow key to select rmP.r.
19. Press scroll until 'tGt' is displayed and use the arrow key to select 30.
20. Press scroll until 'rAtE' is displayed and use the arrow key to select 5.0.
21. Press scroll until 'SEG.n' is displayed and use the arrow key to select 6.
22. Press scroll until 'tYPE' is displayed and use the arrow key to select 'End'.
23. Press scroll until 'End.t' is displayed and use the arrow key to select 'dwEll'.
24. Press the page key until you return to the main display.
25. Press the 'Run' key. The program operates.

1.4 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.
1.4.1 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.

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 1.0 2416 Controller

Product end of cable RS232 Cable: Computer end of cable

female (25-pin) 9-pin product to PC 9-pin (25-pin) male

Rx (2) 3 _____________________ 3 (2) Tx

Tx (3) 2 _____________________ 2 (3) Rx
Com (7) 5 _____________________ 5 (7) Com
7,8 (4,5) Link together
1,4,6 (6,8,20) Link together

1.4.2 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 RS485 Cable: Computer end of cable

female (25-pin) 9-pin product to PC 9-pin (25-pin) female

- (2) 3 3 (2) Tx
+ (3) 2 2 (3) Rx
Com (7) 5 _____________________ 5 (7) Com

1.4.3 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
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.
1.4.4 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

Relay Output 240V 2A

RO
MAX

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 1.0 2416 Controller

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.

1.5 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.

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 1.0 2416 Controller

1.6 Navigation Diagram

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 Notes

Service Record
Engineer Name Date 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: ServiceUK@carbolite-gero.com
Carbolite Gero Ltd,
Parsons Lane, Hope, Hope Valley,
S33 6RB, England.
Telephone: + 44 (0) 1433 620011
Fax: + 44 (0) 1433 621198
Email: Info@carbolite-gero.com
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