VERDER CARBOLITE GERO CAF 16/38, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1600 C Coal Ash Fusion Furnace CAF Model 38mm Ø No Controller CAF 16 38 No Controller MEN CAF1638 005_NOCTRL 09 01 2019 ...

Page 2: ...Unpacking and Handling 8 2 2 Siting and Setting Up 8 2 3 Heating Elements 9 2 4 Telescope 9 2 5 Electrical Connections 10 2 6 Gas Connections 11 3 0 Temperature Controller 12 4 0 2132 Over Temperature Controller Description if fitted 13 4 1 Description 13 4 2 Operation 13 4 2 1 Controls 13 4 2 2 Operation 14 4 2 3 Over Temperature Operation 14 4 2 4 Over Temperature Alarm 14 4 2 5 Resetting the Ov...

Page 3: ...2 Safety Warning Refractory Fibre Insulation 24 7 3 Temperature Controller Replacement 24 7 4 Solid State Relay Replacement 25 7 5 Thermocouple Replacement 25 7 6 Element Replacement 26 7 7 Fuse Replacement 26 8 0 Fault Analysis 27 A Furnace Does Not Heat Up 27 B Product Overheats 28 9 0 Wiring Diagrams 29 9 1 WA 11 00 29 9 2 WA 11 01 30 10 0 Fuses and Power Settings 31 10 1 Fuses 31 10 2 Power Se...

Page 4: ...d 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 ...

Page 5: ...Caution Double Pole Neutral Fusing 5 1 0 Symbols and Warnings ...

Page 6: ...ace involves the use of carbon monoxide Carbon monoxide is a product of reaction of H2 and CO2 Carbon monoxide CO is a colourless odourless tasteless and inflammable gas which is acutely toxic CO is introduced into the blood stream through the lungs and binds with the haemoglobin preventing it from carrying oxygen around the body This can result in rapid damage to body tissues due to oxygen starva...

Page 7: ...possibility of collapse after 2 hours at rest or 45 minutes exertion 1200 Palpitations after 30 minutes at rest or 10 minutes exertion 2000 Unconscious after 30 minutes at rest or up to 10 minutes exertion For further information refer to l Guidance Note EH43 1996 from the Health and Safety Executive ISBN 0 11 883597 1 l EH40 2005 Workplace Exposure Limits 2011 ISBN 978 0 7176 6446 7 7 1 0 Symbols...

Page 8: ...no 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 v...

Page 9: ...ced 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 Heating Elements The silicon carbide elements are VERY FRAGILE and are packed separately Fit them accordingly to the instructions in section 7 0 for element fitting and replacement instructions 2 4 ...

Page 10: ... 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 b...

Page 11: ...rnace Regulated supplies of CO2 and H2 must be connected in a safe manner to ensure that all gas flow is through the work tube The gas supply pressure required is 4 psi 0 276 bar and must not exceed this At the back of the furnace is a copper exhaust vent pipe The exhaust fumes are dangerous see Carbon Monoxide Warning The exhaust must be properly vented into a suitable duct or fume cupboard and m...

Page 12: ...3 0 Temperature Controller 3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 12 ...

Page 13: ... 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 no...

Page 14: ...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 over temperature 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 alternati...

Page 15: ...top 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 Page Key Black Progress OTSP Over Temperature Setpoint Scroll Key Dashed Through to other options AL Access List For factory access to list and parameters not available to the operator 15 4 0 2132 Over Temperature ...

Page 16: ...re isolated Find and correct the cause before resetting the over temperature controller according to the instructions supplied To turn the product off set the instrument switch to its off position The controller display will go blank If the product is to be left unattended isolate it from the electrical supply 5 2 Setting up for Coal Ash Fusion Test The CAF 16 38 is designed to be compatible with ...

Page 17: ...emperature when it is not required The maximum temperature is shown on the product rating label and in section 11 0 towards the back of this manual Lightweight ceramic fibre insulation can easily be marked by accidental contact Some fine cracks may develop in the surface of the insulation due to the progressive shrinkage of the insulation materials Cracks are not usually detrimental to the functio...

Page 18: ...and may break Tubes which extend beyond the heated part of the furnace are more at risk A general rule for maximum heating or cooling rate is 400 internal diameter in mm to give C min for 75 mm i d tubes this comes to 5 C per minute The controller can be set to limit both the heating and cooling rate 18 ...

Page 19: ...extent at high temperatures DO NOT use any conductive tools within the product without isolating it If a metal work tube is used it must be earthed grounded Warning Do not use the product if the work tube is cracked as there is a risk of exposure to carbon monoxide gas See Carbon Monoxide Warning 19 5 0 Operation ...

Page 20: ...r Temperature Safety Circuit if fitted Electrical measurement Door Plug Visual inspection checking the seal and whether it is free of any damage Door Plug Replacement where necessary Extraction Pipe Check that the connection is tight and clean out the pipe if necessary Electrical Safety external Visual check of external cables and plugs Electrical Safety internal Physically check all connections a...

Page 21: ... Check Thorough inspection and report incorporating a test of all functions Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase cir cuit 21 6 0 Maintenance ...

Page 22: ... 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 t...

Page 23: ...ems most likely to be required Ordering a kit in advance can save time in the event of a breakdown Each kit consists of a thermocouple and sheath a solid state relay a set of heating elements and a set of clips and braids When ordering spare parts please quote the model details as requested above 23 6 0 Maintenance ...

Page 24: ... 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 sleev...

Page 25: ...plate Replace the access panel 7 5 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 R orange negative white Disconnect the thermocouple from its terminal block retain any porcelain spacers W...

Page 26: ...ording to the note made above or to the appropriate diagram fig 6 Use the special tool or finger pressure to fit the clips Take care that adjacent clips do not touch each other Replace the product end panels and connect the product to the electrical supply Fig 5 Use of Clip Tool Fig 6 Element Connections 7 7 Fuse Replacement Fuses are marked on the wiring diagram with type codes e g F1 F2 For more...

Page 27: ...The door switch es if fitted may be faulty or need adjustment The contactor relay if fitted may be faulty The heater switch if fitted may be faulty or need adjustment The SSR could be failing to switch on due to internal failure faulty logic wiring from the controller or faulty controller There are no lights glowing on the controller Check the supply fuses and any fuses in the furnace control comp...

Page 28: ...aulty The controller shows a low temperature The thermocouple may be faulty or may have been removed out of the heating chamber The thermocouple may be connected the wrong way around The controller may be faulty 2 Product heats up when the instrument switch is OFF The SSR has failed ON Check for an accidental wiring fault that could have overloaded the SSR 28 ...

Page 29: ...1 F2 F3 Fuses FIL Filter C Temperature Controller TC Control Thermocouple SSR Solid State Relay H Heat Lamp EL Element s SW Instrument Switch es FM Fan Motor Fan Models Only N Neutral L Live PE Earth Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 29 9 0 Wiring Diagrams ...

Page 30: ...9 0 Wiring Diagrams 9 2 WA 11 01 Connections below show single phase with over temperature controller 30 ...

Page 31: ...type F On board 20 mm x 5 mm Other 32 mm x 6 mm F3 Heat Light Fuses May be omitted up to 25 Amp phase supply rating 2 Amps glass type F 32 mm x 6 mm Customer Fuses Required if no supply cable fitted Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating CAF 16 38 1 phase 110 120 63 A CAF 16 38 1 phase 220 240 25 A 10 2 Power S...

Page 32: ...Max Power kW Internal Bore mm Net Weight kg Coal Ash Fusion Testing Furnace CAF 16 38 1600 4 5 38 67 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 32 ...

Page 33: ...Notes Service Record Engineer Name Date Record of Work ...

Page 34: ... 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...