VERDER CARBOLITE GERO CFM 12/1, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1200 C Combustion Tube Furnace CFM Model 12 1 No Controller CFM 12 1 No Controller MEN CFM1201 005_NOCTRL 18 10 2021 ...

Page 2: ...3 0 Temperature Controller 9 4 0 Operation 10 4 1 Operating Cycle 10 4 2 General Operating Advice 10 4 3 Tube Life 11 4 4 Operator Safety 11 4 5 Pressure 12 5 0 Maintenance 13 5 1 General Maintenance 13 5 2 Maintenance Schedule 13 5 2 1 Cleaning 15 5 3 Calibration 15 5 4 After Sales Service 15 5 5 Recommended Spare Parts and Spare Parts Kit 15 5 6 Power Adjustment 15 6 0 Repairs and Replacements 1...

Page 3: ... 21 B Product Overheats 22 8 0 Wiring Diagrams 23 8 1 WA 11 30 23 8 2 WA 11 31 24 9 0 Fuses and Power Settings 25 9 1 Fuses 25 9 2 Power Settings 25 User Power Setting Adjustments 26 10 0 Specifications 27 10 1 Environment 27 3 ...

Page 4: ...ents 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 DA...

Page 5: ...Caution Double Pole Neutral Fusing 5 ...

Page 6: ...nd 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...

Page 7: ...n to tube products Fit any work tube s ordered into place If a metal work tube is being used in the product ensure that it is earthed and that it is mounted so as not to touch the products ceramic tube or insulation 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 ...

Page 8: ...used 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 When connecting the product to the power supply the...

Page 9: ...3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 9 ...

Page 10: ...roller 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 off power to the heating elements use the heater switch To switch the product off use both the heater switch and the instrument switch If the product is to be left switched off and unattended isolate it from the electrical...

Page 11: ...hermal shock 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 4 4 Operator Safety The ceramic materials used in the product manufacture become elec...

Page 12: ...ssurisation of the work tube Note A product should not be heated up if any valves that have been fitted are closed to create a sealed volume A sealed work tube should not be heated from cold due to the pressure increase caused by the trapped air or gas expanding during the heating process Note To minimise the increase of back pressure always increase the pipe diameter of any room vent lines when c...

Page 13: ...ed in this manual Over Temperature Safety Circuit if fitted Electrical measurement Safety Switch Function split models only Set a safe temperature above ambi ent and open the furnace to see if the heater light goes out Safety Switch Function split models only Electrical measurement Electrical Safety external Visual check of external cables and plugs Electrical Safety internal Physically check all ...

Page 14: ...ar and correct positioning Seals if fitted Check all seals and O rings and clamps Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase circuit Cooling Fans if fitted Check whether the cooling fans are working 14 ...

Page 15: ...e 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 Ser...

Page 16: ...A table of standard power limits is supplied with new products it is given in section 9 0 16 ...

Page 17: ... 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 Av...

Page 18: ... or aluminium plate 4 Replace the access panel 6 5 Thermocouple Replacement Disconnect the product from the power supply Remove the appropriate panel 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 ...

Page 19: ...rminal blocks and remove sufficient insulation to allow access to the heating element Check and replace damaged insulation Fit the new heating element ensuring that the tails are separated from the element by at least 25 mm of insulation Feed the heating element tails through the terminal blocks and tighten the clamping screws using two spanners as before Cut off excess element tails Refit the ins...

Page 20: ...e types may or may not be fitted If any fuse has failed it is advisable for an electrician to check the internal circuits Replace any failed fuses with the correct type For safety reasons do not fit larger capacity fuses without first consulting Carbolite Gero The fuses are located at the cable entry point Remove the back panel or control box back panel to gain access to the fuses 20 ...

Page 21: ...mperature 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 co...

Page 22: ... 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 22 ...

Page 23: ...witch es Key F1 F2 F3 Fuses FIL Filter R1 1 R1 2 Relay Contactor R1 Relay C Temperature Controller TC Control Thermocouple SSR Solid State Relay SSW Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L Live PE Earth Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 23 ...

Page 24: ... R1 1 R1 2 Relay Contactor R1 Relay C Temperature Controller OT Over Temperature Controller OTC Over Temperature Thermocouple TC Control Thermocouple SSR Solid State Relay SSW Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L Live PE Earth If Fitted Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 24 ...

Page 25: ...ed Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating CFM 12 1 1 phase 110 120 10 A CFM 12 1 1 phase 220 240 6 A 9 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 atte...

Page 26: ...ower Setting Adjustments Date Power Comments Note If a new set of elements are fitted then return the power settings to the original value Please refer to the rating label for product specific information 26 ...

Page 27: ...CFM 12 1 1200 1 0 1 X 38 35 All models are designed to accept 1 or 2 work tubes 25 mm internal diameter by 750 mm long The number of tubes is indicated by the model name 1 or 2 10 1 Environment The models listed in this manual contain 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...

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Page 29: ...Notes Service Record Engineer Name Date Record of Work ...

Page 30: ... 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...