VERDER CARBOLITE GERO BLF 18/3 + No Controller Handbuch

Installation, Operation and Maintenance Instructions

1800°C Bottom Loading Furnace - BLF Model: 3 Litres

No Controller

BLF 18/3 + No Controller

MEN-BLF1803-003_NOCTRL (29-10-2021)

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 4

1.1 Switches and Lights 4

1.2 General Warnings 4

1.3 Prerequisites to Use 5

2.0 Installation 6

2.1 Unpacking and Handling 6

2.2 Siting and Setting Up 6

2.3 Tie Wrap Removal Instructions 8

2.4 Fitting the Chimney and Heating Elements 9

2.5 Electrical Connections 10

3.0 Temperature Controller 12

4.0 Operation 13

4.1 Operating Cycle 13

4.2 Emergency Stop Button 13

4.3 General Operating Advice 13

4.4 Atmospheres & Corrosive Materials 14

4.5 Operator Safety 15

4.6 Notes on Temperature Control 15

4.7 Insulation Cracking 15

4.8 Thermocouple Warnings 15

4.9 Inverted Crucible Option 16

4.10 Element Protection Tube Option 16

5.0 Maintenance 17

5.1 General Maintenance 17

5.2 Maintenance Schedule 17

5.2.1 Cleaning 19

5.3 Calibration 19

5.4 After-Sales Service 19

5.5 Recommended Spare Parts and Spare Parts Kit 19

5.6 Power Adjustment (Controller) 19

5.7 Power Adjustment (Thyristor) 20

6.0 Repairs and Replacements 21

6.1 Safety Warning - Disconnection from Power Supply 21

6.2 Safety Warning - Refractory Fibre Insulation 21

6.3 Safety Warning - Molybdenum Disilicide Elements 22

6.4 Temperature Controller Replacement 22

6.5 Fuse Replacement 22

6.6 Thermocouple Replacement 22

6.7 Element Protection Tube Option Replacement Procedure 23

6.8 Insulation Replacement 23

6.9 Element Installation and Replacement 24

7.0 Fault Analysis 27

A. Furnace Does Not Heat Up 27

B. Product Overheats 28

8.0 Wiring Diagrams 29

8.1 195-1-1013 29

9.0 Fuses and Power Settings 30

9.1 Fuses 30

9.2 Power Settings 30

10.0 Specifications 31

10.1 Environment 31

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

1.3 Prerequisites to Use

Prior to the commissioning and use of this product, all personnel involved in its

installation, operation and maintenance must be deemed competent and have:

lRead and understood the information contained within this manual

lReceived the relevant training with regard to safety and operation of the product

lBeen provided with the appropriate PPE (Personal Protective Equipment) required

for the safe operation of this product

Note: The customer is responsible for ensuring that all of the above conditions are

satisfied before the product is commissioned for use.

Note: Unless otherwise specified, the customer is responsible for the

installation of this product and the safe connection of any additional

equipment and gas or liquid supply lines.

2.0 Installation

2.1 Unpacking and Handling

When unpacking or moving the product always lift it by its base. Do not use the door or

any other protruding parts. The product contains a transformer and is heavy: use two

or more people to carry the product.

Some models may alternatively be lifted by fitting lifting bolts to captive threads in the

top of the case.

Remove any packing material.

NOTE: This product contains Refractory Ceramic Fibre (also known

as Alumino Silicate Wool - ASW). For precautions and advice on

handling this material see section 6.2.

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.

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 Tie Wrap Removal Instructions

The motor powered arm that operates the hearth movement has been fixed in place

for transit. Please ensure the plastic tie wrap used to fix the arm is removed before

operation.

1. Remove the back panel of the furnace.

2. Locate the tie wrap that has been used to prevent the arm from moving. It is

marked with a tag as shown in the photograph below.

3. Cut the tie wrap and discard.

4. Replace the back panel.

2.4 Fitting the Chimney and Heating Elements

Please refer to the Element Installation and Replacement in section

6.0. Wear eye protection when handling the heating elements.

The molybdenum disilicide elements are EXCEPTIONALLY FRAGILE

and are packed separately, together with other items shown in the

list.

separately packed items BLF

Elements 6

Element Clamps 6

Elements Clips* 12

Braids* 1 set

Separators 6

* or combined clips and braids may be supplied

BLF /3 transit clamps

Upper Clamp:

1. Remove lower clamp first

2. Remove two M8 nuts and washers, supporting

plate (3) from underneath

3. Remove plate

Lower Clamp:

1. Remove bottom M8 nut

2. Remove two M6 bolts

3. Remove plate

4. Unscrew rod, using spanner on (5) if neces-

sary

Transit Clamps – dependent on model: the example shown here is for the 3 litre

models; remove any transit clamps as shown. Fit the ceramic chimney to the hole

that exits the top of the chamber. Most models are supplied with an insulation piece

to fit around the chimney; fit this insulation.

Remove the complete top access panel using the hidden screw in holes in the top of

the panel; loosen the screws two turns and remove the panel.

Fit the heating elements vertically into the chamber. Handle the elements with

great care. The installation of these elements is described in section 6.9.

Connect the aluminium braids securely as indicated in the element installation

instructions.

2.5 Electrical Connections

Connection by a qualified electrician is recommended.

This product requires a single-phase A.C. supply with earth (ground), which may be

Live to Neutral non-reversible (polarised), Live to Neutral reversible (non-polarised), 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. This manual contains a table of the most common fuse ratings.

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.

When connecting the product to the power supply, the plug or isolating switch should

be accessible, easy to remove, and within reach of the operator.

The supply MUST incorporate an earth (ground).

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