VERDER CARBOLITE GERO EST 12/600B Handbuch

Installation, Operation and Maintenance Instructions

1200°C E-Range Tube Furnaces - EST Model: 600mm

No Controller

EST 12/600B + No Controller

MEN-EST12600B-005_NOCTRL (30-01-2018)

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 Symbols and Warnings 4

1.1 Switches and Lights 4

1.2 General Warnings 4

1.3 Warning Labels 5

1.3.1 - Control Box layout and warning labels. 6

1.3.2 - Back of control box showing mains lead socket 6

2.0 Installation 7

2.1 Unpacking and Handling 7

2.2 Siting 7

2.3 Setting Up 7

2.3.1 Figure - Furnace model mounted on a control box 8

2.3.2 Figure - Exploded view showing how to fit the work tube in the furnace 8

2.3.3 Figure - Tube support 9

2.3.4 Figure - Tube support assembly 10

2.3.5 Figure - Tube support and end seal assembly 10

2.3.6 Figure - Tube support and end seal assembly 11

2.3.7 Figure - Cross-section view showing standard length work tube insu-

lation plug fitted 12

2.3.8 Figure - Cross-section view showing extended work tube insulation

plug fitted 12

2.3.9 Figure - Cross-section view showing an extended length work tube with

a radiation shield fitted 12

2.4 Electrical Connections 12

3.0 Temperature Controller 14

4.0 Operation 15

4.1 Operating Cycle 15

4.2 Safe Operation of the Furnace 15

4.3 General Operating Advice 16

4.4 Operator Safety 16

4.5 Tube Life 17

4.6 Pressure 17

4.7 Gas Tightness 17

5.0 Maintenance 18

5.1 General Maintenance 18

5.1.1 Cleaning 18

5.2 Calibration 18

5.3 After-Sales Service 18

5.4 Recommended Spare Parts and Spare Parts Kit 18

6.0 Repairs and Replacements 19

6.1 Safety Warning - Disconnection from Power Supply 19

6.2 Safety Warning - Refractory Fibre Insulation 19

6.3 Temperature Controller Replacement 19

6.4 Solid-state Relay Replacement 20

6.5 Thermocouple Replacement 20

6.6 Element Replacement 20

6.7 Fuse Replacement 21

7.0 Fault Analysis 22

A. Furnace Does Not Heat Up 22

B. Product Overheats 23

8.0 Wiring Diagrams 24

8.1 WA-11-30 24

8.2 WA-11-70 25

9.0 Fuses and Power Settings 26

9.1 Fuses 26

9.2 Power Settings 27

10.0 Specifications 28

10.1 Environment 28

Furnace drying out process 29

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.

Heat light: the adjacent light glows or flashes to indicate that power

is being supplied 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 may be hot.

DANGER – read any warning printed next to this symbol.

Caution – Double Pole/Neutral Fusing

1.3 Warning Labels

On the front control panel there are 2 warning labels as shown in Figure 1.3.1; they are

numbered 7 and 8. These warnings must be followed for the safe operation of this

furnace.

7- Warning label - Do not operate without a work tube.

The furnace must not be operated without the correctly sized work tube

and correspond work tube adaptors or it could be possible for an

operator to access electrically live element coils that could cause serious

injury or death.

8- Warning label - Switch off the furnace before loading and

unloading.

The furnace heaters must be switched OFF using the heater switch, item

2 in Figure 1.3.1, when the furnace is being loaded or unloaded. The

work tube can become electrically conductive at high temperatures,

presenting a possible hazard to the operator. If element failure is left

undetected the element could collapse onto the work tube.

1.0 Symbols and Warnings

Index to numbered items in Figure 1.3.1

and 1.3.2

1. Electrical supply switch - switches

electrical power ON and OFF to the

furnace.

2. Heater switch - switches electrical

power ON and OFF to the furnace

heating elements.

3. Heater ON light - indicates that the

furnace heating elements are ener-

gized.

4. Product rating label indicating the

product serial number and electrical

information.

5. Access holes to front panel fixing.

6. Warning label - Disconnect the

mains supply before removing this

cover.

7. Warning label - Do not operate

without a work tube.

8. Warning label - Switch OFF the fur-

nace before loading and unloading.

9. Electrical power lead socket.

10. Back panel fixing screws.

1.3.1 - Control Box layout and warn-

ing labels.

1.3.2 - Back of control box showing

mains lead socket

2.0 Installation

If the product has been transported or stored in humid conditions it

must be dried out completely before operating the furnace. Contact

Carbolite Gero Service for instructions.

2.1 Unpacking and Handling

When unpacking or moving the product, always lift it by its base or both ends of the

main body. Never lift it by the end insulation or by a work tube. It may take 2 or 3

people to lift the furnace, depending on the size and configuration.

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

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.

Ensure that there is free space around the sides and back of the product. Clear space is

required above the product to dissipate heat.

If the product is to be used in a process which could liberate hazardous gases, then it

should be installed together with a suitable fume extraction system.

Ensure that the product is placed in such a way that it can be quickly switched off or

disconnected from the electrical supply.

2.3 Setting Up

The horizontal models must have work tubes fitted before being used. The diameter of

the work tube is a customer order option and therefore varies between tube furnaces.

Note: If a metal work tube is being used in the furnace, ensure that it is

earthed. See 4.4.

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.

2.0 Installation

Fitting the standard length work tube to furnace

Tools required: 4 mm Allen key

Fitting work tube is as follows with reference to Figure 2.3.2. Please note that standard

length work tubes are also referred to as tubes suitable for working in air. They are 150

mm longer than the heated length of the furnace (see the Specifications table at the

back of this manual). Read section 6.2 before fitting the work tube.

2.3.1 Figure - Furnace model mounted

on a control box

2.3.2 Figure - Exploded view showing

how to fit the work tube in the furnace

Index to numbered items in Figure 2.3.2

1. Tube furnace body

2. Work tube (diameter customer option)

3. Work tube adaptor (size dependent on work tube diameter)

4. Work tube adaptor fixing bracket

5. Work tube end stop (size dependent on work tube diameter)

6. Fixing screws M6 x 15

7. Washer M6

8. Tube furnace end guard

lRemove the work tube end guard (8) then remove the work tube adaptor fixing

bracket (4) that holds in place the work tube end stop (5) and the end adaptor (3)

from one side only. Note that if a different work tube with a different outer diameter

is being fitted it will be necessary to fit new correctly sized work tube adaptors (3) in

which case both end guards and work tube adaptor fixing brackets (4) will need

removing.

lSlide the work tube into the furnace through the work tube adaptor (3) until it

reaches the opposite work tube end stop (5). Note that the work might be a tight fit

when it is new and may need to be twisted backwards and forwards slightly as it

slides in. For long work tubes it may be necessary to use a long wooden pole such as

a broom handle to support and line up the work tube as it pushed through. It may

also take 2 people to perform this operation.

lReassemble the work tube end stop (5), work tube adaptor bracket (4) and tube end

guard (8).

Fitting the extended work tube in the furnace

Tools required 4 mm Allen key.

Fitting of the work tube is as follows with reference to Figure 2.3.2 2.2.

lBefore the extended work tube can be fitted, the work tube end stops for the stand-

ard length work tube (item 5 in figure 2.3.2 ) must be removed from both ends of

the furnace. This is done by removing the furnace end guard (8) and the work tube

adaptor brackets (4) to release the work tube end stop. The guards and brackets

should then be refitted.

lFit the tube support bracket, (15), figure 2.2. Use supplied M6 button head screws

and supplied washers.

lFit the extended work tube guard, (14), figure 2.2. Use supplied M6 button head

screws and supplied washers.

lRe-fit furnace end guard, (13), figure 2.2. Use supplied M6 button head screws and

supplied washers.

lIf supplied fit the optional tube end seal assembly as shown in figure 2.2. refer to

manual MEN-ENDSEALS-01 for detailed fitting instructions.

lFit tube support bracket, (7), figure 2.2. Use supplied M6 button head screws and

supplied washers.

lFinally fit tube support collar, (5) and secure figure tight using (6) until tube is secure

to be used in a vertical arrangement. Fitting arrangement is shown in figure 2.2.

lFigure 2.2 - shows an exploded view of all the required parts.

lFigure 2.2 - shows the assembled parts as they would be used.

2.3.3 Figure - Tube support

2.0 Installation

2.3.4 Figure - Tube support assembly

2.3.5 Figure - Tube support and end seal assembly

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