VERDER Carbolite Gero GHC 12/600 Handbuch

Installation, Operation and Maintenance Instructions

1200°C Tube Furnace (3-zone) - GHC Model: 600mm

No Controller

GHC 12/600 + No Controller

MEN-GHC120600-16_NOCTRL (18-06-2019)

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

2.0 Installation 5

2.1 Unpacking and Handling 5

2.2 Siting and Setting Up 5

2.3 Work Tubes and Fittings 7

2.4 Electrical Connections 9

2.5 Reconfiguring and Adjusting for Voltage 12

3.0 Temperature Controller 13

4.0 Operation 14

4.1 Operating Cycle 14

4.2 Control Method 14

4.3 3-Zone Control Methods 14

A. Back-to-Back Thermocouples 15

B. Retransmission of Setpoint 15

C. Independent Control 16

4.4 General Operating Advice 16

4.5 Operator Safety 16

4.6 Tube Life 17

4.7 Pressure 17

4.8 Gas Tightness 18

4.9 Running at Low Temperatures 18

5.0 Maintenance 19

5.1 General Maintenance 19

5.2 Maintenance Schedule 19

5.2.1 Cleaning 21

5.3 Calibration 21

5.4 After-Sales Service 21

5.5 Recommended Spare Parts and Spare Parts Kit 21

6.0 Repairs and Replacements 22

6.1 Safety Warning - Disconnection from Power Supply 22

6.2 Safety Warning - Refractory Fibre Insulation 22

6.3 Temperature Controller Replacement 22

6.4 Solid-state Relay Replacement 23

6.5 Thermocouple Replacement 23

6.6 Element Replacement 24

6.7 Fuse Replacement 25

7.0 Fault Analysis 26

A. Furnace Does Not Heat Up 26

B. Product Overheats 27

8.0 Wiring Diagrams 28

8.1 WC-13-31 28

8.2 WC-U3-31 29

8.3 WC-U4-31 30

8.4 Higher Voltages 31

8.5 Three-Zone Models 31

8.6 Control by Broadcast Comms (control method B) 31

9.0 Fuses and Power Settings 33

9.1 Fuses 33

9.2 Power Settings 34

10.0 Specifications 35

10.1 Environment 35

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.

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

2.0 Installation

2.1 Unpacking and Handling

When unpacking and handling the product, always lift it by its base. Do not use the door

or any other projecting cover or component to support the equipment when moving it.

Use two or more people to carry the product where possible.

Carefully remove any packing material from inside and around the product before use.

Avoid damaging the surrounding insulation when removing packing materials.

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.

Work tubes:

It is recommended that the work tube has either insulation plugs or

radiation shields fitted to minimise heat loss from both ends of the work

tube. If the work tube has open ends, a significant amount of energy

could be radiated from the ends of the work tube. Adjacent surfaces

should always be made from a non-flammable material.

Ensure that the ends of the work tube are positioned at least 500 mm

away from any adjacent surface so that any energy radiated cannot heat

an adjacent surface to a dangerous temperature.

2.0 Installation

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

disconnected from the electrical supply.

This horizontal tube product is supplied with the controls in an integral base (or, to

order, with the base control panel blanked off and the controls in a separate box). A

horizontal tube support kit.

All G-range tube furnaces have “modular” heating elements in which resistance wire is

partially embedded in vacuum formed light-weight refractory fibre. The modules are

150 mm long. In all standard models the two end elements (one at each end) are rated

at 1170 W maximum, while the other (centre) elements are rated at 780 W.

All models are supplied with a pair of “tube adaptors”, which can be made to suit any

work tube size up to 170 mm outside diameter. Spare or replacement adaptors can be

ordered.

The horizontal models generally require no special setting up. Observe the above

paragraph on siting. See section 2.3 for work tube and end adaptor considerations.

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 Work Tubes and Fittings

Tubes of various diameters and

lengths may be fitted.

Type C: minimum length for the

product.

Type D: 400 mm longer than C, to

allow for the fitting of end seals.

A pair of removable 'end adaptors' form part of the end insulation. These may be blank

(no hole) or may have a hole to suit a work tube, depending on the customer order.

Additional adaptors may be ordered to suit different work tube sizes. Check that the

end adaptors are correct for the tube: if not, seek advice from Carbolite Gero. Small

alterations to the hole in the adaptors may be made with a file, but first read the

section on ceramic fibre safety 6.2. To insert a work tube it is often convenient to use a

long pole (such as a broom handle) to guide it into the far end of the product.

For optimum temperature uniformity, insulating plugs should be placed in the tube ends

as shown in fig.1. With a long work tube, the stem of the plug assembly should line up

with the end of the tube as in fig.2. Alignment of radiation shields is similar to that of

plugs.

If stainless steel seals with gas inlets are supplied, they are to be fitted as shown in

fig.3; the stem of any insulating plug should touch the seal.

Horizontal use: if heavy fittings are to be clamped to the end of an extended work tube

they can increase the bending stress at the centre of the tube. Support such fittings in

such a way that expansion of the tube is allowed. A horizontal tube support kit can be

supplied for this purpose.

If a metal work tube is being used in the product, ensure that it is earthed. See the

"Safety Warning" under "Operator Safety".

2.0 Installation

Fig 1 - Insulating Plug

(standard length tube) Key

A Tube

B Insulating Plug

C Stem

Fig 2 - Insulating Plug

(long work tube)

Key

A Clamp

B Seal plate

C 'O' Ring seal

D Seal sleeve

E Clamp seal

F End plate

Key

A Clamp

B End plate

CClamp seal (between Seal

sleeve and Clamp

D Seal sleeve

ESeal plate & 'O' Ring seal

(underneath clamp)

F Tube

Fig 3 'Twin Clamp' End Seal

For assembly details refer to the separate work tube end seal manual.

2.4 Electrical Connections

Connection by a qualified electrician is recommended.

The product covered by this manual normally requires a single phase A.C. supply, which

may be Live to Neutral non-reversible, Live to Neutral reversible or Live to Live. Some

models may be ordered for 3-phase use, which may be star or delta.

2.0 Installation

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. A table of the most common fuse ratings is also given towards the back of this

manual. 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.

If the product is to be connected by line plug. The plug should be within reach of the

operator and should be easy to remove.

When connecting the product to an isolating switch ensure that both conductors (single

phase) or on all live conductors (three phase), and should be within reach of the

operator.

The supply MUST incorporate an earth (ground).

Supply Terminal Label Cable Colour

Supply Types

Live - Neutral Reversible or Live-

Live

1-phase L Brown to live

to either power

conductor

(For USA 200-240V,

connect L1)

N Blue to neutral

to the other power

conductor

(For USA 200-240V,

connect L2)

PE Green/ Yellow to earth

(ground) to earth (ground)

Electrical Connection Details:

3-phase L1 Black to phase 1

L2 Black to phase 2

L3 Black to phase 3

N Light Blue to neutral (except delta)

PE Green/ Yellow to earth (ground)

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