VERDER Carbolite Gero SCF 48 Handbuch

Installation, Operation and Maintenance Instructions

1200 °C Smelting Crucible Furnace - SCF Model: 48

No Controller

SCF 48 + No Controller

MEN-SCF48-005_NOCTRL (30-03-2023)

ORIGINAL: ENGLISH

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 & Handling 6

2.2 Siting and Setting Up 6

2.3 Hearth 7

2.4 Extraction 7

2.5 Electrical Connections 8

2.6 Voltage and Power Limit 9

3.0 Temperature Controller 10

4.0 Time Switch 11

4.1 Digital Time Switch - Theben TR 635 top2 11

Important Note 12

Reset 12

Setting the Time and Date (and Daylight Saving Rules) 12

Setting a Switch-On or Switch-Off Time 12

Modifying or deleting a Switch-On or Switch-Off Time 12

Overriding the Program 13

Pulse and Cycle 13

5.0 Operation 14

5.1 Operating Cycle 14

5.2 General Operating Advice 15

5.3 Operator Safety 15

5.4 Over-Temperature Control (if fitted) 15

6.0 Maintenance 17

6.1 General Maintenance 17

6.2 Maintenance Schedule 17

6.2.1 Cleaning 19

6.3 Safety Switch 19

6.4 Calibration 19

6.5 After-Sales Service 20

6.6 Recommended Spare Parts and Spare Parts Kit 20

6.7 Element Ageing 20

6.8 Power Adjustment 21

7.0 Repairs and Replacements 22

7.1 Safety Warning - Disconnection from Power Supply 22

7.2 Safety Warning - Refractory Fibre Insulation 22

7.3 Temperature Controller Replacement 22

7.4 Solid-State Relay Replacement 23

7.5 Element Fitting and Replacement 24

7.6 Thermocouple Replacement 25

7.7 Fuse Replacement 25

8.0 Fault Analysis 26

A. Furnace Does Not Heat Up 26

B. Product Overheats 27

9.0 Wiring Diagrams 28

10.0 Fuses and Power Settings 29

10.1 Fuses 29

10.2 Power Settings 29

11.0 Specifications 30

11.1 Environment 30

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 & Handling

When unpacking or moving the product, always lift by its base; do not use the door or

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

a fork lift or pallet truck to move the product; position the product on a level surface

and use an adequate number of personnel to safely move the product into position.

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 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 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 Hearth

The hearth and chamber are supported during transport by packing foam. Remove and

dispose of this packaging.

2.4 Extraction

If the product is to be used to heat substances that emit fumes, a fume extraction duct

may be placed directly above the furnace.

Do not make a sealed connection to the product chimney as this causes excessive

airflow through the chamber and results in poor temperature uniformity.

A heatproof drip tray will be supplied to prevent corrosion to the floor underneath the

furnace. The tray should be placed directly under the air inlet as shown in the image

below.

2.5 Electrical Connections

Connection by a qualified electrician is recommended.

The model covered in this manual has three internal circuits and is normally supplied

for connection to a three phase power supply. This may be either star or delta, but a

product must only be connected to the type and voltage of supply for which it was

made. If the product is ordered for a single phase supply, this may be Live to Neutral

reversible or non-reversible, 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).

Supply Terminal Label Cable Colour

Supply Types

Live - Neutral Reversible or Live-

Live

1-phase L1 Brown to live

to either power

conductor

(For USA 200-240V,

connect L1)

N / L2 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:

2- or

3-phase L1 Black to phase 1

L2 Black to phase 2

L3 Black to phase 3 (except 2-phase)

N Light Blue to neutral (except delta)

PE Green/ Yellow to earth (ground)

2.6 Voltage and Power Limit

When first starting up the product, check the setting of the OP.Hi

parameter (see the controller instructions) and compare it with

the data in section 10.0 towards the back of this manual.

If the power limit setting is incorrect for the voltage of the electrical supply, change it.

This must be done immediately if the setting of OP.Hi is higher than it should be.

3.0 Temperature Controller

If this product is fitted with a temperature controller, instructions are provided

separately.

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