VERDER CARBOLITE GERO STF 16/180 Handbuch

Installation, Operation and Maintenance Instructions

1600 °C Tube Furnace - STF Model: 180mm

No Controller

STF 16/180 + No Controller

MEN-STF16180-05_NOCTRL (17-07-2018)

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

2.0 Installation 6

2.1 Unpacking and Handling 6

2.2 Siting and Setting Up 6

2.3 Tube Fitting 8

2.4 Heating Elements 10

2.5 Electrical Connections 10

3.0 Temperature Controller 12

4.0 2132 Over-Temperature Controller Description (if fitted) 13

4.1 Description 13

4.2 Operation 13

4.2.1 Controls 13

4.2.2 Operation 14

4.2.3 Over-Temperature Operation 14

4.2.4 Over-Temperature Alarm 14

4.2.5 Resetting the Over-Temperature Alarm 14

4.2.6 Sensor Break 14

4.3 Audible Alarm 15

4.4 Navigation Diagram 15

5.0 Operation 16

5.1 Operating Cycle 16

5.2 General Operating Advice 16

5.3 Operator Safety 17

5.4 Tube Life 17

5.5 Pressure 17

6.0 Maintenance 19

6.1 General Maintenance 19

6.1.1 Cleaning 19

6.2 Calibration 19

6.3 After-Sales Service 19

6.4 Recommended Spare Parts and Spare Parts Kit 19

6.5 Power Adjustment 20

6.6 Element Ageing 20

7.0 Repairs and Replacements 21

7.1 Safety Warning - Disconnection from Power Supply 21

7.2 Safety Warning - Refractory Fibre Insulation 21

7.3 Temperature Controller Replacement 21

7.4 Solid-State Relay Replacement 22

7.5 Thermocouple Replacement 22

7.6 Element Fitting and Replacement 23

7.7 Fuse Replacement 24

8.0 Fault Analysis 25

A. Furnace Does Not Heat Up 25

B. Product Overheats 26

9.0 Wiring Diagrams 27

9.1 WA-11-30 27

9.2 WA-11-31 28

10.0 Fuses and Power Settings 29

10.1 Fuses 29

10.2 Power Settings 29

User Power Setting Adjustments 30

11.0 Specifications 31

11.1 Environment 31

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

1.0 Symbols and Warnings

2.0 Installation

2.0 Installation

2.1 Unpacking and Handling

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

main body. Never lift it by its work tube or the surrounding insulation. Use two or more

people to carry the product and control box. Remove any packing material from inside

the product before use.

If an optional or special stand is separately supplied, assemble the product on to it.

Some models may be supplied for customer mounting and may require customer

preparation of mounting components before installation.

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.

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.

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.

If the product is supplied with a work tube then the holes at the end of the product

chamber should be supplied at the correct size. Carefully line up the tube and ease it

through the chamber.

For a tube of customer supply, ensure that there is approximately 1 mm free play at

each end; if the tube is too tight, it may crack when heated. Increase the diameter of

the hole by rotating the tube, which is abrasive. Remove loose powdered ceramic fibre

with a vacuum cleaner and see section 7.0.

Contact Carbolite Gero if the holes in the product chamber are too large.

Ensure that the tube is centrally placed and reaches to or through the product end

covers, so that there is no access to exposed electrical connections.

2.0 Installation

2.3 Tube Fitting

Vertical Mode. The product (if a tube is also supplied) has a plate or clip to retain the

tube in position. See fig.1.

Key

A End guard

B Plate

C Standard tube

D Long tube

E Strap

F Ring clip

Fig 1 - Vertical Tube Retention

Key

A Furnace body

B Tube

C Insulating plug

D End guard

E Stem

Fig 2 - Insulating End Plug

Fit any accessories supplied. For optimum temperature uniformity, ceramic insulation

plugs or radiation shields should be placed in the tube ends as shown in fig.2. The ends

of the insulation plugs or radiation shields should not protrude outside of the work tube.

NOTE: Insulation plugs or Radiation shields are strongly recommended

for this product. Contact Carbolite Gero or Carbolite Gero Service for

further information.

Expanded View of "Twin Clamp" End Seals:

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 (under-

neath clamp)

F Tube

Fig 3 'Twin Clamp' End Seal

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

If stainless steel end 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 end plate.

When stainless steel end seals are fitted in the vertical mode, a hook and eye, on the

end of the plate holds the upper insulating plug or radiation shield assembly.

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 the fittings in such a way

that longitudinal expansion of the tube is allowed.

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

There can be leakage of current through ceramic insulation at high temperatures.

2.0 Installation

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.

2.4 Heating Elements

The silicon carbide elements are VERY FRAGILE and are packed separately. Fit them

accordingly to the instructions in section 7.0.

2.5 Electrical Connections

Connection by a qualified electrician is recommended.

All models covered by this manual may be ordered for single phase A.C. supply, which

may be Live to Neutral non-reversible, Live to Neutral 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. 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).

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