VERDER CARBOLITE GERO AAF 11/3 Installation, Operation And Maintenance Instructions
1100c ashing furnace
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- Page 1 Installation, Operation and Maintenance Instructions 1100°C Ashing Furnace - AAF Model: 3 Litres No Controller AAF 11/3 + No Controller MEN-AAF1103-005_NOCTRL 01-08-2019...
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Page 2: Table Of Contents
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. - Page 3 6.2.2 Safety Switch Calibration After-Sales Service Recommended Spare Parts and Spare Parts Kit 7.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Safety Warning - Refractory Fibre Insulation Temperature Controller Replacement Solid-State Relay Replacement Thermocouple Replacement Element Replacement Door Plug Replacement Fuse Replacement 8.0 Fault Analysis...
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Page 4: Symbols And Warnings
1.0 Symbols and Warnings 1.0 Symbols and Warnings 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. General Warnings DANGER –... -
Page 5: Installation
2.0 Installation 2.0 Installation 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. -
Page 6: Chimney
2.0 Installation 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. -
Page 7: Electrical Connections
2.0 Installation Duct (75mm-150mm diameter) Ambient air is drawn into duct Chimney D 25mm vertical gap between chimney and duct 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. - Page 8 2.0 Installation Electrical Connection Details: Supply Types Supply Terminal Label Cable Colour Reversible or Live- Live - Neutral Live to either power conductor 1-phase L Brown to live (For USA 200-240V, connect L1) to the other power conductor Blue to neutral (For USA 200-240V, connect L2) to earth...
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Page 9: Temperature Controller
3.0 Temperature Controller 3.0 Temperature Controller If this product is fitted with a temperature controller, instructions are provided separately. -
Page 10: 2132 Over-Temperature Controller Description (If Fitted)
4.0 2132 Over-Temperature 4.0 2132 Over-Temperature Controller Description (if fitted) Description Alarm Light Page Scroll D Down Display This over-temperature controller is fitted and supplied ready to use by Carbolite Gero. It is a digital instrument with a latching alarm, requiring no additional panel controls. The controller features easy setting of over-temperature setpoint and reading of current temperature by the over-temperature sensor. -
Page 11: Operation
4.0 2132 Over-Temperature 4.2.2 Operation When switched on, the controller lights up, goes through a short test routine and then displays the measured temperature or the over-temperature setpoint. The page key allows access to parameter lists within the controller. A single press of the page key displays the temperature units, normally set to °C;... -
Page 12: Audible Alarm
4.0 2132 Over-Temperature Audible Alarm If an audible alarm is supplied for use with the over-temperature controller, it is normally configured to sound on over-temperature condition and to stop sounding when the alarm is acknowledged as given in section 4.2. Note: the alarm may sound during controller start-up. -
Page 13: Operation
5.0 Operation 5.0 Operation Operating Cycle This product is fitted with an instrument switch which cuts off power to the control circuit. Connect the product to the electrical supply. Turn on the instrument switch to activate the temperature controllers. The controllers illuminate and go through a short test cycle. -
Page 14: Use Of Probes
5.0 Operation Materials such as case hardening compounds and other reactive salts may penetrate the furnace chamber lining and attack the wire elements, causing premature failure. Use of a hearth tile may be advisable: please consult the Carbolite Gero technical department. Use of Probes Any metal object used to probe into the product chamber while the product is connected to the electrical supply must be earthed. -
Page 15: Thermal Catalytic Oxidiser Option
5.0 Operation Thermal Catalytic Oxidiser Option Catalytic oxidation allows the purification of exhaust air from volatile organic components at low temperature without an open flame. By the use of a suitable catalyst, complete oxidation of the volatiles takes place at temperatures between 250°C and 400°C. -
Page 16: Power Adjustment
5.0 Operation Power Adjustment The product control system incorporates electronic power limiting. Depending on the model and the destination country the power limit maybe set to 100% or a lower figure. Where appropriate the power limit parameter OP.Hi is accessible to the operator, but it should not generally be altered. -
Page 17: Maintenance
6.0 Maintenance 6.0 Maintenance General Maintenance Preventive rather than reactive maintenance is recommended. The type and frequency depends on the product use; the following are recommended. Maintenance Schedule CUSTOMER QUALIFIED PERSONNEL DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically qualified personnel should attempt these maintenance procedures. - Page 18 6.0 Maintenance Thorough inspection and report incor- Operational Check porating a test of all functions Performance Element Circuit Electrical measurement Measure the current drawn on each phase / Power Consumption circuit Hearth Visual check for fit and damage Cooling Fans (if fitted) Check whether the cooling fans are working...
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Page 19: Cleaning
6.0 Maintenance 6.2.1 Cleaning Soot deposits may form inside the furnace, depending on the process. At appropriate intervals remove these by heating as indicated in the General Operation Notes. The product's outer surface may be cleaned with a damp cloth. Do not allow water to enter the interior of the case or chamber. -
Page 20: After-Sales Service
6.0 Maintenance thermocouple and temperature indicator should be made from time to time to determine whether full calibration is required. Carbolite Gero can supply these items. Depending on the controller fitted, the controller instructions may contain calibration instructions. After-Sales Service Carbolite Gero Service has a team of Service Engineers who can offer repair, calibration and preventive maintenance of furnace and oven products both at the Carbolite Gero factory and at customers’... -
Page 21: Repairs And Replacements
7.0 Repairs and Replacements 7.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Immediately switch the product off in the event of unforeseen circumstances (e.g. large amount of smoke). Allow the product to return to room temperature before inspection. Always ensure that the product is disconnected from the electrical supply before repair work is carried out. -
Page 22: Solid-State Relay Replacement
7.0 Repairs and Replacements Solid-State Relay Replacement Disconnect the product from the power supply and remove the appropriate cover as given above. 1. Make a note of the wire connections to the solid state relay, then disconnect them. 2. Remove the solid state relay from the base panel or aluminium plate. 3. -
Page 23: Element Replacement
7.0 Repairs and Replacements Element Replacement See section 7.2 - wearing a face mask is required. The chamber of this type of furnace is formed by winding resistance heating wire on to a refractory muffle former. In the event of failure, the whole "wound muffle" assembly must be replaced. - Page 24 7.0 Repairs and Replacements Switch the furnace ON and heat to 900 °C without interruption and then dwell for 1 hour. Some smoke may be observed during this process, which should be carried out in a well ventilated area. Check that the furnace is controlling properly to rule out the possibility that previous element failed because of a fault in the control circuit.
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Page 25: Door Plug Replacement
7.0 Repairs and Replacements Door Plug Replacement See section 7.2 - wearing a face mask is required. Open the door and remove the door cover from the plug carrier assembly. Remove the old door plug by sliding it upwards out of its carrier. Slide the new plug into the carrier assembly making sure that the plug is the correct way up. - Page 26 7.0 Repairs and Replacements If any fuse has failed, it is advisable for an electrician to check the internal circuits. Replace any failed fuses with the correct type. For safety reasons do not fit larger capacity fuses without first consulting Carbolite Gero. The fuses are located at the cable entry point.
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Page 27: Fault Analysis
8.0 Fault Analysis 8.0 Fault Analysis Furnace Does Not Heat Up The HEAT The heating element Check also that the SSR is working light is ON has failed correctly The controller shows a The HEAT The thermocouple has broken or has very high temperature light is OFF a wiring fault... -
Page 28: Product Overheats
8.0 Fault Analysis Product Overheats Product only heats up The controller when the instrument shows a very high The controller is faulty switch is ON temperature The thermocouple may be The controller faulty or may have been shows a low removed out of the heating temperature chamber... -
Page 29: Wiring Diagrams
9.0 Wiring Diagrams 9.0 Wiring Diagrams WA-11-30 Connections below show single phase with indirect safety switch(es). F1, F2, F3 Fuses Filter R1/1, R1/2 Relay Contactor Relay Cables Temperature Controller Blue Control Thermocouple Solid State Relay GR/Y Green + Yellow Safety Switch Grey Heat Lamp Pink... - Page 30 9.0 Wiring Diagrams WA-11-31 Connections below show single phase with safety switches and over-temperature control. F1, F2, F3 Fuses Filter R1/1, R1/2 Relay Contactor Relay Temperature Controller Cables Over-Temperature Controller Blue Over-Temperature Thermocouple Control Thermocouple GR/Y Green + Yellow Solid State Relay Grey Safety Switch Pink...
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Page 31: Fuses And Power Settings
10.0 Fuses and Power Settings 10.0 Fuses and Power Settings 10.1 Fuses F1-F3: Refer to the circuit diagrams. GEC Safeclip of the type shown Fitted if supply cable fitted. Internal (glass type F up to 16 A) Supply Fitted on board to some types 38 mm x 10 mm type F fitted on Fuses of EMC filter. -
Page 32: Specifications
11.0 Specifications 11.0 Specifications Carbolite Gero reserves the right to change the specification without notice. External Size Chamber Size (mm) (mm) Model Temp Power Weight (°C) (kW) (kg) Ashing Burn-off and Coal and Coke Testing Furnace 585 375 485 90 AAF 11/3 1100 150 250... - Page 33 Notes Service Record Engineer Name Date Record of Work...
- Page 34 The products covered in this manual are only a small part of the wide range of ovens, chamber furnaces and tube furnaces manufactured by Carbolite Gero for laboratory and industrial use. For further details of our standard or custom built products please contact us at the address below, or ask your nearest stockist.
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