VERDER Carbolite Gero EST 12/450B Installation, Operation And Maintenance Instructions
E-range tube furnace no controller
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- Page 1 Installation, Operation and Maintenance Instructions 1200°C E-Range Tube Furnaces - EST Model: 450mm No Controller EST 12/450B + No Controller MEN-EST12450B-005_NOCTRL 30-01-2018...
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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 Tube Life Pressure Gas Tightness 5.0 Maintenance General Maintenance 5.1.1 Cleaning Calibration After-Sales Service Recommended Spare Parts and Spare Parts Kit 6.0 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...
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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. Heat switch: the switch disconnects power to the heating elements;... -
Page 5: Warning Labels
1.0 Symbols and Warnings Caution – Double Pole/Neutral Fusing 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. -
Page 6: Control Box Layout And Warning Labels
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. -
Page 7: Installation
2.0 Installation 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. Unpacking and Handling When unpacking or moving the product, always lift it by its base or both ends of the main body. -
Page 8: Removed From The View For Clarity To Show The End Adaptor And Tube End Stop
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. -
Page 9: End Stop
2.0 Installation Index to numbered items in Fig- ure 2.3.1 1. Top lifting handle 2. Work tube (diameter cus- tomer 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 2.3.2 Figure - Close-up view of the tube end diameter) - Page 10 2.0 Installation 2.3.3 Figure - Tube support 2.3.4 Figure - Tube support assembled...
- Page 11 2.0 Installation 2.3.5 Figure - Tube support and end seal 2.3.6 Figure - Tube support and end seal assembly Index to numbered items in figure 2.3.5 - 2.3.12 1. Blank plate 2. Seal 3. Clamp 4. Boss 5. Tube support collar 6.
- Page 12 2.0 Installation 8. M6 button head screw 9. M6 washer 10. Clamp 11. O Ring 12. Clamp ring 13. Standard end guard 14. Extended work tube guard 15. End adaptor Fitting the Optional Insulation Plugs and Radiation Shield For optimum temperature uniformity, insulation plugs or radiation shields should be placed in the work tube ends as shown below.
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Page 13: Plug Fitted
2.0 Installation 2.3.8 Figure - Cross-section view show- 2.3.7 Figure - Cross-section view show- ing extended work tube insulation plug ing standard length work tube insulation fitted plug fitted 2.3.9 Figure - Cross-section view showing an extended length work tube with a radi- ation shield fitted Electrical Connections Connection by a qualified electrician is recommended. - Page 14 2.0 Installation The external connection should be either a permanent connection to a fused isolator supply or to a socket on a fused isolator supply; the isolating switch must operate on both conductors. Make sure that the isolator switch is within easy reach of the furnace operator.
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Page 15: Temperature Controller
3.0 Temperature Controller 3.0 Temperature Controller If this product is fitted with a temperature controller, instructions are provided separately. -
Page 16: Operation
4.0 Operation 4.0 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 controller. The controller illuminates and goes through a short test cycle. -
Page 17: General Operating Advice
4.0 Operation Explosive Materials The furnace must not be used to heat materials which could explode, or which could emit gases that could form explosive mixtures. If the safe heating of a material is dependent on its temperature, only heat these type of materials if the furnace has the optional over-temperature protection device fitted. -
Page 18: Tube Life
4.0 Operation Switch off the heater switch whenever loading or unloading the product. The elements are isolated when the heater switch is OFF. This switch cuts both sides of the circuit via a contactor. Tube Life A ceramic work tube may crack if work pieces are inserted too quickly or at temperatures below 900 °C (when the tube is more brittle). -
Page 19: Maintenance
5.0 Maintenance 5.0 Maintenance General Maintenance Preventive rather than reactive maintenance is recommended. The type and frequency depends on the product use; the following are recommended. 5.1.1 Cleaning 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: Repairs And Replacements
6.0 Repairs and Replacements 6.0 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 21: Solid-State Relay Replacement
6.0 Repairs and Replacements Solid-state Relay Replacement Disconnect the product from the power supply and remove the appropriate cover as given above. Make a note of the wire connections to the solid state relay and disconnect them. Remove the solid state relay from the base panel or aluminium plate. Replace and reconnect the solid state relay ensuring that the bottom of it has good thermal contact with the base panel or aluminium plate. -
Page 22: Fuse Replacement
6.0 Repairs and Replacements Fuse Replacement Fuses are marked on the wiring diagram with type codes, e.g. F1, F2. For more information on fuses refer to section 9.0. Depending on model and voltage, the different fuse types may or may not be fitted. If any fuse has failed, it is advisable for an electrician to check the internal circuits. -
Page 23: Fault Analysis
7.0 Fault Analysis 7.0 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 24: Product Overheats
7.0 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 25: Wiring Diagrams
8.0 Wiring Diagrams 8.0 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 26 8.0 Wiring Diagrams WA-11-70 Connections below show single phase with safety switches. 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 SSW-A, SSW-B Safety Switch(es) Grey Heat Lamp Pink Element(s)
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Page 27: Fuses And Power Settings
9.0 Fuses and Power Settings 9.0 Fuses and Power Settings... -
Page 28: Power Settings
9.0 Fuses and Power Settings 9.1 Power Settings The power limit settings (OP.Hi) for this model is as follows. The figures represent the maximum percentage of time that controlled power is supplied to the elements. Do not attempt to "improve performance" by setting a value higher than the one from the table. -
Page 29: Specifications
10.0 Specifications 10.0 Specifications Carbolite Gero reserves the right to change the specification without notice. EVA models - vertical single-zone tube furnaces. All models have cylindrical elements with wire formed in the surface of the insulation material. All models can accept work tubes up to a maximum outside diameter of 60 mm. All models have a maximum operation temperature of 1200 °C (1100°C continuous). -
Page 30: Furnace Drying Out Process
10.0 Specifications Furnace drying out process Step 1. Before the furnace is connected to the electrical supply, remove the back panel and check for signs of moisture on the electrical circuits. If visible signs of moisture are present then allow it to dry out in ambient temperature for at least 24 hours. If the problem persists ensure that the furnace is isolated and contact Carbolite Gero Service for more information. - Page 31 Notes Service Record Engineer Name Date Record of Work...
- Page 32 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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