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Summary of Contents for VERDER CARBOLITE GERO GHC 12/450
- Page 1 Installation, Operation and Maintenance Instructions 1200°C Tube Furnace (3-zone) - GHC Model: 450mm No Controller GHC 12/450 + No Controller MEN-GHC120450-16_NOCTRL 18-06-2019...
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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 Safety Warning - Refractory Fibre Insulation Temperature Controller Replacement Solid-state Relay Replacement Thermocouple Replacement Element Replacement Fuse Replacement 7.0 Fault Analysis Furnace Does Not Heat Up Product Overheats 8.0 Wiring Diagrams WC-13-31 WC-U3-31 WC-U4-31 Higher Voltages Three-Zone Models Control by Broadcast Comms (control method B) 9.0 Fuses and Power Settings Fuses 9.2 Power Settings...
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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 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).
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Page 7: Work Tubes And Fittings
2.0 Installation 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. - Page 8 2.0 Installation Fig 1 - Insulating Plug (standard length tube) Tube Insulating Plug Stem Fig 2 - Insulating Plug (long work tube)
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Page 9: Electrical Connections
2.0 Installation Clamp Seal plate 'O' Ring seal D Seal sleeve Clamp seal End plate Clamp End plate Clamp seal (between Seal sleeve and Clamp D Seal sleeve Seal plate & 'O' Ring seal (underneath clamp) Tube Fig 3 'Twin Clamp' End Seal For assembly details refer to the separate work tube end seal manual. - Page 10 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.
- Page 11 2.0 Installation DO NOT connect a product ordered for three phase use to a single phase supply or to the wrong type of three phase supply.
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Page 12: Reconfiguring And Adjusting For Voltage
2.0 Installation 2.5 Reconfiguring and Adjusting for Voltage The standard single-phase models can operate over the voltage range 200 - 240 V. The 2-phase models can operate over the range 380/220 V to 415/240 V. The 3-phase models can operate over the range 380/220 V to 415/240 V. The product is wired according to the original order and conversion from 1-phase to 2- phase or 1-phase to 3-phase is not possible. -
Page 13: Temperature Controller
3.0 Temperature Controller 3.0 Temperature Controller If this product is fitted with a temperature controller, instructions are provided separately. -
Page 14: 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 controllers. The controllers illuminate and go through a short test cycle. -
Page 15: Back-To-Back Thermocouples
4.0 Operation Note: Option A is NOT applicable when using the CC-T1 controller Option B is NOT applicable when using the Eurotherm 2132 End Zone Controller A. Back-to-Back Thermocouples This is the most commonly supplied option. The centre zone of the tube furnace is controlled directly by the centre zone temperature controller. -
Page 16: Independent Control
4.0 Operation It is possible to set an offset (local trim) between the centre and end zone controllers. This can be either a positive or negative difference from the centre zone temperature. Once entered, this offset will always be added to, or subtracted from, the retransmitted setpoint temperature. -
Page 17: 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 18: Gas Tightness
4.0 Operation Gas Tightness Work tubes of IAP material are impervious. Sillimanite may look similar but is porous. Ensure that the correct tube material is in use before connecting and using gases other than inert gases, such as nitrogen. 4.9 Running at Low Temperatures The power limit may be adjusted to a low level in order to achieve better control when operating the product at a low temperature. -
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. Maintenance Schedule CUSTOMER QUALIFIED PERSONNEL DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically qualified personnel should attempt these maintenance procedures. - Page 20 5.0 Maintenance Seals (if fitted) Check all seals and O-rings and clamps Performance Element Circuit Electrical measurement Measure the current drawn on each Power Consumption phase / circuit Check whether the cooling fans are work- Cooling Fans (if fitted)
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Page 21: Cleaning
5.0 Maintenance 5.2.1 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 22: 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 23: 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 24: Element Replacement
6.0 Repairs and Replacements Element Replacement See section 6.2 - wearing a face mask is required. Disconnect the product from the electrical supply. Remove all outer guards, meshes and terminal covers from the product body. For a horizontally mounted product remove the product body from its base; to reach the bolts or screws that fix the body to the base, remove the back panel from the base. -
Page 25: 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 26: 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 27: 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 28: Wiring Diagrams
8.0 Wiring Diagrams 8.0 Wiring Diagrams WC-13-31 Connections below show single phase with indirect safety switches and over- temperature control. -
Page 29: Wc-U3-31
8.0 Wiring Diagrams WC-U3-31 Connections below show 3-phase +N with safety switches and over-temperature control. Products with this wiring arrangement may be converted between the following supply voltages (please refer to the table within section 9.0 for compatible phases with the product): 3-phase + neutral in the range 380/220 V - 415/240 V 3-phase delta in the range 220 V - 240 V... -
Page 30: Wc-U4-31
8.0 Wiring Diagrams WC-U4-31 Connections below show 3-phase +N with safety switches and over-temperature control. Products with this wiring arrangement may be converted between the following supply voltages (please refer to the table within section 9.0 for compatible phases with the product): 3-phase + neutral in the range 380/220 V - 415/240 V 3-phase delta in the range 220 V - 240 V... -
Page 31: Higher Voltages
8.0 Wiring Diagrams Higher Voltages For 254 V or above 1-phase or 440/254 V or above 3-phase, an isolating transformer is included in the control circuit after the F2 fuses. Three-Zone Models The element circuit in the 3-zone versions remains the same as in the above diagrams, but the control circuit contains three controllers and additional thermocouples. - Page 32 8.0 Wiring Diagrams...
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Page 33: Fuses And Power Settings
9.0 Fuses and Power Settings 9.0 Fuses and Power Settings Fuses F1 - F2: 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 34: Power Settings
9.0 Fuses and Power Settings 9.2 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 35: Specifications
10.0 Specifications 10.0 Specifications Carbolite Gero reserves the right to change the specification without notice. 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 170 mm. All models have a maximum operating temperature of 1200 °C (1100°C continuous). - Page 37 Notes Service Record Engineer Name Date Record of Work...
- Page 38 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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