Related Manuals for Carbolite Gero TS1 12/60/150
Summary of Contents for Carbolite Gero TS1 12/60/150
- Page 1 Maintenance Instructions 1200°C Split Tube Furnace - TS1 150mm ø60mm TS1 12/60/150 MEN-TS_1260150-M 06-10-2020...
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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 Dismounting the Furnace from the Control Box 7.2 Mounting the Furnace on the Vertical Stand 7.3 Securing Vertical Stands to a Surface 7.3.1 Horizontal Surface 7.3.2 Vertical Surface 8.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Temperature Controller Replacement 8.3 Electrical Connections 8.3.1 1-Phase Connections...
- Page 4 10.1 Decommissioning 10.2 Storage (Long Term) 10.3 Disposal...
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Page 5: Introduction
Operation Manual" provided with the product. Note: If this product is used for any application other than its intended purpose, as stated by Carbolite Gero, the protection provided by this equipment may be impaired. Note: Failure to comply with the instructions as stated within this manual will constitute misuse and subsequently void any warranty provided by Carbolite Gero. -
Page 6: Safety
2.0 Safety Symbols and Warnings Note: Observe and take the appropriate precautions if any of the following warning symbols are displayed on this product or in your working environment. Disconnect the product from Refer to the instruction the power supply before manual before operating or performing any maintaining the equipment... -
Page 7: Operator Safety
PPE (Personal Protective Equipment). Carbolite Gero recommend that the appropriate PPE is worn at all times whilst working with and around this product. Risk Prevention and Mitigating Residual Risks... -
Page 8: Safety Warning - Refractory Fibre Insulation
European Association representing the High Temperature Insulation Wool industry (www.ecfia.eu). Further information can be provided on request. Alternatively, Carbolite Gero Service can quote for any repairs to be carried out either on site or at the Carbolite Gero factory. Manual Handling Refer to the "Specifications"... -
Page 9: Product Overview
The product rating label is located on the side of the product control box. Note: The image below is an example and does not reflect the product(s) covered by this manual. UKCA Mark Carbolite Gero address and website CE Mark Country of Origin Product Model... -
Page 10: Part Identification
3.2 Part Identification Outer Casing Handle End Guards Insulation Collar Heating Element Pneumatic Strut Insulation Bar Door Latch Control Box 10 Instrument Switch 11 Controller 12 Control Box Foot 13 Work Tube 14 Lid Prop 15 Heating Element Access Panel (1) 16 Hinge 17 Electrical Conduits 18 Heating Element Access Panel (2) -
Page 11: Control Box Input / Output Identification
Control Box Input / Output Identification Warning! Isolate power supply before removing this panel! Heating Lamps Relay Inputs (optional) Ethernet Communication Port Serial Communications Port(s) (optional) Power Supply Input Power Output to Heating Elements Alternating Current (AC) Thermocouple Input... -
Page 12: Product Labels
Product Labels Before commissioning this product, ensure that the following product information and warning labels are in the positions detailed below: 1 Carbolite Gero Logo 2 Verder Scientific logo 3 Product ID Label 4 WARNING: ISOLATE POWER SUPPLY BEFORE REMOVING THIS PANEL... -
Page 13: Dimensions
3.5 Dimensions... -
Page 14: Specifications
Specifications Furnace 1200 Maximum Temperature (°C) 1100 Maximum Continuous Operating Temperature (°C) Maximum Power (kW) 0.75 Net Weight (kg) Heated Length (mm) Minimum recommended work tube length (mm) Maximum recommended work tube length (mm) Control Box Height x Width x Depth (mm) 228 x 485 x 480 Net Weight (kg) Options and Accessories Vertical Stand... -
Page 15: Electrical Specifications
5.0 Electrical Specifications This equipment MUST be earthed! Product Ingress Protection (IP) Rating: 20 Fuses and Power Settings Main Fuse Power Turndown Phases Voltage (V) (Amps, Type, Size) 10, gG, 10x38mm 10, gG, 10x38mm 6, gG, 10x38mm 1 phase + Neutral 6, gG, 10x38mm 6, gG, 10x38mm 6, gG, 10x38mm... - Page 16 Temperature: 5°C - 40°C Relative Maximum 80% up to 31°C decreasing linearly to 50% at 40°C humidity: Not exceeding 2000 metres Altitude:...
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Page 17: 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. Frequency Maintenance Method... - Page 18 required Check that all functions are working nor- Operational Check mally Thorough inspection and report incor- Operational Check porating a test of all functions Visually check that the tube is central to Work Tube Position the heated zone (horizontally / vertically) Visual check for damage or wear, and cor- End Plugs / Radiation Shields rect positioning...
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Page 19: Cleaning
Ensure that power to the heating elements is switched off when the door is opened. Contact Carbolite Gero Service and discontinue use of the product if it is found that the heating elements are not fully isolated during these checks. -
Page 20: After-Sales Service
Recommended Spare Parts and Spare Parts Kit Carbolite Gero can supply individual spare parts or a kit of the items most likely to be required. Ordering a kit in advance can save time in the event of a breakdown. -
Page 21: Furnace Mounting Options
7.0 Furnace Mounting Options Dismounting the Furnace from the Control Box Note: Disconnect the product from the electrical supply before carrying out any maintenance procedures. Note: DO NOT attempt to move the product when it is hot. Wait until it has cooled down to room temperature. - Page 22 There are a set of spacer brackets securing the fur- nace to the control box. Remove the bottom screw on all the spacer brackets, ensuring that the furnace body is sufficiently sup- ported. Slide the furnace body back- wards to disengage the tabs on the spacer brackets from the slots on the top of the control box.
- Page 23 Using the appropriate lifting equipment, carefully lift the furnace body from the con- trol box. Lower the furnace down onto two support blocks. The blocks should be no smaller than 100mm square section and at least the same depth as the furnace body. The front section of the blocks should rest behind the red section of the casing.
- Page 24 Additional feet are provided to support the furnace when dismounted from the control box. Screw the feet into the holes provided on the under- side of the casing. Use the appropriate lifting equipment to move the fur- nace from the blocks to its desired position.
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Page 25: Mounting The Furnace On The Vertical Stand
The vertical stand is only included as part of the "Vertical Stand and Vertical Tube Support Package". Please contact Carbolite Gero for details. Note: DO NOT attempt to move the product when it is hot. Wait until it has cooled down to room temperature. - Page 26 Replace the pneumatic strut on the left-hand side of the furnace with the pneumatic strut sup- plied as part of the "Ver- tical Operation Package". Note: The replacement strut is of a lower force rating (N) than the standard pneumatic struts to prevent the furnace opening too rapidly when it is orientated vertically.
- Page 27 On the underside of the furnace there are tapered slots that allow the furnace to be fixed to the mounting bracket. Using the appropriate lift- ing equipment (see sec- tion 2.5) lower the furnace down onto the mounting bracket, ensur- ing that all hooks are loc- ated securely into the tapered slots.
- Page 28 Insert the security screw (s) through the back of the mounting bracket and into the base of the furnace to lock it securely in place. Using the appropriate lift- ing equipment, raise the furnace stand into a ver- tical orientation.
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Page 29: Securing Vertical Stands To A Surface
7.3 Securing Vertical Stands to a Surface Note: The customer is responsible for ensuring that the surface to which the stand is to be mounted is suitable to support the weight of both the stand and furnace. The customer is also responsible for providing appropriate hex head fixings and washers for securing the stand to the intended mounting surface. -
Page 30: Vertical Surface
Using the appropriate lifting equipment, vertically orientate the furnace and stand, pos- itioning them so that the holes in the base of the stand align with the holes made in the sur- face. Feed four hex head fixings through the holes in the base of the stand. - Page 31 y 1147 Feed four hex head fixings through the appropriate holes in the stand. Use the appropriate lifting equipment (see section 2.5) to lift and hold the furnace and stand in position, then tighten the fixings into the vertical sur- face.
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Page 32: Repairs And Replacements
8.0 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 33: Electrical Connections
8.3 Electrical Connections For products supplied without pre-fitted plugs, it is recommended that all electrical connections are carried out by a qualified electrician. The product covered by this manual normally requires a 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. -
Page 34: Mains Supply Cable
Mains Supply Cable 3-core, 1.5mm rated to 16 Amp, 250 VAC Connecting a Supply Cable to Internal Terminals For products rated above 16 Amps supplied without pre-fitted plugs, all electrical connections should be carried out by a qualified electrician. Locate the electrical com- ponent access panel at the rear of the control box. - Page 35 On the electrical component access panel, fit an appropriate sized gland for the cable required. To connect the Live and Neut- ral wires (e.g. L1, N/L2), loosen the screw on the top of the fuse holder and fully insert the wire into the slot. Tighten the screw to secure the wire in place.
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Page 36: End Guard Installation
Where a work tube emerges from the furnace its surface and any adjacent metalwork can be too hot to safely touch. To prevent operators from accidentally touching these hot surfaces, end guards are available and included with all Carbolite Gero work tube packages that require an extended work tube. -
Page 37: Work Tube Installation
8.7 Work Tube Installation Note: Disconnect the product from the electrical supply before carrying out any maintenance procedures. Note: Do not operate the furnace without a work tube installed! Note: If using a metal work tube it MUST be earthed! Work tubes are fragile pieces of equipment. -
Page 38: Work Tube Supports
8.7 Note: The customer is responsible for all external fittings and equipment not provided by Carbolite Gero. If external fittings are to be attached to the work tube end seals, ensure that they will not prevent the work tube from expanding and contracting due to changes in temperature. - Page 39 parts or fragments from dropping if the work tube breaks during use. To allow for thermal expansion, the top of work tube is not gripped in place, but guided by an additional metal bracket at the top of the furnace. This reduces the mechanical stress upon the structure of the work tube.
- Page 40 Insert the work tube into the fur- nace (refer to section 8.7), care- fully sliding one end through the support clamp assembly so as not to damage the tube. Refit the adjustment bar(s) and securing nuts, then gently tighten the support clamp assembly until it securely grips the work tube.
- Page 41 Adjust the positioning of the guid- ing bracket until it is close to the work tube, but not gripping it, then tighten the screws to secure it in position. The loose fit will help allow for thermal expansion of the work tube. Once the work tube is safely secured in place, refit the furnace end guards.
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Page 42: Lid Prop
8.9 Lid Prop For additional safety whilst performing maintenance procedures that require the removal of the pneumatic struts, this product is supplied with a specially designed lid prop. The lid prop is fixed to the inside of the control box back panel. Note: Disconnect the product from the electrical supply before carrying out any maintenance procedures. -
Page 43: Panel Removal
Hook the end of the lid prop under- neath the head of the screws and retighten them to secure the prop in place. Check the prop is secure before removing any pneumatic struts or proceeding with any maintenance tasks. 8.10 Panel Removal Note: Disconnect the product from the electrical supply before carrying out any maintenance procedures. -
Page 44: Heating Element Access Panels
Disconnect the earth con- nection, then carefully slide the panel out of the control box, tak- ing care not to disconnect or damage any wiring 8.10.2 Heating Element Access Panels At the rear of the furnace body there are two heating element access panels, one for the top half and one for the bottom half of the furnace... - Page 45 The panel will lever down due to the tabs on the bottom edge Disconnect the earth tab Lever the panel down to dis- engage the tabs from the furnace casing, and slide it out to reveal the heating element and ther- mocouple connections behind...
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Page 46: Pneumatic Strut Replacement
8.11 Pneumatic Strut Replacement To support the lid of the furnace when opened, a pneumatic strut is fitted at either end of the furnace to limit the opening angle to 60°. To replace the pneumatic struts: Remove the furnace end guards (if fitted). Open the tube furnace and insert the lid prop to support the upper half. - Page 47 located on the left-hand side of the furnace. To replace the door switch: If fitted, remove the lower end guard. Open the furnace and insert the lid prop, then remove the pneumatic strut on the left hand side (see section 8.11). Disconnect the door switch assembly by removing the screws holding the two halves of the mechanism together.
- Page 48 Carefully slide the end plate away from the furnace. The door switch assembly is attached to the inside of the end plate. Make a note of the electrical con- nections to the switch, then disconnect the two spade terminals on the switch. Dismount the old door switch assembly by removing the two screws holding it to the metalwork.
- Page 49 Reconnect the door switch assembly by replacing the two screws connecting the mechanism. Refit the pneumatic strut and end guard (if supplied) Note: Test that the door switch functions correctly before recommissioning the furnace. The heating elements should be isolated when the furnace is opened.
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Page 50: Insulation Collar Replacement
8.13 Insulation Collar Replacement Note: Disconnect the product from the electrical supply before carrying out any maintenance procedures. Note: This component is made from refractory ceramic fibre. Wear appropriate PPE. Please refer to section 2.4 for more information Note: Remove the work tube before proceeding with the following maintenance procedure. - Page 51 Using a flexible 8mm hexagon nut driver, loosen the M5 flange nuts hold- ing the furnace end plate in place. Gently slide the end plate away from the furnace to provide an accessible gap. Remove the M5 screw securing the insu- lation collar bracket in position.
- Page 52 Carefully rotate and lift the old insu- lation collar out of position. Carefully insert the new insulation col- lar, ensuring that the groove on the flat face of the collar fits under the fixed bracket . Refit the insulation collar bracket and tighten it securely onto the groove on the insulation collar.
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Page 53: Insulation Bar Replacement
Secure the end plate by tightening the flange nuts to 4Nm (Newton Metres of torque). Reconnect the door switch assembly by replacing the two screws connecting the mechanism. Refit the pneumatic struts, then remove the lid prop and close the furnace. Check that the insulation collars are properly aligned before recom- missioning the furnace. - Page 54 The insulation bars are fitted to the bottom half of the furnace to prevent radiant heat from leaking out between the top and bottom halves of the furnace. They are held in place with a number of metal grippers. To replace the insulation bars: Open the furnace and insert the lid prop (see section 8.9).
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Page 55: Heating Element Replacement
Gently push the grippers forward until their teeth sink into the insu- lation bar. When the insulation bar is securely gripped, tighten the screws to fix them in position. Check that the furnace can be closed without interference from the insulation bar. If the furnace does not close, make adjustments to the positioning of the insulation bar. - Page 56 Note: This component is made from refractory ceramic fibre. Wear appropriate PPE. Please refer to section 2.4 for more information Note: Replacement heating elements are supplied as part of an insulation assembly box. These are available for either the upper or lower half of the furnace; this must be specified at the time of order.
- Page 57 Open the furnace and use the lid prop to hold the top half in position (see section 8.9). Remove the pneumatic struts at either end of the tube fur- nace (see section 8.11). Disconnect the door switch assembly by removing the screws holding the two halves of the mechanism together.
- Page 58 Using the appropriate lifting equipment, separate the two halves of the furnace and lay them down with the insulation assembly facing upwards Using a flexible 8mm socket screwdriver, loosen the M5 flange nuts holding the furnace end plate in place, then remove the end plates Remove the insulation collars (see section 8.13.).
- Page 59 Remove the screws securing the insulation assembly box to the furnace casing. Using appropriate lifting equip- ment, carefully lift the insu- lation assembly box out of the casing. The furnace casing may require some manipulation in order to allow the insulation assembly to be removed with the terminal blocks attached.
- Page 60 Refit the grippers and insu- lation bars (see section 8.14) and perforated metal plate to cover the electrical con- nections. Refit the insulation collars (see section 8.13.). Refit the end plates. Using the appropriate lifting equipment, lift the top half of the furnace back onto the bot- tom half of the furnace, ensur- ing that the two halves are...
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Page 61: Thermocouple Replacement
8.16 Thermocouple Replacement Note: Disconnect the product from the electrical supply before carrying out any maintenance procedures. Note: Replacement thermocouples are provided pre-bent in ceramic sheaths. To replace a thermocouple: Remove the heating element access panel(s) (see section 8.10). Make a note of all electrical con- nections. -
Page 62: Heating Lamp Replacement
Carefully insert the new ther- mocouple and sheath into the hole in the insulation, wires first. Ensure that the end of the ther- mocouple is pointing in the same dir- ection as the old thermocouple and that it lies flat against the surface of the insulation. -
Page 63: Fuse Replacement
Gently squeeze the clip on the heating lamp fitting and push it out through the back of cutout in the metal panel. Push the replacement lamp fitting through the hole in the back panel so that the lamp is facing outwards. Reconnect the wires to the heating lamp(s) based on your notes. -
Page 64: Main Fuse
8.18.1 Main Fuse The main fuse holders are located beside the power inlet port. Flip open the lid on the top of the fuse holder and remove the old fuse. Slide the new fuse into the fuse holder Close the lid of the fuse holder. 8.18.2 Auxiliary Fuses The auxiliary fuse holders are attached to rails on the base of the power plate... -
Page 65: Electrical Contactor Replacement
1. Remove the electrical component access panel as described in the "Panel Removal" section of this manual. 2. Make a note of the wiring connections to the solid state relay. 3. Disconnect the wiring to the solid state relay. 4. Remove the screw(s) holding the solid state relay in place. -
Page 66: Fault Analysis
9.0 Fault Analysis Note: The heating lamps are located at the rear of the control box. Furnace Does Not Heat Up heating The heating element Check also that the SSR is working lamps are has failed correctly The controller shows a heating very high temperature The thermocouple has broken or has... -
Page 67: Product Overheats
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 The thermocouple may be... -
Page 68: Decommissioning, Storage And Disposal
Within the European Community the disposal of electrically operated devices is regulated according to guidance based on the EU Directive 2012/19/EU on Waste Electrical and Electronic Equipment (WEEE). Disposal regulations may differ worldwide. If uncertain, please contact Carbolite Gero for advice on disposal. - Page 69 Notes Service Record Engineer Name Date Record of Work...
- Page 70 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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