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Carbolite Gero Manuals
Furnace
AAF 11/18
Installation, operation and maintenance instructions
Carbolite Gero AAF 11/18 Installation, Operation And Maintenance Instructions
1100 'c ashing furnace aaf model 18 litres
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Contents
Table of Contents
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Table of Contents
Table of Contents
Program Example
1 0 Symbols and Warnings
Switches and Lights
General Warnings
2 0 Installation
Unpacking and Handling
Siting and Setting up
Chimney
Electrical Connections
3 0 3508 Controller
PID Control
3508P1
3508P10
3508P25
Basic Operation
Controller Layout
Keys
Quick Start Guide
Operation as a Simple Controller
Changing the Setpoint
Resetting the Programmer
Understanding User Levels
Setting up Controller
Maximum Output Power Setting
Customer ID
Units
Language
Programming Notes
Holdback
Wait Segments
Program Cycling
Creating a Program
Running a Program
To Pause (Hold) a Program
To Stop and Reset a Program
To Run a Different Program (P10 and P25)
Program Status
Program Hold with Holdback
Power Failure Recovery
Alarms
Program Example 1
Program Example 2
Controller Options
Digital Communications - RS232
Digital Communications - RS485
Comms Address
Alarm Option
Temperature Controller Replacement
Controller Navigation Diagrams
Operator Level 1 - no Program Running
Operator Level 1 - Program Running
Supervisor Level 2
3508 Dual Loop Cascade Control (if Fitted)
Principle of Cascade Control
Operation of Cascade Control
Bypassing Cascade Control
3508P1 (Three Zone) Element Controller
Caution
Over-Temperature Control
2132 Over-Temperature Controller Description (if Fitted)
Description
Operation
Controls
Over-Temperature Operation
Over-Temperature Alarm
Resetting the Over-Temperature Alarm
Sensor Break
Audible Alarm
Navigation Diagram
6 0 Operation
Operating Cycle
General Operating Notes
Use of Probes
Atmospheres
Operator Safety
Power Adjustment
7 0 Maintenance
General Maintenance
Cleaning
Safety Switch
Calibration
After-Sales Service
Recommended Spare Parts and Spare Parts Kit
8 0 Repairs and Replacements
Safety Warning - Disconnection from Power Supply
Safety Warning - Refractory Fibre Insulation
Temperature Controller Replacement
Solid-State Relay Replacement
Thermocouple Replacement
Panel Element Replacement
Door Plug Replacement
Fuse Replacement
9 0 Fault Analysis
Furnace Does Not Heat up
Product Overheats
10 0 Wiring Diagrams
Wa-U3-30
Wa-U3-31
11 0 Fuses and Power Settings
Fuses
Power Settings
12 0 Specifications
Environment
Service Record
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Installation, Operation and Maintenance Instructions
1100 °C Ashing Furnace - AAF Model: 18 Litres
3508 Controller
AAF 11/18 + 3508 Controller
MEN-AAF1118-002_3508_V01
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Summarization of Contents
Symbols and Warnings
General Hazard Warnings
Details significant hazards like electric shock, hot surfaces, and potential fatal injuries, advising caution.
Operational Indicators
Explains the function of the instrument switch and heat light indicator for operational status.
Installation Procedures
Unpacking, Siting, and Chimney Setup
Instructions for safely unpacking, handling, positioning, setting up the chimney, and preparing the environment.
Electrical Connection Requirements
Detailed guidance on correctly connecting the furnace to the electrical power supply.
3508 Controller Operation and Setup
Controller Models and Basic Operation
Overview of 3508 controller variants (P1, P10, P25) and fundamental operating procedures.
Controller Layout, Keys, and Quick Start
Description of controller display, keys, and initial operating steps for rapid use.
Controller Setup and Configuration
Guidance on setting up parameters, understanding user levels, and configuring units and power settings.
3508 Controller Programming
Programming Notes and Creating Programs
Details on programming notes, segment types, and the process of creating new programs.
Program Control and Execution
Covers Holdback, Wait Segments, Program Cycling, and running/pausing/stopping programs.
Program Status, Alarms, and Examples
Monitoring Program Status and Handling Alarms
Information on viewing program status, handling alarms, and power failure recovery.
Programming Examples and Error Handling
Step-by-step examples for creating programs and understanding alarm indications.
Controller Communication and Options
Digital Communication Interfaces (RS232/RS485)
Details on RS232 and RS485 interfaces for connecting the controller to external systems.
Communication Settings and Alarm Option
Configuration of communication addresses and the use of the alarm option feature.
Controller Navigation Diagrams
Operator and Supervisor Level Navigation
Visual guides for navigating controller menus at Operator Level 1 and Supervisor Level 2.
Cascade Control System
Principle and Operation of Cascade Control
Explanation of how the dual loop cascade control system operates, including setup and bypass.
Over-Temperature Protection
Details on the over-temperature control function, its settings, and safety considerations.
2132 Over-Temperature Controller
Description, Controls, and Operation
Overview of the 2132 controller, its controls, operating procedures, alarms, and resets.
General Operation and Safety
Operating Cycle and General Notes
Description of the operating cycle, heating indicators, and general notes on use.
Probe Usage, Atmospheres, and Safety
Guidelines for probe usage, atmospheric conditions, operator safety, and power adjustment.
Maintenance and Spare Parts
General Maintenance, Calibration, and Service
Procedures for cleaning, safety checks, calibration, and after-sales service.
Recommended Spare Parts Kit
Information on the contents of the recommended spare parts kit for maintenance and repair.
Repairs and Replacements
Safety Warnings and Component Replacement
Critical safety warnings and guidance on replacing controllers, relays, thermocouples, and elements.
Door Plug and Fuse Replacement
Steps for replacing door plugs and fuses, including relevant safety advice.
Fault Analysis
Troubleshooting Heating Issues
Diagnostic steps for when the furnace does not heat up, covering common causes and checks.
Troubleshooting Overheating Conditions
Diagnostic steps for when the product overheats, covering controller and thermocouple issues.
Wiring Diagrams
WA-U3-30 and WA-U3-31 Configurations
Wiring diagrams for WA-U3-30 and WA-U3-31 models, detailing connections and options.
Fuses and Power Settings
Fuse Information and Power Limits
Details on fuses, their ratings, and power limit settings relative to voltage.
Product Specifications
Technical Specifications and Environment
Summary of technical specifications, chamber dimensions, and recommended environmental conditions.
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