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VERDER CARBOLITE GERO, Installation, Operation And Maintenance Instructions

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VERDER CARBOLITE GERO Installation, Operation And Maintenance Instructions Download Page 9

4.2 Input / Output Identification

Gas Inlet

Gas Outlet

Relay Connection to Solenoid Valve (Advanced Gas Package Only)

Gas Flow Enabled

Gas Flow Disabled

4.3

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 Gas Selector Positioning Label

3 Gas Outlet Label

4 Solenoid Valve Relay Connection Label (Advanced Gas Package Only)

5 Gas Inlet Label

9

Summary of Contents for CARBOLITE GERO

Page 1: ...Installation Operation and Maintenance Instructions Operating Instructions Inert Gas Package MEN IGP IO 25 01 2021 ...

Page 2: ...dentification 8 4 2 Input Output Identification 9 4 3 Product Labels 9 4 4 Specifications 10 4 5 Electrical Specifications Advanced Gas Package Only 10 5 0 Installation 11 5 1 Changing Flowmeter Scales 11 5 2 Connecting Flowmeter Modules 13 5 3 Gas Connections 15 5 3 1 Gas Inlet 15 5 3 2 Gas Outlet to Vessel 16 5 3 3 Connecting Multiple Gas Boxes 17 5 4 Electrical Connections Advanced Gas Package ...

Page 3: ... Incorporates an electrically controlled solenoid valve for automatic gas control The modular system of individual gas boxes allows for up to three gas lines per furnace which can be controlled either manually or automatically via a solenoid valve linked to the furnace temperature controller depending on the version ordered The customer can easily reconfigure the module for different gases by exch...

Page 4: ...o 2 0 1 Responsibilities The customer is responsible for conducting their own risk assessment and ensuring that any materials to be processed within the product are suitable to be safely heated to the required temperature and that appropriate safety measures are taken when handling such materials l Any material that is combustible or liable to cause explosions or generate com bustible gas must not...

Page 5: ... is responsible for ensuring that all of the above conditions are satisfied before the product is commissioned for use Note Unless otherwise specified the customer is responsible for the installation of this product and the safe connection of any additional equipment and gas or liquid supply lines Note Throughout this manual written instructions are accompanied by diagrams Diagrams may be highligh...

Page 6: ...cautions if any of the following warning symbols are displayed on this product or in your working environment Refer to the instruction manual before operating or maintaining the equipment Disconnect the product from the power supply before performing any maintenance Wear eye protection Wear a heat resistant face shield Wear heat resistant gloves Wear breathing apparatus Wear protective footwear We...

Page 7: ...erages 3 2 Risk Prevention and Mitigating Residual Risks Risk Prevention Measures Hot Surface l Wear appropriate PPE e g heat resistant gloves l Do not place any objects on top of the product l Ensure the product is sited on a non flammable surface and that all adjacent surfaces are also non flammable Ventilation required l Only operate in a well ventilated area l If necessary only operate in a fu...

Page 8: ...rview 4 1 Part Identification 1 Flowmeter 2 Flowmeter Adjustment Knob 3 Foot 4 Gas Control Valve 5 Pressure Indicator 6 Gas Outlet 7 Gas Inlet 8 Back Panel 9 Solenoid Valve Relay Connection Advanced Gas Package Only 8 ...

Page 9: ... Gas Flow Disabled 4 3 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 Gas Selector Positioning Label 3 Gas Outlet Label 4 Solenoid Valve Relay Connection Label Advanced Gas Package Only 5 Gas Inlet Label 9 ...

Page 10: ...ackage Single Box Height x Width x Depth mm 240 x 135 x 215 Approximate Weight kg 3 2 4 5 Electrical Specifications Advanced Gas Package Only The advanced gas package has a 24 Volt DC power connection via the solenoid valve relay 10 ...

Page 11: ...he flowmeter modules to be used with a range of gases Note The customer is responsible for selecting and installing the correct scale for the intended gas To install a gas scale into the flowmeter l The glass case is held in place by two small metal tabs at the top and bottom of the flowmeter Twist the tabs 90 to release the glass case 11 ...

Page 12: ...e the glass case as shown l Select the correct gas scale insert for the flowmeter module and fold it around the glass tube as shown Insert the scale into the flowmeter then refit the glass case to hold it in position 12 ...

Page 13: ...to their original positions 5 2 Connecting Flowmeter Modules When using more than one gas box it is recommended that the boxes are secured together to reduce the risk of any interconnecting gas pipes being pulled loose l Each flowmeter module has three keyhole slots and three screw threads in the outer cas ing 13 ...

Page 14: ... in the outer casing l Push the two flowmeter mod ules together until the screws on the side of one module locate into the keyhole slots on the other module l Remove the screw securing the back panel of the flowmeter module on the left when viewed from the rear 14 ...

Page 15: ...onnections 5 3 1 Gas Inlet l The gas inlet comprises a 6mm outside diameter fitting into which an appro priately sized hose can be pushed l Fully insert the hose into the fitting to cre ate a secure connection l The other end of the hose should be con nected to an external gas supply cus tomer supplied Note To disconnect any pipes from the gas inlet and push fittings push and hold down the blue ri...

Page 16: ...ully insert one end of the braided hose into the male connector and tighten the nut 1 25 turns l Connect the other end of the braided hose to the product vessel l If the product vessel to which the gas package is to be connected has a 6mm bulkhead fitting the other end of the braided hose can be attached directly into that fitting l If the product vessel to which the gas package is to be connected...

Page 17: ...f the Y fitting 1 Y Fitting 2 Blanking Plug 3 Interconnecting Gas Pipe 4 T Fitting 5 4 Electrical Connections Advanced Gas Package The solenoid valve within the Advanced Gas Package requires an electrical connection between the gas box and product control box to allow the temperature controller relay to activate the electrical valve When the valve is activated the gas can flow Depending on the opt...

Page 18: ... in place by tight ening the screw on the rear of the socket l Push the relay connector at the other end of the cable into the cor responding relay port on the back of the product control box Note If using more than one gas ensure that the correct gas box is connected to the correct relay port 18 ...

Page 19: ...supply set the required gas pressure This should be no greater than 1 5 bar 22 psi WARNING If the inert gas package is connected to a work tube end seal DO NOT set the pressure above 0 05 bar 50mbar l Carefully turn the gas control valve to the vertical pos ition l Standard gas box The gas will be introduced into the vessel l Advanced gas box Gas flow to the furnace will be controlled by the furna...

Page 20: ...se the increase of back pressure always increase the pipe diameter of any room vent lines when connecting to a product exhaust outlet For example 6mm outlet connections should be increased to a diameter of 10mm or greater for room lines between 5 10 metres in length Note Always maintain clean gas lines Regularly inspect vent lines connected to the exhaust outlet as any build up of debris may incre...

Page 21: ...98 Argon Ar 2 Hydrogen H2 1 9 Carbon Dioxide CO2 1 8 5 Helium H2 2 20 21 ...

Page 22: ...re Method Frequency Daily Weekly Monthly Bi Annually Annually Safety Maintain clean gas lines Check gas lines for any moisture block ages or leakages Electrical Safety external Visual check of external cables and plugs Function Operational Check Check that all functions are working nor mally Operational Check Thorough inspection and report incor porating a test of all functions Gas Connection Leak...

Page 23: ... moisture the product should be isolated from the power supply and allowed to dry out at ambient temperature for at least 24 hours Please contact Carbolite Gero Service for further advice 8 3 Disposal Advanced Gas Package Note This product should only be disposed of in accordance with local regulations and requirements regarding electrical equipment Within the European Community the disposal of el...

Page 24: ......

Page 25: ...Notes Service Record Engineer Name Date Record of Work ...

Page 26: ... us at the address below or ask your nearest stockist For preventive maintenance repair and calibration of all furnace and oven products please contact Carbolite Gero Service Telephone 44 0 1433 624242 Fax 44 0 1433 624243 Email ServiceUK carbolite gero com Carbolite Gero Ltd Parsons Lane Hope Hope Valley S33 6RB England Telephone 44 0 1433 620011 Fax 44 0 1433 621198 Email Info carbolite gero com...

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