VERDER CARBOLITE GERO 01964-5001 Installation, Operation And Maintenance Instructions Download

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Installation, Operation and Maintenance Instructions

1600°C Bottom Loading Furnace - BLF Model: 3 Litres
No Controller

BLF 16/3 + No Controller

MEN-BLF1603-003_NOCTRL (29-10-2021)

Summary of Contents for CARBOLITE GERO 01964-5001

Page 1: ...Installation Operation and Maintenance Instructions 1600 C Bottom Loading Furnace BLF Model 3 Litres No Controller BLF 16 3 No Controller MEN BLF1603 003_NOCTRL 29 10 2021 ...

Page 2: ...s 8 2 4 Fitting the Chimney and Heating Elements 9 2 5 Electrical Connections 10 3 0 Temperature Controller 12 4 0 Operation 13 4 1 Operating Cycle 13 4 2 Emergency Stop Button 13 4 3 General Operating Advice 13 4 4 Atmospheres Corrosive Materials 14 4 5 Operator Safety 15 4 6 Notes on Temperature Control 15 4 7 Insulation Cracking 15 4 8 Thermocouple Warnings 15 4 9 Inverted Crucible Option 16 4 ...

Page 3: ...Replacement 22 6 7 Element Protection Tube Option Replacement Procedure 23 6 8 Insulation Replacement 23 6 9 Element Fitting and Replacement 24 7 0 Fault Analysis 26 A Furnace Does Not Heat Up 26 B Product Overheats 27 8 0 Wiring Diagrams 28 8 1 01964 5001 28 9 0 Fuses and Power Settings 29 9 1 Fuses 29 9 2 Power Settings 29 10 0 Specifications 30 10 1 Environment 30 3 ...

Page 4: ...ws or flashes to indicate that power is being supplied to the elements 1 2 General Warnings DANGER Electric shock Read any warning printed next to this symbol WARNING Risk of fatal injury DANGER Hot surface Read any warning printed next to this symbol WARNING All surfaces of a product may be hot DANGER Read any warning printed next to this symbol Caution Double Pole Neutral Fusing 4 ...

Page 5: ...h regard to safety and operation of the product l Been provided with the appropriate PPE Personal Protective Equipment required for the safe operation of this product Note The customer 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 ...

Page 6: ...ate Wool ASW For precautions and advice on handling this material see section 6 2 2 2 Siting and Setting Up Place the product on a level surface in a well ventilated area Site away from other sources of heat and on a non flammable surface that is resistant to accidental spillage or hot materials The surface on which the equipment is mounted should be stable and not subject to movement or vibration...

Page 7: ...that the product is placed in such a way that it can be quickly switched off or disconnected from the electrical supply 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 7 ...

Page 8: ...r transit Please ensure the plastic tie wrap used to fix the arm is removed before operation 1 Remove the back panel of the furnace 2 Locate the tie wrap that has been used to prevent the arm from moving It is marked with a tag as shown in the photograph below 3 Cut the tie wrap and discard 4 Replace the back panel 8 ...

Page 9: ...eath 3 Remove plate Lower Clamp 1 Remove bottom M8 nut 2 Remove two M6 bolts 3 Remove plate 4 Unscrew rod using spanner on 5 if neces sary Transit Clamps dependent on model the example shown here is for the 3 litre models remove any transit clamps as shown Fit the ceramic chimney to the hole that exits the top of the chamber Most models are supplied with an insulation piece to fit around the chimn...

Page 10: ... factory fitted internal fuses are also fitted It is essential that the operator ensures that the product is correctly fused Products with a factory fitted supply cable are designed to be wired directly to an isolator or fitted with a line plug Products without a factory fitted supply cable require a permanent connection to a fused and isolated supply The product s electrical access panel should b...

Page 11: ...L2 Black to phase 2 L3 Black to phase 3 N Light Blue to neutral if fitted PE Green Yellow to earth ground DO NOT connect a product ordered for three phase use to a single phase supply or to the wrong type of three phase supply 11 ...

Page 12: ...3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 12 ...

Page 13: ...he controller setpoint or program unless a time switch is fitted and switched off The heat light glows brightly at first more dimly as the product temperature approaches a program setpoint Over Temperature option only If the over temperature circuit has tripped an indicator on the over temperature controller flashes and the heating elements are isolated Find and correct the cause before resetting ...

Page 14: ...ce 4 4 Atmospheres Corrosive Materials In oxidising atmospheres metal oxides react with the silica layer on the surface of the elements and may lead to premature failure Protect the elements from splashes of molten metal and dust when loading the furnace and from fumes developed when melting especially from fluxes Also avoid compounds with a high alkali content The furnace is designed for use up t...

Page 15: ...ct is designed for heating and cooling at controlled rates The heating and cooling rates can be set in the temperature programmer The programmer enables the furnace to heat or cool at slower rates as desired and variable hold dwell periods can be programmed as required The programmer is used in conjunction with a solid state relay SSR power controller which incorporates a current limit potentiomet...

Page 16: ...the hearth ensure that appropriate tongs are available before starting Clamp Option This option assists the placing of the crucible over tall work pieces The clamp is provided in the form of a support shelf which can be fitted to a hinge on the case and a pair of insulated tongs With the hearth lowered place the support shelf on the hinge and swing to the side Use the tongs to lift the crucible up...

Page 17: ...mergency stop button to prove that it functions correctly Safety Switch Function Check that the hearth will not raise or lower with the cage open Safety Switch Function Electrical measurement Over Temperature Safety Circuit if fitted Set an over temperature setpoint lower than the current displayed temperature and check for an over temperature alarm as detailed in this manual Over Temperature Safe...

Page 18: ...e standard required Operational Check Check that all functions are working nor mally Operational Check Thorough inspection and report incor porating a test of all functions Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase circuit 18 ...

Page 19: ...tomers premises throughout the world A telephone call or email often enables a fault to be diagnosed and the necessary parts to be despatched In all correspondence please quote the serial number and model type given on the rating label of the product The serial number and model type are also given on the back of this manual when supplied with the product Carbolite Gero Service and Carbolite Gero c...

Page 20: ...ease the power limit in steps of 5 until the product regains its original performance If the power limit is set to 100 a new set of heating elements is required Please note it is not possible to use the cold resistance of the element as a measure of ageing as the cold resistance is not an accurate indicator of hot resistance Hot resistance is used to calculate furnace power See the controller inst...

Page 21: ...cant level of airborne dust from these materials but much higher levels may be encountered during maintenance or repair Whilst there is no evidence of any long term health hazards it is strongly recommended that safety precautions are taken whenever the materials are handled Exposure to fibre dust may cause respiratory disease When handling the material always use approved respiratory protection e...

Page 22: ...t is advisable for an electrician to check the internal circuits Replace any failed fuses with the correct type For safety reasons do not fit larger capacity fuses without first consulting Carbolite Gero The fuses are located at the cable entry point Remove the back panel or control box back panel to gain access to the fuses 6 6 Thermocouple Replacement Disconnect the product from the electrical s...

Page 23: ... screws that hold each of them in place Care should be taken as insulation may fall if unsupported during the removal of the sections Once the insulation sections have been removed pass the tube up through the hole in the bottom of the furnace and locate within the recess of the furnace roof Once correctly located re fit the insulation sections and the corresponding brackets Re fit the stainless s...

Page 24: ...eating elements on that circuit should be replaced It may not be necessary to replace all heating elements within a furnace however the configuration of elements varies between products If required please contact Carbolite Gero Service for advice Please provide the serial number of the furnace with all enquiries Disconnect the product from the electrical supply Part Quantity Elements 6 Centre brai...

Page 25: ...s 2 in series between 200 240 V for 110 V 2 in parallel Carefully disconnect the element braids from the heating elements using two 10 mm spanners Use two spanners to avoid putting any force onto the fragile heating elements Make a note of the connections Remove the two centre braids and carefully place them aside Disconnect the four end braids and bend them out of the way Carefully remove the old...

Page 26: ...mperature The door switch es if fitted may be faulty or need adjustment The contactor relay if fitted may be faulty The heater switch if fitted may be faulty or need adjustment The SSR could be failing to switch on due to internal failure faulty logic wiring from the controller or faulty controller There are no lights glowing on the controller Check the supply fuses and any fuses in the furnace co...

Page 27: ... controller shows a low temperature The thermocouple may be faulty or may have been removed out of the heating chamber The thermocouple may be connected the wrong way around The controller may be faulty 2 Product heats up when the instrument switch is OFF The SSR has failed ON Check for an accidental wiring fault that could have overloaded the SSR 27 ...

Page 28: ...8 0 Wiring Diagrams 8 1 01964 5001 28 ...

Page 29: ...or of the rating shown Customer Fuses Required if no supply cable fitted Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating BLF 16 3 3 phase 400 V 16 A 9 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures represent the maximum percentage of time that controlled power ...

Page 30: ...g Height Diameter Bottom Loading Furnaces heated by Silicon Carbide elements with electrically operated hearth BLF 16 3 1600 6 190 150 3 155 10 1 Environment The models listed in this manual contain electrical parts and should be stored and used in indoor conditions as follows Temperature 5 C 40 C Relative humidity Maximum 80 up to 31 C decreasing linearly to 50 at 40 C 30 ...

Page 31: ...Notes Service Record Engineer Name Date Record of Work ...

Page 32: ... 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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VERDER CARBOLITE GERO 01964-5001, Installation, Operation And Maintenance Instructions

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