Carbolite Gero HTRH User manual

Page 1
OPERATING INSTRUCTIONS
STANDARD FURNACE „HTRH/HTRV“
Furnace:
Controller:
(Option)
CARBOLITE-GERO
GmbH & Co.KG
Hesselbachstr. 15
D-75242 Neuhausen
Tel.: [phone]
FAX.: [phone]
URL: www.carbolite-gero.com
mail: [email protected]
These documents are meant only for the customers of our machines / plants and must not be copied, nor
forwarded or made available to a third party without prior written permission.

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Directory
Used Symbols......................................................................................... 3
Warning symbols............................................................................................................................3
Prohibition signs .............................................................................................................................3
Mandatory and first aid signs..........................................................................................................3
Information symbols .......................................................................................................................3
Safety precautions .................................................................................. 4
Protective measures and rules of conduct ...............................................................4
Operation as per destination ................................................................... 5
Operation modes......................................................................................................5
Remaining risk..........................................................................................................6
Safety facilities........................................................................................ 7
Protective equipment for the operating personnel................................... 7
Operator’s obligations ............................................................................. 8
Operating and working instructions......................................................... 9
Instructions for the furnace operation .......................................................................9
Instructions for electrical / electronic equipment.....................................................10
Cleaning instructions ..............................................................................................11
Delivery................................................................................................. 12
Installation and connection to the mains ............................................... 12
Liability information ............................................................................... 13
Installation structure.............................................................................. 14
Notes on the MoSi heating elements .................................................... 15
Processing instructions ................................................................................................................16
Commissioning ..................................................................................... 18
Switching on the furnace ........................................................................................18
Shut-down............................................................................................. 19
Switching off the furnace ........................................................................................19
For your safety ...................................................................................... 20
Maintenance Schedule.......................................................................... 21
Manufacturer’s Declaration of ConformityFehler! Textmarke nicht definiert.

Page 3
Used Symbols
Warning
symbols
The following warning symbols serve as work-safety instructions in
these operating instructions. They are also fixed to the exterior of the
plant if the respective operations could jeopardise the safety of the
operating personnel.
Please, pay attention to these instructions and act with particular care
under the specified circumstances.
Warning! Danger spot Warning! Electrical power and voltage Warning! Suspending loads
Warning! Explosive atmosphere Warning! Hot liquids or parts Warning! Danger of being
squashed
Risk of skippingr
Fire riskr
Prohibition
signs
No admittance
Do not throw substances into rubbish bin!
Smoking forbidden during work!
Eating forbidden during work!
Mandatory and
first aid signs
Use eye protection Use protective hand-gloves
First aid
Use respiratory equipment
Use prostective clothes
Information
symbols
Used for additional information
Refers to other facts, causes, or consequences
•Fordert sie zum handeln auf
Used for enumerations

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Safety precautions
Protective measures and rules of conduct
When working When working on the furnace, wear protective glasses, protective
clothes, and protective hand-gloves.
Health risk Eating, drinking, and smoking are prohibited when working.
What to do in
the case of
emergency
Remove spilt liquid or absorb with binder. Dispose of these substances
as per the proper procedure.
Proper disposal
Please, pay attention to the manufacturer’s instructions.
Remaining substances and waste materials must be disposed with
other hazardous materials.
First aid
If your eyes get in contact with irritants, rinse eyes immediately with
sufficient water. Consult a doctor.

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Operation as per destination
Operation modes
Permissible
operation
modes
Operation of the furnace is permitted
after thoroughly reading and fully understanding the operating
instructions. Furthermore, the procedures described in the operating
instructions must be observed.
This furnace is designed for:
a furnace temperature of max. 1600°C (HTR.....-.../16), of
max. 1700°C (HTR.....-.../17), von max. 1800°C (HTR.....-.../18).
The use of the furnace for other purposes than those referred to in this
document such as processing products other than those fulfilling the
furnace’s purpose of design in addition to handling hazardous materials
or harmful substances, is considered as an improper application.
The operator is fully liable for damages resulting there from.
For nominal values of the plant, please refer to the technical data.
Proper application of the plant includes observation of the procedures
described in these operating instructions during installation,
commissioning, and maintenance.
The furnace corresponds to „protective degree 0“, i. e. it must be
operated under supervision. (Please, refer to EN 60519-2:1993).
Only furnaces with a separate over temperature sensor can be
operated without supervision. (Please, refer to EN 60519-2:1993).
Prohibited
operation modes
Operation of the furnace is not permitted
us
ing sources of power, products, operating material, aids, etc. which
are subject to an ordinance on hazardous materials or which affect
the operating personnel’s health in any way.
using plant equipment which was modified by the plant operator
Manipulations When operating the furnace protective facilities are not allowed to be
removed, by-passed, or shut off.
Otherwise, the plant operator acts on his own responsibility!

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Operation as per destination
Operation modes
Requirements
for the operating
personnel
Persons operating powered working equipment must make sure that
they do not put their own or other person’s health at risk as a result of
dangerous vehicle manoeuvres.
The plant operator may only assign works with powered working
equipment and entailing dangerous vehicle manoeuvres to persons
who are appropriately authorised and who
can carry out works independently and safely or who
after prior instruction, are supervised by a person familiar with these
types of works.
This furnace can be highly dangerous if put to improper use by
unskilled personnel.
Danger of accident!
Works on and with this furnace may only be carried out by persons who
are appropriately authorised with the appropriate training or
qualifications.
Moreover, these persons require prior instructions from the operator.
Remaining risk
Danger Warning
The furnace has been built according to the latest state of the art.
Therefore, a high degree of operational reliability is guaranteed.
Nonetheless, improper use may result in dangers to the user and third
parties in addition to impairments of the plant and other material assets.

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Safety facilities
For protection of the operating personnel and the environment, the
furnace is equipped with the following safety facilities:
No. Protective equipment
1 Main switch
2 Casing of parts under voltage
3 Galvanised isolation of the heater
4 Over temperature controller (Option)
Protective equipment for the operating
personnel
The following protective equipment must be worn when working at the
furnace:
No. Protective equipment
1 Protective hand-gloves
2 Protective glasses

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Operator’s obligations
Accident danger!
The operator is obliged to operate the furnace in a perfect condition.
Danger spots resulting from connected plants must be secured
appropriately by the operator.
Assign and
instruct
responsible
persons
Only skilled and instructed personnel may be assigned to these
works. Clearly determine the personnel’s areas of responsibility for
operating, setting-up, and maintaining the plant.
Check if personnel are aware of safety requirements and dangers
and observes the relevant operating instructions.
Obligation to
inform
Store operating instructions and applicable regulations in a place
where they are quickly available for the maintenance personnel.
Note!
Observe operating instructions in all life phases of the furnace. The
operator must take care that the operating personnel always wears the
mandatory protective equipment.

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Operating and working instructions
Instructions for the furnace operation
Basic safety
instructions
Please observe these instructions. Non-observance may result in
danger to life and limb!
Instructions
1
Do not de-mount or amend protective clothing.
2
Immediately inform the senior employee responsible about any
defects or damages to the furnace. Interrupt production until
damage is repaired.
3
Observe all safety and danger information on the furnace and make
sure it is at all times legible.
4
Prior to the work to be carried out on the furnace:
Cordon off a wide area around the working space (barrier chains,
warning plates).
Inform operating personnel and assign a supervisor.
Observe instructions concerning remaining risk.
5
Do not modify or re-construct the furnace. This applies also for the
installation or the adjusting of safety facilities in addition to welding
structural parts.
6
Spare parts must correspond to the technical requirements
specified by the manufacturer.
The installation of non-genuine parts may result in danger to man
and furnace. In this case, the manufacturer will not assume liability.
7
See to proper disposal of non-usable hazardous waste material
such as lubrication oils and cleaning agents.

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Operating and working instructions
Instructions for electrical / electronic equipment
Note!
Works with electrical components / component may only be affected by
skilled electricians in accordance with the appropriate electro-technical
regulations.
The five safety rules
1 Switch off main switch.
2 Lock main switch and secure against re-activation.
3 Verify safe isolation from supply.
4 Ground work place and shunt out.
5 Cover adjoining parts which are under voltage.
Alternative => unplug power supply
Danger!
Defective electrical components may be under voltage and could be
fatal.
Detected deficiencies of electrical furnaces / component / operating
equipment must be repaired immediately. If exist an acute danger the
furnace, component and / or operating equipment must no longer be
used until the repair of the deficiency.
Only work according to circuit diagram!

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Operating and working instructions
Cleaning instructions
Caution!
For cleaning works other than those described above, switch off the
furnace thus avoiding unintentional activation of the furnace.
Wet cleaning of the furnace is not permitted!
Cleaning agents
For medium amount of dirt
Use customary non-flammable cleaning agent and vacuum air.
For stubborn dirt
Use non-flammable solvent.
Safety
instructions
Please pay attention to the labels and instructions on the packing of the
cleaning agents.
After cleaning, examine all supply lines and connections for leakage,
loosened connections, chafe marks, and damages; If possible, repair
detected deficiencies on your own or after consulting the manufacturer!
Maintenance instructions
Caution!
Maintenance work entails risks of crushing, impact and electric shocks
etc..
This is why it is important that maintenance work is only performed by
adequately trained professional personnel!!

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Delivery
Check
completeness
Compare scope of delivery with delivery note and ordering documents.
Missing parts or damages resulting form inadequate packing or
transport must be reported immediately to the forwarder or supplier.
Packing The type of packing used depends on the transport route.
If necessary, the furnace is delivered in transport units.
Installation and connection to the mains
Installation It is recommended to have the furnace installed by
CARBOLITE-GERO-Service.
Position the furnace components with a fork-lifter or in accordance with
the layout plan and adjust all units to their exact height, angle, and
position.
Securing of the
plant
Re-fix all de-mounted parts and check their proper function. Check firm
position of complete furnace.
Connection to
the mains
Only skilled personnel are allowed to carry out the installation of the
mains connection while observing the relevant local regulations and
legal provisions.
Check if mains voltage and frequency are identical with the values
stated on the rating plate.
Cooling system The furnace is provided with housing with convection cooling. The flow
of fresh and waste air must not be restricted to avoid overheating.

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Liability information
Storage of
furnace
The manufacturer / supplier will not assume liability or warranty for
damages resulting from corrosion which can be put down to improper
storage, e.g. in a damp location or similar.
Store furnace on an even ground and secure it from tilting, rolling, and
unauthorised use.
Protective rights All rights for drawings and other documents in addition to any kind of
distribution rights are reserved by Firma CARBOLITE-GERO
GmbH&Co.KG. This also applies to the case of patent applications.

Page 14
Installation structure
Complete
furnace
The furnace consists of the following sub-assemblies:
Sub-assemblies:
Standard pipe furnace
Control system Option
Furnace case The furnace consists of an enamelled case with covered power supply
points in the interior of the case.
Heating
elements
The heating elements are from a metal ceramic material (MoSi2).
Power requirement see Label.
Furnace
Housing Cooling
System
The furnace housing is cooled by means of convection.
Automatic
control system
(Option)
The automatic control system consists of an enamelled housing.
Power requirement see label.
Process control
(Option)
Please refer to automatic controller operating instructions.

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Notes on the MoSi heating elements
General The air supply of the heating elements should be ensured, as the
heating elements need this oxygen supply for creating a quartz
protective layer. This protective layer has got the function to protect
the basic material from extreme oxidation and pollution.
The air supply should be realized by small openings at the furnace
inlet and outlet, so that there gets not too much power lost.
The heating elements should be able to radiate heat without
limitation.
Continuous
operation
The furnace is operated at its maximum temperature for a rather long
time (>10 h). To increase the life time of the heating elements it is
recommended for this kind of operation to cool down the furnace not
completely (T>650°C). If possible, never cool down to ambient
temperature.
Running times of up to 2,000-5,000 hours at high temperatures can
be realized.
Variable parameters must be chosen so that during continuous
operation there is no change of the correcting variables of more than
±10%.
Discontinuous
operation
Enables the cooling down to ambient temperature.
Daily heating ramps up to maximum temperature are possible.
However, the rest period should not be longer than 5 hours.
The life expectancy is about 100-300 heating cycles.

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Functional description
Step Procedure
Processing instructions
1. When heating the furnace for the first time, small amounts of water can flow from
the insulation (fibre insulation, hygroscopic).
2. The heating element is designed to stand a maximum furnace temperature of
1600°C (HTR.....-.../16), of 1700°C (HTR.....-.../17) or of 1800°C (HTR.....-.../18).
Temperatures exceeding this limit by only 20° may shorten the service life of the
furnace considerably.
3. The maximum heating-up rate of the furnace depends on the size of the ceramic
working pipe (accessories). Below, you will find the recommended heating-up rates
for pipes of:
•an external diameter of up to 100mm, heating-up rate of 300K/h
•an external diameter of up to 150mm, heating-up rate of 120K/h
•an external diameter of up to 200mm, heating-up rate of 80K/h
•an external diameter of more than 200mm, heating-up rate of 50K/h
When cooling down and using APM working pipes it is possible to double the
value.
If you use a quartz glass tube: The tube must not operate higher as 1050°C.
For a short time you can operate with 1100°C.
4. If the furnace is installed in an outlet, check if the chemical vapours can
generate in the outlet. Even only slight chemical loads can strongly decrease
the working temperature.
5. Regulators, which are configured with the thermocouple type B, will show a
temperature of -2°C on the display after switching on, without the furnace having
been heated. Small thermoelectric voltages of the thermocouple at room
temperature are responsible for this erroneous indication. From about 150°C on the
display should be correct. The linearization accuracy is achieved at approx. 400°C.
To be able to check the thermocouple with the first commissioning, a nominal value
has to be set in any case, which lies above the current actual value.

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Functional description
Step Procedure
Processing instructions
6. After the first commissioning or after the first hours of operation at higher
temperatures, the contacts of the Kanthal Super heating elements have to be
checked. If the elements are operated with loose contacts, the power
connections of the MoSi heaters can burn off.
For the working tube and the plug, please note:
Push the working tube very carefully through the furnace. It must not
touch the heater not the thermo couple.

Page 18
Commissioning
Switching on the furnace
Requirements The furnace must be connected as per the required technical procedure
as long as it shows no signs of technical deficiencies. No disturbances
may occur during operation of the system.
For operation of the furnace, please observe the safety precautions in
chapter 1.
Step Procedure Graphic/Operating
element
1 •Switch on main switch
Enter charge/sample piece
2 Charge furnace, close ends of the tube.
Furnace control via control system
3 Switch power on by button.
4 Temperature setpoint, output power or
programmer (see user manual controller).

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Shut-down
Switching off the furnace
Step Procedure Graphics / Operating
element
Terminating the process
1. Switch the controller to OFF: Standby (see user
manual controller).
Necessary because the controller starts after
switch on poss. unintentional.
2. Switch power off by button
3. Main switch OFF
4. Remove charge/sample piece
Securing against
unintentional
activation of the
system
By means of the following measures
unintentional activation of the furnace can
be avoided:
Turn the main switch on the control
cabinet to the OFF-position and secure
with a padlock.

Page 20
For your safety
You are responsible!
“Observe safety precautions!“
Personal
requirements
Who is allowed to operate the furnace?
Persons with appropriate training and the appropriate qualifications
who have been authorised and assigned to operate the furnace and
who are familiar with its operation.
The persons are required to be familiar with the operation of the
furnace, to be aware of the possible dangers of the furnace and
confirm their knowledge with their signature.
Avoid any procedure which might endanger safety at work!
Take appropriate measures so that it is only possible to operate the
furnace in a safe and operative condition.
Operate furnace only after installation and activation of all protective
facilities and safety-related facilities such as detachable protective
facilities, emergency devices, sound insulations, and suction
implements!
Before switching on the furnace make sure that nobody can
endanger the safe operation of the furnace.
Liability The furnace may only be used for its intended purpose. Any application
deviating from the intended use is not permitted. Operation by
unauthorised personnel must be prohibited by the operator.
Modification must not be effected on the furnace with prior consent by
CARBOLITE-GERO GmbH&Co.KG.
Attach these regulations on a place near the furnace where they are
always access able.