VERDER CARBOLITE GERO CAF 16/38 Manual

Installation, Operation and Maintenance Instructions
1600°C Coal Ash Fusion Furnace - CAF Model: 38mm Ø
No Controller
CAF 16/38 + No Controller
MEN-CAF1638-005_NOCTRL (09-01-2019)

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. Use the product for the purpose for which it is intended.
1.0 Symbols and Warnings 4
1.1 Switches and Lights 4
1.2 General Warnings 4
1.3 Hydrogen and Carbon Dioxide Warning 6
1.4 Carbon Monoxide Warning 6
2.0 Installation 8
2.1 Unpacking and Handling 8
2.2 Siting and Setting Up 8
2.3 Heating Elements 9
2.4 Telescope 9
2.5 Electrical Connections 10
2.6 Gas Connections 11
3.0 Temperature Controller 12
4.0 2132 Over-Temperature Controller Description (if fitted) 13
4.1 Description 13
4.2 Operation 13
4.2.1 Controls 13
4.2.2 Operation 14
4.2.3 Over-Temperature Operation 14
4.2.4 Over-Temperature Alarm 14
4.2.5 Resetting the Over-Temperature Alarm 14
4.2.6 Sensor Break 14
4.3 Audible Alarm 15
4.4 Navigation Diagram 15
5.0 Operation 16
5.1 Operating Cycle 16
5.2 Setting up for Coal Ash Fusion Test 16
5.3 General Operating Advice 17
5.4 Tube Life 17
5.5 Operator Safety 19
6.0 Maintenance 20
6.1 General Maintenance 20
2

6.2 Maintenance Schedule 20
6.2.1 Cleaning 22
6.3 Element Ageing 22
6.4 Calibration 22
6.5 After-Sales Service 22
6.6 Recommended Spare Parts and Spare Parts Kit 23
7.0 Repairs and Replacements 24
7.1 Safety Warning - Disconnection from Power Supply 24
7.2 Safety Warning - Refractory Fibre Insulation 24
7.3 Temperature Controller Replacement 24
7.4 Solid-State Relay Replacement 25
7.5 Thermocouple Replacement 25
7.6 Element Replacement 26
7.7 Fuse Replacement 26
8.0 Fault Analysis 27
A. Furnace Does Not Heat Up 27
B. Product Overheats 28
9.0 Wiring Diagrams 29
9.1 WA-11-00 29
9.2 WA-11-01 30
10.0 Fuses and Power Settings 31
10.1 Fuses 31
10.2 Power Settings 31
11.0 Specifications 32
11.1 Environment 32
3

1.0 Symbols and Warnings
1.0 Symbols and Warnings
1.1 Switches and Lights
Instrument switch: when the instrument switch is operated the
temperature control circuit is energised.
Heat light: the adjacent light glows or flashes to indicate that power
is being supplied to the elements.
Heat switch: the switch disconnects power to the heating elements;
unless this switch is OFF there is a danger of electric shock when
inserting objects into the product.
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.
4

Caution – Double Pole/Neutral Fusing
5
1.0 Symbols and Warnings

1.0 Symbols and Warnings
1.3 Hydrogen and Carbon Dioxide Warning
Applicable for furnaces constructed to use H2and CO2test gases with CO2'Purge' gas.
H2can form explosive gas mixtures, take precautions to avoid leakage
of H2.
H2and CO2can react to form CO.
see section 1.4.
Carbon dioxide (CO2) is a colourless, odourless and tasteless gas that is an asphyxiant.
Rapid unconsciousness occurs at levels above 11%, levels of 20 - 30% are immediately
hazardous to life.
Information extracted from Croner Publications Ltd. Substances Hazardous To
Health.
To minimise the risks associated with CO2it is most important that the product is
installed and operated in accordance with this instruction manual. If the product
operator experiences any of the effects listed above, the product must be isolated from
the gas and electricity supplies immediately and expert advice sought. For safety
guidelines seek the gas manufacturers advice.
1.4 Carbon Monoxide Warning
Operation of the CAF furnace involves the use of carbon monoxide.
Carbon monoxide is a product of reaction of H2and CO2.
Carbon monoxide (CO) is a colourless, odourless, tasteless and inflammable gas which
is acutely toxic. CO is introduced into the blood stream through the lungs and binds with
the haemoglobin preventing it from carrying oxygen around the body. This can result in
rapid damage to body tissues due to oxygen starvation. Since CO is an accumulating
toxin it can be dangerous even when present in quite low concentrations over long
periods of time. Individuals vary considerably in their reactions to concentrations of toxic
gases; table 1 shows the typical effects of cumulative CO exposure.
Information extracted from Guidance Note EH43 (1996) from the Health and
Safety Executive.
To minimise the risks associated with CO it is most important that the furnace is installed
and operated in accordance with this instruction manual. If the furnace operator
experiences any of the effects listed above, the furnace must be isolated from the gas
and electricity supplies immediately and expert advice sought. For safety guidelines seek
the gas manufacturers advice.
Table 1. Carbon monoxide in air:
6

Parts per
million Effect
50 Recommended Exposure Limit (8 hours time weighted average
concentration)
200 Headache after approximately 7 hours if resting or after 2 hours
exertion
400 Headache with discomfort with possibility of collapse after 2 hours at
rest or 45 minutes exertion.
1200 Palpitations after 30 minutes at rest or 10 minutes exertion.
2000 Unconscious after 30 minutes at rest or up to 10 minutes exertion.
For further information refer to:
lGuidance Note EH43 (1996) from the Health and Safety Executive. ISBN 0 11
883597 1
lEH40/ 2005 Workplace Exposure Limits 2011. ISBN 978 0 7176 6446 7
7
1.0 Symbols and Warnings

2.0 Installation
2.0 Installation
2.1 Unpacking and Handling
When unpacking and handling the product, always lift it by its base. Do not use the door
or any other projecting cover or component to support the equipment when moving it.
Use two or more people to carry the product where possible.
Carefully remove any packing material from inside and around the product before use.
Avoid damaging the surrounding insulation when removing packing materials.
NOTE: This product contains Refractory Ceramic Fibre (also known as
Alumino Silicate Wool - ASW). For precautions and advice on handling
this material see section 7.2.
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 vibrations.
The height of the mounting surface is important to avoid operator strain when loading
and unloading samples.
Unless otherwise stated elsewhere in this manual, ensure that there is at least 150
mm of free space around the back and sides of the product. Clear space is required
above the product to dissipate heat.
8

Depending on the application of the product, it may be appropriate to position it under
an extraction hood. Ensure the extraction hood is switched on during use.
Ensure 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.
2.3 Heating Elements
The silicon carbide elements are VERY FRAGILE and are packed separately. Fit them
accordingly to the instructions in section 7.0 for element fitting and replacement
instructions.
2.4 Telescope
The telescope and its trunnion arm are packed separately and should be attached to the
front of the product.
9
2.0 Installation

2.0 Installation
2.5 Electrical Connections
Connection by a qualified electrician is recommended.
This product requires a single-phase A.C. supply with earth (ground), which may be Live
to Neutral non-reversible (polarised), Live to Neutral reversible (non-polarised), or Live
to Live.
Check the product rating label before connection. The supply voltage should agree with
the voltage on the label and the supply capacity should be sufficient for the current on
the label.
The supply should be fused at the next size equal to, or higher than the current on the
label. A table of the most common fuse ratings is also given towards the back of this
manual. When the mains cable is 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 be temporarily
removed, and connections made to the internal terminals.
If the product is to be connected by line plug. The plug should be within reach of the
operator and should be easy to remove.
When connecting the product to an isolating switch ensure that both conductors (single
phase) or on all live conductors (three phase), and should be within reach of the
operator.
The supply MUST incorporate an earth (ground).
Supply Terminal Label Cable Colour
Supply Types
Live - Neutral Reversible or Live-
Live
1-phase L Brown to live
to either power
conductor
(For USA 200-240V,
connect L1)
N Blue to neutral
to the other power
conductor
(For USA 200-240V,
connect L2)
PE Green/ Yellow to earth
(ground) to earth (ground)
Electrical Connection Details:
10

2.6 Gas Connections
The product is fitted with two flow meters, one for Carbon Dioxide (CO2) on the left and
the other for Hydrogen (H2) on the right. The output from the flow meters is mixed and
taken directly to the work tube through a connection at the front.
There are no valves or non-return devices on this furnace. Regulated
supplies of CO2and H2must be connected in a safe manner to ensure
that all gas flow is through the work tube. The gas supply pressure
required is 4 psi (0.276 bar) and must not exceed this.
At the back of the furnace is a copper exhaust vent pipe. The exhaust
fumes are dangerous (see "Carbon Monoxide Warning"). The exhaust
must be properly vented into a suitable duct or fume cupboard and must
not be allowed to contaminate the atmosphere of the room in which the
furnace is sited.
11
2.0 Installation

3.0 Temperature Controller
3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
12

4.0 2132 Over-Temperature Controller Description (if
fitted)
4.1 Description
Key
A Alarm Light
B Page
C Scroll
D Down
E Up
F Display
This over-temperature controller is fitted and supplied ready to use by Carbolite Gero.
It is a digital instrument with a latching alarm, requiring no additional panel controls.
The controller features easy setting of over-temperature setpoint and reading of
current temperature by the over-temperature sensor.
4.2 Operation
4.2.1 Controls
Most Carbolite Gero products are fitted with an instrument switch which cuts off power
to the controller and other parts of the control circuit.
To operate the controller, power must be supplied to the product and the instrument
switch must be on. If a time switch is included in the product circuit, this must be in the
'ON' position.
When an over-temperature condition occurs, the controller cuts the power to a
contactor, which in turn cuts power to the heating elements. Power is not restored until
the controller is 'reset'.
Some components will operate after the over-temperature feature isolates the power
supply e.g. cooling fans will continue to operate, provided that there is a power supply
to the product. In some cases the product may not do so, if other options (such as a
door switch) are fitted.
13
4.0 2132 Over-Temperature

4.0 2132 Over-Temperature
4.2.2 Operation
When switched on, the controller lights up, goes through a short test routine and then
displays the measured temperature or the over-temperature setpoint.
The page key allows access to parameter lists within the controller.
A single press of the page key displays the temperature units, normally set to °C;
further presses reveal the lists indicated in the navigation diagram. See section 4.4.
The scroll key allows access to the parameters within a list. Some parameters are
display-only; others may be altered by the operator.
A single press of the scroll key in the 'Home' list displays the temperature units;
further presses reveal the parameters in the current list indicated in the navigation
diagram.
To return to the 'Home' list at any time, press page and scroll together, or wait
for 45 seconds.
The down and up keys are used to alter the setpoint or other parameter values.
4.2.3 Over-Temperature Operation
Use down and up to alter the over-temperature setpoint. This should normally be
set a little above the working temperature (for example 15 °C above). The product is
supplied with the over-temperature set at 15 °C above the furnace or oven maximum
working temperature.
Press scroll twice view the present temperature as measured by the over-
temperature controller. Press it twice, the first press shows the temperature units (°C).
4.2.4 Over-Temperature Alarm
If an over-temperature condition occurs, the OP2 indicator flashes and an alarm
message 2FSH also flashes, alternating with the setpoint. Power to the heating
elements is disconnected.
4.2.5 Resetting the Over-Temperature Alarm
To acknowledge the alarm press scroll and page together.
If the alarm is acknowledged while there is still an over-temperature condition, the OP2
indicator stops flashing but continues to glow. The 2FSH alarm continues to flash until
the over-temperature condition is cleared (by the temperature falling), when normal
operation resumes.
If the alarm is acknowledged when the temperature has dropped (or after the over-
temperature setpoint has been raised) so that the over-temperature condition no longer
exists, then the furnace or oven immediately resumes normal operation.
4.2.6 Sensor Break
The over-temperature cut-out system also operates if the over-temperature control
thermocouple breaks or becomes disconnected. The message S.br flashes where the
measured temperature is normally displayed.
14

4.3 Audible Alarm
If an audible alarm is supplied for use with the over-temperature controller, it is
normally configured to sound on over-temperature condition and to stop sounding when
the alarm is acknowledged as given in section 4.2.
Note: the alarm may sound during controller start-up.
4.4 Navigation Diagram
HL Home List Page Key Black = Progress
OTSP Over-Temperature
Setpoint Scroll Key
Dashed = Through to
other options
AL Access List For factory access to list and parameters not
available to the operator.
15
4.0 2132 Over-Temperature

5.0 Operation
5.0 Operation
5.1 Operating Cycle
This product is fitted with an instrument switch which cuts off power to the control
circuit.
Connect the product to the electrical supply.
Turn on the instrument switch to activate the temperature controllers. The controllers
illuminate and go through a short test cycle.
Over-Temperature option only. If the digital over-temperature option has not yet
been set as required, set and activate it according to the over-temperature controller
instructions.
The product will heat up according to the controller setpoint or program, unless a time
switch is fitted and switched off.
As the product heats up, the heat light glows steadily at first and then flashes as the
product approaches the desired temperature. For more information on temperature
control see the controller instructions.
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 the over-temperature controller
according to the instructions supplied.
To turn the product off, set the instrument switch to its off position. The controller
display will go blank. If the product is to be left unattended, isolate it from the electrical
supply.
5.2 Setting up for Coal Ash Fusion Test
The CAF 16/38 is designed to be compatible with the following:
BS 1016 : Part 113 : 1995 ISO 540 : 1995 Methods for Analysis and Testing of Coal and
Coke. Part 113. Determination of Ash Fusibility.
The test procedure is entirely manual and under the operator's control. An example of
the procedure is as follows:
Heat the product up to its starting temperature.
Open the product door and swing it clear of the work tube to
allow access. Load the sample into the work tube. The sample
tile with one or two samples on it should be placed centrally
along the length of the work tube.
Set the ramp rate on the controller, if required, to limit the
heating rate. A rate of 7 °C/ min is suggested and is factory
pre-set.
Set the controller to heat the product up to the final temperature. Swing the telescope
into place to allow observation of the sample.
16

Watch the sample and record the temperature at which it fuses. Make all other records
such as time and temperature as required by your own organisation.
Switch off and allow to cool down; or set the setpoint to zero or to the normal test
starting temperature, so that the temperature is displayed as the furnace cools.
Note: Do not operate the product at temperatures above 815 °C (1499 °F) with the
door open. The product door must not be left open longer than is necessary to load
and unload samples from the work tube.
Sample tiles can be obtained from Carbolite Gero. A brass mould to assist with forming
samples is supplied with the product.
5.3 General Operating Advice
Heating element life is shortened by overheating. Do not leave the
product at high temperature when it is not required. The maximum
temperature is shown on the product rating label and in section 11.0
towards the back of this manual.
Lightweight ceramic fibre insulation can easily be marked by accidental
contact. Some fine cracks may develop in the surface of the insulation
due to the progressive shrinkage of the insulation materials. Cracks are
not usually detrimental to the functioning or the safety of the product.
5.4 Tube Life
A ceramic work tube may crack if work pieces are inserted too quickly or at
temperatures below 900 °C (when the tube is more brittle). Large work pieces
should also be heated slowly to ensure that large temperature differences do not
arise.
Poor thermal contact should be encouraged between the work piece and the tube;
crucibles or boats should be of low thermal mass and should have feet to reduce
the contact with the tube (fig. 4).
Key
A Tube
B Crucible
Fig 4 - Avoidance of thermal contact
17
5.0 Operation

5.0 Operation
Do not set too high a heating or cooling rate. As tubes are susceptible to thermal shock
and may break. Tubes which extend beyond the heated part of the furnace are more at
risk. A general rule for maximum heating or cooling rate is 400 ÷ internal diameter in
mm to give (°C/ min); for 75 mm i/ d tubes this comes to 5 °C per minute. The
controller can be set to limit both the heating and cooling rate.
18

5.5 Operator Safety
The ceramic materials used in the product manufacture become
electrically conductive to some extent at high temperatures. DO NOT
use any conductive tools within the product without isolating it. If a
metal work tube is used, it must be earthed (grounded).
Warning: Do not use the product if the work tube is cracked as there is a
risk of exposure to carbon monoxide gas. See "Carbon Monoxide
Warning"
19
5.0 Operation

6.0 Maintenance
6.0 Maintenance
6.1 General Maintenance
Preventive rather than reactive maintenance is recommended. The type and frequency
depends on the product use; the following are recommended.
6.2 Maintenance Schedule
CUSTOMER
QUALIFIED PERSONNEL
DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically
qualified personnel should attempt these maintenance procedures.
Maintenance
Procedure Method
Frequency
Daily Weekly Monthly Bi-
Annually Annually
Safety
Over-Temperature Safety
Circuit
(if fitted)
Set an over-temperature setpoint lower than the
displayed temperature and check for an over-tem-
perature alarm as detailed in this manual
Over-Temperature Safety
Circuit
(if fitted) Electrical measurement
Door Plug Visual inspection, checking the seal and whether
it is free of any damage
Door Plug Replacement where necessary
Extraction Pipe Check that the connection is tight, and clean out
the pipe if necessary
Electrical Safety (external) Visual check of external cables and plugs
Electrical Safety (internal) Physically check all connections and cleaning of
the power plate area
Gas Safety (external)
Visually check that all pipework is in place and
free of damage. Physically check that all con-
nections are tight
Gas Safety (internal) Leak test the gas system
Cooling Fans Check whether the cooling fans are working
Function
Temperature Calibration Tested using certified equipment, frequency
dependent on the standard required
Operational Check Check that all functions are working normally
20