VERDER CARBOLITE GERO CF 24B Manual

Installation, Operation and Maintenance Instructions
1200°C Cupellation Furnace - CF Model: 24B
No Controller
CF 24B + No Controller
MEN-CF24B-005_NOCTRL (10-07-2020)

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 5
1.1 Switches and Lights 5
1.2 General Warnings 5
2.0 Installation 6
2.1 Unpacking & Handling 6
2.2 Door Counterbalance 6
2.3 Siting and Setting Up 7
2.4 Split Model CF24 8
2.5 Heating Elements 8
2.6 Baffle 8
2.7 Electrical Connections 8
3.0 Temperature Controller 11
4.0 2132 Over-Temperature Controller Description (if fitted) 12
4.1 Description 12
4.2 Operation 12
4.2.1 Controls 12
4.2.2 Operation 13
4.2.3 Over-Temperature Operation 13
4.2.4 Over-Temperature Alarm 13
4.2.5 Resetting the Over-Temperature Alarm 13
4.2.6 Sensor Break 13
4.3 Audible Alarm 14
4.4 Navigation Diagram 14
5.0 Time Switch 15
5.1 Digital Time Switch - Theben TR 635 top2 15
Important Note 16
Reset 16
Setting the Time and Date (and Daylight Saving Rules) 16
Setting a Switch-On or Switch-Off Time 16
Modifying or deleting a Switch-On or Switch-Off Time 16
Overriding the Program 17
Pulse and Cycle 17
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6.0 Operation 18
6.1 Operating Cycle 18
6.2 Instrument Layout 19
6.3 General Operating Advice 19
6.4 Operator Safety 20
6.5 Over-Temperature Control (if fitted) 20
7.0 Maintenance 21
7.1 General Maintenance 21
7.2 Maintenance Schedule 21
7.2.1 Cleaning 23
7.3 Safety Switch 23
7.4 Calibration 23
7.5 After-Sales Service 24
7.6 Recommended Spare Parts and Spare Parts Kit 24
7.7 Element Ageing 24
7.8 Power Adjustment 25
8.0 Repairs and Replacements 26
8.1 Safety Warning - Disconnection from Power Supply 26
8.2 Safety Warning - Refractory Fibre Insulation 26
8.3 Temperature Controller Replacement 26
8.4 Solid-State Relay Replacement 27
8.5 Element Fitting and Replacement 28
8.6 Thermocouple Replacement 29
8.7 Fuse Replacement 29
9.0 Fault Analysis 30
A. Furnace Does Not Heat Up 30
B. Product Overheats 31
10.0 Wiring Diagrams 32
10.1 WA-33-32 32
10.2 WA-33-33 33
10.3 WS-01-01 34
10.4 WS-01-02 34
11.0 Fuses and Power Settings 35
11.1 Fuses 35
11.2 Power Settings 35
User Power Setting Adjustments 36
3

12.0 Specifications 37
12.1 Environment 37
4

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.
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
5

2.0 Installation
2.1 Unpacking & Handling
When unpacking or moving the product, always lift by its base; do not use the door or
any other projecting cover or component to support the equipment when moving it. Use
a fork lift or pallet truck to move the product; position the product on a level surface and
use an adequate number of personnel to safely move the product into position.
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 8.2.
2.2 Door Counterbalance
Door counterbalance are used as handles to open and close the door. These may be
supplied unfitted. If supplied unfitted two grub screws and two door counterbalances
should be present. Place the counterbalance into the door shaft as shown in the image
below. Fasten the grub screw into the end of the shaft and tighten using an M8 allen
key.
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2.3 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.
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.
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2.4 Split Model CF24
When transported as two components, connect them as follows. Remove the side
panels from the top and the left-hand side from the base. Remove the four fixing bolts
from the top of the base. Place the top onto the base, with the door above the control
panel and bolt the two halves together.
Connect the thermocouple comp. cables to the
appropriate terminal blocks. There are two such
cables, or three if chamber over-temperature
control is fitted. The blocks and cables are
labelled (e.g. 1, 2 , 3).
Connect the door switch wire pair to the terminal
block near the door mechanism.
Connect the power cables to the terminal blocks below the lower element holes.
Because of different power supplies and national standards, the details may differ from
the details shown, or the terminals may be in reverse order.
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.
2.5 Heating Elements
The silicon carbide elements are VERY FRAGILE and are packed separately. Fit them
accordingly to the instructions in section 8.0 for element fitting and replacement
instructions.
2.6 Baffle
This product is supplied with a baffle, a refractory tile. It should be carefully placed at
the back of the furnace chamber, as shown in the image below.
2.7 Electrical Connections
Connection by a qualified electrician is recommended.
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The model covered in this manual has three internal circuits and is normally supplied for
connection to a three phase power supply. This may be either star or delta, but a
product must only be connected to the type and voltage of supply for which it was
made. If the product is ordered for a single phase supply, this may be Live to Neutral
reversible or non-reversible, 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. This manual contains a table of the most common fuse ratings.
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.
When connecting the product to the power supply, the plug or isolating switch should be
accessible, easy to remove, and 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 L1 Brown to live
to either power
conductor
(For USA 200-240V,
connect L1)
N / L2 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:
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2- or
3-phase L1 Black to phase 1
L2 Black to phase 2
L3 Black to phase 3 (except 2-phase)
N Light Blue to neutral (except delta)
PE Green/ Yellow to earth (ground)
Technical Notes
This model has an electronically controlled power limit. Do not attempt to calculate the
Amps from the Wattage. High break capacity fuses should be used. Avoid fast-blow
fuses and magnetic trip circuit breakers - consult Carbolite Gero if in doubt.
10

3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
11

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.
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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.
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.
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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.
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5.0 Time Switch
5.1 Digital Time Switch - Theben TR 635 top2
The Theben TR 635 top2 is a 7 day digital
time switch with 84 memory locations
each of which can contain a switching
time for any or all or the days in a week.
It is battery backed with approximately
10 years power reserve. The shortest
switching interval is 1 minute.
A choice of languages is included. There
is a real-time clock and a choice of
daylight saving rules.
The facia features a digital display and
four buttons as shown in the image.
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Important Note
In the instructions below, "select" an item means the following:
Press the arrow keys (usually the right) until the item appears on the screen. Then press
OK.
Reset
To reset press all four buttons simultaneously all stored programs can be retained or
deleted. Normally avoid reset except to change the language, as follows.
Press all four buttons simultaneously. Then select the required language.
Set the time and date by pressing the arrow keys and using OK. After changing
language it may be necessary also to change the daylight saving rules: see the next
section.
Setting the Time and Date (and Daylight Saving Rules)
Press the MENU key then use the right arrow key to display TIME/ DATE and then press
OK. Use the arrow keys and OK to set the time and date.
After setting the date, the next display shows the current SU – WI selection. To alter the
daylight saving rules, press the arrow keys to select between six different countries or
FREE or FIX DATE or NO SU-WI.
If FREE is chosen, a month and date entry sequence is entered: follow the display
requests.
Setting a Switch-On or Switch-Off Time
A program entry comprises a function (on or off), a switching time and the days to
which it applies.
Press MENU.
PROGRAM is displayed. Press OK.
NEW is displayed. Press OK.
Use the arrow keys to select ON (for switch on times) or OFF (for switch off times).
Press OK.
HOUR is displayed. Use the keys to enter hour, minute and confirm by pressing OK.
MONDAY is displayed. Select the day required then press OK.
COPY is displayed. Press OK to copy the switching time to other days or use the arrow
key to select SAVE.
Other choices are CHECK, MODIFY, CLEAR or END.
Modifying or deleting a Switch-On or Switch-Off Time
Press MENU.
PROGRAM is displayed. Press OK.
NEW is displayed. Use the arrow keys to select CHECK, MODIFY or DELETE. Press OK
after selecting one of these options. If modifying confirm MODIFY HOUR by pressing
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OK. The first of the switching times is shown. Use the keys to adjust the time and
confirm by pressing OK.
Once the date and time memories are entered, the time switch automatically obeys
them. Note that if the same time is used for an on as an off, off takes priority.
Overriding the Program
To change the present state between on and off, press MENU, select MANUAL. Within
the MANUAL choices are PERMANENT ON; PERMANENT OFF; MANUAL ON; TIMER;
HOLIDAY; RANDOM & END.
Avoid random, which is irrelevant to furnaces. The holiday feature may be left as an
exercise for the reader.
Pulse and Cycle
These features are not required and should be off.
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6.0 Operation
6.1 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.
This product if fitted with a time switch which operates in conjunction with the
temperature controller as follows:
Temperature
Controller Time Switch Function Operation
301
Controller
or
3216CC
Controller
Time switch cuts power to the
temperature controller
Switch on the instrument switch.
Set the required setpoint on the
temperature controller.
Timer in 'OFF' state: furnace does not
heat.
Timer in 'ON' state: furnace heats to the
setpoint.
3216
Programmer
or
3508
Programmer
Time switch starts a
temperature program
Switch on the instrument switch.
Set the required temperature program
in the temperature controller.
Timer in 'ON' state: the program is
started.
Timer in 'OFF' state: the program is
stopped.
Set the time switch as required.
Set the element over-temperature controller to approximately 100 °C above the
maximum or setpoint temperature. The element over-temperature controller protects
the heating elements from excessive temperature and if activated is self resetting.
When correctly set it may be ignored (see section 6.5).
Chamber 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.
Unless the time switch is switched off, the product starts to heat up according to the
controller setpoint or program.
Chamber 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.
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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.
6.2 Instrument Layout
The controllers are normally laid out as follows, although this may vary:
1. = Controller/ Programmer
2. = Element over-temperature Controller
3. = Chamber over-temperature Controller (if fitted)
4. = Time Switch
6.3 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 12.0
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.
Clean up any spillages in the insulation, as these can increase the rate of degradation of
the insulation material.
19

6.4 Operator Safety
This product incorporates a safety switch which interrupts the heating
element circuit when the furnace is opened. This prevents the operator
touching a live heating element and also prevents the product from
heating up if the furnace is left open. The operation of this switch should
be checked periodically.
Depending on use, the surfaces in the working chamber and the
chamber load may still be very hot after the appliance is switched off.
Touching these surfaces may cause burns. Use suitable personal
protective equipment or wait until the appliance cools down to ambient
temperature.
Before removing a hot object from the product, make sure there is a safe place to put it
down. If necessary use tongs, face masks and heat resistant gloves. Heat resistant
clothing and face protection can guard against the effects of radiated heat when the
furnace is open.
When the product is opened during operation there is considerable radiated heat. Do
not keep any flammable objects near the product, nor objects which could be damaged
by radiated heat.
6.5 Over-Temperature Control (if fitted)
The product may be fitted with a “chamber over-temperature control”, if this has been
ordered. The chamber Over-Temperature control stops further heating if an over-
temperature condition is reached and heating is not resumed until the system is
manually reset. Operating instructions for the over-temperature controller are referred
to in section 6.1 and detailed in the controller instructions.
All cupellation furnaces also have an “element over-temperature control” which serves
to cut power temporarily to the heating elements if the temperature in the immediate
vicinity of the elements is too high. Heating resumes when the temperature drops and
manual resetting is not required. This is controlled by a Eurotherm 2132 Controller (or
similar).
20