VERDER CARBOLITE GERO CRF/1 Manual

Installation, Operation and Maintenance Instructions
1000°C CO2 Reactivity Furnace - CRF Model: 1
3508 Controller
CRF/1 3508 Controller
MEN-CRF01-001_3508 (18-10-2021)

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 Warnings 4
1.1 General Warnings 4
2.0 Installation 5
2.1 Unpacking and Handling 5
2.2 Siting and Setting Up 5
2.3 Electrical Connections 6
2.4 Gas Supply Connections 7
2.5 Glass Retort Thermocouple 9
3.0 Operation 11
3.1 Operating Cycle 11
3.2 General Operating Advice 15
3.3 Recovery of Glass Retort 16
3.4 Over-Temperature 17
3.5 Adjustment of Reaction Time 18
3.6 Power Adjustment 19
4.0 Temperature Controller 20
5.0 Maintenance 21
5.1 General Maintenance 21
5.2 Maintenance Schedule 21
5.3 Maintenance Schedule 23
5.3.1 Cleaning 25
5.4 Calibration 25
5.5 After-Sales Service 25
5.6 Recommended Spare Parts and Spare Parts Kit 25
6.0 Repairs and Replacements 26
6.1 Safety Warning - Disconnection from Power Supply 26
6.2 Safety Warning - Refractory Fibre Insulation 26
6.3 Temperature Controller Replacement 26
6.4 Thermocouple Replacement 27
6.5 Solid-State Relay Replacement 27
6.6 Fuse Replacement 27
6.7 Element Replacement 28
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7.0 Fault Analysis 29
A. Furnace Does Not Heat Up 29
B. Product Overheats 30
8.0 Wiring Diagrams 31
9.0 Fuses and Power Settings 32
9.1 Fuses 32
9.2 Power Settings 32
10.0 Specifications 33
10.1 Environment 33
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1.0 Warnings
1.1 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
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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 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 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.
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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 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. 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.
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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:
2.4 Gas Supply Connections
High quality bulkhead connectors are provided for the connection of suitable gas. The
incoming supply piping should measure 6 mm outside diameter
When fitting the incoming pipe refer to the following instructions, this will ensure a
leak-free joint is made. The Swagelok fittings will allow disconnection and re-
connection many times providing the instructions are followed.
The gas should be clean, dry and free from impurities.
Gas Supply Connection Pipe
CO2ø6 mm
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1. The CO2gas supply should be isolated and regulated above 2 bar. (Approximately
5 bar).
2. Turn on the gas supply.
3. Slowly increase the CO2pressure regulator until the pressure gauge reads 2 bar.
4. This may need fine adjustment when the test has started.
5. Connect glass retort to CO2OUT
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2.5 Glass Retort Thermocouple
1. Remove front right hand side panel.
2. Un-plug the thermocouple
3. Remove the centre MI thermocouple, by turning the fixing screw out.
4. Lower the thermocouple down and through the hole in bottom mesh.
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5. Fit outer glass retort into heating chamber, locating the bottom end of the smaller
retort tube through the base of the heating chamber.
6. Carefully slide the thermocouple into the glass tube to the top of the sheath.
7. Pull back from the top 2mm and re-fit the fixing screw.
8. Plug back in the thermocouple.
9. Re-fit front panel.
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3.0 Operation
3.1 Operating Cycle
1. Plug the furnace in with the plug supplied.
2. Switch on the mains isolator.
3. The temperature controller will illuminate and start its test cycle.
4. Press "ON".
5. The "FURNACE ON" light will be on, and the furnace will start to heat up to the
pre-set program in the Eurotherm 3508 to ISO 12981-1
6. The "GAS ON" light will be on, and gas will flow into the glass retort.
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7. Set the flowmeter to 50 L/H.
8. Check the pressure gauge, and make adjustment if need.
9. After the temperature has reached 1000°C, the controller will dwell for 10
minutes.
10. After 10 minutes an alarm will sound for 10 seconds, and then stop.
11. The "SAMPLE IN" light will be flashing.
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12. Load sample.
13. Press "SAMPLE IN".
14. The "SAMPLE IN" light will stop flashing, and stay on.
15. The furnace will dwell at 1000°C for 100 minutes, with gas as to the ISO12981-1.
16. After the dwell the "FURNACE ON" light will switch off.
17. The furnace will start to cool down for 30 minutes with the gas on.
18. After 30 minutes the alarm sounds for 10 seconds.
19. The gas will turn off.
20. The "SAMPLE OUT" light will be on.
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21. Remove the inner retort, and place in the Retort Cooling Area.
22. Retort Cooling Area.
23. Press "ON" to reset for the next test.
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3.2 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 10.0
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.
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3.3 Recovery of Glass Retort
If at any time the glass retort breaks within the heating chamber, or the test has to be
stopped, the control has to be reset.
1. Press Page on the Eurotherm3508 Controller, until "PROGSTAT" is displayed.
2. Press Scroll until "STATUS" is displayed.
3. Press the arrow keys until "Reset" is displayed.
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4. Wait, and allow the controller to reset; the display will then go back to normal.
5. If the glass retort breaks within the Retort Cooling Area:
lAlways disconnect power to the furnace prior to carrying out recovery of the
glass retort.
lRemove the front right panel.
lTake care when removing the element chamber.
6. If the glass breaks within the element chamber:
lRemove with vacuum cleaner.
3.4 Over-Temperature
Built within the control panel, there is an element over-temperature controller.
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This has been factory set and should not be adjusted.
The over temperature thermocouple is positioned within the element winding:
3.5 Adjustment of Reaction Time
1. Enter Security Level 2 in the main controller (pass code 9); see the Eurotherm
3508 Controller section of this manual.
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2. Press the Page key until "Program Edit" is reached.
3. Press Scroll until the segment 6 dwell time is reached.
4. Adjust the dwell period to the calculated figure. The standard setting as supplied,
is 1 hour 40 minutes.
3.6 Power Adjustment
The product control system incorporates electronic power limiting. The power limit
parameter OP.Hi is accessible to the operator and can be used to adjust the product to
the actual supply voltage.
Some models covered by this manual are fitted with 208 V elements and are designed
for use over the range of voltages 200 V- 250 V; the power limit parameter is set
accordingly. These models may be relocated to a different voltage within the range: the
power limit should be reset to match the voltage.
To check whether the furnace is a 208 V model:
llook at the OP.Hi parameter
lmake a note of the value and compare with the 9.0;
lobserve the rating label; if a range of voltages is stated, it is not a 208 V multi
voltage model;
lif in doubt, check with Carbolite Gero – each product has its own record card.
Refer to the controller instructions for how to change the power limit.
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4.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
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