VERDER CARBOLITE GERO VMF-ASTM Manual

Installation, Operation and Maintenance Instructions
1000 °C Volatile Matter Test Furnace - VMF Model: 50 mm Ø
No Controller
VMF-ASTM + No Controller
MEN-VMF-ASTM-04_NOCTRL (29-10-2021)

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 Symbols and Warnings 4
1.1 Switches and Lights 4
1.2 General Warnings 4
1.3 Prerequisites to Use 5
2.0 Installation 6
2.1 Unpacking and Handling 6
2.2 Siting and Setting Up 6
2.3 Electrical Connections 7
3.0 Temperature Controller 9
4.0 Operation 10
4.1 Operating Cycle 10
4.2 General Operating Advice 10
4.3 Notes on Test 11
4.4 Operator Safety 11
5.0 Maintenance 12
5.1 General Maintenance 12
5.2 Maintenance Schedule 12
5.2.1 Cleaning 14
5.3 Calibration 14
5.4 After-Sales Service 14
5.5 Recommended Spare Parts and Spare Parts Kit 14
5.6 Power Adjustment 14
6.0 Repairs and Replacements 16
6.1 Safety Warning - Disconnection from Power Supply 16
6.2 Safety Warning - Refractory Fibre Insulation 16
6.3 Panel Removal 16
6.4 Temperature Controller Replacement 17
6.5 Thermocouple Replacement 17
6.6 Element Replacement 17
6.7 Fuse Replacement 17
6.8 Solid-State Relay Replacement 18
7.0 Fault Analysis 19
2

A. Furnace Does Not Heat Up 19
B. Product Overheats 20
8.0 Wiring Diagrams 21
8.1 WA-11-00 21
8.2 WA-11-01 22
9.0 Fuses and Power Settings 23
9.1 Fuses 23
9.2 Power Settings 23
10.0 Specifications 24
10.1 Environment 24
3

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
4

1.3 Prerequisites to Use
Prior to the commissioning and use of this product, all personnel involved in its
installation, operation and maintenance must be deemed competent and have:
lRead and understood the information contained within this manual
lReceived the relevant training with regard to safety and operation of the product
lBeen 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 and the safe connection of any additional
equipment and gas or liquid supply lines.
5

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.
6

Ensure that the product is placed in such a way that it can be quickly switched off or
disconnected from the electrical supply.
This product is supplied with a crucible holder (a small component made of wire).
Ensure that this is present.
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.
7

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:
8

3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
9

4.0 Operation
4.1 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.
4.2 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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4.3 Notes on Test
This furnace is intended for use with tests in accordance with ASTMD3175-11.
Before commencing the test, the furnace chamber lid should be opened and the
temperature allowed to stabilise for no longer than 2 minutes. The test should be
conducted with the furnace lid open. When the test is completed, close the lid to
conserve energy and prolong element life.
4.4 Operator Safety
Ceramic materials used in the furnace insulation can become
conducting at high temperatures; therefore there is a potential
danger to the operator, as this furnace is designed to be used with
the chamber lid open.
To guard against this danger, the furnace is fitted with a 30mA earth leakage (residual
current) circuit breaker mounted in the back of the case. This trips out in the event of
accidental contact with the heating element or current leakage through the insulation.
The device may be reset after tripping out. From time to time, test it using the integral
test button.
11

5.0 Maintenance
5.1 General Maintenance
Preventive rather than reactive maintenance is recommended. The type and frequency
depends on the product use; the following are recommended.
5.2 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-temperature alarm as detailed in this
manual
Over-Temperature Safety
Circuit
(if fitted) Electrical measurement
Lid Insulation Visual inspection, checking the seal and
whether it is free of damage
Lid Insulation Replacement where necessary
Electrical Safety
(external)
Test the 30mA RCD trip with the test button
daily before use.
Electrical Safety
(external) Visual check of external cables and plugs
Electrical Safety (internal) Physically check all connections and cleaning
of the power plate area
Function
Temperature Calibration Tested using certified equipment, frequency
dependent on the 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
12

Performance
Element Circuit Electrical measurement
Power Consumption Measure the current drawn on each phase /
circuit
13

5.2.1 Cleaning
Soot deposits may form inside the furnace, depending on the process. At appropriate
intervals remove these by heating as indicated in the General Operation Notes.
The product's outer surface may be cleaned with a damp cloth. Do
not allow water to enter the interior of the case or chamber. Do not
clean with organic solvents.
5.3 Calibration
After prolonged use, the controller and/or thermocouple may require recalibration. This
is important for processes that require accurate temperature readings or for those that
use the product close to its maximum temperature. A quick check using an independent
thermocouple and temperature indicator should be made from time to time to
determine whether full calibration is required. Carbolite Gero can supply these items.
Depending on the controller fitted, the controller instructions may contain calibration
instructions.
5.4 After-Sales Service
Carbolite Gero Service has a team of Service Engineers who can offer repair, calibration
and preventive maintenance of furnace and oven products both at the Carbolite Gero
factory and at customers’ 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 contact information can be found on the
back page of this manual.
5.5 Recommended Spare Parts and Spare Parts Kit
Carbolite Gero can supply individual spare parts or a kit of the items most likely to be
required. Ordering a kit in advance can save time in the event of a breakdown.
Each kit consists of one thermocouple, one solid state relay, one element and one lid
insulation piece.
When ordering spare kits please quote the model details as requested above.
Crucibles with lids and spare crucible holders, can also be supplied.
5.6 Power Adjustment
The control system incorporates electronic power limiting, but for the model listed in
this manual the power limit is set to 100%. The power limit parameter OP.Hi may be
accessible to the operator, but should not generally be altered.
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In some cases the supply voltage may be outside the range 220-240 V or the 3-phase
equivalent, the power limit parameter may be set to a value other than 100%. Do not
increase the value to 100%, see section 9.0 for details of power limit settings.
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6.0 Repairs and Replacements
6.1 Safety Warning - Disconnection from Power Supply
Immediately switch the product off in the event of unforeseen
circumstances (e.g. large amount of smoke). Allow the product to
return to room temperature before inspection.
Always ensure that the product is disconnected from the electrical
supply before repair work is carried out.
Caution: Double pole/neutral fusing may be used in this product.
6.2 Safety Warning - Refractory Fibre Insulation
Insulation made from High Temperature Insulation Wool
Refractory Ceramic Fibre, better known as (Alumina silicate
wool - ASW).
This product contains alumino silicate wool products in its thermal insulation. These
materials may be in the form of blanket or felt, formed board or shapes, slab or loose
fill wool.
Typical use does not result in any significant 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
equipment (RPE-eg. FFP3), eye protection, gloves and long sleeved clothing.
Avoid breaking up waste material. Dispose of waste in sealed containers.
After handling, rinse exposed skin with water before washing gently with
soap (not detergent). Wash work clothing separately.
Before commencing any major repairs it is recommended to make reference to the
European Association representing the High Temperature Insulation Wool industry
(www.ecfia.eu).
Further information can be provided on request. Alternatively, Carbolite Gero Service
can quote for any repairs to be carried out either on site or at the Carbolite Gero
factory.
6.3 Panel Removal
Except for temperature controller replacement, access to components is by removal of
the top panel. Remove 10 self-tapping screws. Carefully save the 10 spacers (between
16

the product case and the top panel). Lift off the top panel; ensure there is somewhere
to place it without pulling on the wire connections.
6.4 Temperature Controller Replacement
Refer to the controller instructions for more information on how to replace the
temperature controller.
6.5 Thermocouple Replacement
Disconnect the product from the power supply. Remove the appropriate
panel to gain access to the thermocouple connections. Make a note of the
thermocouple connections.
Thermocouple cable colour codings are:
Thermocouple Leg Colour
positive (type K) green
negative white
1. Disconnect the thermocouple to be replaced from its terminal block and withdraw
it.
2. Re-assemble the new thermocouple, observing the colour coding.
3. Refit the element access panel.
6.6 Element Replacement
See section 6.2 - wearing a face mask is required.
Remove the top panel as above.
The heating chamber is suspended from the top plate. Make a note of the wiring
connections; identify those to the heating element and disconnect it.
Separate the inner chamber by removing 4 screws. The heating element with its
surrounding insulation can then be lifted out of the chamber.
Replace the element with the new one and reverse the disassembly procedure.
6.7 Fuse Replacement
Fuses are marked on the wiring diagram with type codes, e.g. F1, F2. For more
information on fuses refer to section 9.0.
Depending on model and voltage, the different fuse types may or may not be fitted.
If any fuse has failed, it 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.
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The fuses are located at the cable entry point. Remove the back panel or control box
back panel to gain access to the fuses.
6.8 Solid-State Relay Replacement
Disconnect the product from the power supply and remove the
appropriate cover as given above.
1. Make a note of the wire connections to the solid state relay, then disconnect them.
2. Remove the solid state relay from the base panel or aluminium plate.
3. Replace and reconnect the solid state relay ensuring that the bottom of it has good
thermal contact with the base panel or aluminium plate.
4. Replace the access panel.
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7.0 Fault Analysis
A. Furnace Does Not Heat Up
1. The temperature
controller is OFF
No power from the
supply
Check the fuses in the
supply line
There are no lights
glowing on the
controller
The controller may be
faulty or not receiving a
supply due to a faulty
switch or a wiring fault
2. The temperature
controller is ON
The controller shows a
very high temperature
or a code such as S.br
The thermocouple has
broken or has a wiring
fault
The controller shows a
low temperature
The SSR could be failing
to switch on due to
internal failure, faulty
logic wiring faulty which
could have overloaded the
SSR
19

B. Product Overheats
1.
Product only heats
up when the
instrument switch is
ON
The controller
shows a very high
temperature
The controller is faulty
The 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
20