VERDER Carbolite Gero CSR User manual

Installation and Operation Instructions
Coke Strength after Reaction Tumbler - Model: CSR
CSR
MEN-CSR-IO (09-08-2021)

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 Introduction 4
1.1 Scope and Purpose 4
1.1.1 Responsibilities 4
1.2 Prerequisites to Use 6
2.0 Safety 7
2.1 Symbols and Warnings 7
2.2 Operator Safety 8
2.3 Risk Prevention and Mitigating Residual Risks 9
3.0 Product Overview 10
3.1 Product Rating Label 10
3.2 Part Identification 11
4.0 Specifications 12
5.0 Electrical Specifications 13
5.1 Fuses and Power Settings 13
5.2 Operating / Storage Environment 13
6.0 Options and Accessories 14
7.0 Installation 15
7.1 Manual Handling 15
7.2 Unpacking 15
7.3 Siting and Setting Up 16
7.4 Installing the Tumbler Vessel 17
7.5 Electrical Connections 18
7.5.1 3-Phase Connections 18
8.0 Controller 19
9.0 Commissioning 20
9.1 Pre-Commissioning 20
9.2 Commissioning - Initial Function Checks 21
10.0 Operation 22
10.1 Safe Operation 22
10.2 Loading the Tumbler 22
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10.3 Unloading the Tumbler 24
10.4 Operating Cycle 26
11.0 Maintenance 27
11.1 General Maintenance 27
11.2 Maintenance Schedule 27
11.3 Cleaning 28
11.4 After-Sales Service 28
11.5 Recommended Spare Parts and Spare Parts Kit 28
12.0 Decommissioning, Storage and Disposal 29
12.1 Decommissioning 29
12.2 Storage (Long Term) 29
12.3 Disposal 29
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1.0 Introduction
1.1 Scope and Purpose
This product is intended to be used within a laboratory or industrial environment to test
the strength of coke after reaction. It is designed to meet the requirements of the
Standard Test Method for Coke Strength After Reduction (ASTM D5341-19/D5341M-19
and ISO 18894-2018).
It must be installed, commissioned, and operated in accordance with the instructions
contained within this manual, and only by trained personnel.
For maintenance assistance, please contact Carbolite Gero.
Note: Depending on customer specifications at the time of order, this product may
incorporate bespoke design features that are not covered in this manual. Please refer
to the supplementary product documentation pack and/or contact Carbolite Gero for
additional assistance.
Note: If this product is used for any application other than its intended
purpose, as stated by Carbolite Gero, the protection provided by this
equipment may be impaired.
Note: Failure to comply with the instructions as stated within this manual will
constitute misuse and subsequently void any warranty provided by Carbolite Gero.
This product is supplied with a documentation pack, including instruction
manuals and supplementary technical information. Read all documentation
before proceeding with the installation and operation of this product.
1.1.1 Responsibilities
The customer is responsible for conducting their own risk assessment and ensuring that
any materials to be processed within the product are suitable to be safely heated to the
required temperature, and that appropriate safety measures are taken when handling
such materials:
lAny material that is combustible or liable to cause explosions or generate com-
bustible gas must not be processed unless the product is supplied with specialist
equipment designed to manage such reactions
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lThe customer must provide an adequate ventilation and fume extraction system to
manage any fumes given off by materials during processing
The customer is responsible for providing and maintaining the connections for the
electrical power supply. The furnace should not be operated until all required supplies
are connected.
This product should not be modified or used for any purpose other than that for which
it is intended.
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1.2 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.
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2.0 Safety
2.1 Symbols and Warnings
Note: Observe and take the appropriate precautions if any of the following warning
symbols are displayed on this product or in your working environment.
Refer to the instruction
manual before
operating or
maintaining the
equipment
Disconnect the product
from the power supply
before performing any
maintenance
Wear eye protection Wear a heat-resistant
face shield
Wear heat-resistant
gloves
Wear breathing
apparatus
Wear protective
footwear Wear protective clothing
Minimum of 2 people
required to lift
DANGER: Heavy load.
Specialist equipment
required!
WARNING! DANGER: Risk of electric
shock!
DANGER: Fire risk! DANGER: Hot surface!
CAUTION:
Double Pole/ Neutral
Fusing!
DANGER:
Risk of slipping!
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DANGER:
Suspended loads!
WARNING:
Adequate ventilation
required!
CAUTION: ROTATING
EQUIPMENT
DANGER:
Risk of crushing injury!
DANGER:
Explosive materials /
atmosphere!
Any action noted beside
this symbol is strictly
forbidden!
DO NOT use this
product to cook or heat
food or beverages!
DONOTdispose!
Recycle according to
WEEE Regulation
guidelines!
2.2 Operator Safety
Note: It is the responsibility of the customer to ensure that all personnel required to
operate this product are fully trained and equipped with the appropriate PPE
(Personal Protective Equipment).
Carbolite Gero recommend that the appropriate PPE is worn at all times whilst working
with and around this product.
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2.3 Risk Prevention and Mitigating Residual Risks
Risk Prevention Measures
Hot
Surface
lWear appropriate PPE e.g. heat resistant gloves
lDo not place any objects on top of the product
lEnsure the product is sited on a non-flammable sur-
face, and that all adjacent surfaces are also non-flam-
mable
Ventilation
required
lOnly operate in a well ventilated area
lIf necessary, only operate in a fume cupboard
Fire /
Explosion
lOnly trained operators should use this equipment
lOnly process materials for which a suitable risk assess-
ment has been carried out
Electric
shock
lEnsure the product is isolated from the electrical sup-
ply before performing maintenance
Unit
Toppling
Over
lEnsure that the correct manual handling procedures
are followed when manoeuvring the product
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3.0 Product Overview
3.1 Product Rating Label
The product rating label is located on the side of the product control box.
Note: The image below is an example and does not reflect the product(s) covered by
this manual.
1 UKCA Mark
2 Carbolite Gero address and website
3 CE Mark
4 Country of Origin
5 Product Model
6 Year of Manufacture
7
Dispose of according to WEEE reg-
ulations (Waste Electrical and Elec-
tronic Equipment Directive)
8 Product Serial Number
9 Maximum Temperature
10 Power Rating
11 Frequency (Hertz)
12 Design Voltage
13 Design Phases
14 Current (Amps)
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3.2 Part Identification
Note: Some models may have additional options and features that are not
represented by the following images.
1 Safety Guard
2 Rotary System
3 Control Panel
4 Clips
5 Removable Tumbler
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4.0 Specifications
Tumbler
External Dimensions (closed):
Height x Width x Length (between doors) (mm) 305 x 115 x 370
External Dimensions (open):
Height x Width x Depth (mm) 1750 x 800 x 700
Rotation Speed (rpm) 20
Note: Please refer to the separate product documentation pack for
additional specifications relevant to your product.
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5.0 Electrical Specifications
This equipment MUST be earthed!
5.1 Fuses and Power Settings
Please refer to the supplementary electrical information in the product document pack
provided with this product.
5.2 Operating / Storage Environment
The products covered by this manual contain electrical parts and should be stored and
used in indoor conditions as follows:
Temperature: 5°C - 40°C
Relative
humidity: Maximum 80% up to 31°C decreasing linearly to 50% at 40°C
Altitude: Not exceeding 2000 metres
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6.0 Options and Accessories
Note: Any additional equipment to be used with this product should be supplied by
Carbolite Gero. Accessories from third-party sources are not designed to Carbolite
Gero's specifications and may result in poor performance, damage to equipment or
dangerous working conditions.
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7.0 Installation
7.1 Manual Handling
Refer to section 4.0 of this manual for product dimensions.
Mechanical lifting equipment may be necessary!
Consult personnel responsible for health and safety before attempting
to move this product!
It is the responsibility of the customer to provide any mechanical
lifting aids, such as pallet trucks, forklifts or cranes, and to ensure that
all operators of such equipment are fully trained and qualified.
All manual handling must be carried out according to local health and
safety guidelines.
Note: The customer is responsible for all manual handling procedures performed on
their own premises.
7.2 Unpacking
Note: Check that all items intended for delivery are present and undamaged before
proceeding to install the product.
For safety and manoeuvrability, the product is delivered secured to a pallet inside a
crate.
It is advised that the product is left on the pallet until it has been moved as close as
possible to its intended installation location.
lUsing the appropriate tools, carefully open the crate and remove all external pack-
aging. Retain the crate panels and packaging.
lEnsuring that the product is stable and secure, remove any straps retaining the
product to the pallet.
lUse appropriate lifting equipment to lift the unit from underneath the base.
lManoeuvre the product into the desired position, ensuring that there is sufficient
clearance above and around the sides of the furnace body.
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7.3 Siting and Setting Up
Use the manual handling method recommended by your health and
safety officer to place the product on a level, stable surface that is not
prone to vibration or movement. The surface upon which the product is
placed must be of a height suitable to allow the operator to easily and
safely use the equipment.
Ensure that the power supply or isolating switch is easily accessible to
the operator.
lThe surface on which the equipment is mounted should be stable and not subject to
movement or vibrations.
lThe height of the mounting surface is important to avoid operator strain when load-
ing and unloading samples.
Note: Adequate space must be provided to accommodate the CSR with the guard
open.
Under no circumstances should any objects be placed on top of the
product.
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7.4 Installing the Tumbler Vessel
Use the manual handling method recommended by your health and
safety officer when handling the tumbler vessel.
To install the vessel into the tumbler unit:
lOpen the safety guard, then
carefully slide the tumbler
vessel into the holding ring
on the rotary system,
ensuring that the lid of the
vessel is facing upwards.
lSecure the vessel in place
using the three clips attached
to the holding ring.
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7.5 Electrical Connections
For products supplied without pre-fitted plugs, it is recommended
that all electrical connections are carried out by a qualified
electrician.
The product covered by this manual normally requires a single phase A.C. supply,
which may be "Live to Neutral non-reversible", "Live to Neutral reversible" or "Live to
Live". Some models may be ordered for 3-phase use, which may be with or without
neutral.
Check the product rating label before connection. The supply voltage should correspond
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.
lWhen the mains cable is factory-fitted / supplied, internal fuses are also fitted. It is
essential that the operator ensures that the power supply is correctly fused.
lProducts with a factory fitted supply cable but without a plug are designed to be
wired directly to an isolator or fitted with a line plug compliant with the customer's
local regulations and supply.
lProducts without a factory-fitted supply cable require a permanent connection to a
fused and isolated supply. The product's electrical component access panel should
be temporarily removed, and connections made to the internal terminals / fuse
holder.
When connecting the product to the power supply, the plug or
isolating switch should be accessible, easy to remove / operate,
and within reach of the operator.
Note: The supply MUST incorporate an earth (ground).
7.5.1 3-Phase Connections
Terminal Label Cable Colour Connection
L1 Black to phase 1
L2 Black to phase 2
L3 Black to phase 3
NLight Blue to neutral (if fitted)
PE Green / Yellow to earth (ground)
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8.0 Controller
Please refer to the separate controller manual(s) provided.
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9.0 Commissioning
Note: This equipment should not be put into use until it has been commissioned by a
competent person in accordance with the instructions contained within this manual,
and any local regulations. Carbolite Gero offer an installation and commissioning
service. Please contact Carbolite Gero Service for details.
9.1 Pre-Commissioning
When the product is cold and disconnected from the power
supply, visually check the following: Checked by:
Siting /
Securing
Check that the product is placed on a secure, level
surface and cannot topple over.
Packaging Check that all packaging material has been removed
from inside and around the product.
General
Condition
Check that no damage has occurred during delivery
and siting.
Panels Check that all covers and access panels are securely
fitted.
General Access Check that there is sufficient clearance around the
top and all sides of the product.
Electrical Supply
lCheck that the voltage stated on the product rat-
ing label matches the electrical supply of the
installation site.
lCheck that all electrical supply cables are
securely attached to/ plugged into the product.
Earth
Connection
Check that an earth connection has been made. The
control cabinet and all removable panels on the
furnace should be earthed.
Rating Label /
Warning Labels
Check that all labels are fitted and all information is
legible.
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