VERDER CARBOLITE GERO Manual

Installation, Operation and Maintenance Instructions
Operating Instructions
Inert Gas Package
MEN-IGP-IO (25-01-2021)

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
product. Use the product for the purpose for which it is intended.
1.0 Introduction 3
2.0 Scope and Purpose 4
2.0.1 Responsibilities 4
2.1 Prerequisites to Use 5
3.0 Safety 6
3.1 Operator Safety 6
3.2 Risk Prevention and Mitigating Residual Risks 7
4.0 Product Overview 8
4.1 Part Identification 8
4.2 Input / Output Identification 9
4.3 Product Labels 9
4.4 Specifications 10
4.5 Electrical Specifications (Advanced Gas Package Only) 10
5.0 Installation 11
5.1 Changing Flowmeter Scales 11
5.2 Connecting Flowmeter Modules 13
5.3 Gas Connections 15
5.3.1 Gas Inlet 15
5.3.2 Gas Outlet to Vessel 16
5.3.3 Connecting Multiple Gas Boxes 17
5.4 Electrical Connections (Advanced Gas Package) 17
6.0 Basic Operation 19
6.1 Gases and Flow Rates 20
7.0 Maintenance 22
7.1 General Maintenance 22
7.2 Maintenance Schedule 22
8.0 Decommissioning, Storage and Disposal 23
8.1 Decommissioning 23
8.2 Storage (Long Term) 23
8.3 Disposal (Advanced Gas Package) 23
2

1.0 Introduction
The Carbolite Gero inert gas package is designed to be used only with inert gases such
as air, argon (Ar), nitrogen (N2) and helium (He).
There are two versions of the inert gas package:
lStandard - Fully manual gas control
lAdvanced - Incorporates an electrically controlled solenoid valve for automatic gas
control
The modular system of individual gas boxes allows for up to three gas lines per furnace,
which can be controlled either manually, or automatically via a solenoid valve linked to
the furnace temperature controller, depending on the version ordered.
The customer can easily reconfigure the module for different gases by exchanging the
scale insert in the flowmeter.
3

2.0 Scope and Purpose
This product is intended to be used within a laboratory environment to introduce inert /
non-flammable gas into a sealed vessel that is to be heated.
This equipment is designed to be connected only to the Carbolite Gero product(s) with
which it is supplied.
It must be installed, commissioned, and operated in accordance with the instructions
contained within this manual, and only by trained personnel.
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.
2.0.1 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
lThe customer must provide an adequate ventilation and fume extraction system to
manage any fumes given off by materials during processing
This product should not be modified or used for any purpose other than that for which it
is intended.
Note: To mitigate the risk of inert gas asphyxiation in the event of a leak, the
customer is responsible for ensuring that the area in which this equipment is to be
used is sufficiently ventilated.
4

2.1 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.
Note: Throughout this manual, written instructions are accompanied by
diagrams. Diagrams may be highlighted in different colours and do not
reflect the actual colouration of the product.
Parts that are to be moved are highlighted in YELLOW and are intended to
be fixed to, or removed from, surfaces highlighted in BLUE. Where
applicable, arrows show the direction of movement.
5

3.0 Safety
3.1 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.
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!
6

CAUTION:
Double Pole/ Neutral
Fusing! DANGER:
Explosive materials /
atmosphere!
DANGER:
Suspended loads!
DANGER:
Risk of slipping!
DANGER:
Risk of crushing injury!
WARNING:
Adequate ventilation
required!
DONOTdispose!
Recycle according to WEEE
Regulation guidelines!
Any action noted beside
this symbol is strictly
forbidden!
DO NOT use this product to
cook or heat food or
beverages!
3.2 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 surface,
and that all adjacent surfaces are also non-flammable
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
7

4.0 Product Overview
4.1 Part Identification
1 Flowmeter
2 Flowmeter Adjustment Knob
3 Foot
4 Gas Control Valve
5 Pressure Indicator
6 Gas Outlet
7 Gas Inlet
8 Back Panel
9Solenoid Valve Relay Connection
(Advanced Gas Package Only)
8

4.2 Input / Output Identification
Gas Inlet
Gas Outlet
Relay Connection to Solenoid Valve (Advanced Gas Package Only)
Gas Flow Enabled
Gas Flow Disabled
4.3 Product Labels
Before commissioning this product, ensure that the following product information and
warning labels are in the positions detailed below:
1 Carbolite Gero Logo
2 Gas Selector Positioning Label
3 Gas Outlet Label
4 Solenoid Valve Relay Connection Label (Advanced Gas Package Only)
5 Gas Inlet Label
9

4.4 Specifications
Inert Gas Package (Single Box)
Height x Width x Depth (mm) 240 x 135 x 215
Approximate Weight (kg) 3.2
4.5 Electrical Specifications (Advanced Gas Package Only)
The advanced gas package has a 24 Volt DC power connection via the solenoid valve
relay.
10

5.0 Installation
5.1 Changing Flowmeter Scales
The inert gas boxes are supplied with a set of interchangeable gas scale inserts to allow
the flowmeter modules to be used with a range of gases.
Note: The customer is responsible for selecting and installing the correct scale for the
intended gas.
To install a gas scale into the flowmeter:
lThe glass case is held in place by two small metal tabs
at the top and bottom of the flowmeter. Twist the tabs
90° to release the glass case.
11

lCarefully remove the glass case as shown.
lSelect the correct gas scale insert for the flowmeter
module and fold it around the glass tube, as shown.
Insert the scale into the flowmeter, then refit the glass
case to hold it in position.
12

lSecure the glass case in place by twisting the metal
tabs at either end of the flowmeter by 90°, returning
them to their original positions.
5.2 Connecting Flowmeter Modules
When using more than one gas box, it is recommended that the boxes are secured
together to reduce the risk of any interconnecting gas pipes being pulled loose.
lEach flowmeter module has
three keyhole slots and three
screw threads in the outer cas-
ing.
13

lInsert the three spacers and
screws provided into the
threads in the outer casing.
lPush the two flowmeter mod-
ules together until the screws on
the side of one module locate
into the keyhole slots on the
other module.
lRemove the screw securing the
back panel of the flowmeter
module on the left (when
viewed from the rear).
14

lRemove the back panel.
lTighten the three hexhead
screws entering through the key-
hole slots to secure the two flow-
meter modules together, taking
care not to damage any internal
tubes or fittings.
lReplace the back panel.
5.3 Gas Connections
5.3.1 Gas Inlet
lThe gas inlet comprises a 6mm outside
diameter fitting, into which an appro-
priately sized hose can be pushed.
lFully insert the hose into the fitting to cre-
ate a secure connection.
lThe other end of the hose should be con-
nected to an external gas supply (cus-
tomer supplied).
Note: To disconnect any pipes from the gas inlet and push fittings, push and hold
down the blue ring whilst withdrawing the hose.
15

5.3.2 Gas Outlet to Vessel
1 Gas Outlet
2 Push-in T-Fitting
3 Blanking Plug
4 6mm Male Connector
5 6mm T-Connector
6 Pressure Relief Valve
7 6mm Braided Hose
8 6mm Union
Note: Parts 2, 3, 4, 5 and 6 are supplied as an assembly.
lIf not already connected, screw the T-fitting, and the connected assembly, onto the
gas outlet at the rear of the gas box, carefully tightening it with an appropriate
sized spanner.
lIf only one gas is to be used, ensure that the blanking plug is fully inserted into
the top of the T-fitting.
lIf multiple gases are to be used, a connecting pipe should be fully inserted into
the top of the T-fitting (see section 5.3.3).
lFully insert one end of the braided hose into the male connector and tighten the nut
1.25 turns.
lConnect the other end of the braided hose to the product/vessel:
lIf the product/vessel to which the gas package is to be connected has a 6mm
bulkhead fitting, the other end of the braided hose can be attached directly
into that fitting.
lIf the product/vessel to which the gas package is to be connected has a stem
fitting/6mm inlet pipe, then the 6mm union can be used to connect this with
the end of the braided hose.
lFully insert the stem end of the braided hose into the union connector,
then tighten the nut 1.25 turns.
Note: To reduce the risk of accidental asphyxiation, any gas that escapes
via the pressure relief valve should be vented away from the operator's
working environment e.g. into a ventilation system or outside of the
building.
16

5.3.3 Connecting Multiple Gas Boxes
Up to 3 gas boxes can be connected together in order to supply a mixture of gases into
the vessel. Additional boxes will be supplied with a Y-fitting (two inlets on top) to
accommodate interconnecting pipes between the boxes.
lFully insert the interconnecting pipes into the top of the Y and T-fit-
tings as shown in the image below.
lEnsure that the blanking plug is fully inserted into the top of the first
Y-fitting (see image below) in order to prevent any gas from leaking
out of the Y-fitting.
1 Y-Fitting
2 Blanking Plug
3Interconnecting
Gas Pipe
4 T-Fitting
5.4 Electrical Connections (Advanced Gas Package)
The solenoid valve within the Advanced Gas Package requires an electrical connection
between the gas box and product control box to allow the temperature controller relay
to activate the electrical valve. When the valve is activated the gas can flow. Depending
on the option specified when ordering the furnace, the temperature controller relay is
configured to be triggered either by a program segment output or a temperature
alarm.
A cable is provided with a solenoid connector socket at one end, and a relay connector
at the other.
To connect the gas box(es) to the product control box:
17

lPush the solenoid connector socket
onto the terminals on the back of the
gas box, and secure it in place by tight-
ening the screw on the rear of the
socket.
lPush the relay connector at the other
end of the cable into the cor-
responding relay port on the back of
the product control box.
Note: If using more than one gas,
ensure that the correct gas box is
connected to the correct relay port.
18

6.0 Basic Operation
lBefore introducing the gas supply through the gas
box ensure the gas control valve on the front of the
gas box is turned off; the gas control valve should be
in the horizontal position.
Note: The gas pressure is controlled at the gas source not by the gas
box.
lOnce the gas box is connected to the gas supply, set
the required gas pressure. This should be no greater
than 1.5 bar (22 psi).
WARNING: If the inert gas package is
connected to a work tube end seal
DONOT set the pressure above
0.05 bar (50mbar)!
lCarefully turn the gas control valve to the vertical pos-
ition.
lStandard gas box: The gas will be introduced
into the vessel.
lAdvanced gas box: Gas flow to the furnace will
be controlled by the furnace controller outputs
via the solenoid valve, provided that the furnace
is connected to a power supply and is switched
on.
19

lWhen the gas is flowing, turn the adjustment knob on
the flowmeter to set the desired gas flow rate.
Note: If using the Advanced gas box, the gas will only
flow when the solenoid valve is activated.
lCheck that the correct gas flow rates are set. The
reading should be taken from the top of the float so
that the flat edge is level with the increments on the
gas scale.
Note: To minimise the increase of back pressure, always increase the
pipe diameter of any room vent lines when connecting to a product
exhaust outlet. For example, 6mm outlet connections should be increased
to a diameter of 10mm or greater for room lines between 5 - 10 metres
in length.
Note: Always maintain clean gas lines. Regularly inspect vent lines
connected to the exhaust outlet as any build up of debris may increase the
back pressure of the vessel/ work tube.
6.1 Gases and Flow Rates
Gas Flow Rate Range (litres/minute)
Air 1 - 10
Nitrogen (N2)1 - 10
Argon (Ar) 1 - 8
95% Nitrogen (N2) / Hydrogen 5% (H2)1.2 - 11
20