VERDER CARBOLITE GERO ABF 8/28 Manuel

Installation, Operation and Maintenance Instructions

800°C Afterburner Ashing Furnace - ABA Model: 28 Litres

2416 Controller

ABF 8/28 + 2416 Controller

MEN-ABF0828-002_2416 (08-10-2018)

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

1.3 Access to the Plenum Chamber 6

1.4 Maintenance or Dismantling 6

2.0 Supplied Items List 6

2.1 Parts Supplied 6

2.2 Tools Required 6

3.0 Installation 7

3.1 Unpacking & Handling 7

3.2 Siting and Setting Up 7

3.3 Fitting the Chimney 8

3.4 Ducting 9

3.5 Electrical Connections 10

4.0 2416 Controller 12

4.1 Description 12

4.2 Operation 14

4.3 Programming 16

4.3.1 Programming Tips 16

4.3.2 Multi-program model (2416P8) 17

4.3.3 Holdback 17

4.3.4 Program Cycling 17

4.3.5 Running a Program 17

4.3.6 Program example 18

4.4 Controller Options 19

4.4.1 Digital Communications - RS232 19

4.4.2 Digital Communications - RS485 19

4.4.3 Comms Address 19

4.4.4 Alarm Option 19

4.5 Temperature Controller Replacement 20

4.6 Navigation Diagram 21

5.0 Afterburner 2132 Controller 22

5.1 Description 22

5.2 2132 Controller Operation 22

5.2.1 Controls 22

5.2.2 2132 Controller Operation 23

5.2.3 Basic Operation 23

5.2.4 Altering the Setpoint 23

5.2.5 Stopping and Starting Control 24

5.2.6 Altering the Ramp Rate 24

5.3 Operating with the Timer 25

5.3.1 Setting the Timer Mode 27

5.3.2 Setting the Time Period 27

5.3.3 Running with the Timer 27

5.3.4 Stopping the Timer 28

5.3.5 End of Time Period 29

5.3.6 Cancelling the Alarm 29

5.3.7 Program Example 29

5.4 Altering Power Limit 29

5.5 Audible Alarm 32

5.6 Temperature Controller Replacement 32

5.7 Navigation Diagram 33

6.0 2132 Over-Temperature Controller Description (if fitted) 35

6.1 Description 35

6.2 Operation 35

6.2.1 Controls 35

6.2.2 Operation 36

6.2.3 Over-Temperature Operation 36

6.2.4 Over-Temperature Alarm 36

6.2.5 Resetting the Over-Temperature Alarm 36

6.2.6 Sensor Break 36

6.3 Audible Alarm 37

6.4 Navigation Diagram 37

7.0 Operation 38

7.1 Switches - Control Panel 38

7.2 General Operating Notes 38

7.3 Operator Safety 39

7.4 Temperature Control 39

8.0 Maintenance 41

8.1 General Maintenance 41

8.2 Maintenance Schedule 41

8.2.1 Cleaning 43

8.3 Cleaning the Plenum Chamber & Fan Impeller 43

8.4 Calibration 43

8.5 After-Sales Service 43

8.6 Recommended Spare Parts and Spare Parts Kit 44

9.0 Repairs and Replacements 45

9.1 Safety Warning - Disconnection from Power Supply 45

9.2 Safety Warning - Refractory Fibre Insulation 45

9.3 Solid-State Relay Replacement 45

9.4 Thermocouple Replacement 46

9.5 Element Replacement 46

9.6 Door Plug Replacement 46

10.0 Fault Analysis 47

A. Furnace Does Not Heat Up 47

B. Product Overheats 48

C. Furnace Slow to Heat Up 48

D. Chimney Emits Smoke 49

11.0 Wiring Diagrams 50

11.1 00348-1-5003-D 50

12.0 Fuses and Power Settings 51

12.1 Fuses 51

12.2 Customer Supply Fusing 51

12.3 Power Settings 51

13.0 Specifications 52

13.1 Environment 52

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

1.0 Symbols and Warnings

2.0 Supplied Items List

1.3 Access to the Plenum Chamber

Soot can accumulate in the airway following the after-burner, giving rise

to fire risk.

There is a plenum chamber with removable panels to give access to

cleaning; see section 8.3.

The operator is responsible for maintaining a clean plenum chamber and also for

regular cleaning of the chimney and the external flue or ducting system.

1.4 Maintenance or Dismantling

The operator should read the warning on refractory fibre insulation,

given in section 9.2, before undertaking any work involving exposure to

the internal insulation material.

The operator should disconnect the equipment from the electrical supply before

removing panels to access the electrical connections and control equipment.

2.0 Supplied Items List

2.1 Parts Supplied

The following items should be present. These should all be checked and identified as

soon as possible after receipt of the equipment.

quantity item

1Afterburner Ashing Furnace:

ABF 8/28

1 Chimney

1 Basket Set

1 Basket Set loading handle

(1) Stand (only if ordered)

In addition, any spare parts ordered should be separately identified and put aside in

safe storage.

2.2 Tools Required

10 mm spanner, 12 mm spanner, cross point screwdriver, flat blade screwdriver.

3.0 Installation

3.1 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 9.2.

3.2 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.

3.0 Installation

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.

3.3 Fitting the Chimney

lRemove the chimney panel, (see Fig 10.)

lFasten the chimney to the top of the product using the screws provided, (see Fig 12.)

lReplace the chimney panel, (see Fig 11.)

Fig 10 - Remove the

chimney panel Fig 11 - Replace the

chimney panel

Fig 12 - Chimney

screws

3.4 Ducting

The chimney must either be placed under a powered exhaust hood, or connected

directly to a 76 mm duct (not supplied) to the outside of the building; any such duct

must NOT have powered extraction.

The fumes should be ducted by either of the above methods to at least 1 metre above

the level of the building.

Rules for ducting:

lDucting diameter must be 76 mm or more.

lDucting must be 76 mm where it connects to the chimney.

lDucting length must not exceed 3 metre for 76 mm diameter; for longer lengths con-

sult a ducting engineer.

lFlexible ducting, if used, must be suitable for exhaust gas extraction.

lIf an extraction fan is fitted an extraction hood is required with free flow of air

around the chimney.

lDo not connect more than one product to a single duct. (Exception: where a fanned

duct with hoods is used)

3.0 Installation

Fig 13 - Ducting Schematic

3.5 Electrical Connections

Connection by a qualified electrician is recommended.

For electrical connection details of the ABF 8/28 refer to drawing 00348-1-5003

Look at the rating label before connection to check the electrical supply voltage and

frequency for which the product is configured. If there is a difference between the

actual supply and the rating label, please call Carbolite Gero.

Either wire directly to an isolator or fit with a line plug. An isolating switch should operate

on all live conductors (three phase); it should be within reach of the operator. A line plug

should be easily removable and should be within reach of the operator.

The electrical supply MUST incorporate an earth (ground).

Failure to wire to the appropriate diagram may damage the ABF.

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