Installation, Operation and Maintenance Instructions

1100°C Ashing Furnace - AAF Model: 3 Litres

No Controller

AAF 11/3 + No Controller

MEN-AAF1103-005_NOCTRL (26-07-2022)
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 Chimney 7
2.4 Electrical Connections 8

3.0 Temperature Controller 10

4.0 Operation 11
4.1 Operating Cycle 11
4.2 General Operating Notes 11
4.3 Use of Probes and Metal Sheathed Thermocouples 12
4.4 Atmospheres 12
4.5 Operator Safety 12
4.6 Thermal Catalytic Oxidiser Option 13
4.7 Power Adjustment 14

5.0 Maintenance 15
5.1 General Maintenance 15
5.2 Maintenance Schedule 15
5.3 Thermal Catalytic Oxidiser Maintenance 17
5.4 Maintenance Checks 17
5.5 Catalyst Failure 18
5.6 Catalyst Limitations 18
5.6.1 Cleaning 19
5.7 Safety Switch 19
5.8 Calibration 19
5.9 After-Sales Service 20
5.10 Recommended Spare Parts and Spare Parts Kit 20

6.0 Repairs and Replacements 21

6.1 Safety Warning - Disconnection from Power Supply 21

2
 6.2 Safety Warning - Refractory Fibre Insulation 21
6.3 Temperature Controller Replacement 21
6.4 Solid-State Relay Replacement 22
6.5 Thermocouple Replacement 22
6.6 Element Replacement 23
6.7 Door Plug Replacement 25
6.8 Fuse Replacement 25

7.0 Fault Analysis 27

A. Furnace Does Not Heat Up 27
B. Product Overheats 28

8.0 Wiring Diagrams 29

8.1 WA-11-30 29
8.2 WA-11-31 30

9.0 Fuses and Power Settings 31

9.1 Fuses 31
9.2 Power Settings 31

10.0 Specifications 32
10.1 Environment 32

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:
l Read and understood the information contained within this manual
l Received the relevant training with regard to safety and operation of the product
l Been 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
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.

2.3 Chimney
The chimney is a length of tubing. If it is supplied unfitted, then fit it through the hole
in the top of the case.
If the product is to be used to heat substances that emit fumes, a fume extraction duct
of approximately 75 mm - 150 mm inlet diameter may be placed directly above the
chimney outlet.
Do not make a sealed connection to the product chimney as this causes excessive
airflow through the chamber and results in poor temperature uniformity.

7
 Key

A Duct (75mm-150mm diameter)

B Ambient air is drawn into duct

C Chimney

D 25mm vertical gap between chimney and duct

2.4 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.
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).

8
Electrical Connection Details:
Supply Types
Supply Terminal Label Cable Colour Reversible or Live-
Live - Neutral
Live
to either power
conductor
1-phase L1 Brown to live
(For USA 200-240V,
connect L1)
to the other power
conductor
N / L2 Blue to neutral
(For USA 200-240V,
connect L2)
to earth
PE Green/ Yellow to earth (ground)
(ground)

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

10
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 Notes

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.

When heating large objects, in particular poor conductors, avoid shielding the
thermocouple from the heating elements. The thermocouple is intended to sense the
temperature near the heating elements. However, if a large object is placed in the
chamber it may record the average temperature of the object and the elements, this
can lead to overheating of the elements. Allow large objects to gain heat at a lower
temperature and then reset the controller to a temperature close to the desired
maximum, or heat using a slowly controlled ramp rate. For more information refer to
the controller instructions.
When heating materials that produce smoke or fumes, the chimney must be correctly
fitted and unobstructed. If not, soot will accumulate in the chamber and could possibly
cause an electrical breakdown of the heating element. If the furnace is used to heat
materials that emit smoke or fumes, regularly heat it up to maximum temperature for
one hour with the chamber empty to burn away the soot.

11
Materials such as case hardening compounds and other reactive salts may penetrate
the furnace chamber lining and attack the wire elements, causing premature failure.
Use of a hearth tile may be advisable: please consult the Carbolite Gero technical
department.

4.3 Use of Probes and Metal Sheathed Thermocouples

Any metal object used to probe into the product chamber while the
product is connected to the electrical supply must be earthed. This
applies in particular to metal sheathed thermocouples, where the
sheaths must be earthed. The refractory material of the chamber
lining becomes partly conductive at high temperatures and the
electric potential inside the chamber can be at any value between
zero and the supply voltage. Unearthed probes can cause serious
electric shock.

4.4 Atmospheres
When an optional gas inlet is fitted, there is a label near the inlet saying "INERT GAS
ONLY". In practice, inert or oxidising gases may be used, but not combustible or toxic
gases.

The chamber is not gas tight, the gas usage may be high and the chamber is always
likely to contain some air. Residual oxygen of approximately 1% to 2% is to be
expected.

4.5 Operator Safety

This product incorporates a safety switch which interrupts the heating

element circuit when the furnace is opened. This prevents the
operator touching a live heating element and also prevents the
product from heating up if the furnace is left open. The operation of
this switch should be checked periodically.

Depending on use, the surfaces in the working chamber and the

chamber load may still be very hot after the appliance is switched off.
Touching these surfaces may cause burns. Use suitable personal
protective equipment or wait until the appliance cools down to
ambient temperature.

Before removing a hot object from the product, make sure there is a safe place to put it
down. If necessary use tongs, face masks and heat resistant gloves. Heat resistant
clothing and face protection can guard against the effects of radiated heat when the
furnace is open.

12
When the product is opened during operation there is considerable radiated heat. Do
not keep any flammable objects near the product, nor objects which could be damaged
by radiated heat.

4.6 Thermal Catalytic Oxidiser Option

Catalytic oxidation allows the purification of exhaust air from volatile organic
components at low temperature without an open flame. By the use of a suitable
catalyst, complete oxidation of the volatiles takes place at temperatures between
250°C and 400°C. Due to the low reaction temperature, catalytic oxidisers require very
little energy. Compared to other exhaust gas purification systems, the catalytic oxidiser
has a very small footprint.
l The catalyst system has its own power cord and should be powered from a ded-
icated source, separate from the furnace supply. The catalyst system has a power
rating of 0.6kW, and requires a 220-240 volt power supply.
l Always power up the catalyst before heating up the furnace.
l Cool the furnace down below 250°C before turning off the catalyst power supply.
l The catalyst fan has the effect of lowering the pressure in the furnace chamber and
assisting fume extraction from the furnace.

Note: To avoid damage to the catalyst system, the catalyst fan must always be
running whenever the furnace is hot.

Avoid overloading the catalyst system with volatiles. Particulate matter will not be
catalysed, so if carbon particles are visible in the exhaust stream, slow the furnace
heat up rate and/or reduce the load in the furnace. The furnace should not be loaded
when hot, as the rapid evolution of volatiles may be too great for the system to cope
with.
If the catalytic effect fails and smoke is constantly exhausted, this may be the result of
a poisoned catalyst, failed catalyst heating element or failed exhaust fan.
These items are available as spare parts from Carbolite Gero.

Note: The addition of the catalytic afterburner option increases the external
dimensions of the furnace. Please refer to the Specifications section of this manual
for amended dimensions.

13
 4.7 Power Adjustment
The product control system incorporates electronic power limiting. Depending on the
model and the destination country the power limit maybe set to 100% or a lower
figure. Where appropriate the power limit parameter OP.Hi is accessible to the
operator, but it should not generally be altered.
See section 9.0 for details of the power limit settings. DO NOT adjust the power to a
level higher than the design level states; this may cause a fuse to blow and could
damage the heating elements.
The power limit may be set to a lower limit if the product is to be used at a low
temperature only: this may give better control stability. It may be set to zero to permit
demonstration of the controls without the heating elements taking power; to resume
heating reset it to its standard value.

14
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.

Frequency
Maintenance
Method Bi-
Procedure Daily Weekly Monthly Annually
Annually

Safety

Set a safe temperature above ambient,

Safety Switch Function and open the door to see if the heater
light goes out

Safety Switch Function

Electrical measurement

Set an over-temperature setpoint lower

Over-Temperature
than the displayed temperature and
Safety Circuit
check for an over-temperature alarm as
(if fitted)
detailed in this manual

Over-Temperature
Safety Circuit
(if fitted) Electrical measurement

Visual inspection, checking the seal and

Door Plug
whether it is free of damage

Door Plug Replacement where necessary

Chimney / Extraction Check and clean if necessary

Electrical Safety
Visual check of external cables and plugs
(external)

Electrical Safety Physically check all connections and

(internal) cleaning of the power plate area

Function

Tested using certified equipment, fre-

Temperature Cal-
quency dependent on the standard
ibration
required

15
 Check that all functions are working nor-
Operational Check
mally

Thorough inspection and report incor-

Operational Check
porating a test of all functions

Performance

Element Circuit
Electrical measurement

Measure the current drawn on each

Power Consumption
phase / circuit

Hearth Visual check for fit and damage

Check whether the cooling fans are work-

Cooling Fans (if fitted)
ing

16
5.3 Thermal Catalytic Oxidiser Maintenance

Note: The customer is responsible for ensuring that the thermal catalytic oxidiser is
both operated and maintained according to the instructions contained within this
manual. Failure to adhere to these instructions may result in damage to the
equipment and/or injury to the operator.

5.4 Maintenance Checks

The thermal catalytic oxidiser must be checked regularly to ensure that it is in correct
working order. It is recommended that these checks are carried out before each use,
and the operator keeps a record of each maintenance inspection.

Recommended Checks:
l Perform a visual check to ensure all equipment is clear and free of obvious
damage.
l Check that the air inlet is free of obstructions.
l Check that the catalyst honeycomb is unobstructed and free of particulate matter.
l Check that the fan beneath the catalyst is clean, free of obstruction, and can spin
freely.
l Check that the heating elements inside the catalytic oxidiser are operational.

Note: For further specialist advice, please contact the manufacturer of the thermal
catalytic oxidiser.

17
 5.5 Catalyst Failure
If a catalyst is damaged or ceases to function, there is the risk that pollutant emissions
and particulates will be released into the surrounding environment. Inactive catalysers
may also accumulate hydrocarbons which may spontaneously combust.

The catalyst may have failed if:

l There is a notable increase in unpleasant smells emitted from the catalyser.
l Particulate matter is emitted.

If the catalyst fails, stop operation and replace the catalyst.

Note: DO NOT operate the furnace until the catalyst is replaced and the unit is
recommissioned!

Note: In the event of repeated failures, please review your heat treatment process
to ensure that it is not poisoning or overloading the catalyst.

5.6 Catalyst Limitations

In certain concentrations, the following substances are capable of poisoning the
catalyst. If your samples are known to contain any of these compounds, ensure that
any exhaust fumes do not contain levels of these substances above the stated
concentration limit. Exceeding these substance limit values will reduce the performance
of the catalyst and can lead to catalyst failure.

Exhaust Gas Substance Concentration Limit (mg/Nm3)

Arsenic (As), and As compounds 0.01
Phosphorous Pentoxide (P2O5) and organic
0.01
Phosphorus compounds
Silicon Dioxide (SiO2) 0.01
Lead (Pb) and Zinc (Zn) 0.1
Mercury (Hg) and Cadmium (Cd) 0.1
Hydrofluoric acid and fluoride compounds 1
Alkaline earth metal compounds 1
Alkaline metals 5
Hydrochloric acid and chlorides 100
Organic Silicon (Si) compounds and siloxanes 1

18
5.6.1 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.

5.7 Safety Switch

When correctly functioning, the safety switch will isolate all live conductors (live and
neutral connections) within the heating element circuit(s) when the product door is
opened. The safety switch should be checked regularly to ensure that this occurs.

The safety switch should not fail under normal working conditions, however rough
handling, exposure to corrosive materials/ environments, or exceptionally frequent
use, could compromise the safety system.

Weekly check:
The following check can be carried out by a general operator:
l On the temperature controller, set a safe temperature above ambient. The heater
lights should illuminate.
l Open the door and check the heater lights. They should no longer be illuminated.

If the heater lights remain illuminated when the door is open, discontinue use and
contact Carbolite Gero Service.

Annual check:
The following checks should be carried out by a qualified electrician, as specified in the
"Maintenance Schedule" section of this manual:
l Remove the element access panel and take a voltage measurement from the heat-
ing element terminals. Do not attempt to take a reading from the heating element
itself as surface oxidation will give an unreliable contact.
l Ensure that power to the heating elements is switched off when the door is opened.

Contact Carbolite Gero Service and discontinue use of the product if it is found that the
heating elements are not fully isolated during these checks.

5.8 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

19
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.

5.9 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.

5.10 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 sheath, one solid state relay, one door
insulation piece and a set of elements.
When ordering spare parts please quote the model details and serial number as
requested above.

20
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 Temperature Controller Replacement

Refer to the controller instructions for more information on how to replace the
temperature controller.

21
 6.4 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.

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
Disconnect the thermocouple from its terminal block and withdraw the thermocouple
from its sheath by bending the metal tag or releasing the screw to release. It is also
advisable to remove the sheath and shake out any broken pieces of thermocouple.
Re-assemble with a new thermocouple, observing the colour coding, ensuring that the
thermocouple is not twisted as it is being inserted and that the metal tag is bent back
to grip the sheath.
Refit the element access panel.

22
6.6 Element Replacement

See section 6.2 - wearing a face mask is required.

The chamber of this type of furnace is formed by winding resistance heating wire on to
a refractory muffle former. In the event of failure, the whole "wound muffle" assembly
must be replaced.
Disconnect the furnace from the electrical supply and remove the furnace back panel.
Pull the chimney out of the top of the furnace.

Make a note of the wiring connections;

"Thermocouple Replacement" above
which refers to the thermocouple
colour coding.
Unfasten the electrical connections to
the inner chamber (brick-box) and
remove the thermocouple and sheath
(see thermocouple replacement
instructions). If the connections are
secured by hexagonal nuts, two
spanners should be used to avoid
cracking the porcelain mounting.

Undo any self-tapping screws and hook bolts necessary to release the brick-box.
Support the front of the brick-box as you withdraw it from the case so it does not fall
onto the electrical connections below.
Remove the brick-box lid and top insulating board, noting how it is assembled and
observing the position of the heating element wires (or “tails”).
Pull the element tails out of the terminal block and remove sufficient insulation to allow
access to the heating element. Check and replace damaged insulation.
Fit the new heating element, ensuring that the tails are separated from the element by
at least 25 mm (preferably 50 mm) of insulation – see the image above.
Feed the element tails through the terminal blocks and tighten the clamping screws
using two spanners as before. Cut off excess element tails.
Complete the fitting of the insulation and refit the lid. Do not use any cement unless
supplied by Carbolite Gero, as other types may chemically attack the heating element.
Replace and fasten the brick-box into the furnace case.
Replace the thermocouple and sheath and remake the electrical connections. In
porcelain and brass terminal blocks the brass connector should be slightly loose in its
porcelain support block to allow for expansion.
Replace the back panel and reconnect the electrical supply.

23
Switch the furnace ON and heat to 900 °C without interruption and then dwell for 1
hour. Some smoke may be observed during this process, which should be carried out in
a well ventilated area.
Check that the furnace is controlling properly to rule out the possibility that previous
element failed because of a fault in the control circuit.

24
6.7 Door Plug Replacement

See section 6.2 - wearing a face mask is required.

Open the door and remove the door cover from the plug carrier assembly.
Remove the old door plug by sliding it upwards out of its carrier.
Slide the new plug into the carrier assembly making sure that the plug is the correct
way up.
Refit the door cover.
When first heating the furnace after a replacement, ensure that the ventilation is good:
emission of some fumes is to be expected.

Key

A Door (seen from the back)

A1 Door Cover

A2 Fixing Screws

A3 Door Plug Carrier

A4 Door Link Arms

B Door Plug

B1 Top

6.8 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.

25
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.
The fuses are located at the cable entry point. Remove the back panel or control box
back panel to gain access to the fuses.

26
7.0 Fault Analysis

A. Furnace Does Not Heat Up

The HEAT The heating element Check also that the SSR is
1.
light is ON has failed working correctly
The HEAT The controller shows a
The thermocouple has broken or
2. light is very high temperature
has a wiring fault
OFF or code such as S.br
The controller shows a The door switch(es) (if fitted) may
low temperature be faulty or need adjustment
The contactor/relay (if fitted) may
be faulty
The heater switch (if fitted) may
be faulty or need adjustment
The SSR could be failing to switch
on due to internal failure, faulty
logic wiring from the controller, or
faulty controller
There are no lights Check the supply fuses and any
glowing on the fuses in the furnace control
controller compartment
The controller may be faulty or
not receiving a supply due to a
faulty switch or a wiring fault.

27
 B. Product Overheats
Product only heats
The controller
up when the
1. shows a very high The controller is faulty
instrument switch is
temperature
ON
The thermocouple may be
The controller
faulty or may have been
shows a low
removed out of the heating
temperature
chamber
The thermocouple may be
connected the wrong way
around
The controller may be faulty
Product heats up Check for an accidental
The SSR has failed
2. when the instrument wiring fault that could have
"ON"
switch is OFF overloaded the SSR

28
8.0 Wiring Diagrams

8.1 WA-11-30
Connections below show single phase with indirect safety switch(es).

Key

F1, F2, F3 Fuses

FIL Filter

R1/1, R1/2 Relay Contactor

R1 Relay

C Temperature Controller Cables

TC Control Thermocouple BU Blue

SSR Solid State Relay R Red

SSW Safety Switch GR/Y Green + Yellow

H Heat Lamp G Grey

EL Element(s) P Pink

SW Instrument Switch(es)

N Neutral

L Live

PE Earth

29
 8.2 WA-11-31
Connections below show single phase with safety switches and over-temperature
control.

Key

F1, F2, F3 Fuses

FIL Filter

R1/1, R1/2 Relay Contactor

R1 Relay

C Temperature Controller
Cables
OT Over-Temperature Controller
BU Blue
OTC Over-Temperature Thermocouple
R Red
TC Control Thermocouple
GR/Y Green + Yellow
SSR Solid State Relay
G Grey
SSW Safety Switch
P Pink
H Heat Lamp

EL Element(s)

SW Instrument Switch(es)

N Neutral

L Live

PE Earth

* If Fitted

30
9.0 Fuses and Power Settings

9.1 Fuses
F1-F3: Refer to the circuit diagrams.

Internal Fitted if supply cable fitted.

38 mm x 10 mm type F fitted on
F1 Supply Fitted on board to some types EMC filter circuit board(s)
Fuses of EMC filter.

Fitted on board to some types 2 Amps glass type F

Auxiliary of EMC filter.
F2 On board: 20 mm x 5 mm
Circuit Fuses May be omitted up to 25 Amp/
phase supply rating. Other: 32 mm x 6 mm

Heat Light May be omitted up to 25 Amp/ 2 Amps glass type F

F3
Fuses phase supply rating. 32 mm x 6 mm

Required if no supply cable

Customer See rating label for current;
fitted.
Fuses See table below for fuse rating.
Recommended if cable fitted.

Model Phases Volts Supply Fuse Rating

AAF 11/3 1-phase 100-120 25 A
AAF 11/3 1-phase 200-240 10 A

9.2 Power Settings

The power limit settings (parameter OP.Hi) for this model are voltage dependant. The
figures represent the maximum percentage of time that controlled power is supplied to
the elements. Do not attempt to “improve performance” by setting a value higher than
the recommended values. To adjust the parameter refer to the "Changing the
Maximum Output Power" of the control section of the manual.
220 V 230 V 240 V 254 V
Volts 110 V 200 V 208 V
380 V 400 V 415 V 440 V
Power (%) 87 100 98 87 80 73 65
Please refer to the rating label for product specific information.

31
 10.0 Specifications
Carbolite Gero reserves the right to change the specification without notice.

Max Max External Size Chamber Size Net

Model Temp Power (mm) (mm) Weight
(°C) (kW) H W D H W D (kg)
Ashing Burn-off and Coal and Coke Testing Furnace
AAF 11/3 1100 2.1 585 375 485 90 150 250 22
with Thermal Catalytic 2.1 740 375 670 25
1100 90 150 250
Oxidiser Option

10.1 Environment
The models listed in this manual contain electrical parts and should be stored and used
in indoor conditions as follows:

Temperature: 5 °C - 40 °C

Relative Maximum 80 % up to 31 °C decreasing linearly to 50 % at 40

humidity: °C

32
 Notes

Service Record
Engineer Name Date Record of Work
The products covered in this manual are only a small part of the wide range of ovens,
chamber furnaces and tube furnaces manufactured by Carbolite Gero for laboratory
and industrial use. For further details of our standard or custom built products please
contact us at the address below, or ask your nearest stockist.

For preventive maintenance, repair and calibration of all furnace and oven products,
please contact:
Carbolite Gero Service
Telephone: + 44 (0) 1433 624242
Fax: +44 (0) 1433 624243
Email: ServiceUK@carbolite-gero.com
Carbolite Gero Ltd,
Parsons Lane, Hope, Hope Valley,
S33 6RB, England.
Telephone: + 44 (0) 1433 620011
Fax: + 44 (0) 1433 621198
Email: Info@carbolite-gero.com
www.carbolite-gero.com
Copyright © 2022 Carbolite Gero Limited