Nabertherm N 7/H, N 11/H, N 11/HR, N 17/HR, N 31/H Operating Instructions Manual

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Page 1

Operating Instructions

Chamber Furnaces for Annealing, Hardening and Brazing

N 7/H - N 87/H

-> 01.2016

Original instructions

www.nabertherm.com

 Made

 in

 Germany

Page 2

 Copyright by Nabertherm GmbH Bahnhofstrasse 20 28865 Lilienthal Federal Republic of Germany

Reg: M01.0071 ENGLISCH Rev: 2016-06

No responsibility is accepted for the correctness of this information. We reserve the right to make technical alterations.

Page 3

1 Introduction ........................................................................................................................................................... 5

1.1 Product Description ........................................................................................................................................... 6

1.2 Overview of the Complete Furnace ................................................................................................................... 8

1.3 Safeguarding against Dangers Posed by Over-Temperature ........................................................................... 12

1.3.1 Key to the Model Names ............................................................................................................................ 13

1.4 Scope of Delivery ............................................................................................................................................ 13

2 Specifications ....................................................................................................................................................... 15

2.1 Warranty and Liability .................................................................................................................................... 16

3 Safety .................................................................................................................................................................... 16

3.1 Intended Use.................................................................................................................................................... 16

3.2 Requirements for the Furnace Operator .......................................................................................................... 18

3.3 Requirements for the Operating Personnel ...................................................................................................... 19

3.4 Protective Clothing .......................................................................................................................................... 20

3.5 Basic Measures During Normal Operation ..................................................................................................... 21

3.6 Basic Measures in Case of Emergency ........................................................................................................... 21

3.6.1 What to do in an Emergency ....................................................................................................................... 21

3.7 Basic Measures for Servicing and Maintenance.............................................................................................. 23

3.8 Environmental Regulations ............................................................................................................................. 24

3.9 Explanation of the Symbols and Warnings ..................................................................................................... 24

3.10 General Risks with the Furnace ....................................................................................................................... 28

4 Transportation, Installation, and Commissioning ............................................................................................ 30 

4.1 Delivery ........................................................................................................................................................... 30

4.2 Unpacking (N 7/H - N 17/HR) ........................................................................................................................ 33

4.3 Unpacking (N 31/H - N 87/H) ......................................................................................................................... 34

4.4 Transportation Securing Equipment/Packaging .............................................................................................. 36

4.5 Constructional and Connection Requirements ................................................................................................ 36

4.5.1 Installation (Furnace Location) ................................................................................................................... 36

4.6 Assembly, Installation, and Connection .......................................................................................................... 38

4.6.1 Venting Exhaust Fumes .............................................................................................................................. 38

4.6.2 Insertion of the Base Plate .......................................................................................................................... 39

4.6.3 Assembling the Controller (Depending on the Model) ............................................................................... 40

4.7 Installation of an Extraction Flue, Extraction Flue with Fan or Extraction Flue with Fan and Catalyst

(Accessories for N 7/H – N 17/HR) .............................................................................................................................. 42

4.7.1 Connecting the Furnace to the Power Supply ............................................................................................. 43

4.8 Commissioning ............................................................................................................................................... 46

4.9 Loading/Charging ........................................................................................................................................... 47

4.10 Recommendations for Heating the Furnace for the First Time ....................................................................... 48

5 Operation ............................................................................................................................................................. 49

5.1 Controller ........................................................................................................................................................ 49

6 Operation, Display and Switch Elements (depending on design) .................................................................... 50

6.1 Turning on the Controller/Furnace .................................................................................................................. 50

6.2 Turning off the Controller/Furnace ................................................................................................................. 51

6.2.1 Handling the Controller .............................................................................................................................. 52

6.3 Opening and Closing the Door ........................................................................................................................ 52

6.3.1 Charging Plate ............................................................................................................................................ 53



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6.4 Operation with Heat Treatment Accessories ................................................................................................... 54

7 Servicing, Cleaning, and Maintenance .............................................................................................................. 55

7.1 Furnace Insulation ........................................................................................................................................... 56

7.2 Shutting Down the Furnace for Servicing, Cleaning, and Maintenance ......................................................... 57

7.3 Regular Maintenance Tasks for the Entire System ......................................................................................... 58

7.4 Regular Maintenance of the Furnace ............................................................................................................... 58

7.5 Regular Maintenance Tasks – Switchgear ...................................................................................................... 59

7.6 Regular Maintenance Tasks – Electrical Testing ............................................................................................ 61

7.7 Regular Maintenance Tasks – Documentation ................................................................................................ 62

7.8 Cleaning Products ........................................................................................................................................... 63

8 Malfunctions ........................................................................................................................................................ 64

8.1 Error Messages of the Controller .................................................................................................................... 64

8.2 Warnings of the Controller .............................................................................................................................. 67

8.3 Malfunctions of the Switchgear ...................................................................................................................... 68

8.4 Controller Check List ...................................................................................................................................... 70

9 Spare Parts/Wearing Parts ................................................................................................................................. 72

9.1 Replacing a Heating Element .......................................................................................................................... 76

9.2 Replacing a Thermocouple .............................................................................................................................. 81

9.3 Electrical Schematics/Pneumatic Schematics ................................................................................................. 83

10 Nabertherm Service ............................................................................................................................................ 83

11 Shut-Down, Dismantling, and Storage............................................................................................................... 84

11.1 Transportation/Return Transportation ............................................................................................................. 85

12 Declaration of Conformity .................................................................................................................................. 86

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1 Introduction

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Dear Customer,

Thank you for choosing a quality product from Nabertherm GmbH.

You can be proud that you have chosen a furnace which has been especially tailored to suit your manufacturing and production conditions.

This product is characterized by

 professional workmanship  high performance due to its high efficiency  high-quality insulation  low power consumption  low noise level  simple installation  easy to maintain  high availability of spare parts

Your Nabertherm Team

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Note

These documents are intended only for buyers of our products and may not be copied or disclosed to third parties without our written consent. (Law governing copyright and associated protective rights, German Copyright Law from Sept. 9, 1965)

Protective Rights

Nabertherm GmbH owns all rights to drawings, other documents and authorizations, also in case of applications for protective rights.

Note

All the figures in the instructions have a descriptive character; in other words, they do not represent the exact details of the furnace.

Note

The pictures contained in the instruction manual may contain inaccuracies in terms of the function, design and furnace model.

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1.1 Product Description

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These electrically heated furnaces are a high-quality product which will give you many years of reliable service if they are properly cared for and maintained. One basic prerequisite is that the furnace is used the way it was designed to be used.

During development and production a high priority was placed on safety, functionality and economy.

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These universal chamber furnaces with radiation heating are designed for tough heat treatment applications. They are perfect for processes in toolmaking and in the hardening shop, such as annealing, hardening and forging. A wide variety of accessories enables these furnaces to be tailored to the relevant application.

Other Characteristics of this Product are:

 Heating from three sides (both sides and the floor)  Heating elements on carrier tubes ensure free heat radiation and a long service life  Bottom heating protected by heat-resistant SiC tiles  Multi-layer insulation with high-quality refractory insulation inside the furnace  Exhaust air opening on the left side of the furnace, from N 31/H in the rear wall  Models N 7/H – N 17/HR are designed as tabletop models  Base included from model N 31/H  Parallel swing door, which opens downward; if required, also available with lift door

that opens upward (N 31/H to N 87/H)

 Top part of door with stainless steel plates to prevent burning when the door is opened

at high temperatures (from model N 31/H)

 Temperature uniformity according to DIN 17052-1 to +/- 10 °C  Door movement cushioned with gas springs (from model N 31/H)

Additional Equipment

 Over-temperature limiter with adjustable cutout temperature for thermal protection

class 2 in accordance with EN 60519-2 as temperature limiter to protect the furnace and load

 Process control and documentation via VCD software package for monitoring,

documentation and control

Accessories

 Extraction flue with fan or catalyst (not for model N 31/H – N 87/H)  NTLog for Nabertherm controller: Recording process data with a USB flash drive  Charging plate  Annealing and hardening foil  Protective gas boxes for protective gas atmosphere with additional charge

thermocouple Type K

 Manual or automatic gas supply system  Protective gas hardening system

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 Digital temperature measurement device to measure the temperature in the protective

gas boxes

 Roller conveyors  Cooling station

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1.2 Overview of the Complete Furnace

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Furnace model N 7/H – N17/HR (similar to picture)

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Fig. 1: Overview: Example shows chamber furnace N 7/H (table-top model) (similar to picture)

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Furnace model N 31/H - N 87/H (similar to picture)

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Fig. 2: Overview: Example chamber furnace N 41/H (similar to picture)

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Fig. 3: Chamber furnace, rear view N 7/H – N 17/HR (similar to picture)

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Furnace model N 31/H – N 87/H with power supply cable (depending on connection voltage)

Furnace model N 31/H – N 87/H with fixed

power connection and main switch (depending on connection voltage)

Fig. 4: Chamber furnace, rear view N 31/H – N 87/H (similar to picture)

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No. Name 1 2 3 4 5 6 7 8 9 10

Controller B400/C440/P470 (depending on model)

USB interface (NTLog for Nabertherm Controller: Recording Process Data with a USB Flash Drive)

Parallel swing door, opens downward

Power switch with integrated fuse (switching furnace on/off)

Base included from model N 31/H

Multi-layer insulation with high-quality refractory insulation inside the furnace

Furnace chamber

Opening for a gas supply system (remove perforation)

Heating elements on carrier tubes ensure free heat radiation and a long service life

Bottom heating protected by heat-resistant SiC tiles

11 12

Door movement cushioned with gas springs (from model N 31/H – N 87/H)

Exhaust air opening

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No. Name 13 14 15 15a 16 17 18

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Additional Equipment

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Thermocouple

Extraction flue (Model N 7/H – N 17/HR)

Power plug with snap-in coupling (to 3600 watts)

CEE power plug (from 3600 watts) (depending on connection voltage)

Additional power connection (for accessories)

Fuse for additional power connection (for accessories)

Main switch (depending on connection voltage)

Fig. 5: Example (similar to picture)

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Accessories

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Over-temperature limiter with adjustable cutout temperature for thermal protection class 2 in accordance with EN 60519-2 as temperature limiter to protect the furnace and load

Extraction flue with fan, to improve extraction of

exhaust gases from the furnace. Can be switched with Controller B400 - P480, depending on the program (only for N 7/H – N 17/HR)

Catalyst to clean organic components in the exhaust air. The

organic components are catalytically incinerated at approx. 600 °C; i.e. separated into carbon dioxide and steam. This largely eliminates smells. With Controllers B400 - C440, the catalyst can be switched in relation to the program (only for N 7/H – N 17/HR)

*Note: If other controllers are used, an adapter cable must be ordered for connection to a separate socket. The device is activated when it is plugged in.

Fig. 6: Example: (similar to picture)

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1.3 Safeguarding against Dangers Posed by Over-Temperature

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Over-temperature limiters with manual reset/with automatic reset to protect against overtemperature in the furnace chamber are available for Nabertherm GmbH furnaces either as a standard feature (depending on the model series) or as additional equipment (customized design).

The over-temperature limiter with manual reset/with automatic reset monitors the furnace chamber temperature. The display shows the most recently set cut-off temperature. If the furnace chamber temperature rises about the pre-set cut-off temperature the heating is shut

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down to protect the furnace, the charge and/or the operating equipment.

DANGER

• Danger caused by incorrectly entered cut-off temperature at the over-temperature limiter with manual reset/over-temperature limiter with automatic reset.

• Mortal danger

• If, as a result of over-temperature from the charge and/or the

operating equipment, a charge is likely to be damaged at this preset cut-off temperature of the over-temperature limiter with manual reset/over-temperature limiter with automatic reset, or if the charge itself becomes a source of danger for the furnace or its surroundings, the cut-off temperature must be reduced at the over-temperature limiter with manual reset/automatic reset to the maximum permissible value.

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Read the operating instructions of the over-temperature limiter with manual reset/with automatic reset before starting the furnace. The safety sticker must be removed from the over-temperature limiter with manual reset/with automatic reset. Any time a change is made in the heat treatment program, the maximum permissible cut-off temperature (alarm trigger temperature) at the over-temperature limiter with manual reset/with automatic reset must be checked or re-entered.

We recommend setting the maximum setpoint temperature of the heating program in the limiter between 5 °C and 30 °C, depending on the physical characteristics of the furnace, below the trigger temperature of the over-temperature limiter with manual reset/with automatic reset. This prevents an unwanted triggering of the over-temperature limiter with manual reset/with automatic reset.

Description and function, see the Operating Instructions of the overtemperature limit controller/guard

Fig. 7: Removing the sticker (similar to picture)

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1.3.1 Key to the Model Names

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Example Explanation N 41/H

N = Chamber furnace

N 41/H

7 = 9 liter furnace (volume in l) 11 = 11 liter furnace (volume in l) 17 = 17 liter furnace (volume in l) 25 = 25 liter furnace (volume in l) 31 = 31 liter furnace (volume in l) 41 = 41 liter furnace (volume in l) 61 = 61 liter furnace (volume in l) 87 = 87 liter furnace (volume in l)

N 41/HR

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13 = Tmax. 1300 °C (2372 F) H = High temperature Tmax. 1280 °C (2336 F) R = Increased power

Fig. 8: Example model designation (type plate)

1.4 Scope of Delivery

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The scope of delivery includes:

System components Quantity Comment

Chamber furnace 1 x Nabertherm GmbH

Power cable1) 1 x Nabertherm GmbH

SiC floor plate 1 x Nabertherm GmbH

Charging plate2) 1 x Nabertherm GmbH

Page 14

System components Quantity Comment

)

Annealing and hardening foil2)

Nabertherm GmbH

Protective gas box1) 1 x Nabertherm GmbH

Other components, variable depending on the

- - - See shipping documents

particular design

Document type Quantity Comment

Operating Instructions 1 x Nabertherm GmbH

Operating Manual for Controller 1 x Nabertherm GmbH

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Operating Instructions for Protective Gas and Carburization Systems1)

Other documents, variable depending on the

1 x Nabertherm GmbH

1 x

particular design

included with delivery depending on design/furnace model

included with delivery if required, see shipping documents

quantity depends on furnace model

quantity as required, see shipping documents

Note

Store all documents carefully. All the functions of this furnace were tested during manufacturing and prior to shipping.

Note

The documents included do not always contain the electrical schematics and pneumatic schematics.

If you need the respective schematics they can be ordered from Nabertherm Service.

Page 15

2 Specifications

Electrical specifications are on the type plate located on the side of the furnace.



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Model Tmax Inner dimensions in

°C w d h in l W D H in kW in kg

N 7/H1 1280 250 250 140 9 600 650 600 3,0 60 180

N 11/H1 1280 250 350 140 11 600 750 600 3,5 70 180

N 11/HR1 1280 250 350 140 11 600 750 600 5,5 70 120

N 17/HR1 1280 250 500 140 17 600 900 600 6,4 90 120

N 31/H 1280 350 350 250 31 880 1100 1340 15,0 210 105

N 41/H 1280 350 500 250 41 880 1250 1340 15,0 260 120

N 61/H 1280 350 750 250 61 880 1500 1340 20,0 400 120

Volume Outer dimensions in mm Heating

power

Weight Minutes

to Tmax2

N 87/H 1280 350 1000 250 87 880 1750 1340 25,0 480 120

table-top model

If connected at 230 V 1/N/PE rsp. 400 V 3/N/PE

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Fig. 9: Dimensions

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Electrical connection 1-phase: 3-phase:

, N 17/HR1

Furnace model

N 7/H

N 11/H

N 11/HR

N 31/H, N 41/H

N 61/H, N 87/H

Thermal protection class

Voltage (V): See type plate on furnace

Frequency (Hz): See type plate on furnace

according to DIN EN 60519-2

Furnaces:

without safety controller: Class 0 with safety controller: Class 2

Page 16

Protection rating

Furnaces:

Protection type Ambient conditions for

electrical equipment Weights

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Temperature: Humidity:

Furnace with accessories Varies (see shipping documents)

Emissions

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Heating only between two phases

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2.1 Warranty and Liability

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As regards warranty and liability, the normal Nabertherm warranty terms apply, unless individual terms and conditions have been agreed. However, the following conditions also apply:

Warranty and liability claims for personal injury or damage to property shall be excluded if they are attributable to one or more of the following causes:

 Everyone involved in operation, installation, maintenance, or repair of the furnace

must have read and understood the operating instructions. No liability will be accepted for damage or disruptions to operation resulting from non-compliance with the operating instructions.

 Not using the furnace as intended,  Improper installation, start-up, operation, or maintenance of the furnace,  Operation of the furnace with defective safety equipment or improperly installed or

non-functioning safety and protective equipment,

 Not observing the references in the operating instructions to transportation, storage,

installation, start-up, operation, maintenance, or equipping the furnace,

 Making unauthorized changes to the furnace,  Making unauthorized changes to the operating parameters,  Making unauthorized changes to the parameterization, the settings, or the program,  Original parts and accessories are designed especially for Nabertherm furnaces.

Replace parts only with original Nabertherm parts. Otherwise the warranty will be void. Nabertherm accepts absolutely no liability for damage caused by using parts that are not original Nabertherm parts.

 Catastrophes due to third-party causes and force majeure.

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IP20

+5 °C to + +40 °C max. 80% non-condensing

Continuous sound pressure level:

< 80 dB(A)

3 Safety

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3.1 Intended Use

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The Nabertherm furnace was designed and built in conformance with a careful selection of the applicable harmonized standards and other technical specifications. Hence, it corresponds to the state of the art and assures the greatest degree of safety.

Only materials whose characteristics and melting temperatures are known may be heated. Consult any available safety-related material data sheets.

These universal chamber furnaces with radiation heating are designed for tough heat treatment applications. They are perfect for processes in toolmaking and in the hardening

Page 17

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shop, such as annealing, hardening and forging. A wide variety of accessories enables these furnaces to be tailored to the relevant application.

 Under certain circumstances gases or materials may be released from the materials in

the furnaces that settle on the insulation or the heating elements and destroy them. If

applicable, read the labels and instructions on the packaging of materials that you use.

 Only materials whose characteristics and melting temperatures are known may be

heated. Consult any available safety data sheets of the materials. Any other use beyond this is improper, including the processing of products other than those for which the furnace was intended as well as handling hazardous materials or materials dangerous to health, and must be approved in writing by the manufacturer Nabertherm GmbH.

 Any other use, such as processing of products other than those for which the furnace

was intended as well as handling hazardous materials or materials dangerous to health is deemed IMPROPER and such uses must be approved in writing by Nabertherm.

 Furnaces with over-temperature limit controllers must have their shut-down

temperatures set to prevent any overheating of the material.

 The set-up instructions and safety regulations must be followed, otherwise the furnace

will be considered improperly used, effectively cancelling any claims against Nabertherm GmbH. The EC Declaration of Conformity will cease to be valid if any modifications are made to the machine without our approval.

 The set-up instructions and safety regulations must be followed, otherwise the furnace

will be considered improperly used, effectively cancelling any claims against Nabertherm GmbH.

 Opening the furnace while it is still hot, over 200 °C (392 °F), can lead to increased

wear of the following components: insulation, door seal, heating elements and furnace housing. No liability shall be accepted for any damage to the goods or the furnace resulting from non-compliance with this warning.

Operation with power sources, products, operating equipment, auxiliary materials, etc., which are listed as hazardous or which may in any way harm the health of the operator is prohibited.

The furnace must not be filled with materials or substances that release explosive gases or vapors. Only materials and substances whose properties are known may be used.

- This furnace was designed for commercial use. The furnace is not designed

for heating food, animals, wood, grain, etc.

- The furnace must not be used to heat the workplace.

- Do not use the furnace to melt ice or for similar purposes.

- Do not use the furnace as a clothes dryer.

Caution

Applicable safety instructions are contained in individual chapters.

Page 18

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Pos: 71 /TD/Allgemeine Hinweise (für alle Anleitungen) /Hinweis - Dieses Produkt entspricht nicht der ATEX- Richtlinie und darf nicht ..-nicht brennbare Gase @ 2\ mod_1184228756893_51.docx @ 19686 @ @ 1

The operator is liable for any resulting damages.

Caution

Operating the furnace with explosive gases or mixtures, including explosive gases or mixtures created as a result of heating/drying, is prohibited.

This furnace features no safety technology for processes which produce combustible

mixtures, for example debinding.

If the furnace is still used for such processes despite this fact, the concentration of organic gas mixtures in the furnace must never exceed 3% of the lower explosion limit (LEL). This pre-requisite applies not only to normal operation but, in particular, to exceptional situations such as process disruptions (caused, for example, by the failure of a power unit). You must ensure that the furnace is adequately ventilated and vented.

Nabertherm offers a broad range of furnaces which were especially developed for processes involving the use of combustible gas mixtures.

Note

This product does not comply with the ATEX Directive and may not be used in ignitable

atmospheres. It must not be operated with explosive gases or mixtures or during processes where explosive gases or mixtures are produced.

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3.2 Requirements for the Furnace Operator

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The set-up instructions and safety regulations must be followed, otherwise the furnace will be deemed to have been used improperly, effectively cancelling any claims against Nabertherm GmbH.

This level of safety when operating the furnace can be achieved only if all the necessary measures have been taken. It depends on the furnace operator's diligence in planning these measures and controlling how they are carried out.

The operator must ensure that

 all harmful gases are removed from the workplace, for example by an extraction

system,

 the extraction system is switched on,  the workplace is properly ventilated,  the furnace is operated only in a perfect operating condition and, in particular, that the

functions of the safety components are checked regularly.

 the required personal protective equipment is available for and used by the operating,

maintenance, and repair personnel.

 these operating instructions, including the supplier documentation, are kept near the

furnace. These instructions must be available at all times for anyone working with or on the furnace;

 all the safety and operating instruction signs on the furnace can be read properly.

Damaged or unreadable signs must be replaced immediately,

 furnace personnel are informed regularly about all issues involving occupational

safety and environmental protection and are familiar with all the operating instructions, especially those involving safety,

 a risk assessment is carried out (in Germany, covered of the Occupational Safety Act)

to determine any other hazards that may result from the working conditions particular to the furnace's location,

Page 19

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 all other instructions and safety guidelines that have been determined in a risk

assessment for the workplace are compiled in an operation manual (in Germany, covered of the Ordinance Regulating the Use of Operating Equipment).

 Only sufficiently qualified and authorized personnel may operate, maintain and repair

the system. This personnel must be trained in how to operate the furnace and must confirm their participation in the training with a personal signature. The training program must be documented in detail. In case an operator is replaced, additional training must also take place. The additional training may only be performed by authorized, trained individuals familiar with the system. The additional training must be painstakingly documented and participation must be evidenced by the names and signatures of the participating employees.

Operating the Furnace

 Operating the furnace with explosive gases or mixtures, i.e., including any explosive

gases or mixtures created as a result of heating/drying, is prohibited.

 A furnace opened while still hot radiates enormous heat energy, which can cause

burns.

 Working with the furnace, for example opening the furnace door, etc., is only

permissible when the whole space needed for the door to swing out, the danger zone, is visible to the operator.

 When working at the furnace with high temperatures, the appropriate protective

clothing and protective goggles must be worn.

 Danger! Risk of burns:  Several spots on the housing and components of the control box can become hot

enough during normal operation to cause skin burns.

 When the vent supports are hot, touching them will lead to burns.

Note

If the protective gas boxes are used, a working temperature to 1100 °C (2012 °F) is recommended; with working temperatures to 1150 °C (2102 °F) the boxes will suffer increased wear.

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Note

In Germany, the general accident protection guidelines must be observed. The national accident prevention regulations of the country of operation apply.

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3.3 Requirements for the Operating Personnel

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Everyone involved in operation, installation, maintenance, or repair of the furnace must have read and understood the operating instructions. No liability will be accepted for damage or disruptions to operation resulting from non-compliance with the operating instructions.

Only adequately qualified and authorized persons may operate, maintain, or repair the furnace.

Operating personnel are instructed regularly in all aspects of occupational safety and environmental protection and are familiar with all the operating instructions, in particular, safety instructions.

Only trained personnel may operate the control and safety equipment.

The operator should complete these details:

 Operator

Page 20

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_______________________________________________________________

 The furnace may only be transported by

_______________________________________________________________

 The furnace may only be installed by

_______________________________________________________________

 The furnace may only be commissioned by

_______________________________________________________________

 Initial instructions may only be given by

_______________________________________________________________

 Malfunctions may only be rectified by

_______________________________________________________________

 The furnace may only be maintained by

_______________________________________________________________

 The furnace may only be cleaned by

_______________________________________________________________

 The furnace may only be serviced by

_______________________________________________________________

 The furnace may only be repaired by

_______________________________________________________________

 The furnace may only be shut down by

_______________________________________________________________

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3.4 Protective Clothing

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When close to furnaces, heat treatment accessories and similar components, wear protective clothing that is resistant to heat and splashes of quenching media.

Wear a full-face mask that is resistant to heat and splashes of quenching media.

DANGER

• Danger caused by incorrectly entered cut-off temperature at the over-temperature limiter with manual reset/over-temperature limiter with automatic reset.

• Mortal danger

• If, as a result of over-temperature from the charge and/or the

Page 21

Protect your hands when handling heat treatment accessories and similar components by wearing heat-resistant gloves.

Protect your hands when cutting annealing and hardening foil/annealing envelopes by wearing firm gloves.

Wear safety boots to protect your feet.

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3.5 Basic Measures During Normal Operation

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Risks during Normal Operation!

Before switching the furnace on, check and ensure that only authorized persons are in the working area of the furnace and that no one can be injured as a result of operating the furnace.

Before starting production each time, check and ensure that all the safety equipment works properly.

Before starting production each time, check the furnace for obvious damage and ensure that it is operated only in a perfect condition. Report any defects to a supervisor immediately.

Before starting production each time, remove all materials and objects that are not needed for production from the working area.

At least once every day (see also Servicing and Maintenance) check the following:

 Check the furnace for obvious external damage,  Check all hydraulic or pneumatic hoses, make sure that they are not leaking and that

they are connected properly (if applicable),

 Check all gas and oil lines, make sure that they are not leaking and that they are

connected properly (if applicable),

 Check that the fan works properly (if applicable)

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3.6 Basic Measures in Case of Emergency

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3.6.1 What to do in an Emergency

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Furnaces with power plug

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Note

The power plug is to be pulled out to stop the furnace in case of an emergency.

Therefore, the power plug must be accessible at all times when the furnace is operating so that it can be pulled out quickly in case of an emergency.

Page 22

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Fig. 10: Pull the power plug (similar to picture)

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Furnaces with main switch

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I ON

Note

In an emergency, immediately switch off the voltage supply to the furnace at the main

O OFF

switch (position "O/OFF"). Wait until the furnace chamber and attaching parts have cooled

to room temperature.

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Fig. 11: Disconnect power to the system using the main switch (similar to picture)

Risks during Normal Operation!

Switch the furnace off immediately in case of unexpected occurrences in the furnace (e.g. a lot of smoke or unusual smells). Wait until the furnace has cooled naturally to room temperature.

Page 23

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In case of a fire, keep the door closed. This will allow you to prevent the spread of smoke and keep out a supply of oxygen.

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DANGER

• Danger from electric shock.

• Danger to life.

• Work on the electrical

equipment may be performed only by qualified electricians or by technicians authorized by Nabertherm.

• Disconnect the furnace

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Warning - Danger of Electric Shock!

Work on the electrical equipment may be done only by qualified, authorized electricians.

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3.7 Basic Measures for Servicing and Maintenance

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Maintenance work must be performed by authorized persons following the maintenance instructions and the accident prevention regulations. We recommend that the maintenance and repair work be carried out by the service team of Nabertherm GmbH. Non-compliance may cause injuries, death, or considerable damage to property.

Switch off the furnace and make sure it cannot be switched on again inadvertently (lock the main switch and secure it with a padlock), or pull out the power plug.

Clear an adequate area around the furnace to facilitate the repair work.

Suspended loads are dangerous. Working beneath a suspended load is prohibited. There is a risk of fatal injury.

Relieve the pressure on hydraulic or pneumatic equipment before carrying out maintenance or repair work (if applicable).

When cleaning furnaces, control cabinets, or electrical equipment housings, never spray them with water.

When maintenance or repair work has been completed, before recommencing production ensure the following:

 Check that loosened screw connections have been re-tightened,

Page 24

 Reinstall protective equipment, screens, and filters,  Remove all material, tools, and other equipment used for the maintenance or repair

work from the working area of the furnace,

 Remove any liquids that have leaked,  Check that all safety functions (e.g. emergency stop button) work properly,

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 Power cables may be replaced only with similar, approved cables.

3.8 Environmental Regulations

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All statutory duties regarding waste avoidance, proper recycling, and disposal must be observed when work is carried out on and with the furnace.

Problem materials that are no longer needed, such as lubricants or batteries, must not be placed in normal waste disposal systems or allowed to enter the sewage system.

During installation, repair, and maintenance work, substances that are hazardous to water, such as

 lubricating grease and oils  hydraulic oils  refrigerants  solvent-based cleaning fluids must not be allowed to contaminate the soil or enter the

sewage system.

These substances must be stored, transported, collected, and disposed of in suitable containers.

Note

The operator must ensure that national environmental regulations are observed.

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When it is delivered, this furnace contains no substances that make a hazardous waste classification necessary. However, residues of process materials may accumulate in the furnace insulation during operation. These may be hazardous to health and/or the environment.

 Dismantle the electronic components and dispose of them as electric scrap.  Remove the insulation and dispose of it as hazardous waste (See Servicing, Cleaning,

and Maintenance with Ceramic Fiber Material)

 Dispose of the housing as scrap metal.

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3.9 Explanation of the Symbols and Warnings

Note

In the following operating instructions, specific warnings are given to draw attention to residual risks that cannot be avoided when the furnace is operating. These residual risks include dangers for humans/products/ the furnace, and the environment.

The symbols used in the operating instructions are especially intended to draw attention to safety information.

The symbols used cannot replace the text of the safety information. Therefore, always read the entire text.

Graphic symbols correspond to ISO 3864. In accordance with the American National Standard Institute (ANSI) Z535.6 the following warning information and words are used in

this document:

Page 25

The general hazard symbol, in combination with the words CAUTION, WARNING and DANGER warns about the risk of serious injury. Observe the following information to

prevent injury or death.

NOTICE

Refers to a hazard that could damage or destroy the equipment.

CAUTION

Refers to a hazard with a minor or medium risk of injury.

WARNING

Refers to a hazard that could cause death, serious or irreversible injury.

DANGER

Refers to a hazard that could directly cause death, serious or irreversible injury.

Page 26

Structure of the Warning: All Warnings are Structured as Follows

Hazard symbol

Indicates the risk of injury

Signal word

Classifies the danger

WARNING

• Type and source of the danger

• Consequences of non-compliance

• Action to prevent danger

Graphical symbols (optional) according to ISO 3864:

Consequences, measures, and prohibitions

Reference texts:

• Type and source of the danger

• Possible consequences of noncompliance

• Measures/Prohibitions

Hazard symbol

Indicates the risk of injury

Signal word

Classifies the danger

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DANGER

• Type and source of the danger

• Consequences of non-compliance

• Action to prevent danger

Graphical symbols (optional) according to ISO 3864:

Consequences, measures, and prohibitions

Graphical symbols (optional) according to ISO 3864:

Instructions or prohibitions

Reference texts:

• Type and source of the danger

• Possible consequences of noncompliance

• Measures/prohibitions

Information Symbols in the Instructions:

Note

Below this symbol you will find instructions and particularly useful information.

Page 27

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Rule - Rule Sign

This symbol draws attention to important rules that must be followed. Rule signs protect people against injury and show what is to be done in certain situations.

Rule - Important Information for Operators

This symbol draws the operator's attention to important information and operating instructions that must be followed.

Rule - Important Information for Maintenance Personnel

This symbol draws the maintenance personnel's attention to important operating and maintenance instructions (service) that must be followed.

Rule - Pull Out the Power Plug

This symbol tells the operator to pull out the power plug.

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Mandatory rule - Disconnect the furnace

This symbol informs the operator that before beginning any work the furnace must be disconnected from the power supply and the applicable safety rules and accident prevention regulations must be observed.

Rule - Lift only with Several People

This symbol draws the personnel's attention to the fact that this device may only be lifted and moved to its final destination by several people.

Caution – Fingers or Hands May Be Crushed

This symbol warns the operator of the potential for fingers or hands to be crushed. Ignoring this can lead to injury.

Warning - Hot Surface, Do Not Touch

This symbol warns the operator that the surface is hot and should not be touched.

Warning - Danger of Electric Shock

This symbol warns the operator that there is a risk of an electric shock if the following warnings are not heeded.

Warning – Risk of Device Toppling Over

This symbol tells the operator that there is a risk of the device toppling over if the following warnings are not heeded.

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Warning – Suspended Load

This symbol warns the operator of potential dangers of suspended loads. Working below a suspended load is strictly forbidden. Ignoring this can lead to fatal injury.

Warning – Danger if Heavy Loads Are Lifted

This symbol warns the operator of the potential dangers of lifting heavy loads. Ignoring this can lead to injury.

Warning – Risk to the Environment

This symbol warns the operator of the risk to the environment if the following information is not heeded. The operator must ensure that national environmental regulations are observed.

Warning - Fire Danger

This symbol warns operators of the danger of fire if the following information is not followed.

Warning – Risk of Explosive Substances or Explosive Atmosphere

These symbols warn the operator of explosive substances or an explosive atmosphere

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Prohibited - Important Information for Operators

This symbol warns the operator that water or cleaning products must NOT be poured over the objects. A high-pressure cleaning device must also not be used.

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Warning Signs on the Furnace:

Warning - Hot Surface, Danger of Burning – Do Not Touch

You may not always realize that surfaces, such as furnace components, furnace walls, doors and materials, and even liquids are hot. Do not touch the surface.

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Warning - Danger of Electric Shock!

Warning, dangerous electric voltage

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3.10 General Risks with the Furnace

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Warning! General Hazards!

Risk of burning on the furnace housing

The door handle/grip can become very hot during operation; wear gloves.

Risk of crushing on moving parts (door hinge)

The switchgear cabinet (if present) and the terminal boxes on the system contain dangerous

Page 29

electrical voltages.

Do not insert any objects into the openings on the furnace housing, exhaust air holes, or cooling slots on the switchgear or furnace (if present). This poses a risk of electric shock.

Fire hazard if an extension cable is used:

With 230 V furnace models make sure that:

On use of an extension cable or a multipoint socket, the maximum electrical rating must not be exceeded. Do not use the furnace with an extension cable if you are uncertain whether grounding is guaranteed.

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Warning! General Hazards!

No objects may be placed or set down on the furnace or switchgear. Doing so creates a fire or explosion hazard.

DANGER

• Danger from electrocution

• If there is no earth connection, or the

earth connection is poorly connected, the result may be a deadly electrical shock.

• Do not insert any metallic objects such as

thermocouples, sensors or tools into the furnace chamber without having previously ensured that the plant has been correctly earthed. Entrust the job of making a earth connection between the object and the furnace housing to a qualified electrical technician. Any objects inserted into the furnace must be inserted only through those openings intended for this purpose.

Page 30

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DANGER

• Danger caused by incorrectly entered cut-off temperature at the over-temperature limiter with manual reset/over-temperature limiter with automatic reset.

• Mortal danger

• If, as a result of over-temperature from the charge and/or the

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4 Transportation, Installation, and Commissioning

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4.1 Delivery

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Check that Everything is Complete

Compare the delivered items with the delivery note and the purchase order documents.

Immediately notify the carrier and Nabertherm GmbH of any missing or damaged parts, as

complaints at a later date cannot be acknowledged.

Danger of Injury

When the furnace is being lifted, parts of the furnace or the furnace itself could topple over, slip, or fall. Before the furnace is lifted, make sure no one is in the working area. Wear safety footwear and a hard hat.

Safety Instructions

 Forklifts must be operated only by authorized personnel. The operator bears sole

responsibility for safe operation and the load.

 When the furnace is being lifted, make sure that the ends of the forks or the load do

not catch on neighboring goods. Use a crane to move tall parts, such as control cabinets.

 Use only lifting equipment with sufficient load-bearing capacity.  Lifting gear must be attached only to positions that have been designated for this

purpose.

 Attachments, piping, or cable conduits must never be used to affix lifting gear.  Unpackaged parts should only be lifted with ropes or straps.  Attach transportation equipment only to positions intended for this purpose.  Lifting and securing equipment must conform to the provisions contained in accident

prevention regulations.

 Consider the weight of the furnace when choosing lifting and securing equipment.

(see Specifications)

 Stainless steel parts (including mounting elements) must always be kept separate from

unalloyed steel parts.

 Do not remove corrosion protection until immediately prior to assembly.

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Risks during Normal Operation!

Suspended loads are dangerous. Working beneath a suspended load is prohibited. There is a risk of fatal injury.

Note

Safety and accident prevention guidelines applicable for forklift trucks must be followed.

Transportation with a Pallet Truck

Observe the maximum permitted capacity of the pallet truck.

1. Our furnaces are delivered ex works on wooden frames to facilitate unloading. Transport the furnace in its original packaging and with suitable equipment to prevent any damage. Remove the packaging only when the furnace is in its final location. When transporting the furnace, make sure it is secured against sliding, toppling over, and damage. The furnace should be transported and installed by at

least two persons. Do not store the furnace in damp rooms or outdoors.

2. Push the pallet truck underneath the transportation frame. Make sure that the pallet

truck is completely beneath the frame. Pay attention to neighboring goods.

Fig. 12: Pallet truck is pushed completely beneath the transportation frame

3. Lift the furnace carefully and pay attention to its center of gravity. When the furnace is being lifted, make sure that the ends of the forks or the load do not catch on neighboring goods.

4. Make sure that the furnace is balanced safely; if not, attach securing equipment. Push the furnace carefully, slowly and with the pallet truck at its lowest position. Do not transport the furnace on inclines.

5. Carefully lower the furnace at its final position. Pay attention to neighboring goods. Try not to set it down too abruptly.

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Note

In Germany, the general accident protection guidelines must be observed. The national accident prevention regulations of the country of operation apply.

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CAUTION

• Device may slip or topple over.

• Damage to the device.

• Risk of injury from lifting heavy loads.

• Transport device only in original packaging.

• Several people must carry the device.

Symbols:

The international standard symbols for handling packaging are defined in ISO R/780 (International Organization for Standardization) and in DIN 55 402 (German

Institute for Standardization).

Description Symbol Explanation

Fragile

This symbol is to be attached to fragile goods. Goods marked like this are to be handled carefully and must not be thrown or tied up.

This side up

The freight must be transported, transshipped, and stored in such a way that the arrows point upward. The freight must not be rolled, folded, or stored on edge. However, the package does not have to be packed on top of other freight.

Keep dry

Products with this symbol must be protected against high air moisture, hence, they must be stored under cover. If particularly heavy or bulky packages cannot be stored in halls or sheds, they must be covered carefully with a tarpaulin or similar.

Sling here The symbol shows only where the sling should be

attached, not the method of slinging. If the symbols are at an equal distance from the middle or center of gravity of the package, the package hangs straight if the slings are the same length. If this is not the case, the sling on one side has to be shortened.

Page 33

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4.2 Unpacking (N 7/H - N 17/HR)

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Wear protective

gloves

1. Check the transportation packaging for possible damage.

2. Remove tensioning straps from the transportation packaging.

3. Slacken screws and remove wooden casing from the covering box (if available 3a).

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4. Carefully lift the cardboard box and remove it from the pallet.

5. Remove the foil and packaging material. Compare the delivered items with the delivery note and the order documents, see "Delivery".

6. With two people, carefully lift the furnace out of the lower packaging unit, using the

lifting straps on the furnace. We recommend that you attach the lifting straps

around the sides (across) beforehand so that you can lift the furnace out of the packaging unit.

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7. To carry, grip furnace from below at the sides and make sure you have a firm grip.

8. For furnaces weighing more than 25 kg, transport work must be carried out by at least 2 people. If transport straps are used, they must be attached crosswise only. Ensure that they are secure.

Note

In Germany, the general accident protection guidelines of VBG or BGZ must be observed. The national accident prevention regulations of the country of operation apply.

Note

Save the packaging for possible shipping or for storing the furnace.

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4.3 Unpacking (N 31/H - N 87/H)

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Wear protective

gloves

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1. Check the transport packaging for any signs of damage. The packaging differs depending on size, weight or installation site and, based on this, is provided in one of the following ways. On a pallet, in a wooden cage or in a wooden box (shown in figures 1a to 1c).

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2. Remove screws/staples and then carefully remove the wooden siding from around the base. Remove any plastic transportation sheeting.

3. Remove any transportation sheets, straps and packaging materials.

Transportation with suitable forklift truck

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4. The furnace frame is made of thick steel sections. Drive the forklift forks under the furnace watching out for fragile parts such as attachments and cables. Remove as

necessary. Make sure that the forks of the forklift are completely under the frame.

Mind the nearby transported goods.

Carefully lift the furnace from below minding the center of gravity. When lifting

make sure that the fork tips or the load itself do not get caught on nearby stacked

goods. Drive carefully, slowly and in the lowest position. Do not drive over any

steep surfaces. When the installation site is reached, lower the base carefully on the wheels. Avoid any sudden drops.

Caution

We recommend that the system be moved to the installation site over longer distances or over bumpy surfaces using a forklift or a pallet lift.

Note

In Germany, the general accident protection guidelines must be observed. The national accident prevention regulations of the country of operation apply.

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4.4 Transportation Securing Equipment/Packaging

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Note

No special transportation securing equipment is available for this furnace

The furnace packaging prevents damage during transportation. Make sure that you remove all packaging material (also inside the furnace chamber). All packaging material can be recycled. The packaging was designed so that no special description is necessary.

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Safety information

Do not allow children to play with packaging parts. They are at risk of suffocation from folding boxes and plastic film.

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1 Remove the plastic transportation sheet for the protection of the surrounding insulation.

Fig. 13: Removing the transportation protection

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Note

Please keep the packaging for possible shipping or storing of the furnace.

4.5 Constructional and Connection Requirements

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4.5.1 Installation (Furnace Location)

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When setting up the furnace, these safety instructions must be followed:

 The furnace must be installed in a dry room in accordance with the safety instructions.  The table/supporting surface must be flat to enable the furnace to be installed straight.

Place the furnace on a non flammable surface (fire safety class A DIN 4102 –

Example: concrete, tiles, glass, aluminum or steel) so that any hot material falling from the furnace cannot ignite the surface.

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 The carrying capacity of the table must be designed to bear the weight of the furnace

incl. accessories.

 The floor covering must be made of nonflammable material so that hot material

falling out of the furnace will not cause the floor covering to ignite.

Installation Location

 The operator is responsible for adequate ventilation by installing the appropriate

systems to supply fresh air and to vent exhaust air. If a batch emits gases or vapors, adequate ventilation of the installation site must be provided as well as a suitable exhaust air venting system. A suitable vent for combustion exhaust must be supplied by the customer

 Make sure that the heat radiated by the furnace is vented (consult a ventilation expert,

if necessary)

 Although the furnace is well-insulated, the exterior surfaces of the furnace radiate

heat. If necessary, this heat must be dissipated (a ventilation technician may need to be consulted). In addition, a minimum clearance (S) of 0.5 m on all sides and 1 m

above the furnace must be maintained to flammable materials. In individual cases,

more space must be chosen in order to match the local conditions. For nonflammable materials, the minimum side clearance can be reduced to 0.2 m.

 The furnace must be protected against weather and caustic atmospheres. Nabertherm

accepts no liability or warranty claim for any corrosion damage as a result of installation in damp surroundings or for similar reasons.

 The furnace and switchgear are not designed to be operated outdoors.

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Fig. 14: Minimum safety distance to flammable materials (similar to picture)

DANGER

• Fire- danger to health.

• Risk of fatal injury.

• Adequate ventilation must be ensured at the installation location to conduct waste heat and any exhaust gases away.

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• Danger associated with the use of an atomatic extinguishing system

• Mortal danger posed by electrocution through wetness, suffocation caused by extinguishing gas, etc.

• If automatic extinguishing systems are in place to fight fires and

protect the building, e.g. sprinkler systems, care must be taken during their planning and installation that no additional hazards are created, for example by extinguishing a pilot light, mixing hardening oil and extinguishing water, the disablement of electrical equipment, etc.

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4.6 Assembly, Installation, and Connection

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4.6.1 Venting Exhaust Fumes

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When the furnace is heating, hazardous gases and vapors may be released. Therefore, "exhaust gases" emitted from the exhaust air opening must be directed outdoors in a suitable manner (example: ventilate the working area). If adequate ventilation cannot be ensured at the working area, the "exhaust gases" must be removed via a suitable pipe. We recommend that you install a suitable extraction flue above the furnace or, if this is already

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installed on the furnace, connect suitable extraction pipes and remove the exhaust gases.

A suitable metal exhaust gas pipe can be used. Use only metal pipes (example: stainless steel). It must be attached facing upwards and be fixed to the wall or ceiling.

A maximum exhaust gas temperature of approx. 200 °C can be assumed for the exhaust system. There is a risk of burning at the bypass connection and the piping. The wall duct (1) must be made from heatproof material.

The size and design of the exhaust system must be defined by a ventilation engineer.

DANGER

Fig. 15: Example: Installation of exhaust air piping (similar to picture)

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Caution

Steps must be taken to ensure that the flow of hot air emitted from the furnace's exhaust outlet flap is not hazardous to people, property or the building.

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Note

The exhaust gases can only be discharged if the room is aerated via an appropriate supply air opening.

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Note

Roof work and/or masonry by the customer is required for the exhaust gas discharge. The size and design of the exhaust gas discharge must be determined by a ventilation technician. The national regulations of the local country apply.

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4.6.2 Insertion of the Base Plate

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Compare the delivered items with the delivery note and the purchase order documents.

Immediately notify the carrier and Nabertherm GmbH of any missing or damaged parts, as

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complaints received at a later date cannot be acknowledged.

Carefully place the insert plate(s) *) (number of insert plates depends on the furnace model), distributed across the floor of the furnace, starting from the middle. When placing the insert plate(s) make sure that neither the door collar nor the heating elements are damaged. Absolutely avoid touching the heating elements when inserting the heating plate(s). Contacting the heating elements can result in their immediate destruction.

The furnace floor is made of high-quality refractory material but this material is highly sensitive to impact or pressure.

Some models are supplied with one insert plate as a standard in order to prevent the soft furnace floor from being damaged. Nabertherm accepts no liability for damage (e.g. depressions) in the furnace floor resulting from not using these insert plates. *) Damaged insert plate(s) must be immediately replaced with new ones (see the section "Spare Parts/Wearing Parts").

The charge must be positioned in the furnace chamber, on the floor, as centered as possible. This ensures uniform heating.

After charging, the furnace door must be closed carefully.

*) in scope of delivery depending on the design/furnace model

Note

It must be ensured that the load on the furnace base does not exceed 2 kg/dm

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Fig. 16: Inserting the ceramic insert plate (in scope of delivery depends on design/furnace model)

Note

Since SiC plates expand continuously, they should be replaced after about 3-5 years. Otherwise there is a risk that the collar bricks will be pushed outwards. In this case, we will not accept warranty claims.

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4.6.3 Assembling the Controller (Depending on the Model)

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Attach the supplied controller with holder (model-related) to the furnace.

At the controller position there are screws to attach the holder; these must be unscrewed beforehand.

Place the controller holder (2) with the screws loosened on to the correct position on the furnace and fasten it with suitable tools (3).

Fig. 17: Install the holder on the furnace housing (similar to picture)

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Tighten the screws (3) of the holder and check that is sits properly (4).

Fig. 18: Tighten the screws on the holder (similar to picture)

Place the controller in the holder on the furnace.

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Fig. 19: Place the controller in the holder (similar to picture)

Make sure that the controller is placed correctly in the holder. If this is ignored, the controller may be damaged or destroyed. Nabertherm accepts no liability if the controller is not handled properly.

Fig. 20: Place the controller in the holder on the furnace (similar to the picture)

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4.7 Installation of an Extraction Flue, Extraction Flue with Fan or Extraction Flue with Fan and Catalyst (Accessories for N 7/H – N 17/HR)

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Which vents are supplied vary depending on the application/order (does not apply to protective gas connection):

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Vent with fan

 Supports the venting of gases and vapors from the furnace chamber. Exhaust air cross

section: 85 x 60 mm

 Install by slipping the vent onto the connecting piece on the back wall of the furnace

and fasten it with the screws included in the scope of delivery. Plug the connecting plug into the socket on the back of the switchgear (optional) or in an external socket.

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Fig. 21: Vent with fan

Vent with Fan and Catalytic Converter

 Heats the gases and vapors from the furnace chamber to approx. 600 °C and feeds it

through the catalytic converter honeycomb. The converter incinerates most of the organic substances, i.e. breaks them down into carbon dioxide and steam. This largely eliminates any annoying odors (for example, during dewaxing).

 Warning! Inorganic substances such as heavy metals halogens, silicons and

particulates (even in small quantities) will destroy the catalytic converter!

 The temperature of the catalytic converter must be checked; from the start of the

program the converter must be operating at approx. 600 °C. A statement cannot be made regarding residues which may be released into the environment. This is largely dependent on the individual materials/embedding masses used and their compositions. Exhaust air cross section: 120 x 120 mm

 Installation: Fasten the U-shaped brackets to the back wall of the furnace using the

screws included in the scope of delivery, slide the included section of pipe onto the connecting piece of the furnace and screw the vent (with CAT) firmly to the bracket. Plug the power plug into the socket on the back side (optional) of the switchgear or into an external socket.

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Fig. 22: Catalytic converter

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4.7.1 Connecting the Furnace to the Power Supply

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On the building side, the required services must be provided, i.e. the carrying capacity of the installation surface, provision of power (electricity), etc.

 The furnace must be installed in accordance with its intended use. The power

connection values must correspond to the values on the furnace type plate.

 The power socket must be located close to the furnace and must be easily accessible.

The safety requirements are not met if the furnace is not connected to a socket with grounding contact.

 On use of an extension cable or a multipoint socket, the maximum electrical rating

must not be exceeded. Do not use the furnace with an extension cable if you are uncertain whether grounding is guaranteed.

 The power cable must not be damaged. Do not place any objects on the power cable.

Route the cable so that nobody can tread on or stumble over it.

 A damaged power cable must be replaced immediately.

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 Ensure that the furnace's connection cable is routed so that it is protected.

Note

Before connecting the power, make sure that the power switch is set to "Off" or "0".

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Power Connection with Plug-In Power Line:

When you plug the power plug into an appropriate socket check the type plate for specifications related to mains voltage, mains type and max. power requirement. The distance between the furnace and the socket should be as short as possible. Extensions must be avoided.

The power plug (furnace with feeder) enables the furnace and control box to be connected and disconnected from the power grid.

The power plug must be easy to reach while the furnace is in operation to be able to pull it quickly in case of emergency (see section entitled "What to do in an emergency").

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Fig. 23: Furnace up to 3600 kW (the power cable is supplied) (similar to picture)

1. Plug the supplied connection cable with snap-in coupling into the rear wall of the furnace.

2. Then connect the power cable to the power supply. Use only a grounded socket.

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Fig. 24: Furnace from 3.600 W (CEE plug) (similar to picture)

1. Connect the power cable to the power supply. Use only a grounded socket.

Check the ground resistance (acc. to VDE 0100); see also accident prevention regulations.

Electrical systems and equipment according to DGUV V3.

Power Connection without Plug-In Power Line:

The power line must have a fixed connection in the switchgear cabinet, either at the available terminals or, in models without a separate switchgear, to the main switch. When carrying out this work pay attention to the specs on the type plate: network voltage and type, and maximum power consumption.

The fuse protection and the cross-section of the required power connection depend on the surrounding conditions, the length of the line and how it is installed. For this reason, the type of protection and how it should be installed must be decided by a qualified electrician.

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 The power cable must not be damaged. Do not place any objects on the power cable.

Lay the cable so that nobody can step on it or trip over it.

 The power line may only be replaced by an approved, equivalent line.  Ensure that the connection line of the furnace is protected.

This protection must be compliant with locally applicable standards and regulations.

Ensure that the protective conductor terminal is correct.

When several phases are involved, they must be connected with a clockwise rotating field in the sequence L1, L2, L3.

Before you switch on the furnace for the first time make sure that a clockwise rotating field is in place. This is a prerequisite for the smooth functioning of the furnace.

Warning - Danger of Electric Shock!

Work on the electrical equipment may be done only by qualified, authorized electricians.

The customer must provide the required services, such as ensuring the carrying capacity of the setup location and provision of energy (electricity).

 Pay attention to sufficient sizing and fuse protection of the power supply cable to suit

the characteristics of the furnace.

 Ensure that the cable connecting the furnace and the switching system is laid out so

that it is protected.

 Under normal operation conditions, contact voltages which may exceed the

operating current of an FI circuit breaker with personal protection can occur. The requirements of EN 60519-2 “Safety in electroheat installations – Part 2: Particular requirements for resistance heating equipment” are maintained for electrical safety.

 Check the grounding resistor (according to VDE 0100); also refer to the Accident

Prevention Regulations.

 Electrical systems and equipment according to provision (DGUV V3) of the German

Trade Association.

Note

The national regulations of the respective country of operation apply.

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NOTICE

• Danger from incorrect voltage

• Damage to the furnace.

• Check voltage before connecting and commissioning the furnace.

• Compare the voltage with the details on the type plate.

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4.8 Commissioning

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The furnace may be put into operation only by qualified persons and in compliance with the safety instructions.

Read the section on "Safety". When the furnace is put into operation, the following safety information must also be observed to prevent serious injury, damage to the furnace, and damage to other property.

Make sure that the instructions and information in the controller instructions are observed and followed.

The furnace may be used only for its intended purpose.

Ensure that only authorized persons remain in the working area of the furnace and that no other persons are put at risk when the furnace is put into operation.

Before starting the furnace for the first time, make sure that all tools, foreign parts, and transportation securing equipment have been removed.

Activate all safety equipment (power switch, emergency stop button if applicable) before putting the furnace into operation.

Incorrectly wired connections may destroy electric/electronic components.

Observe the special protective measures (e.g. grounding, …) for components that are at risk.

Faulty connections can cause the furnace to start unexpectedly.

Before you switch on the furnace, make sure that you know what to do in case of faults or emergencies.

Before starting the furnace for the first time, check the electrical connections and control displays.

Before placing materials in the furnace, check whether they could harm or destroy the insulation or the heating elements. Materials that could damage the insulation include: alkalis, alkaline earths, metal vapors, metal oxides, chlorine compounds, phosphorous compounds, and halogens.

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Caution

Before you switch on the furnace for the first time, make sure that the motor achieves a clockwise rotating field. This is a prerequisite for the smooth functioning of the furnace.

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Note

Before starting the furnace for the first time, allow it to acclimatize at its installation location for 24 hours.

DANGER

• Fire- danger to health.

• Risk of fatal injury.

• Adequate ventilation must be ensured at the installation location to conduct waste heat and any exhaust gases away.

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Note

If the protective gas boxes are used, a working temperature to 1100 °C (2012 °F) is recommended; with working temperatures to 1150 °C (2102 °F) the boxes will suffer increased wear.

The formation of a layer of oxide is necessary for the correct function of the heating element.

This procedure is for the first start-up and must be repeated after every replacement of

heating elements.

The duration of the oxidation firing can be found in the section entitled "Recommendation for Heating the Furnace for the First Time".

Nest formation is a natural process and requires no correction. Considerable nest formation, however, can influence temperature distribution.

Before

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4.9 Loading/Charging

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Only materials whose characteristics are known may be heated. Consult any available safety data sheets for the materials.

Loading a very large quantity of material into the furnace chamber can substantially lengthen the heating-up time.

If it can be at all avoided, do not open the furnace when it is hot. When it is necessary to

open the furnace at a high temperature, the time should be kept to an absolute minimum. Personnel must wear the appropriate protective clothing, and the workspace must be adequately ventilated as stated in the section entitled “Safety”.

Stainless steel sheet can discolor (especially if the furnace is opened while hot), but this does not impair the functionality of the furnace.

Additional Precautionary Measures

Please make sure that objects such as teapots and bottles are kept away from the furnace.

Warning - Danger of Electric Shock!

For the protection of the operator and the furnace, the heating program must be stopped before the furnace is loaded. Ignoring this warning can result in electric shock.

After (nest formation)

Page 48

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4.10 Recommendations for Heating the Furnace for the First Time

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To generate an protective oxide coating on the heating elements the furnace must be heated up over approx. 6 hours from a temperature of 100 °C (212 °F) to under the maximum temperature (example: The furnace is designed for a maximum temperature of

approx. 1280 °C (2336 °F), that means that a temperature of approx. 1180 °C (2156 °F)

must be entered at the the controller. But this temperature must be reached over the full

period of 6 hours. The entered temperat ure (example: 1180 °C) must be held for approx. 1 hour.

This procedure must be conducted when starting up for the first time, after heating elements have been replaced, or to regenerate the oxide coating. During heating up noxious odors may be emitted, this is due to the binding agent in the insulation material. We recommend that the furnace location be well ventilated during the first warm-up phase. Let the furnace cool down naturally to room temperature.

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Pos: 226 /TD/Allgemeine Hinweise (für alle Anleitungen) /Hinweis - Bei Verwendung von Begasungskästen wird ei ne Arbeitstemperatur bis zu 1100 °C (2012 °F)... @ 123\ mod_1465290938112_51.docx @ 545676 @ @ 1

 Ventilate the furnace chamber during the initial heating up. If included, open the

exhaust-air flap/s. For furnaces without exhaust-air flap/s, alternatively, the door can be opened during heating up a few cm for 30 seconds at a time. This procedure must be repeated several times during the heating up phase.

 Operate without the cooling blower function  Heat the furnace without a charge  Closing the door  Switch on the furnace/controller (see section "Operation")

Cracks in the Insulation

The insulation of the furnace consists of a very high-quality refractory material. Heat expansion may cause cracks in the insulation even after a few heating cycles. However, these have no effect on the functioning or quality of the furnace. This is no reason for a complaint.

Wearing parts such as muffles, insert boxes, roller conveyors, charging plates or steel sheet panels may warp.

Note

If the protective gas boxes are used, a working temperature to 1100 °C (2012 °F) is recommended; with working temperatures to 1150 °C (2102 °F) the boxes will suffer increased wear.

Page 49

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before after

Fig. 25: Example: Cracks in the insulation after a few warm-up cycles.

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5 Operation

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5.1 Controller

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B400/C440/P470 4 1 2 3

Fig. 26: Control field B400/C440/P470 (similar to picture)

No. Description

Display

Page 50

B400/C440/P470

Control keys for "Start/Hold/Stop", "Menu" selection, "Back" function and information menu selection

Jog dial

USB interface for a USB stick

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Note

See the separate operating instructions for a description of how to enter temperatures and times and to "start" the furnace.

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6 Operation, Display and Switch Elements (depending on design)

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6.1 Turning on the Controller/Furnace

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Furnaces with power plug

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Switching on the Controller Steps Display Comments

Turn on the power switch

Turn on the power switch by setting it to

"I"

(power switch type differs depending on

The overview screen appears.

After a couple of

features/furnace model)

If the temperature is displayed at the controller, the controller is ready to operate.

seconds, the temperature is displayed.

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Furnaces with main switch

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I ON

O OFF

Turn on main switch [1]  I/ON

The furnace and switching system are connected to the power supply using the main power switch.

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Switching on the Controller Steps Display Comments

Turn on the power switch

Turn on the power switch by setting it to

"I"

(power switch type differs depending on

features/furnace model)

Page 51

Switching on the Controller Steps Display Comments

The overview screen appears.

After a couple of

If the temperature is displayed at the controller, the controller is ready to operate.

seconds, the temperature is displayed.

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6.2 Turning off the Controller/Furnace

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Furnaces with power plug

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Turn off the controller Steps Display Comments

Turn off the power switch

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Furnaces with main switch

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Turn off the controller

Turn off the power switch by setting it to

"O"

(power switch type differs depending on features/furnace model)

Steps Display Comments

Turn off the power switch

Turn off the power switch by setting it to

"O"

(power switch type differs depending on features/furnace model)

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I ON

O OFF

Turn off main switch [1]  O/OFF

The furnace and switching system are disconnected from the power supply and deenergized using the main power switch .

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All the necessary settings for perfect functions have already been made at the factory.

Note

See the separate operating instructions for a description of how to enter temperatures and times and to "start" the furnace.

Page 52

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6.2.1 Handling the Controller

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The controller can simply be removed from the holder for especially ergonomic handling

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and more comfortable operation.

Simple operation directly on the controller

Easy and ergonomic handling by removing the controller from its holder

Fig. 27: Handling the controller (similar to picture)

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6.3 Opening and Closing the Door

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Opening the Swinging Door

The swinging door can be easily opened by pressing down the rod located across the front of the door. Always open and close the door completely to avoid the paint being burnt by the furnace's radiant heat (this will not hamper the furnace's function in any way).

Fig. 28: Opening the swinging door (similar to picture)

Closing the Door

Close the swinging door carefully (do not slam). "Slamming" the door can damage the insulation around the door's edge.

Page 53

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After the swinging door is closed make sure that it is uniformly closed all around the door's edge (visual check).

Fig. 29: Closing the swinging door (similar to picture)

6.3.1 Charging Plate

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The charging plate must be clean and dry before it is used. Wait until the furnace chamber has cooled to room temperature before placing the charging plate on the base of the furnace.

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NOTICE

• Damage to the heating elements when inserting the charging plate

• Damage to the heating elements

• Carefully place the charging plate in the middle of the furnace base

Open the furnace door and carefully place the charging plate in the middle of the furnace base and slide it in until it touches the back wall. The furnace base must be level and clean, vacuum the base if necessary. When you are inserting the charging plate, make sure that you do not touch the heating elements. If you do not follow this advice, you may damage the heating elements.

To protect the bottom furnace collar (e.g. when charging an annealing box), make sure that part of the charging plate lies on the bottom furnace collar (A).

Page 54

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Fig. 30: Example: Placing the charging plate (similar to picture)

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Note

The use of a charging plate to protect the furnace floor is strongly recommended.

6.4 Operation with Heat Treatment Accessories

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For heat treatments in protective gas Nabertherm offers protective-gas boxes and an extensive range of accessories for use in the furnaces. The advantage of protective-gas boxes is that they achieve a better protective gas atmosphere than furnaces that feed gas directly into the furnace chamber. In furnace models whose door opens downwards the penetration for the gas line is located in the upper part of the door collar, in larger furnaces whose door opens upwards, the gas line is located in the lower door collar. The protectivegas box is supplied through the protective gas inlet coupling with protective gas that, then, is released through the protective gas outlet.

The box is connected to a gassing unit and can be heated while filled with protective gas. After the heat treatment is completed, the protective-gas box is pulled out and the workpieces can then be quenched in a fluid medium or in air or be left in the furnace with the lid closed until they have cooled.

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Note

Connections, operation and safety recommendations for protective gas and carburizing systems see separate operating manual M04.0001

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For furnace models to N 17/HR For furnace models to N 87/HR

Fig. 31: Example: Protective-gas box for small and large furnace models

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When charging the annealing box pay attention to the recess of the furnace collar and the protective gas pipes.

Page 55

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1 Furnace housing 2 Furnace collar (insulation brick) 3 Recess in the furnace collar 4 Protective gas pipes

Fig. 32: Pay attention to the furnace collar and the protective gas pipes (similar to picture)

Note

If the protective gas boxes are used, a working temperature to 1100 °C (2012 °F) is recommended; with working temperatures to 1150 °C (2102 °F) the boxes will suffer increased wear.

Warning - Danger of Suffocation

There is a danger of suffocation when process/purge or exhaust gases escape, e.g. as a results of leaks (e.g. at doors, pipes, valves, etc.).

Due to their specific weight gases can displace oxygen. This poses a danger of suffocation.

Measures: Switch on the extraction system.

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Note

When working with protective gases always make sure that the room is adequately ventilated. Country-specific safety regulations must also be observed.

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7 Servicing, Cleaning, and Maintenance

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Warning! General Hazards!

Cleaning, lubrication, and maintenance tasks may only be performed by authorized experts following the maintenance instructions and accident protection guidelines. We recommend that maintenance and repair be performed by Nabertherm GmbH Service. Failure to comply runs the risk of bodily injury, death, or significant property damage!

Warning - Danger due to Electrical Current!

Work on the electrical equipment may only be performed by qualified, authorized electricians!

During maintenance work, the voltage supply to the furnace and/or switching system must be switched off to prevent unintentional commissioning. Disconnect the mains power connector due to reasons of safety.

Operators may only correct malfunctions which are obviously due to operational error!

Wait until the furnace chamber and attaching parts have cooled to room temperature.

Page 56

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The furnace must be visually inspected at regular intervals for damage. The interior of the

furnace must also be cleaned as required (e.g. vacuuming out) Attention: Do not bang

against the heating elements to avoid breaking them.

While work is being performed on the furnace, the furnace and work room must additionally be ventilated with fresh air.

Safety systems removed during maintenance tasks must be replaced after the work.

Warning of swinging loads in the workshop (e.g. crane systems). Work under a lifted load (e.g. a lifted furnace or switching system) is not permitted.

Safety switches and any limit switches present must be checked for function periodically (DGUV V3) or according to the national guidelines of the country of operation.

To ensure proper temperature regulation of the furnace, the thermocouple must be checked for damage before every process.

If necessary, retighten the element holders (see chapter "Replacing the Heating Element"). Before carrying out this work, the voltage supply to the furnace and/or switching system must be switched off (disconnect mains power connector). The regulations (DGUV V3) or corresponding national regulations in the relevant country of operation must be observed.

There are one or more contactors in the control system. The contacts of these circuit breakers are wearing parts and must therefore be serviced and/or replaced regularly (DGUV V3) or according to the national guidelines of the country of operation.

The switching system cabinet (if available) contains vent grilles with integrated filter mats. These must be cleaned and/or replaced at regular intervals in order to ensure sufficient intake and outflow of air from the switching system. During melting operation, the switching cabinet door must always be firmly closed.

7.1 Furnace Insulation

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Repairs to the insulation or the replacement of components in the heating chamber may only be performed by persons who are trained about possible hazards and protective measures and can apply this knowledge without supervision.

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During the work on the insulation or the replacement of components in the furnace chamber, the following points must be observed:

When repairs are made or demolition work is performed, silicon dust may be released. Depending heat-treated materials contained in the furnace, further contaminants may be contained in the insulation. To exclude possible health risks, dust concentrations must be kept to a minimum during any work performed at or near the insulation. In many countries there are specific occupational safety limits. You can acquire more relevant information by investigating the relevant legal specifications in your country.

Dust concentrations should be kept as low as possible. Dust must be removed using a suction device or a vacuum cleaner with a high-performance filter (HEPA – category H). Strong air currents such as drafts, for example, must be prevented. Pressurized air or brush must not be used for cleaning. Piles of dust must be sprinkled.

During work on the insulation a respirator mask with an FFP2 filter or an FFP3 filter must be used. The work clothing must be loose and cover the body completely. Gloves and goggles must be worn. Soiled clothing should be cleaned before it is removed with a vacuum cleaner equipped with a HEPA filter.

Contact with skin and eyes should be avoided. The impact of fibers on skin or eyes can lead to mechanical irritation which, in turn, causes reddening and itchiness. After completing the work, or after direct contact, the skin must be washed with soap and water. If there is

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contact with the eyes, they must be washed out carefully for several minutes. If necessary, an eye doctor should be consulted.

Smoking, eating and drinking at the workplace is prohibited.

In Germany, during work involving insulation, the technical rules for hazardous substances must be applied. In particular: TRGS 500, TRGS 521, TRGS 558, TRGS 559, TRGS 900;

http://www.baua.de (German).

Additional information regarding how to handle fibrous materials can be found at

http://www.ecfia.eu (English).

When the materials are discarded, national and regional guidelines must be observed. The possible presence of hazardous contaminants generated by the furnace process must be taken into account.

Note

Data sheets and safety data sheets can be requested as needed from Nabertherm GmbH.

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7.2 Shutting Down the Furnace for Servicing, Cleaning, and Maintenance

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Warning! General Hazards!

Wait until the furnace chamber and attached parts have cooled to room temperature.

 The furnace must be completely emptied  Inform operating personnel and name supervisors  Switch off main switch and/or disconnect the power cord.  Lock the main switch (if available) and secure against restoration of power using a

padlock.

 Attach a warning sign on the main switch  Clean up the maintenance area as far as possible.  Check for disconnection of power.  Ground and short-circuit the working area.

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 Cover any nearby parts still under power.

Warning - Dangers During Normal Operation!

Do not touch any object without first having checked its temperature.

Warning - Danger of Electric Shock!

Work on the electrical equipment may be done only by qualified, authorized electricians. During work it must be ensured that the furnace and the switching equipment cannot be activated by mistake (pull out the power plug) and that all moving parts in the furnace are secured. Observe DGUV V3 or the corresponding national regulations in the country where the furnace is installed. Wait until the furnace and the connected parts have cooled to room temperature.

Page 58

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7.3 Regular Maintenance Tasks for the Entire System

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A B C D E F

1 2 3 T W M Q J X1 X2

Drives and thirdparty subassemblies

Maintenance according to manufacturer

●

instructions

Safety test in accordance with DGUV V3 or

According to regulation

● corresponding national regulations

EMERGENCY STOP systems

Press the "EMERGENCY OFF" button, power

● ●

switch or main

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switch

Note

Maintenance work must be performed by authorized personnel following the maintenance instructions and the accident prevention regulations. We recommend that the maintenance and repair work be carried out by the service team of Nabertherm GmbH.

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7.4 Regular Maintenance of the Furnace

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A W C D E F

1 2 3 D W M Q J X1 X2

Heating elements Visual check: oxide

film formation, crack

● ●

formation

Bearing parts: chains, ropes, etc. (if included)

Visual check: for damage, functional

● ●

check

Moving parts, possibly in additional equipment (if included)

Safety switches: door lock mechanism

Visual check: for damage, functional check

Functional test

● ●

(if included)

Drives and aggregates made by other companies

Check according to manufacturer's maintenance

●

instructions

Safety and warning lamp (if included)

Functional test

● ●

Page 59

A W C D E F

1 2 3 D W M Q J X1 X2

Insulation Visual inspection ● ●

Furnace chamber Clean (vacuum) ● ●

Seals and sealing surfaces (if included)

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SiC/mullite tiling Check for correct

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Visual check: Check for damage, repair or

● ●

replace as necessary

position and for

● ● ●

deformations

Note

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Symbols: A = Component/Position/Function / B = Measure / C = Spare Part Stocks / D = Maintenance Interval /

E = Performed by / F = Comment Spare part stocks:

1 = Stocks urgently recommended 2 = Stocks recommended / 3 = As required, not relevant

Maintenance Interval

Note: If environmental conditions

are severe, the maintenance intervals

must be shorter.

D = Daily, before each start of the furnace W = Weekly M = Monthly / Q = Quarterly Y = Yearly /

● = Check, replace

Implemented by:

X1 = Operating personnel X2 = Specialist personnel

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7.5 Regular Maintenance Tasks – Switchgear

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A W C D E F

1 2 3 D W M Q J X1 X2

Visual check of the

Thermocouple

Check setting values

(if included)

Switch contactors (if included)

Setting overtemperature at safety controller (if included)

indicator on the controller

Check against work plan

Contacts: maintain/replace

Every time the heat treatment program is changed

● ●

Page 60

A W C D E F

1 2 3 D W M Q J X1 X2

Check uniform power consumption of the

Functional test ● ●

heating system

Indicator instruments (text and and LED

Functional test

● ●

displays, if included)

Air intake filter (if included)

Clean or replace filter mat

● ●

Ignoring this can lead to the failure of electronic devices. We accept no liability in case of a production stoppage.

EMERGENCY STOP system

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Functional test: press the "EMERGENCYOFF" key, power switch

● ●

Symbols: A = Component/Position/Function / B = Measure / C = Spare Part Stocks / D = Maintenance Interval /

E = Performed by / F = Comment Spare part stocks:

1 = Stocks urgently recommended 2 = Stocks recommended / 3 = As required, not relevant

Maintenance Interval

Note: If environmental conditions

are severe, the maintenance intervals must be shorter.

D = Daily, before each start of the furnace W = Weekly M = Monthly / Q = Quarterly Y = Yearly /

● = Check, replace

Implemented by:

X1 = Operating personnel X2 = Specialist personnel

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Warning - Danger of Electric Shock!

Work on the electrical equipment may be done only by qualified, authorized electricians.

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Note

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Note

If used, over-temperature limiters with manual or automatic reset (see “overview of the furnace”) must be checked regularly to ensure that they function as intended. To check whether the over-temperature limiters respond, start the furnace and set the required set point on the temperature control unit below the set point of the controller. For more information, see the operating instructions for over-temperature limiter with automatic reset/over-temperature limiter with manual reset.

Page 61

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Note

The switching system must be serviced at regular intervals by an electrician. Circuit breakers and wearing parts must be checked regularly, depending on environmental conditions and frequency of use, and replaced after no more than a year.

Note

Operating furnaces with heating transformers can trigger an upstream fault-current circuit breaker due to the EMC filter circuitry. For this reason, fault-current circuit breakers should not be used as protection switchgear.

Note

The filters for the control cabinet ventilation must be cleaned at regular intervals in order to ensure good air circulation. Depending on the type and variant of the ventilation system, 2 or 3 filters may be present in other areas in the switching cabinet. The door of the switching system must be kept closed and locked (otherwise the lifetime of the electronic devices will be shortened by contamination).

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Note

If the furnace has an uninterruptable power source (UPS), you must be sure that the rechargeable battery has an operating life of roughly 2 years when operating in an ambient temperature up to +40 °C. A higher ambient temperature or long down-times (furnace is shut down) shorten the life of the battery. The rechargeable battery is an ageing part and, depending on the ambient conditions, must be replaced every 1 to 2 years.

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7.6 Regular Maintenance Tasks – Electrical Testing

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A B C D E F

1 2 3 T W M Q J X1 X2

Insulation resistance check

High-voltage check If possible ● ●

Protective conductor Correct fit of

protective conductor at the connections between the system parts and covers

● ●

Check function All electrical

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Over-temperature

components

Functional test protection provided by TWB (if included)

Switch contactors Check contacts for

wear in the switchgear

● ●

●

Page 62

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Symbols: A = Component/Position/Function / B = Measure / C = Spare Part Stocks / D = Maintenance Interval /

E = Performed by / F = Comment Spare part stocks:

1 = Stocks urgently recommended 2 = Stocks recommended / 3 = As required, not relevant

Maintenance Interval

Note: If environmental conditions

are severe, the maintenance intervals

must be shorter.

D = Daily, before each start of the furnace W = Weekly M = Monthly / Q = Quarterly Y = Yearly /

● = Check, replace

Implemented by:

X1 = Operating personnel X2 = Specialist personnel

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Note

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7.7 Regular Maintenance Tasks – Documentation

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A B C D E F

1 2 3 T

Type plate Readable condition ● ●

Instruction Manual Ensure it is kept at

the furnace

Instructions for components

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Ensure they are kept at the furnace

● ● ●

Symbols: A = Component/Position/Function / B = Measure / C = Spare Part Stocks / D = Maintenance Interval /

E = Performed by / F = Comment Spare part stocks:

1 = Stocks urgently recommended 2 = Stocks recommended / 3 = As required, not relevant

Maintenance Interval

Note: If environmental conditions

are severe, the maintenance intervals

must be shorter.

D = Daily, before each start of the furnace W = Weekly M = Monthly / Q = Quarterly Y = Yearly /

● = Check, replace

Implemented by:

X1 = Operating personnel X2 = Specialist personnel

M Q J X1 X2

Page 63

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7.8 Cleaning Products

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Follow the procedure for shutting down the furnace system (in the "Operation" section). Then the power plug must be pulled out of the socket. Wait until the furnace cools down naturally.

Use commercially available detergent which is either water-based or non-combustible and free of any solvents to clean the housing of any deposits; use a vacuum cleaner for the interior.

Follow the labeling and the instructions on the packaging of the detergent.

Wipe the surface with a damp, lint-free cloth. The following detergents can also be used:

This list must be completed by the operator.

Component and

Detergent

location

Outer surfaces (frames *)

Outer surface

Use commercially available detergent which is either water-or noncombustible and free of any solvents for cleaning *)

Stainless still cleaner

(stainless steel)

Interior Carefully clean with a vacuum cleaner

(avoid the heating elements)

Insulation materials Carefully clean with a vacuum cleaner

(avoid the heating elements)

Door seal (if included)

Use commercially available detergent which is either water-or noncombustible and free of any solvents for cleaning

Instrument panel Wipe the surface with a damp, lint-free cloth. (e.g. glass cleaner)

You must be sure that the cleaner does not damage the water-soluble and, hence, environmentally safe

paint (the clear should be tried first on an interior, normally unseen location).

Fig. 33: Detergent

Do the cleaning from beginning to end without breaks to protect the surfaces. Remove the detergent completely from the surfaces by wiping them with a damp, lint-free cloth. After cleaning all the supply lines, check all the connections for leaks, loose connections, abrasion and damage; report any shortcomings found immediately!

Please follow the section entitled "Environmental Protection Rules and Regulations"

Caution

The furnace, the furnace chamber and attached components must NOT be cleaned using a

high-pressure cleaner.

Page 64

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8 Malfunctions

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DANGER

• Danger of electric shock.

• Risk of fatal injury

• Before cleaning, pull out the power plug.

• Do NOT pour water or cleaning products over the inside or outside surfaces

• Allow furnace to dry completely before operating it again

Work on the electrical system may be done only by qualified, authorized electricians. Operators may only rectify faults that are obviously due to operating errors.

Call your local electrician for faults that you cannot localize.

If you have any questions, problems, or requirements, contact Nabertherm GmbH. By mail, phone, or e-mail -> See "Nabertherm Service".

Phone advice is free and non-binding for our customers – all you pay is the phone costs.

In case of mechanical damage, send an email containing the above information and a digital photo of the damaged part and a photo of the complete furnace to the following address:

-> see "Nabertherm Service".

If a fault cannot be rectified with the described solutions, contact our service hotline directly.

Have the following information at hand when you phone. This makes it easier for our customer service to answer your questions.

8.1 Error Messages of the Controller

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ID+ subID

Communication errors

01-01 Bus zone The communication connection

01-02 Bus

Text Explanation Remedy

to a controller module is malfunctioning

The communication connection communication module

to the communication module

(Ethernet/USB) is

malfunctioning

Check whether the controller module is securely seated.

Are the LEDs on the controller modules red?

Check the cable between the operating unit and the controller module.

The plug of the connecting cable in the operating unit is incorrectly plugged in.

Check whether the communication module is securely seated

Check the cable between the operating unit and the communication module

Page 65

ID+

Text Explanation Remedy

subID

Sensor errors

02-01 TC open Check the thermocouple, thermocouple terminals

and cable

Check the contact of the thermocouple cable in connector X1 on the controller module (contacts 1+2)

02-02 Beyond TC range Check the set thermocouple type

Check the polarity of the thermocouple connection

02-03 Reference

The controller module is defective junction error

02-04 Reference

junction too hot

The temperature in the switchgear is too high

(approx. 70 °C)

The controller module is defective

02-05 Reference

junction too cold

02-06 Encoder

disconnected

The temperature in the switchgear is too low

(approx. -10 °C)

Fault on the 4-20 mA input of

the controller (<2 mA)

Check the 4-20 mA sensor

Check the connection cable to the sensor

02-07 Sensor element

defective

The PT100 or PT1000 sensor is

defective

Check the PT sensor

Check the connection cable to the sensor (cable break / short-circuit)

System errors

03-01 System memory Error after firmware updates1)

Defect in the operating unit1)

03-02 ADC error The communication between the

Replace the controller module1) ADC converter and the controller is malfunctioning

03-03 System file faulty The communication between the

Replace the operating unit display and the memory module is malfunctioning

03-04 System

monitoring

Execution of the program on the operating unit is malfunctioning (watchdog)

Replace the operating unit

The USB flash drive was pulled out prematurely

or is defective

Replace the controller and switch it on

03-05 Zone system

monitoring

Execution of the program on a controller module is

Replace the controller module1)

Replace the controller and switch it on1) malfunctioning (watchdog)

03-06 Self-test error Contact Nabertherm Service

Page 66

ID+

Text Explanation Remedy

subID

Monitoring

04-01 No heat output No temperature increase in

ramps when the heating output does not equal 100% for 12 minutes and if the temperature setpoint is greater than the current furnace temperature

04-02 Over-temperature The temperature of the guide

zone exceeds the max. program setpoint or the maximum furnace temperature by 50° Kelvin (200 °C or higher)

The equation for the shutdown threshold is:

maximum program setpoint + zone offset of the master zone + batch control offset [max] (if batch control is active) + overtemperature shutdown threshold (P0268, e.g. 50 K)

Acknowledge the error (deenergize if necessary)

and check the safety contactor, door switch,

heating control and controller.

Check the solid state relay

Check the thermocouple

Check the controller

A program has started at a

furnace temperature that is greater than the maximum setpoint in the program

04-03 Power failure The set limit for restarting the

furnace has been exceeded

04-04 Alarm A configured alarm has been

triggered

04-05 Self-optimization

failed

The measured values are not plausible

Battery weak A power failure may no longer

be processed properly.

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Wait until the temperature of the furnace has

dropped before starting the program.

If this is not possible, add a wait time as a start

segment, followed by a ramp with the desired

temperature (STEP = 0 minute duration for both

segments)

Example:

700 °C -> 700 °C, time: 00:00

700 °C -> 300 °C, time: 00:00

The normal program then starts here.

In version 1.14 and later, the actual temperature is

also taken into account at the start.

If necessary, use an uninterruptible power supply

Do not perform self-optimization in the lower

temperature range of the furnace work area

Export all the parameters to a USB flash drive

Replace the battery (see “Specifications”)

Error messages can be reset by pressing twice the jog dial . If there is another error

message, contact Nabertherm Service. Recirculation motors (if included) also remain switched on in case of an error until the temperature falls below the set cut-off temperature.

Page 67

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8.2 Warnings of the Controller

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Warnings are not displayed in the error archive. They are only displayed on the display and in the file of the parameter export. Warning do not generally lead to a program crash.

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No. Text Explanation Remedy

00 Gradient

monitoring

The limit value of the configured gradient monitoring has been exceeded

01 No control

parameters

02 Batch element

defective

No “P” value has been entered for the PID parameters

No batch element has been determined with the program running and with batch control activated

03 Cooling element

defective

04 Documentation

element defective

The cooling thermocouple is not plugged in or is defective

The documentation thermocouple is missing or defective.

05 Power failure A power failure has been

detected.

Program termination has not occurred

For the causes of this error, see “Gradient

monitoring”

The gradient is set too low

Enter at least one “P” value in the control

parameters. This may not be 0

Insert a batch element

Disable the batch control in the program

Check the batch thermocouple and its cable for

damage

Plug in a cooling thermocouple

Check the cooling thermocouple and its cable for

damage

If a defect in the cooling thermocouple occurs

when controlled cooling is active, the system

switches to the thermocouple of the master zone.

Plug in a documentation thermocouple

Check the documentation thermocouple and its

cable for damage

None

06 Alarm 1 - belt The configured belt alarm 1 has

been triggered

07 Alarm 1 - min The configured min alarm 1 has

been triggered

08 Alarm 1 - max The configured max alarm 1 has

been triggered

09 Alarm 2 - belt The configured belt alarm 2 has

been triggered

10 Alarm 2 - min The configured min alarm 2 has

been triggered

11 Alarm 2 - max The configured max alarm 2 has

been triggered

12 Alarm - external The configured alarm 1 on input

1 has been triggered

Optimization of the control parameters

Alarm value too rigid

Optimization of the control parameters

Alarm value too rigid

Optimization of the control parameters

Alarm value too rigid

Optimization of the control parameters

Alarm value too rigid

Optimization of the control parameters

Alarm value too rigid

Optimization of the control parameters

Alarm value too rigid

Check the source of the external alarm

Page 68

No. Text Explanation Remedy

13 Alarm - external The configured alarm 1 on input

2 has been triggered

14 Alarm - external The configured alarm 2 on input

1 has been triggered

15 Alarm - external The configured alarm 2 on input

2 has been triggered

16 No USB flash

When exporting data, insert a USB flash drive

drive inserted

17 Import / export of

data using the USB flash drive was not successful

The file has been edited using a PC (text editor) and stored in the wrong format, or the USB flash drive was not recognized.

You want to import data that are not located in the Import folder on the USB flash drive

When importing

programs,

The temperature, time or rate are outside the limits

programs are rejected

When importing

programs, “Error occurred” appears

The complete set of parameters (at least the configuration files) has not been placed in the “Import” folder

Check the source of the external alarm

into the controller

Do not edit XML files with a text editor, but

always in the controller itself.

Format the USB flash drive (format: FAT32)

Use another USB flash drive (1-8 GB)

In a complete import, all data must be stored in

the Import folder on the USB flash drive.

Import only programs that are suitable for the

furnace. The controllers differ in the number of

the program and number of segments and in the

maximum furnace temperature.

If you deliberately omitted files during the import,

the message can be ignored. Otherwise, please

check the completeness of the import files.

18 “Heating

disabled”

If a door switch is connected to the controller, and the door is

-Close the door

-Check the door switch

open, this message appears

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8.3 Malfunctions of the Switchgear

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Error Cause Remedy Controller does not light

Controller displays error

Furnace does not heat

Controller is switched off Switch the power switch to “I”

No power available Is the power cord plugged into the

socket?

Check the building fuses.

Check the fuse of the controller (if present) and replace it if necessary.

Switch the power switch on. If the error occurs again, contact Nabertherm Service

See the separate instructions of the controller See the separate instructions of the

controller

Door / cover is open Close the door / cover

The door contact switch is faulty (if present) Check the door contact switch

Page 69

Error Cause Remedy

Very slow heating of the heating space

The program does not jump to the next segment

The controller module can not be registered on the operating unit

The “wait” or clock icon (series 400 controllers) lights up

The program is waiting for the programmed start time.

Set the wait time to 00:00 or disable it

Error in entering the program Check the heating program (see the

separate instructions of the controller)

Heating element defective Have this checked by Nabertherm

Service or a qualified electrician.

The fuse(s) of the connection is/are defective.

Check the fuse(s) of the connection and replace if necessary.

Notify Nabertherm service if the new fuse fails again immediately.

In one TIME segment in the program input,

Do not set the wait time to INFINITE the wait time is set to INFINITE (series 400 controllers).

If batch control is activated, the temperature of the batch is higher than the zone temperatures.

If batch control is activated, the temperature of the batch is higher than the zone

The parameter [LOWER BLOCK] must

be set to [NO]. temperatures.

Addressing error (series 400 controllers) Perform a bus reset

The controller is not

No optimization temperature has been set The temperature to be optimized must be

heating in the optimization

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The temperature rises faster than the controller setting allows

The switch element of the heating unit (semiconductor relay, thyristor or switch contactor) is defective.

Individual defective components inside a furnace cannot be completely ruled out in advance. That is why the controllers and the switchgear units must be equipped with safety facilities. For example, the furnace shuts down the heating unit in response to error message 04 - 02 via an independent

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Glass bubbles on the surface of the heating element

contact element.

At temperatures above 1550 °C (2822 °F) fine glass bubbles can settle on the surface of the heating elements due to residual silicon during the production process.

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entered (see the separate instructions of

the controller)

Have the switch element tested by a

qualified electrician and replaced as

necessary.

Before heating the furnace again remove

the glass bubbles carefully (with a

paintbrush or brush).

Page 70

8.4 Controller Check List

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Customer: Furnace model: Controller model:

Controller version (see information menu ): Controller serial number Furnace serial number Error code in the display: The following errors are dependent on external

influences:

Detailed error description:

02-05 Ambient temperature too low: <-10 °C (-50 °F)

02-04 Ambient temperature too high: > 70 °C (158 °F)

Export of the service information:

Please export all the data to a USB stick using the function [EXPORT COMPLETELY] Generate a zip file using the ZIP function integrated in Windows (compression) of the exported folder (see the section "Importing and Exporting Data and Parameters") and send them to your contact at Nabertherm Service.

When does this error occur?

At specific point in the program or at certain times of day:

At specific temperatures:

How long has the error existed?

 Error is new

 Error has existed for a long time

 Unknown

Page 71

Error frequency

 Error occurs frequently

 Error occurs regularly

 Error occurs rarely

 Unknown

Substitute controller:

Has a substitute controller already been used?

Did the error continue with the substitute

 yes  no

controller?

Checked according to the error search list

 yes  no

(see the furnace operating instructions)

Please enter the following test program so that the furnace heats up at full power:

Program point Value Segment 01- Start Temperature Segment 01- Target Temperature Segment 01- Time Segment 01- Target Temperature

0 °C

500 °C

30 minutes

500 °C

Close door/lid and start the example program

Please check the following items:

 Does the furnace heat (temperature rise)?  Is the "Heating" symbol displayed?

Please call up the information menu in the heating up phase for further details.

Date: _______________ Name: ______________________ Signature: ___________________

Page 72

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9 Spare Parts/Wearing Parts

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Fig. 34: Spare/wearing parts (similar to picture)

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Model N 7/H No. Name Part number Quantity Comment 1 Furnace

1.1 Heating element 602211388 1 set 

1.2 Support tubes 602000749 1 set 

1.3 Ceramic ducts 692010070 4



1.4 SiC floor plate 691600173 1 

1.5 Tension spring 601402997 2 

2.1 Controller B4001 801000090 1 

Page 73

Controller C4401 801000094 1 

Controller P4701 801000095 1 

2.2 Thermocouple 540300009 1

2.3 Power switch 541800259 1 with fuse 

depending on the design

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Model N 11/H – N11/HR



No. Name Part number Quantity Comment 1 Furnace

1.1 Heating element N 11/H 602211389 1 set 

Heating element N 11/HR 602211394 1 set



1.2 Support tubes 602000750 1 set 

1.3 Ceramic ducts 692010070 4 

1.4 SiC floor plate 691600686 1



1.5 Tension spring 601402997 2 

2 Electrical/controllers

2.1 Controller B4001 801000090 1



Controller C4401 801000094 1 

Controller P4701 801000095 1 

2.2 Thermocouple 540300009 1



2.3 Power switch 541800259 1 with fuse 

depending on the design

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Model N17/HR No. Name Part number Quantity Comment 1 Furnace

1.1 Heating element 602211393 1 set 

1.2 Support tubes 602000751 1 set 

1.3 Ceramic ducts 692010070 4



1.4 SiC floor plate 691600173 2 

1.5 Tension spring 601402997 2 

2 Electrical/controllers

2.1 Controller B4001 801000090 1 

Controller C4401 801000094 1 

Controller P4701 801000095 1



2.2 Thermocouple 540300009 1 

2.3 Power switch 541800259 1 with fuse 

depending on the design

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Model N 31/H No. Name Part number Quantity Comment 1 Furnace

1.1 Heating element 602211453 1 set 

Page 74

Model N 31/H

1.2 Support tubes 602000753 1 set 

1.3 Ceramic ducts 692010070 6 

1.4 SiC floor plate 691600993 1

1.5 Gas damper 691401904 2 

2 Electrical/controllers

2.1 Controller B4001 801000090 1

Controller C4401 801000094 1 

Controller P4701 801000095 1 

2.2 Thermocouple 540300009 1

2.3 Power switch 541800259 1 with fuse 

depending on the design

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Model N 41/H





No. Name Part number Quantity Comment 1 Furnace

1.1 Heating element 602261031 1 set 

1.2 Support tubes 602000754 1 set



1.3 Ceramic ducts 692010070 6 

1.4 SiC floor plate 691600015 1 

1.5 Gas damper 691401904 2



2 Electrical/controllers

2.1 Controller B4001 801000090 1 

Controller C4401 801000094 1 

Controller P4701 801000095 1



2.2 Thermocouple 540300009 1 

2.3 Power switch 541800259 1 with fuse 

depending on the design

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Model N 61/H No. Name Part number Quantity Comment 1 Furnace

1.1 Heating power 602261033 1 set



1.2 Support tubes 602000755 1 set 

1.3 Ceramic ducts 692010070 6 

1.4 SiC floor plate 691600015 1



1.5 Gas damper 691401904 2 

2 Electrical/controllers

2.1 Controller B4001 801000090 1



Controller C4401 801000094 1 

Controller P4701 801000095 1 

2.2 Thermocouple 540300009 1

2.3 Power switch 541800259 1 with fuse

depending on the design

 

Page 75

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Model N 87/H No. Name Part number Quantity Comment 1 Furnace

1.1 Heating element 602212815 1 set 

1.2 Support tubes 602000968 1 set 

1.3 Ceramic ducts 692010071 6



1.4 SiC floor plate 691600015 2 

1.5 Gas damper 691401904 2 

2 Electrical/controllers

2.1 Controller B4001 801000090 1 

Controller C4401 801000094 1 

Controller P4701 801000095 1



2.2 Thermocouple 540300010 1 

2.3 Power switch 541800259 1 with fuse 

depending on the design

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Symbols





Can be replaced by the customer with tools and instructions.





Can be replaced by trained personnel with tools and instructions.



NT Nabertherm Service required

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Ordering Spare Parts:

Our Nabertherm Service team is available to you all around the world. Due to our considerable production depth we deliver most spare parts from the warehouse overnight or can make them ready for delivery within short deadlines. You can order Nabertherm spare parts easily and simply directly from the factory. If you fail to find the spare part you are looking for in the spare part list or in the separate spare part list we would be happy to help you. Spare parts can be ordered in writing, by phone or on the Internet -> see the section entitled "Nabertherm Service".

Availability of Spare Parts and Wearing Parts:

Although Nabertherm has many spare parts and wearing parts on stock, we cannot guaranty the short-term availability of all of them. We recommend that certain parts be ordered in advance. If you need any assistance when selecting spare parts and wearing parts, the staff at Nabertherm will be glad to set aside time for you.

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Note

Original parts are designed especially for Nabertherm furnaces. Replace parts only with original Nabertherm parts. Otherwise the warranty will be void. Nabertherm accepts absolutely no liability for damage caused by using parts that are not original Nabertherm parts.

Page 76

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Note

Contact our Nabertherm Service for removing and installing replacement and wear parts. See section on "Nabertherm Service". Work on the electrical equipment may only be performed by qualified and authorized specialist electricians. This applies also to repairs not described below.

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9.1 Replacing a Heating Element

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Warning - Danger of Electric Shock!

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Note

In Germany, the general accident protection guidelines must be observed. The national accident prevention regulations of the country of operation apply.

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Note

For wiring and electrical connections, see the attached circuit diagram. The electrical equipment of the machine can also be seen in the circuit diagram.

Tip: Because we build many different furnace models, we recommend that you take several

photos of the installed heating elements and the switchgear. That simplifies subsequent installation and wiring of new heating elements.

Note

The pictures contained in the instruction manual may contain inaccuracies in terms of the function, design and furnace model.

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Removing Cover/s

We refuse to accept any responsibility for any and all direct and indirect damages resulting from faulty installation. This also applies to all cases in which generally required installation steps are not described. The replacement of the heating elements requires the cover/s (protective paneling) on the furnace (depending on model). Use an appropriate tool to remove the screws around the sides of the cover and keep them in a safe place for later use. The number and position of the screws may differ from one furnace model to the next.

Page 77

similar to picture

Fig. 35: Example: Removing Cover/s

Arrangement of the Heating Elements (depending on model)

similar to picture

1 Heating elements furnace interior 2 Heating elements (remove base plates) depending on model

Fig. 36: Example: Heating elements (depending on model)

Arrangement of the Connection Terminals (depending on model)

Fig. 37: Example: Connection terminals of the heating elements (similar to picture)

Page 78

Tools Required by Customer for the Installation

The following tools are required to replace the heating elements. Hammer, cable cutter, long-nose pliers, pipe wrench, screwdriver (depending on the age of the furnace, Phillips screwdriver, flat-tip screwdriver, jaw wrench and a wood block to hammer in the ceramic penetration pipes.

Replacing the Heating Elements (short description)

1 Heating element (heating coil) 2 Support tube

Fig. 38: Designation of the required attachments

similar to picture

3 Holding tube (depending on model) 4 Holding clamp/s 5 Fiber wadding

Page 79

7 Ceramic penetration pipe, 6 Fiber wadding 8 Connection terminal 9 Heating element end (twisted)

Fig. 39: Example: Connection terminal/s (similar to picture)

 Removing the Heating Elements  Remove the protective paneling of the electrical connections.  Loosen the connection terminals at the ends of the heating coils. Replace ceramic

penetration pipe as necessary.

 Draw out the existing holding clamps and ceramic tubes for holding the heating

element in place out of the masonry (old holding clamps are highly fragile. If a holding clamp breaks, the piece still stuck in the masonry must be removed).

 Remove heating coils carefully with the support tubes (Caution: older heating

elements are highly fragile)-

 Installing the Heating Elements  Clean firing deposits from heating chamber, support tubes, support bricks, terminals

and ceramic penetrations.

 Warning: We recommend using new support tubes, terminals and ceramic

penetration pipes (soiled support tubes/ceramic penetration pipes result in early failure of the new heating elements).

 The new heating elements have heating element ends (twisted) protected by a lug. Nip

the lugs before installation. Install the heating coil with the support tubes

 Insert the holding clamps into the wall masonry. Warning: Never use the old holes for

the new holding clamps. This may result in problems with the Fi switch (if included) Depending on the furnace model, ceramic tubes can also be installed as holders instead of holding clamps.

 Insulate the ceramic penetration pipes with a small amount of fiber wadding from

outside. Make the electric connections using the connection terminals: Hold the lower part with a pliers and tighten the screw (6 Nm) firmly.

 Recommendation: Retighten all the screws of the connection terminals of the heating

elements after one week of operation and, thereafter, once a year. Avoid placing any stress, pressure or twist on the heating wire. If you fail to follow this instruction the result is the immediate destruction of the sensitive heating elements.

 If necessary trim any overlaying fibers to somewhat longer than one terminal width

(approx. 2-3 cm).

Page 80

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 Check electrical connections and protective lines to ensure they are correctly

connected.

Screw tightening torque

Tighten power cable clamps and screws on the heating elements with a defined torque.

If this advice is not followed, the heating elements may be damaged.

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Thread diameter

Torque in Nm

Metric thread (M)

M 4 2.0

M 5 6.0

M 6 8.0

M 7 14.0

M 8 20.0

M 10 39.0

The formation of a layer of oxide is necessary for the correct function of the heating element.

This procedure is for the first start-up and must be repeated after every replacement of

heating elements.

The duration of the oxidation firing can be found in the section entitled "Recommendation for Heating the Furnace for the First Time".

Nest formation is a natural process and requires no correction. Considerable nest formation, however, can influence temperature distribution.

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Note

If the protective gas boxes are used, a working temperature to 1100 °C (2012 °F) is recommended; with working temperatures to 1150 °C (2102 °F) the boxes will suffer increased wear.

Before

After (nest formation)

Page 81

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Note

Re-install in reverse sequence.

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Note

Make sure that all screwed and plugged connections are in working order.

9.2 Replacing a Thermocouple

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Warning - Danger of Electric Shock!

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Warning! General hazards!

If installed improperly, functioning and safety of the system can no longer be guaranteed. The connection must be properly installed and put into operation by qualified personnel.

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Caution - damage to components!

Thermocouples are extremely sensitive to breakage. Any strain on or rotation of the thermocouples must be avoided. Failure to observe this rule will lead to the immediate destruction of the sensitive thermocouples.

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Note

The pictures contained in the instruction manual may contain inaccuracies in terms of the function, design and furnace model.

Use an appropriate tool to remove the screws all around the cover and keep them in a secure place for later use. The cover must be lowered onto a soft material (such as foam rubber). The number and position of the screws may differ from one furnace model to the next. The furnace may look different than the picture depending on the furnace model and additional equipment.

Page 82

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Fig. 40: Removing the back furnace wall (similar to picture)

You can find the position and labeling of built-in thermocouples in the schematic contained in the appendix.

First remove the two screws (A) from the thermocouple connection. Remove screw (B) and pull out the thermocouple (C).

Insert the new thermocouple carefully into the thermal channel (C), install and connect in reverse order. Make sure that the polarity of the electrical connections (D) is correct*).

Fig. 41: Removing the thermocouple/s (similar to picture)

Page 83

+-+

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Note

*) The connections of the connecting lines from the thermocouple to the controller are

labeled with and . It is absolutely essential to observe the correct polarity.

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to to

Note

Make sure that all screwed and plugged connections are in working order.

9.3 Electrical Schematics/Pneumatic Schematics

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Note

The documents included do not always contain the electrical schematics and pneumatic schematics.

If you need the respective schematics they can be ordered from Nabertherm Service.

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10 Nabertherm Service

Contact Nabertherm Service at any time for maintenance and repair.

If you have any questions, problems, or requirements, contact Nabertherm GmbH. By mail, phone or e-mail.

Mail

Nabertherm GmbH







Bahnhofstrasse 20

28865 Lilienthal/Germany

Phone or Fax

Phone: +49 (4298) 922-0

Fax: +49 (4298) 922-129

Web or E-mail

www.nabertherm.com

contact@nabertherm.de

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When you contact us, please have the type plate details of the furnace or controller at hand.

Provide the following details from the type plate:

Page 84

Fig. 42: Example (type plate)

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11 Shut-Down, Dismantling, and Storage

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To be Completed by the Operator

When the furnace is shut down, the following safety information must be observed to prevent serious injury, damage to property, and damage to the environment.

The furnace may only be shut down by authorized, trained personnel.

The following operating materials/parts are to be disposed of by:

_________________________________________________________________

Furnace model Serial number

Article number

Year of construction

Oils and other substances that are hazardous to water must be completely removed before the furnace is dismantled for reuse or scrap.

Ensure that operating materials, lubricants, and consumables are disposed of in an environmentally compliant manner. Regulations relating to proper waste recycling and disposal must be observed.

The furnace may be lifted only at the intended points.

Use only the stated lifting and securing equipment to lift the furnace/parts.

Consider a total weight of ___________kg when choosing suitable lifting equipment.

For transportation, consider a permitted floor weight of at least ___________kg/m².

Before transporting the furnace, attach the following securing equipment:

_________________________________________________________________

Note

Read the sections on "Safety" and "Transportation"

Page 85

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11.1 Transportation/Return Transportation

If you still have the original packaging, this is the safest way to send a furnace.

Otherwise:

Choose suitable, adequately sturdy packaging. During transportation, packages are often stacked, bumped, or dropped; the packaging acts as external protection for your furnace.

+45 °

-5 °C

- Drain all piping and containers before transportation/return transportation (e.g. cooling water). Pump off operating materials and di spose of properly.

- Do not subject the furnace to extreme cold or hot temperatures (direct sunlight). Storage temperature -5 °C to 45 ° (-23 °F to 113 °F) Humidity 5 % to 80 %, non condensing

- Place the furnace on a level floor to prevent distortion.

- Packaging and transportation may be carried out only by qualified and authorized persons

If your furnace has transportation securing equipment (see "Transportation Securing Equipment"), use this.

Otherwise, in general:

"Fix" and "secure" (adhesive tape) all moving parts and cushion and protect any projecting parts against breakage.

Protect your electronic equipment against moisture and make sure that no loose packaging material can get inside it.

Fill gaps in your packaging with soft but adequately firm material (e.g. foam mats) and make sure that the equipment cannot slide around in the packaging.

If the goods are damaged during return transportation due to inadequate packaging or some other breach of duty, the costs will be borne by the customer.

As a rule:

The furnace is sent without accessories, unless the technician expressly requests them.

Enclose a detailed description of the malfunction along with the furnace – this saves the technician time and costs.

Don't forget to enclose the name and phone number of a contact in case there are any questions.

Note

Return transportation may only be carried out according to the information given on the packaging or in the transportation documents.

Note

Transportation and return transportation not covered by a warranty claim are paid for by

the customer.

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Page 86

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12 Declaration of Conformity

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EC Declaration of Conformity

Compliant with EC Directive 2006/42/EC on machinery, Annex II A

We,

Nabertherm GmbH

Bahnhofstr. 20, 28865 Lilienthal, Germany

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hereby declare that the following product:

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Electrically Heated Chamber Furnaces

Model

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fulfills all the pertinent provisions contained in Directive 2006/42/EC.

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The product named is also compliant with all the provisions of the following directives:

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 Directive 2014/35/EU for electrical equipment designed for use within certain voltage limits

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 Directive 2014/30/EU on electromagnetic compatibility

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N 7/H N 11/H N 11/HR N 17/HR N 31/H N 41/H

N 61/H N 87/H

The signatories are authorized to compile the relevant technical documents. The address is the stated manufacturer's address.

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Any change in the product not approved by the manufacturer invalidates this declaration.

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The following harmonized standards were applied:

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 DIN EN 60335-1 (10.2012)

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 DIN EN 61000-6-1 (10.2007), DIN EN 61000-6-3 (09.2011)

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Lilienthal, 01.05.2016

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________________________ _______________________

Michael Oberschmidt Thomas Adamek

Vice President R & D Quality Management

=== Ende der Liste für Textmarke Inhalt ===

Page 87

Page 88

Headquarters: Reg: M01.0071 ENGLISCH

Nabertherm GmbH . Bahnhofstr. 20

28865 Lilienthal/Bremen, Germany . Tel +49 (4298) 922-0, Fax -129 . contact@nabertherm.de

www.nabertherm.com