Related Manuals for VERDER CARBOLITE GERO GPC 12/200
Summary of Contents for VERDER CARBOLITE GERO GPC 12/200
- Page 1 Installation, Operation and Maintenance Instructions 1200°C Chamber Furnace - GPC Model: 200 Litres No Controller GPC 12/200 + No Controller MEN-GPC12200-05_NOCTRL 06-08-2019...
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Page 2: Table Of Contents
Contents This manual is for guidance on the use of the Carbolite Gero product specified on the front cover. This manual should be read thoroughly before unpacking and using the furnace or oven. The model details and serial number are shown on the back of this manual. - Page 3 6.2.1 Cleaning 6.2.2 Safety Switch Calibration After-Sales Service Recommended Spare Parts and Spare Parts Kit 7.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Safety Warning - Refractory Fibre Insulation Temperature Controller Replacement Solid-State Relay Replacement Thermocouple Replacement Element Replacement (Industrial Models) Fuse Replacement 8.0 Fault Analysis...
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Page 4: Symbols And Warnings
1.0 Symbols and Warnings 1.0 Symbols and Warnings Switches and Lights Instrument switch: when the instrument switch is operated the temperature control circuit is energised. Heat light: the adjacent light glows or flashes to indicate that power is being supplied to the elements. General Warnings DANGER –... -
Page 5: Installation
2.0 Installation 2.0 Installation Unpacking & Handling When unpacking or moving the product, always lift by its base; do not use the door or any other projecting cover or component to support the equipment when moving it. Use a fork lift or pallet truck to move the product; position the product on a level surface and use an adequate number of personnel to safely move the product into position. -
Page 6: Hearth
2.0 Installation Depending on the application of the product, it may be appropriate to position it under an extraction hood. Ensure the extraction hood is switched on during use. Ensure that the product is placed in such a way that it can be quickly switched off or disconnected from the electrical supply. -
Page 7: Chimney
2.0 Installation Chimney The chimney is a length of tubing. If it is supplied unfitted, then fit it through the hole in the top of the case. If the product is to be used to heat substances that emit fumes, a fume extraction duct of approximately 75 mm - 150 mm inlet diameter may be placed directly above the chimney outlet. - Page 8 2.0 Installation manual. When the mains cable is factory fitted, internal fuses are also fitted. It is essential that the operator ensures that the product is correctly fused. Products with a factory fitted supply cable are designed to be wired directly to an isolator or fitted with a line plug.
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Page 9: Voltage And Power Limit
2.0 Installation Voltage and Power Limit When first starting up the product, check the setting of the OP.Hi parameter (see the controller instructions) and compare it with the data in section 10.0 towards the back of this manual. If the power limit setting is incorrect for the voltage of the electrical supply, change it. This must be done immediately if the setting of OP.Hi is higher than it should be. -
Page 10: Temperature Controller
3.0 Temperature Controller 3.0 Temperature Controller If this product is fitted with a temperature controller, instructions are provided separately. -
Page 11: 2132 Over-Temperature Controller Description (If Fitted)
4.0 2132 Over-Temperature 4.0 2132 Over-Temperature Controller Description (if fitted) Description Alarm Light Page Scroll D Down Display This over-temperature controller is fitted and supplied ready to use by Carbolite Gero. It is a digital instrument with a latching alarm, requiring no additional panel controls. The controller features easy setting of over-temperature setpoint and reading of current temperature by the over-temperature sensor. -
Page 12: Operation
4.0 2132 Over-Temperature 4.2.2 Operation When switched on, the controller lights up, goes through a short test routine and then displays the measured temperature or the over-temperature setpoint. The page key allows access to parameter lists within the controller. A single press of the page key displays the temperature units, normally set to °C;... -
Page 13: Audible Alarm
4.0 2132 Over-Temperature Audible Alarm If an audible alarm is supplied for use with the over-temperature controller, it is normally configured to sound on over-temperature condition and to stop sounding when the alarm is acknowledged as given in section 4.2. Note: the alarm may sound during controller start-up. -
Page 14: Operation
5.0 Operation 5.0 Operation Operating Cycle This product is fitted with an instrument switch which cuts off power to the control circuit. Connect the product to the electrical supply. Turn on the instrument switch to activate the temperature controllers. The controllers illuminate and go through a short test cycle. -
Page 15: Use Of Probes
5.0 Operation materials that emit smoke or fumes, regularly heat it up to maximum temperature for one hour with the chamber empty to burn away the soot. Materials such as case hardening compounds and other reactive salts may penetrate the furnace chamber lining and attack the wire elements, causing premature failure. Use of a hearth tile may be advisable: please consult the Carbolite Gero technical department. -
Page 16: Power Adjustment
5.0 Operation When the product is opened during operation there is considerable radiated heat. Do not keep any flammable objects near the product, nor objects which could be damaged by radiated heat. Power Adjustment The product control system incorporates electronic power limiting. Depending on the model and the destination country the power limit maybe set to 100% or a lower figure. -
Page 17: Maintenance
6.0 Maintenance 6.0 Maintenance General Maintenance Preventive rather than reactive maintenance is recommended. The type and frequency depends on the product use; the following are recommended. Maintenance Schedule CUSTOMER QUALIFIED PERSONNEL DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically qualified personnel should attempt these maintenance procedures. - Page 18 6.0 Maintenance Thorough inspection and report incor- Operational Check porating a test of all functions Performance Element Circuit Electrical measurement Measure the current drawn on each phase / Power Consumption circuit Hearth Visual check for fit and damage Cooling Fans (if fitted) Check whether the cooling fans are working...
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Page 19: Cleaning
6.0 Maintenance 6.2.1 Cleaning Soot deposits may form inside the furnace, depending on the process. At appropriate intervals remove these by heating as indicated in the General Operation Notes. The product's outer surface may be cleaned with a damp cloth. Do not allow water to enter the interior of the case or chamber. -
Page 20: After-Sales Service
6.0 Maintenance thermocouple and temperature indicator should be made from time to time to determine whether full calibration is required. Carbolite Gero can supply these items. Depending on the controller fitted, the controller instructions may contain calibration instructions. After-Sales Service Carbolite Gero Service has a team of Service Engineers who can offer repair, calibration and preventive maintenance of furnace and oven products both at the Carbolite Gero factory and at customers’... -
Page 21: Repairs And Replacements
7.0 Repairs and Replacements 7.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Immediately switch the product off in the event of unforeseen circumstances (e.g. large amount of smoke). Allow the product to return to room temperature before inspection. Always ensure that the product is disconnected from the electrical supply before repair work is carried out. -
Page 22: Solid-State Relay Replacement
7.0 Repairs and Replacements Solid-State Relay Replacement Disconnect the product from the power supply and remove the appropriate cover as given above. 1. Make a note of the wire connections to the solid state relay, then disconnect them. 2. Remove the solid state relay from the base panel or aluminium plate. 3. -
Page 23: Element Replacement (Industrial Models)
7.0 Repairs and Replacements Element Replacement (Industrial Models) See section 7.2 - wearing a face mask is required. This operation requires two people and a cold product. Check that the door counter weights hold the door up safely. The chambers contain 12 off IAP tubes on which the 6 “hairpin” elements are mounted. The elements operate from back-to-front-to-back. - Page 24 7.0 Repairs and Replacements If any fuse has failed, it is advisable for an electrician to check the internal circuits. Replace any failed fuses with the correct type. For safety reasons do not fit larger capacity fuses without first consulting Carbolite Gero. The fuses are located at the cable entry point.
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Page 25: Fault Analysis
8.0 Fault Analysis 8.0 Fault Analysis Furnace Does Not Heat Up The HEAT The heating element Check also that the SSR is working light is ON has failed correctly The controller shows a The HEAT The thermocouple has broken or has very high temperature light is OFF a wiring fault... -
Page 26: Product Overheats
8.0 Fault Analysis Product Overheats Product only heats up The controller when the instrument shows a very high The controller is faulty switch is ON temperature The thermocouple may be The controller faulty or may have been shows a low removed out of the heating temperature chamber... -
Page 27: Wiring Diagrams
9.0 Wiring Diagrams 9.0 Wiring Diagrams In all models the safety switch in the diagram is a positive-break door switch. EMC Filters (if fitted): dependent on the model there may be one filter, or more than one fitted in parallel. The circuit diagram examples do not show multiple filter arrangements. - Page 28 9.0 Wiring Diagrams WA-33-31 Connections below show 3-phase +N with indirect safety switches and over- temperature control. F1, F2, F3 Fuses Filter (if fitted) Controller Control Thermocouple Over-Temperature Controller Cables Over-Temperature Thermocouple Blue Relay R1/1, R1/2, R1/3 Relay contactor Black Instrument Switch(es) GR/Y Green + Yellow Safety Switch...
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Page 29: Wa-U3-30
9.0 Wiring Diagrams WA-U3-30 Connections below show 3-phase +N with indirect safety switches. - Page 30 9.0 Wiring Diagrams F1, F2, F3 Fuses Filter (if fitted) Controller Control Thermocouple Cables R1, R2, R3 Relay Blue R1/1, R1/2, R2/1, R2/2, R3/1, R3/2 Relay contactor Instrument Switch(es) Black Safety Switch GR/Y Green + Yellow Element Grey Solid State Relay Pink Neutral Live...
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Page 31: Wa-U3-31
9.0 Wiring Diagrams WA-U3-31 Connections below show 3-phase +N with safety switches and over-temperature control. - Page 32 9.0 Wiring Diagrams F1, F2, F3 Fuses Filter (if fitted) Controller Control Thermocouple Cables Over-Temperature Controller Blue Over-Temperature Thermocouple R1, R2, R3 Relay Black R1/1, R1/2, R2/1, R2/2, R3/1, R3/2 Relay contactor GR/Y Green + Yellow Instrument Switch(es) Grey Safety Switch Pink Element Solid State Relay...
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Page 33: Fuses And Power Settings
10.0 Fuses and Power Settings 10.0 Fuses and Power Settings F1 - F3: Refer to the circuit diagrams. GEC Safeclip of the type shown Fitted if supply cable fitted. Internal (glass type F up to 16 A) Supply Fitted on board to some types 38 mm x 10 mm type F fitted on Fuses of EMC filter. -
Page 34: Specifications
11.0 Specifications 11.0 Specifications Carbolite Gero reserves the right to change the specification without notice. Approx Chamber Size Temp Power Capacity Weight Model (°C) (kW) (kg) Chamber furnaces heated by resistance wire resting on refractory formers. GPC 12/200 1200 11.1 Environment The models listed in this manual contains electrical parts and should be stored and used in indoor conditions as follows:... - Page 35 Notes Service Record Engineer Name Date Record of Work...
- Page 36 The products covered in this manual are only a small part of the wide range of ovens, chamber furnaces and tube furnaces manufactured by Carbolite Gero for laboratory and industrial use. For further details of our standard or custom built products please contact us at the address below, or ask your nearest stockist.
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