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Summary of Contents for VERDER Carbolite Gero CWF 13/23
- Page 1 Installation, Operation and Maintenance Instructions 1300°C Chamber Furnace - CWF Model: 23 Litres No Controller CWF 13/23 + No Controller MEN-CWF1323-005_NOCTRL (29-11-2022)
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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 Safety Warning - Refractory Fibre Insulation Temperature Controller Replacement Solid-State Relay Replacement Thermocouple Replacement Panel Element Replacement Door Plug Replacement Fuse Replacement 7.0 Fault Analysis Furnace Does Not Heat Up Product Overheats 8.0 Wiring Diagrams WA-U3-30 WA-U3-31 9.0 Fuses and Power Settings Fuses Power Settings 10.0 Specifications...
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Page 4: 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: Prerequisites To Use
1.3 Prerequisites to Use Prior to the commissioning and use of this product, all personnel involved in its installation, operation and maintenance must be deemed competent and have: Read and understood the information contained within this manual Received the relevant training with regard to safety and operation of the product Been provided with the appropriate PPE (Personal Protective Equipment) required for the safe operation of this product Note: The customer is responsible for ensuring that all of the above conditions are... -
Page 6: Installation
2.0 Installation Unpacking and Handling When unpacking and handling the product, always lift it by its base. Do not use the door or any other projecting cover or component to support the equipment when moving it. Use two or more people to carry the product where possible. Carefully remove any packing material from inside and around the product before use. -
Page 7: Chimney
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 8 Duct (75mm-150mm diameter) Ambient air is drawn into duct Chimney 25mm vertical gap between chimney and duct...
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Page 9: A105 Retort Installation (Optional)
2.4 A105 Retort Installation (optional) If the furnace has been ordered with the A105 retort option, it is important that the retort is correctly installed within the furnace before operation. Note: Before installing the retort, ensure that all packaging is removed from both the retort and the furnace. - Page 10 Secure the retort in place with the washers and bolts. Remove the two screws to separate the two sections of the insulated door surround. Carefully slide the top of the door surround behind the door, until it rests on the top of the retort. Carefully position the bottom section of the door surround beneath the retort.
- Page 11 Secure the two sections of the door surround together with the two screws. Using a 10 mm spanner and appropriately-sized cross head screwdriver, tighten the four long bolts at either side of the retort. Connect the earthing plug from the retort to the corresponding socket on the side of the furnace.
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Page 12: Electrical Connections
Electrical Connections Connection by a qualified electrician is recommended. The product covered by this manual normally requires a single phase A.C. supply, which may be Live to Neutral non-reversible, Live to Neutral reversible or Live to Live. Some models may be ordered for 3-phase use, which may be with or without neutral. Check the product rating label before connection. - Page 13 3-phase L1 Black to phase 1 Black to phase 2 Black to phase 3 Light Blue to neutral (if fitted) Green/ Yellow to earth (ground) DO NOT connect a product ordered for three phase use to a single phase supply or to the wrong type of three phase supply.
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Page 14: Temperature Controller
3.0 Temperature Controller If this product is fitted with a temperature controller, instructions are provided separately. -
Page 15: Operation
4.0 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. Over-Temperature option only. -
Page 16: Use Of Probes And Metal Sheathed Thermocouples
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. Use of Probes and Metal Sheathed Thermocouples Any metal object used to probe into the product chamber while the product is connected to the electrical supply must be earthed. -
Page 17: A105 Retort (Optional)
4.5 A105 Retort (optional) Note: Before connecting the product to the electrical supply, the retort MUST be earthed! This product contains ceramic insulation materials that can become conductive at high temperature. Also, in furnaces with exposed heating elements, there is a danger of a metal retort directly coming into contact with the elements. -
Page 18: Pressure
4.5.3 Pressure The gas supply to the retort should be restricted to a maximum of 200 mbar (0.2 bar / 3 psi). For most processes, the lower pressure of 70 mbar (0.07 bar / 1 psi) should be sufficient to achieve the required flow rates. A suitably regulated gas supply should always be used. -
Page 19: Power Adjustment
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 20: Maintenance
5.0 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. Frequency Maintenance Method... - Page 21 Check that all functions are working nor- Operational Check mally Thorough inspection and report incor- Operational Check porating a test of all functions Performance Element Circuit Electrical measurement Measure the current drawn on each Power Consumption phase / circuit Hearth Visual check for fit and damage Check whether the cooling fans are work- Cooling Fans (if fitted)
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Page 22: Cleaning
5.2.1 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. Do not clean with organic solvents. -
Page 23: After-Sales Service
use the product close to its maximum temperature. A quick check using an independent thermocouple and temperature indicator should be made from time to time to determine whether full calibration is required. Carbolite Gero can supply these items. Depending on the controller fitted, the controller instructions may contain calibration instructions. -
Page 24: Repairs And Replacements
6.0 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 25: Solid-State Relay Replacement
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 26: Panel Element Replacement
Panel Element Replacement See section 6.2 - wearing a face mask is required. The chambers have two side-mounted refractory panels in which coiled heating elements are inserted and one unheated hearth slab. Disconnect the furnace from the electrical supply and remove the furnace back panel. Make a written plan showing ALL the element and thermocouple connections. - Page 27 Element Example Connections Terminal Block Link CWF/23 element connection example (1-phase 200-240V) 5 & 13 litre models Live Neutral...
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Page 28: Door Plug Replacement
Door Plug Replacement See section 6.2 - wearing a face mask is required. Open the door and remove the door cover from the plug carrier assembly. Remove the old door plug by sliding it upwards out of its carrier. Slide the new plug into the carrier assembly making sure that the plug is the correct way up. - Page 29 If any fuse has failed, it is advisable for an electrician to check the internal circuits. Replace any failed fuses with the correct type. For safety reasons do not fit larger capacity fuses without first consulting Carbolite Gero. The fuses are located at the cable entry point. Remove the back panel or control box back panel to gain access to the fuses.
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Page 30: Fault Analysis
7.0 Fault Analysis Furnace Does Not Heat Up The HEAT The heating element Check also that the SSR is light is ON has failed working correctly The HEAT The controller shows a The thermocouple has broken or light is very high temperature has a wiring fault or code such as S.br The controller shows a... -
Page 31: Product Overheats
Product Overheats Product only heats The controller up when the shows a very high The controller is faulty instrument switch is temperature The thermocouple may be The controller faulty or may have been shows a low removed out of the heating temperature chamber The thermocouple may be... -
Page 32: Wiring Diagrams
8.0 Wiring Diagrams... -
Page 33: Wa-U3-30
WA-U3-30 Connections below show 3-phase +N with indirect safety switches. - Page 34 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 Earth Products with this wiring arrangement may be converted between the following supply...
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Page 35: Wa-U3-31
WA-U3-31 Connections below show 3-phase +N with safety switches and over-temperature control. - Page 36 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 Neutral L1, L2, L3...
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Page 37: Fuses And Power Settings
9.0 Fuses and Power Settings Fuses F1 - F3: Refer to the circuit diagrams. Fitted if supply cable fitted. Internal 38 mm x 10 mm type F fitted on Supply Fitted on board to some types EMC filter circuit board(s) Fuses of EMC filter. -
Page 38: Specifications
10.0 Specifications Carbolite Gero reserves the right to change the specification without notice. Chamber Size (mm) Approx Model Temp Power Weight Capacity (l) (°C) (kW) (kg) Chamber furnaces heated by coiled resistance wire inserted into refractory formers. CWF 13/23 1300 10.1 Environment The models listed in this manual contain electrical parts and should be stored and used... - Page 39 Notes Service Record Engineer Name Date Record of Work...
- Page 40 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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