VERDER CARBOLITE GERO CARBOLITE GERO WA-22-30 Installation, Operation And Maintenance Instructions Download Page 8 | Manualshive

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2.0 Installation

2- or

3-phase

L1

Black

to phase 1

L2

Black

to phase 2

L3

Black

to phase 3 (

except 2-phase

)

N

Light Blue

to neutral (

except delta

)

PE

Green/ Yellow

to earth (

ground

)

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Summary of Contents for CARBOLITE GERO CARBOLITE GERO WA-22-30

Page 1: ...Installation Operation and Maintenance Instructions 1200 C Vertical Chamber Furnace VCF Model 23 Litres No Controller VCF 12 23 No Controller MEN VCF12023 005_NOCTRL 05 08 2019 ...

Page 2: ... Up 5 2 3 Chimney 6 2 4 Electrical Connections 7 3 0 Temperature Controller 9 4 0 2132 Over Temperature Controller Description if fitted 10 4 1 Description 10 4 2 Operation 10 4 2 1 Controls 10 4 2 2 Operation 11 4 2 3 Over Temperature Operation 11 4 2 4 Over Temperature Alarm 11 4 2 5 Resetting the Over Temperature Alarm 11 4 2 6 Sensor Break 11 4 3 Audible Alarm 12 4 4 Navigation Diagram 12 5 0 ...

Page 3: ...ntroller Replacement 20 7 4 Thermocouple Replacement 21 7 5 Solid State Relay Replacement 21 7 6 Fuse Replacement 21 7 7 Element Replacement 23 8 0 Fault Analysis 24 A Furnace Does Not Heat Up 24 B Product Overheats 25 9 0 Wiring Diagrams 26 9 1 WA 11 30 26 9 2 WA 11 31 27 9 3 WA 22 30 28 9 4 WA 22 31 29 9 5 WA 33 30 30 9 6 WA 33 31 31 10 0 Fuses and Power Settings 32 10 1 Fuses 32 10 2 Power Sett...

Page 4: ...ent light glows or flashes to indicate that power is being supplied to the elements 1 2 General Warnings DANGER Electric shock Read any warning printed next to this symbol WARNING Risk of fatal injury DANGER Hot surface Read any warning printed next to this symbol WARNING All surfaces of a product may be hot DANGER Read any warning printed next to this symbol Caution Double Pole Neutral Fusing 4 ...

Page 5: ...lso known as Alumino Silicate Wool ASW For precautions and advice on handling this material see section 7 2 2 2 Siting and Setting Up Place the product on a level surface in a well ventilated area Site away from other sources of heat and on a non flammable surface that is resistant to accidental spillage or hot materials The surface on which the equipment is mounted should be stable and not subjec...

Page 6: ... product are clear of any obstruction Always ensure all cooling vents and cooling fans if fitted are clear of any obstruction 2 3 Chimney The chimney is a length of tubing If it is supplied unfitted then fit it through the hole in the top of the case If the product is to be used to heat substances that emit fumes a fume extraction duct of approximately 75 mm 150 mm inlet diameter may be placed dir...

Page 7: ...supply cable are designed to be wired directly to an isolator or fitted with a line plug Products without a factory fitted supply cable require a permanent connection to a fused and isolated supply The product s electrical access panel should be temporarily removed and connections made to the internal terminals If the product is to be connected by line plug The plug should be within reach of the o...

Page 8: ...2 0 Installation 2 or 3 phase L1 Black to phase 1 L2 Black to phase 2 L3 Black to phase 3 except 2 phase N Light Blue to neutral except delta PE Green Yellow to earth ground 8 ...

Page 9: ...3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 9 3 0 Temperature Controller ...

Page 10: ...strument switch which cuts off power to the controller and other parts of the control circuit To operate the controller power must be supplied to the product and the instrument switch must be on If a time switch is included in the product circuit this must be in the ON position When an over temperature condition occurs the controller cuts the power to a contactor which in turn cuts power to the he...

Page 11: ... set at 15 C above the furnace or oven maximum working temperature Press scroll twice view the present temperature as measured by the over temperature controller Press it twice the first press shows the temperature units C 4 2 4 Over Temperature Alarm If an over temperature condition occurs the OP2 indicator flashes and an alarm message 2FSH also flashes alternating with the setpoint Power to the ...

Page 12: ...erature 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 4 4 Navigation Diagram HL Home List Page Key Black Progress OTSP Over Temperature Setpoint Scroll Key Dashed Through to other options AL Access List For factory access to list and parameters not available to the operator 12 ...

Page 13: ...ontroller display will go blank If the product is to be left unattended isolate it from the electrical supply 5 2 General Operating Notes Heating element life is shortened by overheating Do not leave the product at high temperature when it is not required The maximum temperature is shown on the product rating label and in section 11 0 towards the back of this manual When heating large objects in p...

Page 14: ...ly to contain some air Residual oxygen of approximately 1 to 2 is to be expected 5 5 Operator Safety This product incorporates a safety switch which interrupts the heating element circuit when the furnace is opened This prevents the operator touching a live heating element and also prevents the product from heating up if the furnace is left open The operation of this switch should be checked perio...

Page 15: ...ed See section 10 0 for details of the power limit settings DO NOT adjust the power to a level higher than the design level states this may cause a fuse to blow and could damage the heating elements The power limit may be set to a lower limit if the product is to be used at a low temperature only this may give better control stability It may be set to zero to permit demonstration of the controls w...

Page 16: ...re Safety Circuit if fitted Set an over temperature setpoint lower than the displayed temperature and check for an over tem perature alarm as detailed in this manual Over Temperature Safety Circuit if fitted Electrical measurement Lid Insulation Visual inspection checking the seal and whether it is free of damage Lid Insulation Replacement where necessary Chimney Extraction Check and clean if nece...

Page 17: ...Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase cir cuit Hearth Visual check for fit and damage 17 6 0 Maintenance ...

Page 18: ...fe temperature above ambient The heater lights should illuminate l Open the door and check the heater lights They should no longer be illuminated If the heater lights remain illuminated when the door is open discontinue use and contact Carbolite Gero Service Annual check The following checks should be carried out by a qualified electrician as specified in the Maintenance Schedule section of this m...

Page 19: ...y parts to be despatched In all correspondence please quote the serial number and model type given on the rating label of the product The serial number and model type are also given on the back of this manual when supplied with the product Carbolite Gero Service and Carbolite Gero contact information can be found on the back page of this manual 6 5 Recommended Spare Parts and Spare Parts Kit Carbo...

Page 20: ... higher levels may be encountered during maintenance or repair Whilst there is no evidence of any long term health hazards it is strongly recommended that safety precautions are taken whenever the materials are handled Exposure to fibre dust may cause respiratory disease When handling the material always use approved respiratory protection equipment RPE eg FFP3 eye protection gloves and long sleev...

Page 21: ...carefully to match the shape of the original working from the terminal end Should the length differ from that of the original this will usually not be important provided that the thermocouple tip is within a tube diameter s distance from the product centre Insert the new thermocouple into position restoring any removed porcelain spacers and ensuring correct polarity Re assemble the product 7 5 Sol...

Page 22: ...d 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 22 ...

Page 23: ...nd in the case of MTF10 models Use a sharp knife to cut right through the insulation down to the wire wound tube element along the whole length of the body but do not cut either of the ceramic board end discs The knife cut must be in line with the element lead wires Slide the element gently out through the end of the product body Check the cylindrical case and clean out as appropriate Remove any i...

Page 24: ... a low temperature The door switch es if fitted may be faulty or need adjustment The contactor relay if fitted may be faulty The heater switch if fitted may be faulty or need adjustment The SSR could be failing to switch on due to internal failure faulty logic wiring from the controller or faulty controller There are no lights glowing on the controller Check the supply fuses and any fuses in the f...

Page 25: ...r shows a low temperature The thermocouple may be faulty or may have been removed out of the heating chamber The thermocouple may be connected the wrong way around The controller may be faulty 2 Product heats up when the instrument switch is OFF The SSR has failed ON Check for an accidental wiring fault that could have overloaded the SSR 25 8 0 Fault Analysis ...

Page 26: ...t safety switch es Key F1 F2 F3 Fuses FIL Filter R1 1 R1 2 Relay Contactor R1 Relay C Temperature Controller TC Control Thermocouple SSR Solid State Relay SSW Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L Live PE Earth Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 26 ...

Page 27: ... Relay Contactor R1 Relay C Temperature Controller OT Over Temperature Controller OTC Over Temperature Thermocouple TC Control Thermocouple SSR Solid State Relay SSW Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L Live PE Earth If Fitted Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 27 9 0 Wiring Diagrams ...

Page 28: ...ches Key F1 F2 F3 Fuses FIL Filter R1 1 R1 2 Relay Contactor R1 Relay C Temperature Controller TC Control Thermocouple SSR Solid State Relay SSW Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L1 L2 Live PE Earth Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 28 ...

Page 29: ... Filter R1 1 R1 2 Relay Contactor R1 Relay C Temperature Controller TC Control Thermocouple OT Over Temperature OTC Over Temperature Thermocouple SSW Safety Switch H Heat Lamp EL Element s SW Instrument Switch es N Neutral L1 L2 Live PE Earth If fitted Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 29 9 0 Wiring Diagrams ...

Page 30: ...witches Key F1 F2 F3 Fuses FIL Filter if fitted C Controller TC Control Thermocouple R Relay R1 1 R1 2 R1 3 Relay contactor SW Instrument Switch es SSW Safety Switch EL Element SSR Solid State Relay N Neutral L Live PE Earth Cables BU Blue R Red BL Black GR Y Green Yellow G Grey P Pink 30 ...

Page 31: ...if fitted C Controller TC Control Thermocouple OT Over Temperature Controller OTC Over Temperature Thermocouple R Relay R1 1 R1 2 R1 3 Relay contactor SW Instrument Switch es SSW Safety Switch EL Element SSR Solid State Relay N Neutral L Live PE Earth Cables BU Blue R Red BL Black GR Y Green Yellow G Grey P Pink 31 9 0 Wiring Diagrams ...

Page 32: ...ly cable fitted Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating VCF 12 23 1 phase 220 240 25 A VCF 12 23 2 phase 380 220 415 240 16 A VCF 12 23 3 phase 380 220 415 240 12 A VCF 12 23 3 phase delta 220 240 16 A 10 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures r...

Page 33: ...D Vertical chamber furnaces heated by resistance wire embedded in refractory cement slabs VCF 12 23 1200 6 450 250 200 23 130 11 1 Environment The models listed in this manual contains electrical parts and should be stored and used in indoor conditions as follows Temperature 5 C 40 C Relative humidity Maximum 80 up to 31 C decreasing linearly to 50 at 40 C 33 11 0 Specifications ...

Page 34: ......

Page 35: ...Notes Service Record Engineer Name Date Record of Work ...

Page 36: ... us at the address below or ask your nearest stockist For preventive maintenance repair and calibration of all furnace and oven products please contact Carbolite Gero Service Telephone 44 0 1433 624242 Fax 44 0 1433 624243 Email ServiceUK carbolite gero com Carbolite Gero Ltd Parsons Lane Hope Hope Valley S33 6RB England Telephone 44 0 1433 620011 Fax 44 0 1433 621198 Email Info carbolite gero com...

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