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7.0 Repairs and Replacements

7.4

Temperature Controller Replacement

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

7.5

Thermocouple Replacement

Disconnect the product from the power supply. Remove terminal cover to gain
access to the thermocouple connections. Make a note of the thermocouple
connections.

Thermocouple cable colour codings are:

Thermocouple Leg

Colour

positive (type K)

green

negative

white

Disconnect the thermocouple to be replaced from its terminal block and withdraw it.

Re-assemble the new thermocouple, observing the colour coding.

Refit the element access panel.

7.6

Element Replacement

See section 7.2 - wearing a face mask is required.

Remove the top panel as above.

The heating chamber is suspended from the top plate. Make a note of the wiring
connections; identify those to the heating element and disconnect it.

Separate the inner chamber by removing 4 screws. The heating element with its
surrounding insulation can then be lifted out of the chamber.

Replace the element with the new one and reverse the disassembly procedure.

7.7

Fuse Replacement

Fuses are marked on the wiring diagram with type codes, e.g. F1, F2. For more
information on fuses refer to section 10.0.

Depending on model and voltage, the different fuse types may or may not be fitted.

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.

Содержание CARBOLITE GERO SNF

Страница 1: ...Installation Operation and Maintenance Instructions 900 C Swelling Number Furnace SNF 2132 Controller SNF 2132 Controller MEN SNF 003_2132 10 01 2019 ...

Страница 2: ...9 3 1 Description 9 3 2 2132 Controller Operation 9 3 2 1 Controls 9 3 2 2 2132 Controller Operation 10 3 2 3 Basic Operation 10 3 2 4 Altering the Setpoint 10 3 2 5 Stopping and Starting Control 11 3 2 6 Altering the Ramp Rate 11 3 3 Operating with the Timer 12 3 3 1 Setting the Timer Mode 14 3 3 2 Setting the Time Period 14 3 3 3 Running with the Timer 14 3 3 4 Stopping the Timer 15 3 3 5 End of...

Страница 3: ...on 29 6 4 After Sales Service 29 6 5 Recommended Spare Parts and Spare Parts Kit 29 6 6 Power Adjustment 29 7 0 Repairs and Replacements 31 7 1 Safety Warning Disconnection from Power Supply 31 7 2 Safety Warning Refractory Fibre Insulation 31 7 3 Panel Removal 31 7 4 Temperature Controller Replacement 32 7 5 Thermocouple Replacement 32 7 6 Element Replacement 32 7 7 Fuse Replacement 32 7 8 Solid ...

Страница 4: ...10 2 Power Settings 38 11 0 Specifications 39 11 1 Environment 39 4 ...

Страница 5: ...s 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 5 1 0 Symbols and Warnings ...

Страница 6: ...no 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 subject to movement or v...

Страница 7: ...clear of any obstruction 2 3 Electrical Connections Connection by a qualified electrician is recommended This product requires a single phase A C supply with earth ground which may be Live to Neutral non reversible polarised Live to Neutral reversible non polarised or Live to Live Check the product rating label before connection The supply voltage should agree with the voltage on the label and the...

Страница 8: ...ade to the internal terminals If the product is to be connected by line plug The plug should be within reach of the operator and should be easy to remove When connecting the product to an isolating switch ensure that both conductors single phase or on all live conductors three phase and should be within reach of the operator The supply MUST incorporate an earth ground Supply Terminal Label Cable C...

Страница 9: ... an audible alarm at the end of the timing period 3 2 2132 Controller Operation 3 2 1 Controls Most Carbolite Gero products are fitted with an instrument 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 mus...

Страница 10: ...e altered by the operator A single press of the scroll key in the Home list displays the temperature units further presses reveal the parameters in the current list indicated in the navigation diagram To return to the Home list at any time press page and scroll together or wait for 45 seconds The down and up keys are used to alter the setpoint or other parameter values 3 2 3 Basic Operation Normal...

Страница 11: ... It is only possible to limit the rate of heating by setting a ramp rate if the timer feature is not in use To enable direct setting of the ramp rate first ensure that the StAt parameter and dwEll parameter are both set to OFF see sections 3 3 1 and 3 3 2 Press scroll until SPrr setpoint ramp rate is displayed Use down or up to display and adjust the value The ramp rate sets the maximum rate of he...

Страница 12: ...e Timer This controller can be used as a process timer allowing timed heating or timed delay according to the options in the table There are 5 timer modes but 2 of them are affected by whether the setpoint ramp rate feature is being used making 7 entries in the table The table also shows the status of the timer light on the controller A visual impression of the different modes is given in fig 3 12...

Страница 13: ...iming period mode 3 with SPrr active Dwell from working setpoint and switch off The timer starts timing when the working setpoint is within 1 C of the setpoint At the end of the timing period control switches off i e goes into Manual to allow cooling and End flashes on the display On during the timing period Off from the end of the timing period mode 4 with SPrr off Time from cold and stay on The ...

Страница 14: ... StAt parameter changes to run Note that the tmr display shows 0 zero during the last minute of timing and also shows 0 when the time has expired The timer light indicates whether timing is still in progress Method 2 Scroll to dwEll and use or to set the timing duration The advantage of method 2 is that dwEll need only be set once if repeated use of the same time period is required Scroll to StAt ...

Страница 15: ... setpoint ramp rate 5 Modes 3 4 with setpoint ramp rate off 6 Reaching temperature and continuing temperature Mode 5 7 Continuing at temperature modes 2 4 or cooling down modes 1 3 3 3 4 Stopping the Timer To stop the timer at any time while it is operating change the StAt User Calibration parameter to OFF This is the same as reducing tmr to zero The controller then acts as though it has reached t...

Страница 16: ...ode 1 as on the first row of the timer table but also includes the use of ramp rate To create this program 1 Start with display at home use arrow keys to alter the setpoint to 500 2 Press scroll until sp rr shows use arrow key to set value to 10 if you do not want to limit the ramp rate ignore this step or set the value to OFF 3 Press scroll until tm op shows use arrow key to set value to opt 1 4 ...

Страница 17: ... If a product is to be used at temperatures much lower than its design maximum control stability can often be improved by reducing the power limit Remember to make a record of the original setting before altering the power limit Example It is desired to operate a 1200 C furnace at 300 C The normal control settings can be expected to cause excessive overshoot as the furnace reaches temperature If t...

Страница 18: ... the calibration of the controller or of the complete system remember to reset the controller to factory calibration values by setting the CAL P parameter to FACt To enter a user calibration scroll to each of the following parameters in turn and set the desired values Pnt L low temperature for which an offset is to be entered OFS L offset value for the low temperature Pnt H high temperature for wh...

Страница 19: ... 6 It is not feasible to cover all possible alarm features which may be included by customer special order within this manual 3 6 Temperature Controller Replacement Before handling the controller wear an anti static wrist strap or otherwise avoid any possibility of damage to the unit by static electricity Refer to the detailed instructions supplied with the replacement controller Ease apart the tw...

Страница 20: ...3 0 2132 Controller 3 7 Navigation Diagram 20 ...

Страница 21: ... if SPrr in use 4 Manual Auto mAn off Auto on 5 Setpoint ramp rate OFF or value 6 Timer mode 7 Time remaining 8 Dwell time for timer 9 Timer status run or OFF 10 Enter password 11 If User Calibration 12 User 2 Point Calibration 13 Power limit setting if present 14 For factory acess to lists and parameters not available to the operator 21 3 0 2132 Controller ...

Страница 22: ...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...

Страница 23: ...perature 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...

Страница 24: ...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 24 ...

Страница 25: ...erature option only If the over temperature circuit has tripped an indicator on the over temperature controller flashes and the heating elements are isolated Find and correct the cause before resetting the over temperature controller according to the instructions supplied To turn the product off set the instrument switch to its off position The controller display will go blank If the product is to...

Страница 26: ...ment life 5 4 Operator Safety Ceramic materials used in the furnace insulation can become conducting at high temperatures therefore there is a potential danger to the operator as this furnace is designed to be used with the chamber lid open To guard against this danger the furnace is fitted with a 30mA earth leakage residual current circuit breaker mounted in the back of the case This trips out in...

Страница 27: ... 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 Electrical Safety external Test the 30mA RCD trip with the test button daily before use Electrical Safety external Visual check of external cables and plugs Electrical Safety internal...

Страница 28: ...6 0 Maintenance Power Consumption Measure the current drawn on each phase cir cuit 28 ...

Страница 29: ... both at the Carbolite Gero factory and at customers premises throughout the world A telephone call or email often enables a fault to be diagnosed and the necessary parts to be despatched In all correspondence please quote the serial number and model type given on the rating label of the product The serial number and model type are also given on the back of this manual when supplied with the produ...

Страница 30: ...the supply voltage may be outside the range 220 240 V or the 3 phase equivalent the power limit parameter may be set to a value other than 100 Do not increase the value to 100 see section 10 0 for details of power limit settings 30 ...

Страница 31: ...ards it is strongly recommended that safety precautions are taken whenever the materials are handled Exposure to fibre dust may cause respiratory disease When handling the material always use approved respiratory protection equipment RPE eg FFP3 eye protection gloves and long sleeved clothing Avoid breaking up waste material Dispose of waste in sealed containers After handling rinse exposed skin w...

Страница 32: ...e The heating chamber is suspended from the top plate Make a note of the wiring connections identify those to the heating element and disconnect it Separate the inner chamber by removing 4 screws The heating element with its surrounding insulation can then be lifted out of the chamber Replace the element with the new one and reverse the disassembly procedure 7 7 Fuse Replacement Fuses are marked o...

Страница 33: ...ote of the wire connections to the solid state relay and disconnect them Remove the solid state relay from the base panel or aluminium plate Replace and reconnect the solid state relay ensuring that the bottom of it has good thermal contact with the base panel or aluminium plate Replace the access panel 33 7 0 Repairs and Replacements ...

Страница 34: ... controller may be faulty or not receiving a supply due to a faulty switch or a wiring fault 2 The temperature controller is ON The controller shows a very high temperature or a code such as S br The thermocouple has broken or has a wiring fault The controller shows a low temperature The SSR could be failing to switch on due to internal failure faulty logic wiring faulty which could have overloade...

Страница 35: ...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 35 8 0 Fault Analysis ...

Страница 36: ...w single phase Key F1 F2 F3 Fuses FIL Filter C Temperature Controller TC Control Thermocouple SSR Solid State Relay H Heat Lamp EL Element s SW Instrument Switch es FM Fan Motor Fan Models Only N Neutral L Live PE Earth Cables BU Blue R Red GR Y Green Yellow G Grey P Pink 36 ...

Страница 37: ...9 2 WA 11 01 Connections below show single phase with over temperature controller 37 9 0 Wiring Diagrams ...

Страница 38: ...240 1 phase 4 A SNF 110 120 1 phase 10 A 10 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures represent the maximum percentage of time that controlled power is supplied to the elements Do not attempt to improve performance by setting a value higher than the recommended values To adjust the parameter refer to the Changing the Maximum Output P...

Страница 39: ...r Size mm Net Weight kg Swelling Number Furnace SNF 900 1 0 70 dia x 80 deep 26 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 39 11 0 Specifications ...

Страница 40: ......

Страница 41: ...Notes Service Record Engineer Name Date Record of Work ...

Страница 42: ... 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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