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7.0 Repairs and Replacements

7.0

Repairs and Replacements

7.1

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.

Caution

: Double pole/neutral fusing may be used in this product.

7.2

Safety Warning - Refractory Fibre Insulation

Insulation made from High Temperature Insulation Wool

Refractory Ceramic Fibre, better known as (Alumina silicate
wool - ASW).

This product contains

alumino silicate wool

products in its thermal insulation. These

materials may be in the form of blanket or felt, formed board or shapes, slab or loose
fill wool.

Typical use does not result in any significant level of airborne dust from these materials,
but much 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 sleeved clothing.

Avoid breaking up waste material. Dispose of waste in sealed containers.

After handling, rinse exposed skin with water before washing gently with soap
(not detergent). Wash work clothing separately.

Before commencing any major repairs it is recommended to make reference to the
European Association representing the High Temperature Insulation Wool industry
(www.ecfia.eu).

Further information can be provided on request. Alternatively, Carbolite Gero Service
can quote for any repairs to be carried out either on site or at the Carbolite Gero
factory.

7.3

Panel Removal

Disconnect the product from the electrical supply.

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Содержание CARBOLITE GERO VCF 12/100

Страница 1: ...Installation Operation and Maintenance Instructions 1200 C Vertical Chamber Furnace VCF Model 100 Litres No Controller VCF 12 100 No Controller MEN VCF12100 005_NOCTRL 05 08 2019 ...

Страница 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 ...

Страница 3: ...perature Controller Replacement 21 7 5 Fuse Replacement 21 7 6 Thermocouple Replacement 21 7 7 Solid state Relay Replacement 22 7 8 Element Replacement 22 Example Element Connections 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 33 30 28 9 4 WA 33 31 29 10 0 Fuses and Power Settings 30 10 1 Fuses 30 10 2 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 7: ...used Products with a factory fitted 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 ...

Страница 8: ...phase 1 L2 Black to phase 2 L3 Black to phase 3 N Light Blue to neutral except delta PE 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 8 ...

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

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 20: ...ne dust from these materials but much 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...

Страница 21: ...ting 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 7 6 Thermocouple Replacement Disconnect the product from the electrical supply lay the product on its back and remove the bottom panel Make a note of the thermocouple connections The negative leg of the thermocouple is marked blue Compensating cable colour ...

Страница 22: ...a removable side loosen this side it should not be necessary to remove it completely Turn the furnace onto its back and remove the bottom panel Make a written plan showing ALL the element and thermocouple connections It is important to make this plan for each individual furnace Disconnect all the element wire tails and thermocouple cables from their terminal blocks Straighten all the element tails...

Страница 23: ...ram below gives schematic examples of how certain models may be connected indicating the number of elements in the series Remember to make a plan of your connections they may differ from these illustrations 23 7 0 Repairs and Replacements ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 28: ...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 28 ...

Страница 29: ...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 29 9 0 Wiring Diagrams ...

Страница 30: ... if no supply cable fitted Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating VCF 12 100 1 phase 220 240 80 A VCF 12 100 3 phase 380 220 415 240 25 A VCF 12 100 3 phase delta 220 240 40 A 10 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures represent the maximum perc...

Страница 31: ...Vertical chamber furnaces heated by resistance wire embedded in refractory cement slabs VCF 12 100 1200 15 600 410 410 101 200 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 31 11 0 Specifications ...

Страница 32: ......

Страница 33: ...Notes Service Record Engineer Name Date Record of Work ...

Страница 34: ... 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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