VERDER CARBOLITE GERO HRF 7/45 Manual

Installation, Operation and Maintenance Instructions
750°C Recirculating Air Furnace - HRF Model: 45 Litres
No Controller
HRF 7/45 + No Controller
MEN-HRF7045-05_NOCTRL (06-08-2019)

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. Use the product for the purpose for which it is intended.
1.0 Symbols and Warnings 4
1.1 Switches and Lights 4
1.2 General Warnings 4
2.0 Installation 5
2.1 Unpacking and Handling 5
2.2 Siting and Setting 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 Operation 13
5.1 Operating Cycle 13
5.2 General Operating Notes 13
5.3 Atmospheres 14
5.4 Operator Safety 14
6.0 Maintenance 15
6.1 General Maintenance 15
6.2 Maintenance Schedule 15
6.2.1 Cleaning 17
6.3 Calibration 17
6.4 After-Sales Service 17
6.5 Recommended Spare Parts and Spare Parts Kit 17
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6.6 Power Adjustment 17
7.0 Repairs and Replacements 19
7.1 Safety Warning - Disconnection from Power Supply 19
7.2 Safety Warning - Refractory Fibre Insulation 19
7.3 Temperature Controller Replacement 19
7.4 Solid-state Relay Replacement 20
7.5 Thermocouple Replacement 20
7.6 Element Replacement 20
7.7 Fuse Replacement 21
8.0 Fault Analysis 22
A. Furnace Does Not Heat Up 22
B. Product Overheats 23
9.0 Wiring Diagrams 24
9.1 WA-11-00-H 24
9.2 WA-U3-00 25
10.0 Fuses and Power Settings 26
10.1 Fuses 26
10.2 Power Settings 26
11.0 Specifications 27
11.1 Environment 27
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1.0 Symbols and Warnings
1.0 Symbols and Warnings
1.1 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.
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

2.0 Installation
2.1 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.
Avoid damaging the surrounding insulation when removing packing materials.
NOTE: This product contains Refractory Ceramic Fibre (also 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 subject to
movement or vibrations.
The height of the mounting surface is important to avoid operator strain when loading
and unloading samples.
Unless otherwise stated elsewhere in this manual, ensure that there is at least 150
mm of free space around the back and sides of the product. Clear space is required
above the product to dissipate heat.
5
2.0 Installation

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.
Under no circumstances should any objects be placed on top of the product.
Always ensure that any vents on the top of the 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 directly above the
chimney outlet.
Do not make a sealed connection to the product chimney as this causes excessive
airflow through the chamber and results in poor temperature uniformity.
6

Key
A Duct (75mm-150mm diameter)
B Ambient air is drawn into duct
C Chimney
D 25mm vertical gap between chimney and duct
2.4 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 supply capacity should be sufficient for the current on
the label.
The supply should be fused at the next size equal to, or higher than the current on the
label. A table of the most common fuse ratings is also given towards the back of this
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.
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
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).
7
2.0 Installation

2.0 Installation
Supply Terminal Label Cable Colour
Supply Types
Live - Neutral Reversible or Live-
Live
1-phase L Brown to live
to either power
conductor
(For USA 200-240V,
connect L1)
N Blue to neutral
to the other power
conductor
(For USA 200-240V,
connect L2)
PE Green/ Yellow to earth
(ground) to earth (ground)
Electrical Connection Details:
8

3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
9
3.0 Temperature Controller

4.0 2132 Over-Temperature
4.0 2132 Over-Temperature Controller Description (if
fitted)
4.1 Description
Key
A Alarm Light
B Page
C Scroll
D Down
E Up
F 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.
4.2 Operation
4.2.1 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 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 heating elements. Power is not restored until
the controller is 'reset'.
Some components will operate after the over-temperature feature isolates the power
supply e.g. cooling fans will continue to operate, provided that there is a power supply
to the product. In some cases the product may not do so, if other options (such as a
door switch) are fitted.
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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;
further presses reveal the lists indicated in the navigation diagram.
The scroll key allows access to the parameters within a list. Some parameters are
display-only; others may be 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.
4.2.3 Over-Temperature Operation
Use down and up to alter the over-temperature setpoint. This should normally be
set a little above the working temperature (for example 15 °C above). The product is
supplied with the over-temperature 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 heating
elements is disconnected.
4.2.5 Resetting the Over-Temperature Alarm
To acknowledge the alarm press scroll and page together.
If the alarm is acknowledged while there is still an over-temperature condition, the OP2
indicator stops flashing but continues to glow. The 2FSH alarm continues to flash until
the over-temperature condition is cleared (by the temperature falling), when normal
operation resumes.
If the alarm is acknowledged when the temperature has dropped (or after the over-
temperature setpoint has been raised) so that the over-temperature condition no
longer exists, then the furnace or oven immediately resumes normal operation.
4.2.6 Sensor Break
The over-temperature cut-out system also operates if the over-temperature control
thermocouple breaks or becomes disconnected. The message S.br flashes where the
measured temperature is normally displayed.
11
4.0 2132 Over-Temperature

4.0 2132 Over-Temperature
4.3 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.
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

5.0 Operation
5.1 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.
In these products the instrument switch does not cut power to the fan.
The fan is on whenever the product is connected to the electrical supply.
Where the fan is operated by the instrument switch, it does not switch
off unless the product temperature is below 100 °C (to initiate cooling,
lower the controller setpoint). Failure to observe this may reduce the fan
motor life.
Over-Temperature option only. If the digital over-temperature option has not yet
been set as required, set and activate it according to the over-temperature controller
instructions.
The product will heat up according to the controller setpoint or program, unless a time
switch is fitted and switched off.
The heat light glows steadily at first and then flashes as the product approaches the
desired temperature or a program setpoint.
Over-Temperature 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 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 particular poor conductors, avoid shielding the
thermocouple from the heating elements. The thermocouple is intended to sense the
temperature near the heating elements. However, if a large object is placed in the
chamber it may record the average temperature of the object and the elements, this
can lead to overheating of the elements. Allow large objects to gain heat at a lower
temperature and then reset the controller to a temperature close to the desired
13
5.0 Operation

5.0 Operation
maximum, or heat using a slowly controlled ramp rate. For more information refer to
the controller instructions.
When heating materials that produce smoke or fumes, the chimney must be correctly
fitted and unobstructed. If not, soot will accumulate in the chamber and could possibly
cause an electrical breakdown of the heating element. If the furnace is used to heat
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.
5.3 Atmospheres
When an optional gas inlet is fitted, there is a label near the inlet saying "INERT GAS
ONLY". In practice, inert or oxidising gases may be used, but not combustible or toxic
gases.
The chamber is not gas tight, the gas usage may be high and the chamber is always
likely to contain some air. Residual oxygen of approximately 1% to 2% is to be
expected.
5.4 Operator Safety
This product has mineral insulated heating elements and does not require a door safety
switch.
Avoid burns. Carbolite Gero can supply tongs, face masks and heat resistant gloves.
Before you remove a hot object from the product, make sure you have a safe place to
put it down.
14

6.0 Maintenance
6.1 General Maintenance
Preventive rather than reactive maintenance is recommended. The type and frequency
depends on the product use; the following are recommended.
6.2 Maintenance Schedule
CUSTOMER
QUALIFIED PERSONNEL
DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically
qualified personnel should attempt these maintenance procedures.
Maintenance
Procedure Method
Frequency
Daily Weekly Monthly Bi-
Annually Annually
Safety
Over-Temperature 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
Door Seal Visual inspection, checking for splits and fraying
Door Seal Replace where necessary
Chimney / Extraction Check and clean if necessary
Electrical Safety (external) Visual check of external cables and plugs
Electrical Safety (internal) Physically check all connections and cleaning of
the power plate area
Function
Temperature Calibration Tested using certified equipment, frequency
dependent on the standard required
Operational Check Check that all functions are working normally
Operational Check Thorough inspection and report incorporating a
test of all functions
Performance
Element Circuit Electrical measurement
Power Consumption Measure the current drawn on each phase / cir-
cuit
15
6.0 Maintenance

6.0 Maintenance
Metal Liner Visual check for fit and damage
Circulating Fan With the furnace at ambient open the door and
make sure the fan is working
16

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. Do not clean
with organic solvents.
6.3 Calibration
After prolonged use, the controller and/or thermocouple may require recalibration. This
is important for processes that require accurate temperature readings or for those that
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.
6.4 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’ 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 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
Carbolite Gero can supply individual spare parts or a kit of the items most likely to be
required. Ordering a kit in advance can save time in the event of a breakdown.
Each kit consists of one thermocouple, one solid state relay, one door insulation piece
and a set of elements.
When ordering spare parts, please quote the model details as requested above.
6.6 Power Adjustment
The control system incorporates electronic power limiting, but for the model listed in
this manual the power limit is set to 100%. The power limit parameter OP.Hi may be
accessible to the operator, but should not generally be altered.
17
6.0 Maintenance

6.0 Maintenance
In some cases 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.
18

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 Temperature Controller Replacement
Refer to the controller instructions for more information on how to replace the
temperature controller.
19
7.0 Repairs and Replacements

7.0 Repairs and Replacements
7.4 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. Replace and reconnect the solid state relay ensuring that the bottom of it has good
thermal contact with the base panel or aluminium plate.
4. Replace the access panel.
7.5 Thermocouple Replacement
Disconnect the product from the power supply. Remove the appropriate panel
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
1. Disconnect the thermocouple to be replaced from its terminal block and withdraw
it.
2. Re-assemble the new thermocouple, observing the colour coding.
3. Refit the element access panel.
7.6 Element Replacement
See section 7.2 - wearing a face mask is required.
The mineral insulated type of element consists of a resistance wire which is centered in
a metal tube by a compressed powder. Such elements may be bent into "U" or other
shapes without losing the electrical insulation.
Disconnect the furnace from the electrical supply. Remove the furnace back panel.
Carefully note how the elements are connected and remove the electrical leads from
them.
Unscrew the gland caps on the faulty element and carefully prise open the split
compression collars, which should be retained for fitting to the new element.
Remove the chimney, open the furnace door and slide out the chamber liner. Withdraw
the element through the front of the furnace.
20