VERDER Carbolite Gero PN 60 Manual

Installation, Operation and Maintenance Instructions
300 °C Peak Natural Convection Oven - PN Model: 60 Litres
No Controller
PN 60 + No Controller
MEN-PN060-006_NOCTRL (05-01-2023)

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 6
2.1 Unpacking and Handling 6
2.2 Siting and Setting Up 6
2.2.1 Shelf Fitting 8
2.3 Flat Pack Stand (optional) 10
2.3.1 Parts Supplied 10
2.3.2 Flat Pack Stand Assembly 11
2.4 Electrical Connections 12
3.0 Temperature Controller 14
4.0 Operation 15
4.1 Operating Cycle 15
4.2 Over-Temperature Control (if fitted) 15
4.3 Vents 15
4.4 Temperature Uniformity 16
4.5 Explosive Vapours 16
4.6 Atmospheres 16
4.7 Variable Speed Fan (if fitted) 16
4.8 Exhaust Fan and Moisture Extraction Options 16
4.9 Stoving and Curing (if fitted) 17
4.9.1 Pre-heater (if fitted) 17
4.10 Solenoid Valve with Manual Switch (if fitted) 17
4.11 Exhaust Fan (if fitted) 17
5.0 Maintenance 19
5.1 General Maintenance 19
5.2 Maintenance Schedule 19
5.2.1 Cleaning 21
5.3 Calibration 21
5.4 After-Sales Service 21
5.5 Recommended Spare Parts and Spare Parts Kit 21
5.6 Power Adjustment 21
2

6.0 Repairs and Replacements 23
6.1 Safety Warning - Disconnection from Power Supply 23
6.2 Safety Warning - Refractory Fibre Insulation 23
6.3 Panel Removal 24
6.4 Temperature Controller Replacement 24
6.5 Solid-State Relay Replacement 24
6.6 Thermocouple Replacement 24
6.7 Element Replacement 25
6.8 Fuse Replacement 25
7.0 Fault Analysis 26
A. Oven Does Not Heat Up 26
B. Oven Overheats 26
8.0 Wiring Diagrams 27
8.1 WV-11-00 27
8.2 WV-11-01 28
8.3 WV-11-04 29
9.0 Fuses and Power Settings 30
9.1 Fuses 30
9.2 Power Settings 30
10.0 Specifications 31
10.1 Environment 31
3

1.0 Symbols and Warnings
1.1 Switches and Lights
Instrument switch: when the instrument switch is operated the
temperature control circuit is energised.
Door lock indicator: When this lamp is illuminated, the door is locked
and cannot be opened.
Interior light: when the interior light switch is operated the interior
light illuminates.
Solenoid valve (if fitted): see section 4.10 for full details
Exhaust fan (if fitted): see section 4.11 for full details
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.
4

DANGER – Read any warning printed next to this symbol.
Caution – Double Pole/Neutral Fusing
5

2.0 Installation
2.1 Unpacking and Handling
Remove the shelves and runners from the packaging before attempting to move the
equipment.
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.
Locate the shelves and runners as required.
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.
6

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.
If the over-temperature option is not fitted, ensure that the unit can be directly
observed.
7

2.2.1 Shelf Fitting
Runner Shelf
To fit the shelves:
1. Insert the runner into the slots in the side of the oven chamber, as shown in fig-
ures 1 and 2
2. Rotate the runner downwards by 90° so that the runner hooks into place and cre-
ates a level surface upon which the shelf can securely rest, as shown in figures 3
and 4
3. Repeat this process on both sides of the oven chamber
4. Slide the shelves onto the runners so that the spur is positioned on the underside
of the runner towards the back of the chamber (see figure 5). This will prevent the
shelf from tilting forwards when it is partially withdrawn
Figure 1:
Runner
Figure 2:
Runner inserted into slots in the side of
chamber
8

Figure 3:
Rotating runner into position
Figure 4:
Runner in position
Figure 5:
Shelf resting on runners with spur at rear of chamber
(highlighted in green)
Figure 6:
Shelves fitted
9

2.3 Flat Pack Stand (optional)
The flat pack stand is available in a range of sizes depending on the dimensions of the
product for which it has been ordered. Subsequently, the number of fixings may vary
between the different sizes of stand.
2.3.1 Parts Supplied
Stand Top (x1) Stand Leg (x2)
Stand Cross Brace (x2) M10 Bolt
M10 Washer M10 Locking Nut
10

2.3.2 Flat Pack Stand Assembly
11

2.4 Electrical Connections
Connection by a qualified electrician is recommended.
All models covered by this manual may be ordered for single phase A.C. supply, which
may be Live to Neutral non-reversible, Live to Neutral reversible or Live to Live.
12

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. This manual contains a table of the most common fuse ratings.
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.
When connecting the product to the power supply, the plug or isolating switch should
be accessible, easy to remove, and within reach of the operator.
The supply MUST incorporate an earth (ground).
Supply Terminal Label Cable Colour
Supply Types
Live - Neutral Reversible or Live-
Live
1-phase L1 Brown to live
to either power
conductor
(For USA 200-240V,
connect L1)
N / L2 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:
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)
13

3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
14

4.0 Operation
4.1 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.
Over-Temperature option only. If the hydraulic thermostat over-temperature option
is fitted, set the rotary dial to the desired protection temperature.
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.
4.2 Over-Temperature Control (if fitted)
The over-temperature controller should typically be set at 15 °C above the main
controller. If an over-temperature condition occurs, check the main controller is
functioning correctly.
An over-temperature condition cuts off power to the heating elements. A light in the
over-temperature controller flashes. To reset this, refer to the over-temperature
control section of this manual.
For hydraulic thermostat, the over-temperature trip operates then a click occurs and a
warning light near the thermostat lights up; the reset button on the thermostat pops
out. Reset by pressing the button. In some models the reset button is directly
accessibly. In others it is necessary to turn the thermostat dial till the hole lines up with
the reset button and press it using a small diameter rod.
For digital, a light in the over-temperature controller flashes. Reset the over-
temperature controller according to the over-temperature controller instructions.
4.3 Vents
On the back of this product are two vents: inlet and exhaust. The inlet vent is covered
by a baffle that should be left in place.
The exhaust vent is closed by a butterfly valve that can be controlled from the front
panel. Rotate the knob clockwise to open the vent, anticlockwise to close.
In non-fan models there is only a small flow of air through the chamber. With fan
versions, fumes are pushed out through the exhaust vent by fan action and fresh air is
drawn in through the inlet vent.
15

4.4 Temperature Uniformity
Where accurate temperature control of the load is important, use the central part of the
chamber and place or distribute the load to allow free air circulation. Do not place loads
on the chamber floor: use the bottom shelf.
4.5 Explosive Vapours
Unless your product includes the stoving and curing option, this
model is not suitable for drying or heat treatment applications where
vapours are released that are combustible or which can form
explosive mixtures with air. Carbolite Gero manufactures other
products suitable for these applications.
4.6 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.
4.7 Variable Speed Fan (if fitted)
If fitted, the variable speed control is fitted in the air circulation fan circuit. A
panel mounted rotary dial is used to control the speed.
Please note that there is a minimum setting at which the fan motor starts up when the
product is switched on. It is recommended that the speed of the fan is not set below
50%, as there would be very little air flow around the chamber and also risk
overheating the fan motor.
4.8 Exhaust Fan and Moisture Extraction Options
When one of these options is fitted a vent duct at the back adds 45 mm to
the products depth. 25 mm free space should be left behind the vent to
prevent damage. The motor and fan box and outlet vent are on the top of the
product, adding 270 mm height. The outlet vent is a 64 mm o/d tube to
which suitable ducting can be connected if required.
Please note that the heating element power rating may be increased; check the product
rating label for the correct power and fuse rating.
16

Start the extraction process using the switch on the control panel; this is only
functional when the instrument switch is on.
When the unit is turned on, there may be a drop in internal temperature until the
product recovers to the setpoint value.
The amount of air exhaust can be controlled by adjusting the vent control knob on the
control panel.
4.9 Stoving and Curing (if fitted)
The stoving and curing option adds an explosion relief panel and a powered
exhaust fan. With this option the exhaust fan operates continuously when
the product is switched on.
A pressure switch detects that there is sufficient air flow through the chamber. If the
pressure switch does not detect sufficient air flow, a fault light illuminates and heating
is disabled.
At least 610 mm free space must be left around the explosion relief panel to allow this
to break out if there is a rapid build up of pressure inside the chamber.
Please note that if the stoving and curing option is fitted, there may be an increase in
the power rating of the product. See the product rating label located on the side panel
of the product for correct power rating.
4.9.1 Pre-heater (if fitted)
Products with the stoving and curing option may also be fitted with a pre-heater that
pre-heats the incoming air to the same temperature set on the main controller.
The temperature of the pre-heater is controlled by the main controller, but measured
by a separate thermocouple.
4.10 Solenoid Valve with Manual Switch (if fitted)
If ordered the solenoid valve is operated using the panel mounted
switch. When the switch is in the 'ON' position the solenoid valve
will allow gas to
flow. Ensure the installation and use of the product does not create a hazardous
atmosphere. The workspace must have sufficient ventilation.
4.11 Exhaust Fan (if fitted)
To operate the exhaust fan use the fan switch on the control panel; this is
only functional when the instrument switch is on.
The level of air exhaust can be controlled by adjusting the slider under the
exhaust box.
17

When the exhaust fan is turned on, there may be a drop in internal temperature before
the product recovers to the setpoint value.
The airflow should be adjusted to the minimum required by the process to reduce the
amount of energy wasted in heating air.
18

5.0 Maintenance
5.1 General Maintenance
Preventive rather than reactive maintenance is recommended. The type and frequency
depends on the product use; the following are recommended.
5.2 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 tem-
perature 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 - check for splits or
fraying
Door Seal Replacement
Air Vent 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, fre-
quency dependent on the standard
required
Operational Check Check that all functions are working
normally
Operational Check Thorough inspection and report incor-
porating a test of all functions
19

Performance
Cooling Fans (if fitted) Check whether the cooling fans are
working
Circulating Fan
(if fitted) Visual check to see if it is running
Circulating Fan
(if fitted)
Check bearings and replace if neces-
sary
Element Circuit Electrical measurement
Power Consumption Measure the current drawn on each
phase / circuit
Shelves Visual check for fit and damage
20