VERDER CARBOLITE GERO Apex Series Manual

Installation, Operation and Maintenance Instructions
250°C Laboratory Fan Ovens - Apex Range: 30 Litres
R38 Controller
AX 30 + R38 Controller
MEN-AX030-001_R38 (01-08-2019)

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
2.2.1 Shelf Fitting 7
2.3 Electrical Connections 8
3.0 R38 Controller 10
3.1 PID control 10
3.2 Controller Operation 10
3.3 R38 Over-Temperature Controller 10
3.4 Process Timer (if fitted) 11
3.5 Calibration 11
3.6 Over-Temperature Control (if fitted) 12
3.7 Controller Replacement 12
3.8 Temperature Controller Replacement 12
4.0 Operation 13
4.1 Operating Cycle 13
4.2 The Oven Door and Chamber 13
4.3 Loading and Unloading the Chamber 13
4.4 Vents 14
4.5 Temperature Control 14
4.6 Explosive Vapours 14
5.0 Maintenance 15
5.1 General Maintenance 15
5.2 Maintenance Schedule 15
5.2.1 Cleaning 17
5.3 After-Sales Service 17
5.4 Recommended Spare Parts and Spare Parts Kit 17
5.5 Retrofit Kits 17
6.0 Repairs and Replacements 18
2

6.1 Safety Warning - Disconnection from Power Supply 18
6.2 Panel Removal 18
6.3 Temperature Controller Replacement 18
6.4 Control Sensor Replacement 18
6.5 Solid-state Relay Replacement 20
6.6 Fuse Replacement 20
6.7 Element Replacement 20
7.0 Fault Analysis 21
A. Oven Does Not Heat Up 21
B. Oven Overheats 21
C. Process Timer 22
8.0 Wiring Diagrams 23
8.1 WV-11-00 23
8.2 WV-11-01 24
9.0 Fuses and Power Settings 25
9.1 Fuses 25
9.2 Power Settings 25
10.0 Specifications 26
10.1 Environment 26
3

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.
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
Remove the shelves, runners and hangers from the packaging before installing 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, runners and hangers 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.
5
2.0 Installation

2.0 Installation
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.
6

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
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2.0 Installation

2.0 Installation
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
2.3 Electrical Connections
Connection by a qualified electrician is recommended.
8

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).
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:
9
2.0 Installation

3.0 R38 Controller
3.0 R38 Controller
3.1 PID control
This controller uses PID (Proportional Integral Derivative) temperature control. This
type of control uses a complex mathematical control system to adjust the heating
power and achieve the desired temperature.
3.2 Controller Operation
When switched on, the controller lights up, goes through a short test routine and then
displays the measured temperature and starts to control. The output light OUT1
indicates when heating is occurring.
To alter the setpoint, press the down arrow key once, “SPI” flashes. Then use the up
and down arrow keys to adjust the setpoint. Press the P key to accept.
3.3 R38 Over-Temperature Controller
When an R38 Controller is fitted to be used as an over-temperature controller, to
configure the setpoint:
lPress and hold the 'P' key until the display flashes 'SP'.
lPress the 'down' arrow key until the display shows 'AL'.
lPress the 'P' key to enable the setpoint option.
lUse the 'up' and 'down' arrow keys to select the required setpoint. The display will
flash between 'AL' and the setpoint value during this process.
lOnce you have input the required setpoint, press the 'P' key, followed by the 'U' key
to accept.
lThe display will flash 'AL' for 30 seconds before the setpoint is accepted.
Note that if the 'P' and 'U' keys are not pressed, the setpoint will be automatically
accepted after 30 seconds.
Over-Temperature Alarm
If the over-temperature alarm is tripped, then the 'OUT2' and 'AL' lights will illuminate in
the bottom right-hand corner of the controller.
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Resetting the Over-Temperature
To reset the over-temperature controller, power cycle the product by turning the
instrument switch off, then on again.
3.4 Process Timer (if fitted)
To set a process time:
Press the P key; t1 shows momentarily on the display and the SET/ CNT light flashes
quickly. Use the arrow keys to adjust the process time, which is in hours and minutes
(hr.mn). Wait 5 seconds without pressing a key, or press the U key once and the display
returns to normal.
If a process time of zero is set then the timer is disabled and the controller operates as
though the timer is not present.
To start the timer:
Press the U key once. Timing starts. The SET/ CNT light flashes slowly while timing is in
progress and the display counts down (at the end of each minute).
At the end of timing the OUT light comes on continuously and power to the temperature
controller is cut off.
To reset the timer after timing has finished:
Press the U key once. The timer is now idle: it is not stopping the oven from heating,
nor is it timing.
Power is only supplied to the temperature controller when the timer is reset or is timing.
To stop the timer during timing: press U during count down to stop the timer. The
temperature controller remains on. It is not possible to resume timing: pressing U again
will reset the timer.
3.5 Calibration
If the process requires an accurate temperature display it is possible to calibrate the
controller by entering a single temperature offset value as follows:
Please contact Carbolite Gero Service for detailed instructions on entering an offset in
the R38 Controller.
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3.0 R38 Controller

3.0 R38 Controller
3.6 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.
3.7 Controller Replacement
If the over-temperature trip operates, a click occurs and a warning light near the
thermostat lights up; the reset button on the thermostat pops out. The reset button is
hidden behind the control dial. To reset the oven it is necessary to turn the thermostat
dial until the hole lines up with the reset button and press it using a small diameter rod.
3.8 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.
Disconnect the product from the electrical supply and remove the cover (see section
6.0).
Make a note of all the wiring connections before disconnecting the wires. Loosen the
screw that holds the controller body clamp in place. Use a flat screwdriver or similar
object to ease apart the two plastic lugs on the side of the clamp and pull the instrument
forward out of the front control panel.
Reconnect the wires according to the notes made – or see section 8.0 for wiring details.
Note: If the product features an R38 over-temperature controller, then this should
be replaced using the same method described.
12

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.
This product has fan-assisted circulation; the fan is on when the instrument switch is on.
Turn on the instrument switch to activate the temperature controllers. The controllers
illuminate and go through a short test cycle.
If a process timer is not fitted, the controller becomes illuminated and goes through a
short test cycle according to the controller setpoint or program. If a timer is fitted, the
controller may not become illuminated when the unit is switched on – to start the
controller, press the U button on the timer once (see section 3.4).
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.
Unless a process timer is fitted and is off, the product starts to heat up according to the
controller set point.
The product will heat up according to the controller setpoint or program, unless a time
switch is fitted and switched off.
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.
4.2 The Oven Door and Chamber
It is recommended that the instrument switch is turned off if the oven door is to be
opened when the temperature is below 120 °C. If the door is opened when on and the
set temperature is below approximately 120 °C, then the controller will attempt to
compensate for the drop in temperature and the actual temperature may exceed the
set temperature when the door is closed again.
Please note that the fan is on when the instrument switch is on. Opening the door does
not switch off the fan.
The tip of the temperature sensor is visible on the right of the chamber, below the fan.
It is not electrically live, but it is delicate and should not be touched.
4.3 Loading and Unloading the Chamber
Where accurate temperature control of the load is important, use the central part of the
chamber and distribute the load to allow free air circulation. Do not place loads on the
chamber floor; use the bottom shelf.
13
4.0 Operation

4.0 Operation
Remember that the shelves and work pieces may be hot; use suitable
gloves or other handling equipment.
Have a heat-resistant surface available on which to place hot materials.
There is no physical stop to prevent shelf removal; take care not to pull out a shelf
accidentally.
Additional shelves may be obtained from Carbolite Gero. The maximum load for each
shelf is 10 kg.
The maximum number of shelves and the maximum load for the oven are listed below:
model maximum number
of shelves
maximum load
per shelf
maximum load
for product
AX 30 4 10 kg 20 kg
4.4 Vents
On the back of the product are two vents, covered by a sliding baffle
plate. The inlet vent is permanently open, while the outlet may be
opened or closed by means of the sliding plate.
The sliding plate gets hot. Do not touch it when the product is hot. Make adjustments
when the product is cold.
4.5 Temperature Control
The temperature is controlled by an easy-to-operate digital unit. The oven temperature
range is from 40 °C to 250 °C, though the minimum temperature may be higher if the
ambient temperature is above 30 °C.
A matching digital timer is available to order, or may be retro-fitted. A second option is
an over-temperature control device. There is also the option of a locking handle.
Temperature accuracy is enhanced by the use of a Type K thermocouple as the
temperature control sensor. A simple air-flow adjustment may be made by movement
of a sliding vent control mounted at the back of the oven. Typical air-flow with the vent
open is 1850 litres/ hour at 100 °C, giving exchanges in chamber volumes per hour of
65 (AX 30), 28 (AX 60) or 14 (AX 120).
4.6 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.
14

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 temperature and
check for an over-temperature alarm as
detailed in this manual
Over-Temperature Safety Circuit
(if fitted) Electrical measurement
Door Seal Visual inspection - check for splits or fray-
ing
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 nor-
mally
Operational Check Thorough inspection and report incor-
porating a test of all functions
Performance
15
5.0 Maintenance

5.0 Maintenance
Cooling Fans (if fitted) Check whether the cooling fans are work-
ing
Circulating Fan
(if fitted) Visual check to see if it is running
Circulating Fan
(if fitted) Check bearings and replace if necessary
Element Circuit Electrical measurement
Power Consumption Measure the current drawn on each
phase / circuit
Shelves Visual check for fit and damage
16

5.2.1 Cleaning
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.
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.
5.3 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.
5.4 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 a control sensor, a solid state relay, an element or set of elements,
a door seal and a fan kit (fan and motor assembly). Individual spare kits are also
available.
When ordering spare parts please quote the model details as requested above.
5.5 Retrofit Kits
Kits for process timer, over-temperature and locking handle are available. Instructions
for fitting these are supplied with the kits.
17
5.0 Maintenance

6.0 Repairs and Replacements
6.0 Repairs and Replacements
6.1 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.
6.2 Panel Removal
Disconnect the product from the electrical supply.
Side Cover. The complete right-hand side cover may be removed. Remove the screws
at the back that fasten the side cover to the rest of the casing. Push the section
backwards a few millimetres only, then ease it sideways (to the right) off the main case.
Disconnect the earth (ground) wire.
When reassembling take time and care in locating the tabs on the right of the front
control panel into the matching slots in the side cover. Remember to reconnect the
earth wire.
Internal Element Cover. Open the door. Loosen the screw holding the internal side
cover. Pull the cover forward a few millimetres and lift it off to the left.
6.3 Temperature Controller Replacement
Refer to the controller instructions for more information on how to replace the
temperature controller.
6.4 Control Sensor Replacement
Disconnect the product from the electrical supply and remove the side cover and
internal element cover. See section 6.2.
Make a note of the connections to the temperature controller. Disconnect the
connections.
Disconnect any fixing clips or screws inside the product's chamber and remove the
sensor.
Re-assemble with the new sensor. Take care not to damage the head by rough
handling.
18

Check that the product is controlling properly, ensuring that the original fault was with
the temperature sensor.
19
6.0 Repairs and Replacements

6.0 Repairs and Replacements
6.5 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.
6.6 Fuse Replacement
Fuses are marked on the wiring diagram with type codes, e.g. F1, F2. For more
information on fuses refer to section 9.0.
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.
6.7 Element Replacement
Disconnect the product from the supply and remove the side cover and internal element
cover. See section 6.2. The element terminals are low down in the side compartment.
lDisconnect the wires from the heating element terminals.
lRemove any starlock washers - these may need to be cut with wire cutters.
lRemove any clips holding the element inside the chamber and withdraw the ele-
ment.
lReverse the procedure when fitting the new heating element.
lTo find out whether the heating element failure was caused by a fault in the control
circuit, operate the product at a low temperature and check that it is functioning cor-
rectly.
20