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
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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
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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.
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.
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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.
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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:
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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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