VERDER CARBOLITE GERO +GP 220 No Controller Manual

Installation, Operation and Maintenance Instructions
300°C General Purpose Oven - GP A/B Models: 220 Litres
No Controller
GP 220 + No Controller
MEN-GP220AB-005_NOCTRL (07-03-2023)

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
2.3 Flat Pack Stand (optional) 8
2.3.1 Parts Supplied 8
2.3.2 Flat Pack Stand Assembly 9
2.4 Electrical Connections 10
3.0 Temperature Controller 12
4.0 Operation 13
4.1 Operating Cycle 13
4.2 Over-Temperature Control (if fitted) 13
4.3 Vents 14
4.4 Temperature Uniformity 14
4.5 Explosive Vapours 14
4.6 Atmospheres 15
4.7 Interior Light (if fitted) 15
4.8 Solenoid Valve with Manual Switch (if fitted) 15
4.9 Variable Speed Fan (if fitted) 15
4.10 Exhaust Fan (if fitted) 15
4.11 Stoving and Curing (if fitted) 16
4.11.1 Pre-heater (if fitted) 16
4.12 Door Switch (if fitted) 16
5.0 Maintenance 17
5.1 General Maintenance 17
5.2 Maintenance Schedule 17
5.2.1 Cleaning 19
5.3 Calibration 19
5.4 After-Sales Service 19
5.5 Recommended Spare Parts and Spare Parts Kit 19
5.6 Power Adjustment 19
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6.0 Repairs and Replacements 21
6.1 Safety Warning - Disconnection from Power Supply 21
6.2 Safety Warning - Refractory Fibre Insulation 21
6.3 Panel Removal 21
6.4 Temperature Controller Replacement 22
6.5 Fuse Replacement 22
6.6 Element Replacement 22
6.7 Thermocouple Replacement 22
6.8 Solid-state Relay Replacement 23
7.0 Fault Analysis 24
A. Oven Does Not Heat Up 24
B. Oven Overheats 24
8.0 Wiring Diagrams 25
8.1 WV-11-01 25
8.2 WS-10-01 - Isolating for 208 V version only 26
9.0 Fuses and Power Settings 27
9.1 Fuses 27
9.2 Power Settings 27
10.0 Specifications 28
10.1 Environment 28
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1.0 Symbols and Warnings
1.1 Switches and Lights
Instrument switch: when the instrument switch is operated the
temperature control circuit is energised.
Interior light: when the interior light switch is operated the interior
light illuminates.
Solenoid valve (if fitted): see section 4.8 for full details
Variable speed fan (if fitted): see section 4.9 for full details
Exhaust fan (if fitted): see section 4.10 for full details
Stoving and curing (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.
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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
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2.0 Installation
2.1 Unpacking and Handling
When unpacking or moving the product, always lift by its base; do not use the door or
any other projecting cover or component to support the equipment when moving it. Use
a fork lift or pallet truck to move the product; position the product on a level surface
and use an adequate number of personnel to safely move the product into position.
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 as required.
Some models may be lifted by fitting lifting bolts to captive threads which are fitted in
the top of the case, whilst others may have welded on lifting eyes.
Note: This product contains Refractory Ceramic Fibre (also known
as Alumino Silicate Wool - ASW). For precautions and advice on
handling this material see section 6.2.
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.
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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.
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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
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2.3.2 Flat Pack Stand Assembly
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2.4 Electrical Connections
Connection by a qualified electrician is recommended.
Some models may be ordered for 3-phase use, which may be star or delta.
Check the product rating label before connection. The supply voltage should agree with
the voltage on the label and the electrical supply capacity should be sufficient for the
current on the label.
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A table of the most common fuse ratings is also given in section 9.0 towards the back
of this manual. Ensure that the correct fuse is used for the product supplied. When the
mains cable is factory fitted internal fuses are also fitted. Customer fusing is essential.
Product with supply cable: either wire directly to an isolator or fit with a line plug.
Product without supply cable: a permanent connection to a fused and isolated supply
should be made to the internal terminals after temporary removal of the product
access panel. The access panel is located at the top of the 'A' models and the right
hand side of the 'B' models.
Connection by line plug: the plug should be within reach of the operator and should be
easy to remove.
Connection to isolating switch: this should operate on both conductors (single phase)
or on all live conductors (three phase), and should be within reach of the operator.
The electrical 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:
3-phase L1 Black to 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.
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3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
12

4.0 Operation
4.1 Operating Cycle
The product is fitted with an instrument switch. The switch cuts off power to the
controllers and elements. The circulation fan will operate when the instrument switch is
on. An optional door switch may be fitted. If so, ensure that the door is closed to
operate the fans and heating elements.
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 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.
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 switch the product off, turn off the instrument switch. If the product is to be left
unattended, isolate the electricity supply.
DO NOT switch off if the temperature is above 100 °C - damage could be caused to the
fan and motor. Adjust the controller to allow the temperature to fall.
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.
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4.3 Vents
This product has two vents, each 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.
Note: The sliding plate gets hot. Do not touch it when the product
is hot! Only make adjustments when the product is cold.
On vertical (A) models, the vents are located on the side of the unit.
On horizontal (B) models, the two vents are located on the top of the unit.
1 Outlet
2 Inlet
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.
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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 Interior Light (if fitted)
If fitted, the interior light is operated using the panel mounted switch.
It will only operate when the instrument switch is on.
4.8 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.
4.9 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.
4.10 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.
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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.
4.11 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.
4.11.1 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.
4.12 Door Switch (if fitted)
If ordered, the door switch will isolate the heating elements and circulation fan. The
door switch is operated when the door is opened causing the heating elements and air
circulation fan to be switched off.
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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
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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
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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 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.
5.4 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.
5.5 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 a fan and motor assembly, a thermocouple, a solid state relay, an
element (or set of elements) and a door seal. Individual spare parts are also available.
When ordering spare parts please quote the model details as requested above.
5.6 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.
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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 9.0 for details of power limit settings.
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