VERDER CARBOLITE GERO LGP 6/2160 Manual

Installation, Operation and Maintenance Instructions
625°C Large General Purpose Oven - LGP Model: 2160 Litres
No Controller
LGP 6/2160 + No Controller
MEN-LGP6216-001_NOCTRL (18-10-2021)

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 Warnings 4
2.0 Installation 5
2.1 Unpacking and Handling 5
2.2 Siting and Setting Up 5
2.3 Electrical Connections 6
2.4 Fan Rotation Indicator 7
3.0 Temperature Controller 9
4.0 Operation 10
4.1 Operating Cycle 10
4.1.1 Exhaust Fan Adjustment 11
4.2 Operating Cycle 11
4.2.1 Heating Element Over-Temperature Protection 12
4.3 Over-Temperature Control (if fitted) 12
4.4 Explosive Vapours 12
4.5 Exhaust Fan (if fitted) 12
4.6 Door Switch (if fitted) 13
4.7 Loading and Unloading Chamber 13
5.0 Maintenance 14
5.1 General Maintenance 14
5.2 Maintenance Schedule 14
5.2.1 Cleaning 16
5.3 Calibration 16
5.4 After-Sales Service 16
5.5 Recommended Spare Parts and Spare Parts Kit 16
5.6 Power Adjustment 16
6.0 Repairs and Replacements 18
6.1 Safety Warning - Disconnection from Power Supply 18
6.2 Safety Warning - Refractory Fibre Insulation 18
6.3 Panel Removal 18
6.4 Temperature Controller Replacement 19
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6.5 Fuse Replacement 19
6.6 Element Replacement 19
6.7 Thermocouple Replacement 20
6.8 Solid-State Relay Replacement 20
7.0 Fault Analysis 21
A. Oven Does Not Heat Up 21
B. Oven Overheats 21
C. Recirculation Fans Continue to Run 22
8.0 Wiring Diagrams 23
9.0 Fuses and Power Settings 24
9.1 Fuses 24
9.2 Power Settings 24
10.0 Specifications 25
10.1 Environment 25
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1.0 Symbols and Warnings
The following information includes different product options. They may not all apply to
your product.
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.
Exhaust fan (if fitted): see section 4.5 for full details
Supply Light: when the product is connected to the electrical
supply the light in the adjacent switch glows
1.2 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.
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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
Note: This LGP oven is supplied with a floor stand that elevates it approximately 500
mm off the ground.
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.
2.3 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.
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.
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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.
2.4 Fan Rotation Indicator
Note: Do not connect an oven ordered for three phase use to a single phase supply
or to the wrong type of three phase supply.
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Check that the fan motor rotation is as shown on the fan motor(s). If it is incorrect
change the phase rotation of the incoming supply to achieve correct rotation.
The correct rotational direction is essential to achieve the specified temperature
uniformity.
8

3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
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4.0 Operation
4.1 Operating Cycle
Note: The customer is responsible for conducting their own risk
assessment prior to operating this product.
Note: Always ensure that the operator is wearing the appropriate PPE
when operating this product. Please consult your Health and Safety
personnel.
1. After installing all equipment and accessories as required, connect the product to
the electrical supply.
2. Turn on the mains isolator to activate the temperature controllers. The controllers
will illuminate and go through a short test cycle. The "SUPPLY" and
"OVERTEMP.ALARM" lamps will illuminate.
3. Press the "OVERTEMP. RESET" button to reset the over-temperature alarm. This
must be done every time the oven is powered on.
4. Turn the "OVEN" switch to "ON". The oven will not begin to heat until the external
extraction is turned on.
Note: The external extraction system is provided and managed by the
customer.
5. Set up the temperature controllers as required. Please refer to the separate tem-
perature controller manual for details on controller operation.
6. If the product is fitted with over-temperature protection, set the required over-
temperature setpoint according to the instructions detailed in the separate con-
troller manual.
7. Turn on the external extraction. The "EXTERNAL EXTRACTION ON" lamp will illu-
minate.
8. If a setpoint has been set on the main controller, either manually or via a pro-
gram, the product will begin to heat up.
9. Proceed with your heating process.
10. When the "DOORLOCK" switch is set to "AUTO", the door will lock automatically
when the temperature is above 80 °C, and remain locked until the temperature
drops below 80 °C.
11. When the "DOORLOCK" switch is set to "UNLOCKED", the automatic door lock is
disabled and the customer will be able to open the door at any temperature.
12. If the product is fitted with over-temperature protection and the over-temperature
alarm is triggered, press the "OVERTEMP. RESET" button to acknowledge the
alarm. The oven will not continue heating until the temperature has dropped below
the programmed over-temperature setpoint.
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Note: It is not necessary to acknowledge the over-temperature alarm by
pressing the buttons on the over-temperature controllers. Only press the
"OVERTEMP. RESET" button.
13. To switch off power to the heating elements, reduce the setpoint to 0°C on the
main temperature controller.
14. If at any point the external extraction system fails, the "AIR FLOWALARM" lamp
will illuminate.
15. If the explosion relief panel ruptures, the "EXPLOSION RELIEF FAILED" lamp will
illuminate.
16. Switching off the mains isolator will cut power to the heating elements and tem-
perature controller(s).
Note: 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.
Note: If the product is to be left switched off and unattended, isolate it from the
mains electrical supply.
4.1.1 Exhaust Fan Adjustment
To adjust the speed of the exhaust fan, edit "CH1 User Val" in each segment of the
controller program. The value is presented as a percentage e.g. 100 = 100% full
power.
Note: Please refer to the separate Nanodac controller manual for details on how to
edit "Ch1 User Val".
4.2 Operating Cycle
Switch on the mains isolator, the mains on light should glow.
The controller becomes illuminated and goes through a short test cycle. The circulation
fan operates when the oven switch is switched on.
Both the mains on light and overtemperature alarm light will be illuminated. Press the
blue “Over temp reset” button on the front of the control panel.
A simple up and down set point can be entered in the controller or a program can be
created in Program Edit on level 2 (see controller manual).
Adjust the temperature controller – see the controller manual.
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
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isolated. Find and correct the cause before resetting the over-temperature controller
according to the instructions supplied.
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.
To turn the oven off, set the oven switch to it’s off position. If the oven is to be left off
unattended, isolate it from the electrical supply.
4.2.1 Heating Element Over-Temperature Protection
An over-temperature controller is fitted as standard and will normally need no further
adjustment.
It is typically set to 400°C, and if the on/off switch is used to turn off the oven when
the elements are hot, the recirculation fans continue to run to cool the oven in order to
prevent damage to the elements and fans.
DONOT use the main electrical isolator to switch the oven off during normal
operation, or this function will be lost.
4.3 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.
4.4 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.
4.5 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.
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.
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4.6 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.
4.7 Loading and Unloading 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.
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.
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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 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
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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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 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.
6.3 Panel Removal
Control panel:
Unlock the latch and open the hinged doors to gain access to the rear of the control
panel.
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Internal Element Cover/Air Guide:
Attention to either the fan or the heaters is achieved by opening the air guide.
The air guide is a one piece unit which is released without removal of any screws. Open
the door and remove the shelves and the right hand side shelf runners. The air guide is
hinged and swings open to reveal the fans and heaters after removal of the retaining
pins.
6.4 Temperature Controller Replacement
Refer to the controller instructions for more information on how to replace the
temperature controller.
6.5 Fuse Replacement
Fuses are accessed by removal of the appropriate panel, as described in the 'Panel
Removal' section. Depending on the model, supply fuses and control circuit fuses may
be mounted in their own holders, or may be on a circuit board that contains an EMC
filter. The fuses are marked with their ratings.
Take care not to disconnect the wires leading from the EMC filter without first recording
their positions: they must be reconnected to the correct terminals.
6.6 Element Replacement
See section 6.3 for details on how to gain access.
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.
Compression fittings are only fitted to moisture extraction and stoving and curing
products. If fitted, ferrules need replacing.
Old elements may be to be cut to remove from the oven.
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6.7 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
Undo any clips holding the thermocouple. Remove the air guide from the oven
chamber. Disconnect the thermocouple from its terminal block. Unscrew the
compression fitting inside the chamber and pull the thermocouple into the chamber.
Cut through the thermocouple behind the olive and remove the two parts. Loosely
assemble compression fitting with a new ferrule. Feed in new thermocouple through
from the back. Tighten the compression fitting. Refit the air guide. Bend the
thermocouple to match the shape of the previous part and refit any clips.
Refit the element access panel.
Compression fittings are only fitted to moisture extraction and stoving and curing
products. If fitted, ferrules need replacing.
6.8 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.
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