VERDER CARBOLITE GERO TLD 28 Manual

Installation, Operation and Maintenance Instructions
400 °C Annealing Ovens - TLD Model: 28 Litres
No Controller
TLD 28 + No Controller
MEN-TLD28-002_NOCTRL (10-01-2019)

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
2.3 Electrical Connections 6
3.0 Temperature Controller 8
4.0 2132 Over-Temperature Controller Description (if fitted) 9
4.1 Description 9
4.2 Operation 9
4.2.1 Controls 9
4.2.2 Operation 10
4.2.3 Over-Temperature Operation 10
4.2.4 Over-Temperature Alarm 10
4.2.5 Resetting the Over-Temperature Alarm 10
4.2.6 Sensor Break 10
4.3 Audible Alarm 11
4.4 Navigation Diagram 11
5.0 Operation 12
5.1 Operating Cycle 12
5.2 Operating Program 12
5.3 Over-Temperature Control (if fitted) 13
5.4 Solenoid Valve with Manual Switch (if fitted) 13
6.0 Maintenance 14
6.1 General Maintenance 14
6.2 Maintenance Schedule 14
6.2.1 Cleaning 16
6.3 Calibration 16
6.4 After-Sales Service 16
6.5 Recommended Spare Parts and Spare Parts Kit 16
6.6 Power Adjustment 16
2

7.0 Repairs and Replacements 17
7.1 Safety Warning - Disconnection from Power Supply 17
7.2 Safety Warning - Refractory Fibre Insulation 17
7.3 Panel Removal 17
7.4 Temperature Controller Replacement 18
7.5 Thermocouple Replacement 18
7.6 Element Replacement 18
7.7 Fuse Replacement 18
7.8 Solid-State Relay Replacement 19
8.0 Fault Analysis 20
A. Oven Does Not Heat Up 20
B. Oven Overheats 20
9.0 Wiring Diagrams 21
9.1 WV-11-00 21
9.2 WS-02-04 - Alarm-Operated Fan 22
10.0 Fuses and Power Settings 23
10.1 Fuses 23
10.2 Power Settings 23
11.0 Specifications 24
11.1 Environment 24
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.
Solenoid valve (if fitted): see section 5.4 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.
DANGER – Read any warning printed next to this symbol.
Caution – Double Pole/Neutral Fusing
4

2.0 Installation
2.1 Unpacking and Handling
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 as required.
NOTE: This product contains Refractory Ceramic Fibre (also known as
Alumino Silicate Wool - ASW). For precautions and advice on handling
this material see section 7.2.
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.
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.
During the operation of the product, hot air is exhausted from the vent on the top of the
product while the cooling blower is in operation; there must be clearance of at least 500
mm between the top of the product and any surface which must be made of non-
combustible material.
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.
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.
6

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:
7
2.0 Installation

3.0 Temperature Controller
3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
8

4.0 2132 Over-Temperature Controller Description (if
fitted)
4.1 Description
Key
A Alarm Light
B Page
C Scroll
D Down
E Up
F Display
This over-temperature controller is fitted and supplied ready to use by Carbolite Gero.
It is a digital instrument with a latching alarm, requiring no additional panel controls.
The controller features easy setting of over-temperature setpoint and reading of
current temperature by the over-temperature sensor.
4.2 Operation
4.2.1 Controls
Most Carbolite Gero products are fitted with an instrument switch which cuts off power
to the controller and other parts of the control circuit.
To operate the controller, power must be supplied to the product and the instrument
switch must be on. If a time switch is included in the product circuit, this must be in the
'ON' position.
When an over-temperature condition occurs, the controller cuts the power to a
contactor, which in turn cuts power to the heating elements. Power is not restored until
the controller is 'reset'.
Some components will operate after the over-temperature feature isolates the power
supply e.g. cooling fans will continue to operate, provided that there is a power supply
to the product. In some cases the product may not do so, if other options (such as a
door switch) are fitted.
9
4.0 2132 Over-Temperature

4.0 2132 Over-Temperature
4.2.2 Operation
When switched on, the controller lights up, goes through a short test routine and then
displays the measured temperature or the over-temperature setpoint.
The page key allows access to parameter lists within the controller.
A single press of the page key displays the temperature units, normally set to °C;
further presses reveal the lists indicated in the navigation diagram. See section 4.4.
The scroll key allows access to the parameters within a list. Some parameters are
display-only; others may be altered by the operator.
A single press of the scroll key in the 'Home' list displays the temperature units;
further presses reveal the parameters in the current list indicated in the navigation
diagram.
To return to the 'Home' list at any time, press page and scroll together, or wait
for 45 seconds.
The down and up keys are used to alter the setpoint or other parameter values.
4.2.3 Over-Temperature Operation
Use down and up to alter the over-temperature setpoint. This should normally be
set a little above the working temperature (for example 15 °C above). The product is
supplied with the over-temperature set at 15 °C above the furnace or oven maximum
working temperature.
Press scroll twice view the present temperature as measured by the over-
temperature controller. Press it twice, the first press shows the temperature units (°C).
4.2.4 Over-Temperature Alarm
If an over-temperature condition occurs, the OP2 indicator flashes and an alarm
message 2FSH also flashes, alternating with the setpoint. Power to the heating
elements is disconnected.
4.2.5 Resetting the Over-Temperature Alarm
To acknowledge the alarm press scroll and page together.
If the alarm is acknowledged while there is still an over-temperature condition, the OP2
indicator stops flashing but continues to glow. The 2FSH alarm continues to flash until
the over-temperature condition is cleared (by the temperature falling), when normal
operation resumes.
If the alarm is acknowledged when the temperature has dropped (or after the over-
temperature setpoint has been raised) so that the over-temperature condition no longer
exists, then the furnace or oven immediately resumes normal operation.
4.2.6 Sensor Break
The over-temperature cut-out system also operates if the over-temperature control
thermocouple breaks or becomes disconnected. The message S.br flashes where the
measured temperature is normally displayed.
10

4.3 Audible Alarm
If an audible alarm is supplied for use with the over-temperature controller, it is
normally configured to sound on over-temperature condition and to stop sounding when
the alarm is acknowledged as given in section 4.2.
Note: the alarm may sound during controller start-up.
4.4 Navigation Diagram
HL Home List Page Key Black = Progress
OTSP Over-Temperature
Setpoint Scroll Key
Dashed = Through to
other options
AL Access List For factory access to list and parameters not
available to the operator.
11
4.0 2132 Over-Temperature

5.0 Operation
5.0 Operation
5.1 Operating Cycle
The product has fan-assisted circulation which operates when the instrument switch is
switched on.
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.
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.
5.2 Operating Program
The program consists of the stages shown in the graph below. The rates of temperature
rise, dwell temperature and dwell times are all adjustable by the operator. The general
format of the program is installed at the manufacturing stage, with initial values as
shown in the table below.
Function Initial Setting Program
1 Start
2Heat at a
controlled rate
heat up at 480 °C/ hour to
300 °C
SEG n 1 rmP.r
tGt 300 °C
rAtE 8 °C per min
3Dwell for a pre-set
period dwell at 300 °C for 1 hour SEG N 2 dweLL
1 hour
4Cool at a controlled
rate
Cool to 80 °C assisted by
inlet blower
SEG n 3 rmP.r
tGt 80 °C
rAtE 20 ° C per min
5Dwell for a pre-set
period 80 °C for 12 hours SEG n 4 dweLL 12 hours
6Cool naturally to
room temperature SEG n 5 SteP
0 °C
7 Finish SEG n 6 End
This program causes the chamber to heat up at 480 °C per hour to a temperature of
300 °C. The temperature remains at 300 °C for 1 hour. At the end of the 1 hour dwell
the setpoint changes to 80 °C and the product cools down as quickly as possible to this
12

temperature. The rate of cooling is quite fast because of the air inlet blower which is
incorporated in the oven. When the chamber temperature reaches 80 °C the second
dwell period starts and the product remains at 80 °C for 12 hours. At the end of 12
hours the heaters are switched off and the product cools naturally to room
temperature.
5.3 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.
5.4 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.
13
5.0 Operation

6.0 Maintenance
6.0 Maintenance
6.1 General Maintenance
Preventive rather than reactive maintenance is recommended. The type and frequency
depends on the product use; the following are recommended.
6.2 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 the relevant controller manual
Over-Temperature Safety Circuit
(if fitted) Electrical measurement
Door Seals Visual inspection, check for splits or fray-
ing
Door Seals 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 clean-
ing 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
14

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
15
6.0 Maintenance

6.0 Maintenance
6.2.1 Cleaning
Soot deposits may form inside the furnace, depending on the process. At appropriate
intervals remove these by heating as indicated in the General Operation Notes.
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.
6.3 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.
6.4 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.
6.5 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.
Please consult Carbolite Gero's Sales Department for details of recommended spare
parts.
6.6 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.
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 10.0 for details of power limit settings.
16

7.0 Repairs and Replacements
7.1 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.
7.2 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.
7.3 Panel Removal
Disconnect the product from the electrical supply.
17
7.0 Repairs and Replacements

7.0 Repairs and Replacements
To replace components (except controller), remove the front panel. Depending on the
component, it may be necessary to remove an internal panel. If in doubt, please consult
Carbolite Gero’s technical department.
7.4 Temperature Controller Replacement
Refer to the controller instructions for more information on how to replace the
temperature controller.
7.5 Thermocouple Replacement
Disconnect the product from the power supply. Remove terminal cover 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
Disconnect the thermocouple from its terminal block and withdraw the thermocouple
from its sheath by bending the metal tag or releasing the screw to release. It is also
advisable to remove the sheath and shake out any broken pieces of thermocouple.
Re-assemble with a new thermocouple, observing the colour coding, ensuring that the
thermocouple is not twisted as it is being inserted and that the metal tag is bent back to
grip the sheath.
Refit the element access panel.
7.6 Element Replacement
Remove front panel and the internal cover as necessary and locate the element
terminals.
Disconnect the wires from the element terminals. Remove any starlock washers - these
may need to be cut with wire cutters. Remove any clips holding the element inside the
chamber and withdraw the element.
Reverse the procedure with the new element.
To find out whether the element failure was caused by a fault in the control circuit,
operate the product at a low temperature and check that it is functioning correctly.
7.7 Fuse Replacement
Fuses are accessed by removal of the panel as explained in '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.
18

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.
7.8 Solid-State Relay Replacement
Disconnect the product from the power supply and remove the
appropriate cover as given above.
Make a note of the wire connections to the solid state relay and disconnect them.
Remove the solid state relay from the base panel or aluminium plate.
Replace and reconnect the solid state relay ensuring that the bottom of it has good
thermal contact with the base panel or aluminium plate.
Replace the access panel.
19
7.0 Repairs and Replacements

8.0 Fault Analysis
8.0 Fault Analysis
A. Oven Does Not Heat Up
1.
The
temperature
controller is
OFF
No power from
supply Check the fuses in the supply line
2.
The
temperature
controller is
ON
The controller
shows a very high
temperature or a
code such as EEE
or --- or S.br
The temperature sensor has broken
or has a wiring fault
The controller
shows a low
temperature
The SSR could be failing to switch
on due to internal failure, faulty
logic wiring from the controller, or
faulty controller
There are no lights
glowing on the
controller
The controller may be faulty or not
receiving a supply due to a faulty
switch or a wiring fault
B. Oven Overheats
1.
Oven only
heats up
when the
instrument
switch is ON
The controller
shows a very high
temperature
The controller is faulty
The controller
shows a low
temperature
The thermocouple may have been
shorted out or may have been
moved out of the oven
The thermocouple may be
connected the wrong way round
The controller may be faulty
2.
Oven heats
up when the
instrument
switch is OFF
The SSR has failed
"ON"
Replace the SSR. Check for an
accidental wiring fault which could
have overloaded the SSR
20