VERDER CARBOLITE GERO GPC 12/200 Handbuch

Installation, Operation and Maintenance Instructions

1200°C Chamber Furnace - GPC Model: 200 Litres

No Controller

GPC 12/200 + No Controller

MEN-GPC12200-05_NOCTRL (06-08-2019)

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 & Handling 5

2.2 Siting and Setting Up 5

2.3 Hearth 6

2.4 Chimney 7

2.5 Electrical Connections 7

2.6 Voltage and Power Limit 9

3.0 Temperature Controller 10

4.0 2132 Over-Temperature Controller Description (if fitted) 11

4.1 Description 11

4.2 Operation 11

4.2.1 Controls 11

4.2.2 Operation 12

4.2.3 Over-Temperature Operation 12

4.2.4 Over-Temperature Alarm 12

4.2.5 Resetting the Over-Temperature Alarm 12

4.2.6 Sensor Break 12

4.3 Audible Alarm 13

4.4 Navigation Diagram 13

5.0 Operation 14

5.1 Operating Cycle 14

5.2 General Operating Notes 14

5.3 Use of Probes 15

5.4 Atmospheres 15

5.5 Operator Safety 15

5.6 Power Adjustment 16

6.0 Maintenance 17

6.1 General Maintenance 17

6.2 Maintenance Schedule 17

6.2.1 Cleaning 19

6.2.2 Safety Switch 19

6.3 Calibration 19

6.4 After-Sales Service 20

6.5 Recommended Spare Parts and Spare Parts Kit 20

7.0 Repairs and Replacements 21

7.1 Safety Warning - Disconnection from Power Supply 21

7.2 Safety Warning - Refractory Fibre Insulation 21

7.3 Temperature Controller Replacement 21

7.4 Solid-State Relay Replacement 22

7.5 Thermocouple Replacement 22

7.6 Element Replacement (Industrial Models) 23

7.7 Fuse Replacement 23

8.0 Fault Analysis 25

A. Furnace Does Not Heat Up 25

B. Product Overheats 26

9.0 Wiring Diagrams 27

9.1 WA-33-30 27

9.2 WA-33-31 28

9.3 WA-U3-30 29

9.4 WA-U3-31 31

10.0 Fuses and Power Settings 33

10.1 Power Settings 33

11.0 Specifications 34

11.1 Environment 34

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.

Heat light: the adjacent light glows or flashes to indicate that power

is being supplied to the elements.

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

2.0 Installation

2.1 Unpacking & 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.

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.

2.0 Installation

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 Hearth

The product is supplied with the hearth tiles supported in place by a timber batten or

steel plate held by a jacking bolt fixed through the roof chimney hole.

To remove, take off the roof panel and unscrew the bracket complete with the jacking

rod assembly.

Fit the product chimney before replacing the roof panel.

Fit the door counterbalance weights to the door shaft such that the locking screws lock

into the countersunk holes.

Note that one of the weights has a flat surface on the boss opposite the locking screw.

This weight goes on the side by the limit switch assembly such that the plunger of the

switch is depressed when the door is opened.

2.4 Chimney

The chimney is a length of tubing. If it is supplied unfitted, then fit it through the hole in

the top of the case.

If the product is to be used to heat substances that emit fumes, a fume extraction duct

of approximately 75 mm - 150 mm inlet diameter may be placed directly above the

chimney outlet.

Do not make a sealed connection to the product chimney as this causes excessive

airflow through the chamber and results in poor temperature uniformity.

Key

A Duct (75mm-150mm diameter)

B Ambient air is drawn into duct

C Chimney

D 25mm vertical gap between chimney and duct

2.5 Electrical Connections

Connection by a qualified electrician is recommended.

The model covered in this manual has three internal circuits and is normally supplied for

connection to a three phase power supply. This may be either star or delta, but a

product must only be connected to the type and voltage of supply for which it was

made. If the product is ordered for a single phase supply, this may be Live to Neutral

reversible or non-reversible, 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

2.0 Installation

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:

2- or

3-phase L1 Black to phase 1

L2 Black to phase 2

L3 Black to phase 3 (except 2-phase)

N Light Blue to neutral (except delta)

PE Green/ Yellow to earth (ground)

2.6 Voltage and Power Limit

When first starting up the product, check the setting of the OP.Hi

parameter (see the controller instructions) and compare it with the data

in section 10.0 towards the back of this manual.

If the power limit setting is incorrect for the voltage of the electrical supply, change it.

This must be done immediately if the setting of OP.Hi is higher than it should be.

2.0 Installation

3.0 Temperature Controller

3.0 Temperature Controller

If this product is fitted with a temperature controller, instructions are provided

separately.

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