VERDER CARBOLITE GERO LGP 6/2160 Handbuch

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

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

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.

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.

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.

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.

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.

3.0 Temperature Controller

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

separately.

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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