Carbolite Gero GPCMA 174, Installation And Operation Instructions Manual

Page 1: ...Installation and Operation Instructions 1000 1150 C Retort Chamber Furnace Model GPCMA 174 litres GPCMA 174 MEN GPCMA174 IO 07 07 2021...

Page 2: ...bre Insulation 10 3 0 Product Overview 12 3 1 Product Rating Label 12 3 2 Part Identification 13 3 3 Dimensions 14 4 0 Specifications 16 5 0 Electrical Specifications 17 5 1 Fuses and Power Settings 1...

Page 3: ...Function Checks 35 10 0 Operation 36 10 1 Safe Operation 36 10 2 Door Operation 36 10 3 Basic Operating Cycle 37 10 4 Vacuum Operation and Process Gas Control if fitted 38 10 4 1 Programming Example...

Page 4: ...13 0 Decommissioning Storage and Disposal 47 13 1 Decommissioning 47 13 2 Storage Long Term 47 13 3 Disposal 47 4...

Page 5: ...ct is used for any application other than its intended purpose as stated by Carbolite Gero the protection provided by this equipment may be impaired Note Failure to comply with the instructions as sta...

Page 6: ...The customer is responsible for providing and maintaining the connections for the electrical power supply inert gas supply and cooling water supply and drain The furnace should not be operated until...

Page 7: ...is responsible for ensuring that all of the above conditions are satisfied before the product is commissioned for use Note Unless otherwise specified the customer is responsible for the installation o...

Page 8: ...ment Disconnect the product from the power supply before performing any maintenance Wear eye protection Wear a heat resistant face shield Wear heat resistant gloves Wear breathing apparatus Wear prote...

Page 9: ...oduct to cook or heat food or beverages DO NOT dispose Recycle according to WEEE Regulation guidelines 2 2 Operator Safety Note It is the responsibility of the customer to ensure that all personnel re...

Page 10: ...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 boar...

Page 11: ...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 11...

Page 12: ...product s covered by this manual 1 UKCA Mark 2 Carbolite Gero address and website 3 CE Mark 4 Country of Origin 5 Product Model 6 Year of Manufacture 7 Dispose of according to WEEE reg ulations Waste...

Page 13: ...ambda Sensor 4 Retort pressure relief valve 5 Retort cooling water inlet outlet 6 Door gear assembly 7 Retort door 8 Retort securing nuts 9 Electrical door interlock 10 Flowmeter Digital Analogue Mass...

Page 14: ...control panel G Width of unit door closed H Width of unit maximum with door open I Depth of unit from pivot point to fur nace back panel J Height from floor to base of retort K Depth of retort interna...

Page 15: ...dimensions may change depending on the controller options ordered Please refer to the separate product documentation pack for details relevant to your furnace For models ordered with vacuum retorts t...

Page 16: ...314 Stainless Steel 1100 Inconel 601 1150 Haynes 230 Maximum Continuous Operating Temperature C 900 310 Stainless Steel 950 314 Stainless Steel 1000 Inconel 601 1050 Haynes 230 Note Please refer to th...

Page 17: ...in the product document pack provided with this product 5 2 Operating Storage Environment The products covered by this manual contain electrical parts and should be stored and used in indoor conditio...

Page 18: ...m Operating Temperature 310 Stainless Steel 1000 C 314 Stainless Steel 1050 C Inconel 601 1100 C Haynes 230 1150 C Note When a furnace is ordered with the vacuum option a specially designed vacuum ret...

Page 19: ...located at the rear of the trolley If the loading trolley option has been ordered the furnace will be fitted with two guides beneath the frame into which the lower portion of the trolley locates This...

Page 20: ...operate based on a temperature limit Note If a gas system is fitted the electrical door interlock will also activate if the gas is flowing The door interlock is activated when the temperature of the p...

Page 21: ...ow rate electronically but do not control the flow gas flow rates are set manually via needle valves Data can be read on the front panel display and is also transmitted to the temperature programmer a...

Page 22: ...oduces fumes offgassing then a higher process flow rate may be required to compensate 6 6 Forced Cooling Option if fitted The forced cooling system blows room temperature air around the outside of the...

Page 23: ...23...

Page 24: ...Automatic Vacuum Option if fitted The purpose of the cold vacuum system is to reach low oxygen levels within the furnace retort as quickly as possible This is achieved by pulling a rough vacuum in the...

Page 25: ...delivery are present and undamaged before proceeding to install the product For safety and manoeuvrability the product is delivered secured to a pallet inside a crate It is advised that the product i...

Page 26: ...o easily and safely use the equipment The product should be placed on a non flammable surface resistant to the accidental spillage of hot materials All adjacent surfaces should also be non flammable E...

Page 27: ...hood Ensure the extraction hood is switched on during use It is recommended that an extraction system capable of a minimum of 1359 cubic metres per hour 800 CFM is used Under no circumstances should a...

Page 28: ...upply inlet Each inlet outlet is labelled l The cooling water supply pipes enter through the back of the furnace case and exit through two holes in the roof panel l The appropriate sized bulk head con...

Page 29: ...d up before each use check that the retort exhaust pipe is free of any obstructions e g condensed tar l The main gas supply inlet is situ ated at the rear of the furnace beside the water inlet and out...

Page 30: ...essential that the operator ensures that the power supply is correctly fused l Products with a factory fitted supply cable but without a plug are designed to be wired directly to an isolator or fitted...

Page 31: ...7 6 2 3 Phase Connections Terminal Label Cable Colour Connection L1 Black to phase 1 L2 Black to phase 2 L3 Black to phase 3 N Light Blue to neutral if fitted PE Green Yellow to earth ground 31...

Page 32: ...t thermocouples Note Ensure that there is sufficient space at the rear of the furnace to allow for the easy insertion and withdrawal of thermocouples l Gently twist the compression nut on the thermoco...

Page 33: ...8 0 Temperature Controller Please refer to the separate temperature controller manual s provided 33...

Page 34: ...hen there is no power to the furnace Panels Check that all covers and access panels are securely fitted General Access Check that there is sufficient clearance around the top and all sides of the prod...

Page 35: ...by Power Switch Check that when turned to the ON position the instrumentation on the control panel illuminates Gas Connections l Check that all the connections to the gas supply are secure and that g...

Page 36: ...types of materials if the furnace has the optional over temperature protection device fitted l Ensure that the over temperature device is calibrated and set to an over temperature safety limit that i...

Page 37: ...ower left hand side of the furnace case 3 Turn on the instrument switch to activate the temperature controllers The con trollers illuminate and go through a short test cycle 4 Over Temperature option...

Page 38: ...losed until the retort relative pressure reaches approximately 10mbar in order to prevent air being sucked back into the retort Process gas is controlled by two solenoid valves low and high flow rates...

Page 39: ...l Start the vacuum pump 2 DWELL for 10 minutes Event 1 ON l Pump down for a minimum of 10 minutes 3 WAIT for Digital High l Wait until retort pressure is below 950mbar 4 DWELL for 10 minutes Event 2...

Page 40: ...porates electronic power limiting Depending on the model and the destination country the power limit maybe set to 100 or a lower figure Where appropriate the power limit parameter OP Hi is accessible...

Page 41: ...fety Switch Function Electrical measurement Over Temperature Safety Circuit if fitted Set an over temperature setpoint lower than the displayed temperature and check for an over temperature alarm as d...

Page 42: ...functions are working nor mally Operational Check Thorough inspection and report incor porating a test of all functions Performance Element Circuit Electrical measurement Power Consumption Measure the...

Page 43: ...this occurs The safety switch should not fail under normal working conditions however rough handling exposure to corrosive materials environments or exceptionally frequent use could compromise the sa...

Page 44: ...as 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 worl...

Page 45: ...perature The door switch es if fitted may be faulty or need adjustment The contactor relay if fitted may be faulty The heater switch if fitted may be faulty or need adjustment The SSR could be failing...

Page 46: ...controller shows a low temperature The thermocouple may be faulty or may have been removed out of the heating chamber The thermocouple may be connected the wrong way around The controller may be fault...

Page 47: ...efore recommissioning All internal electrical circuits should be checked for signs of moisture If there are visible signs of moisture the product should be isolated from the power supply and allowed t...

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Page 49: ...Notes Service Record Engineer Name Date Record of Work...

Page 50: ...us at the address below or ask your nearest stockist For preventive maintenance repair and calibration of all furnace and oven products please contact Carbolite Gero Service Telephone 44 0 1433 624242...