VERDER CARBOLITE GERO AAF 11/32, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1100 C Ashing Furnace AAF Model 32 Litres No Controller AAF 11 32 No Controller MEN AAF1132 005_NOCTRL 01 08 2019 ...

Page 2: ... Chimney 6 2 4 Electrical Connections 7 3 0 Temperature Controller 9 4 0 2132 Over Temperature Controller Description if fitted 10 4 1 Description 10 4 2 Operation 10 4 2 1 Controls 10 4 2 2 Operation 11 4 2 3 Over Temperature Operation 11 4 2 4 Over Temperature Alarm 11 4 2 5 Resetting the Over Temperature Alarm 11 4 2 6 Sensor Break 11 4 3 Audible Alarm 12 4 4 Navigation Diagram 12 5 0 Operation...

Page 3: ...ulation 21 7 3 Temperature Controller Replacement 21 7 4 Solid State Relay Replacement 22 7 5 Thermocouple Replacement 22 7 6 Element Replacement 22 7 7 Door Plug Replacement 23 7 8 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 U3 30 28 9 2 WA U3 31 30 10 0 Fuses and Power Settings 32 10 1 Fuses 32 10 2 Power Settings 3...

Page 4: ...ent 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 4 ...

Page 5: ...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 hei...

Page 6: ...nts 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 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 diame...

Page 7: ...s 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 fuse...

Page 8: ...ive 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 8 ...

Page 9: ...3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 9 3 0 Temperature Controller ...

Page 10: ...strument 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 he...

Page 11: ... 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 ...

Page 12: ...erature 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 12 ...

Page 13: ...ontroller display will go blank If the product is to be left unattended isolate it from the electrical supply 5 2 General Operating Notes Heating element life is shortened by overheating Do not leave the product at high temperature when it is not required The maximum temperature is shown on the product rating label and in section 11 0 towards the back of this manual When heating large objects in p...

Page 14: ...sage may be high and the chamber is always likely to contain some air Residual oxygen of approximately 1 to 2 is to be expected 5 5 Operator Safety This product incorporates a safety switch which interrupts the heating element circuit when the furnace is opened This prevents the operator touching a live heating element and also prevents the product from heating up if the furnace is left open The o...

Page 15: ... damage to the catalyst system the catalyst fan must always be running whenever the furnace is hot The larger model 32 litre furnace catalyst has a fan speed control this should be set at maximum speed initially During the ashing process the catalyst fan speed may be reduced if required but not beyond the point where smoke escapes from the furnace door area It is recommended not to lower the speed...

Page 16: ...rally be altered See section 10 0 for details of the power limit settings DO NOT adjust the power to a level higher than the design level states this may cause a fuse to blow and could damage the heating elements The power limit may be set to a lower limit if the product is to be used at a low temperature only this may give better control stability It may be set to zero to permit demonstration of ...

Page 17: ...ctrical 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 detailed in this manual Over Temperature Safety Circuit if fitted Electrical measurement Door Plug Visual inspection checking the seal and whether it is free of damage Door Plug Replacement where necessary Chimney Extraction ...

Page 18: ...t incor porating a test of all functions Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase circuit Hearth Visual check for fit and damage Cooling Fans if fitted Check whether the cooling fans are working 18 ...

Page 19: ...bove ambient The heater lights should illuminate l Open the door and check the heater lights They should no longer be illuminated If the heater lights remain illuminated when the door is open discontinue use and contact Carbolite Gero Service Annual check The following checks should be carried out by a qualified electrician as specified in the Maintenance Schedule section of this manual l Remove t...

Page 20: ...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...

Page 21: ...ered 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...

Page 22: ...move 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 th...

Page 23: ...the door cover When first heating the furnace after a replacement ensure that the ventilation is good emission of some fumes is to be expected Key A Door seen from the back A1 Door Cover A2 Fixing Screws A3 Door Plug Carrier A4 Door Link Arms B Door Plug B1 Top 7 8 Fuse Replacement Fuses are marked on the wiring diagram with type codes e g F1 F2 For more information on fuses refer to section 10 0 ...

Page 24: ...check the internal circuits Replace any failed fuses with the correct type For safety reasons do not fit larger capacity fuses without first consulting Carbolite Gero The fuses are located at the cable entry point Remove the back panel or control box back panel to gain access to the fuses 24 ...

Page 25: ...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 to switch on due to internal failure faulty logic wiring from the controller or faulty controller There are no lights glowing on the controller Check the supply fuses and any fuses in the furnace control comp...

Page 26: ...aulty The 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 faulty 2 Product heats up when the instrument switch is OFF The SSR has failed ON Check for an accidental wiring fault that could have overloaded the SSR 26 ...

Page 27: ...9 0 Wiring Diagrams 27 9 0 Wiring Diagrams ...

Page 28: ...9 0 Wiring Diagrams 9 1 WA U3 30 Connections below show 3 phase N with indirect safety switches 28 ...

Page 29: ...reen Yellow G Grey P Pink Products with this wiring arrangement may be converted between the following supply voltages please refer to the table within section 10 0 for compatible phases with the product l 3 phase neutral in the range 380 220 V 415 240 V l 3 phase delta in the range 220 V 240 V l Single phase in the range 220 V 240 V l 208 V model can be converted between 208 V delta and 208 V 1 p...

Page 30: ...9 0 Wiring Diagrams 9 2 WA U3 31 Connections below show 3 phase N with safety switches and over temperature control 30 ...

Page 31: ...Cables BU Blue R Red BL Black GR Y Green Yellow G Grey P Pink Products with this wiring arrangement may be converted between the following supply voltages please refer to the table within section 10 0 for compatible phases with the product l 3 phase neutral in the range 380 220 V 415 240 V l 3 phase delta in the range 220 V 240 V l Single phase in the range 220 V 240 V l 208 V model can be convert...

Page 32: ...mm x 6 mm Customer Fuses Required if no supply cable fitted Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating AAF 11 32 3 phase Neutral 220 240 16 A per phase 10 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures represent the maximum percentage of time that controll...

Page 33: ... Coal and Coke Testing Furnace AAF 11 32 1100 9 820 690 730 250 280 450 105 with Thermal Catalytic Oxidiser Option 1100 9 1570 700 830 250 280 450 115 11 1 Environment The models listed in this manual contains electrical parts and should be stored and used in indoor conditions as follows Temperature 5 C 40 C Relative humidity Maximum 80 up to 31 C decreasing linearly to 50 at 40 C 33 11 0 Specific...

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Page 35: ...Notes Service Record Engineer Name Date Record of Work ...

Page 36: ... 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 Fax 44 0 1433 624243 Email ServiceUK carbolite gero com Carbolite Gero Ltd Parsons Lane Hope Hope Valley S33 6RB England Telephone 44 0 1433 620011 Fax 44 0 1433 621198 Email Info carbolite gero com...