VERDER CARBOLITE GERO CDHT 450, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 200 C Coal Drying Oven CDHT Model 450 Litres 2132 Controller CDHT 450 2132 Controller MEN CDHT450 001_2132 08 10 2018 ...

Page 2: ...9 3 1 Description 9 3 2 2132 Controller Operation 9 3 2 1 Controls 9 3 2 2 2132 Controller Operation 10 3 2 3 Basic Operation 10 3 2 4 Altering the Setpoint 10 3 2 5 Stopping and Starting Control 11 3 2 6 Altering the Ramp Rate 11 3 3 Operating with the Timer 12 3 3 1 Setting the Timer Mode 14 3 3 2 Setting the Time Period 14 3 3 3 Running with the Timer 14 3 3 4 Stopping the Timer 15 3 3 5 End of...

Page 3: ...alibration 29 6 4 After Sales Service 29 6 5 Recommended Spare Parts and Spare Parts Kit 29 6 6 Power Adjustment 29 7 0 Repairs and Replacements 31 7 1 Safety Warning Disconnection from Power Supply 31 7 2 Safety Warning Refractory Fibre Insulation 31 7 3 Panel Removal 31 7 4 Temperature Controller Replacement 32 7 5 Fuse Replacement 32 7 6 Element Replacement 32 7 7 Thermocouple Replacement 32 7 ...

Page 4: ...11 1 Environment 37 4 ...

Page 5: ...rgised 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 5 1 0 Symbols and Warnings ...

Page 6: ... 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 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 ...

Page 7: ...y 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 The product covered by this manual usually requires a single phase A C supply which may be Live to Neutral non reversible Live to Neutral reversible or Live to Live Some models may be ordered for 3 phase use which may ...

Page 8: ...lug 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 L Brown to live ...

Page 9: ... an audible alarm at the end of the timing period 3 2 2132 Controller Operation 3 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 mus...

Page 10: ...e 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 3 2 3 Basic Operation Normal...

Page 11: ... It is only possible to limit the rate of heating by setting a ramp rate if the timer feature is not in use To enable direct setting of the ramp rate first ensure that the StAt parameter and dwEll parameter are both set to OFF see sections 3 3 1 and 3 3 2 Press scroll until SPrr setpoint ramp rate is displayed Use down or up to display and adjust the value The ramp rate sets the maximum rate of he...

Page 12: ...e Timer This controller can be used as a process timer allowing timed heating or timed delay according to the options in the table There are 5 timer modes but 2 of them are affected by whether the setpoint ramp rate feature is being used making 7 entries in the table The table also shows the status of the timer light on the controller A visual impression of the different modes is given in fig 3 12...

Page 13: ...iming period mode 3 with SPrr active Dwell from working setpoint and switch off The timer starts timing when the working setpoint is within 1 C of the setpoint At the end of the timing period control switches off i e goes into Manual to allow cooling and End flashes on the display On during the timing period Off from the end of the timing period mode 4 with SPrr off Time from cold and stay on The ...

Page 14: ... StAt parameter changes to run Note that the tmr display shows 0 zero during the last minute of timing and also shows 0 when the time has expired The timer light indicates whether timing is still in progress Method 2 Scroll to dwEll and use or to set the timing duration The advantage of method 2 is that dwEll need only be set once if repeated use of the same time period is required Scroll to StAt ...

Page 15: ... setpoint ramp rate 5 Modes 3 4 with setpoint ramp rate off 6 Reaching temperature and continuing temperature Mode 5 7 Continuing at temperature modes 2 4 or cooling down modes 1 3 3 3 4 Stopping the Timer To stop the timer at any time while it is operating change the StAt User Calibration parameter to OFF This is the same as reducing tmr to zero The controller then acts as though it has reached t...

Page 16: ...ode 1 as on the first row of the timer table but also includes the use of ramp rate To create this program 1 Start with display at home use arrow keys to alter the setpoint to 500 2 Press scroll until sp rr shows use arrow key to set value to 10 if you do not want to limit the ramp rate ignore this step or set the value to OFF 3 Press scroll until tm op shows use arrow key to set value to opt 1 4 ...

Page 17: ... If a product is to be used at temperatures much lower than its design maximum control stability can often be improved by reducing the power limit Remember to make a record of the original setting before altering the power limit Example It is desired to operate a 1200 C furnace at 300 C The normal control settings can be expected to cause excessive overshoot as the furnace reaches temperature If t...

Page 18: ... the calibration of the controller or of the complete system remember to reset the controller to factory calibration values by setting the CAL P parameter to FACt To enter a user calibration scroll to each of the following parameters in turn and set the desired values Pnt L low temperature for which an offset is to be entered OFS L offset value for the low temperature Pnt H high temperature for wh...

Page 19: ... 6 It is not feasible to cover all possible alarm features which may be included by customer special order within this manual 3 6 Temperature Controller Replacement Before handling the controller wear an anti static wrist strap or otherwise avoid any possibility of damage to the unit by static electricity Refer to the detailed instructions supplied with the replacement controller Ease apart the tw...

Page 20: ...3 0 2132 Controller 3 7 Navigation Diagram 20 ...

Page 21: ... if SPrr in use 4 Manual Auto mAn off Auto on 5 Setpoint ramp rate OFF or value 6 Timer mode 7 Time remaining 8 Dwell time for timer 9 Timer status run or OFF 10 Enter password 11 If User Calibration 12 User 2 Point Calibration 13 Power limit setting if present 14 For factory acess to lists and parameters not available to the operator 21 3 0 2132 Controller ...

Page 22: ...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 23: ...perature 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...

Page 24: ...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 24 ...

Page 25: ...rrect the cause before resetting the over temperature controller according to the instructions supplied To switch the product off turn off the instrument switch If the product is to be left unattended isolate the electricity supply 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 Over Temperat...

Page 26: ... dry and test coal samples in accordance with international standards The oven has air inlet and outlet vents designed to ensure a constant flow of fresh air to dry the samples and carry moisture away Open the inlet and outlet vents to the minimum amount required to ensure consistent drying results 26 ...

Page 27: ...he displayed temperature and check for an over temperature alarm as detailed in this manual Over Temperature Safety Circuit if fitted Electrical measurement Door Seal Visual inspection check for splits or fray ing Door Seal Replacement Air Vent Check and clean if necessary Electrical Safety external Visual check of external cables and plugs Electrical Safety internal Physically check all connectio...

Page 28: ...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 28 ...

Page 29: ...ve 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 ...

Page 30: ... 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 8 0 for details of power limit settings 30 ...

Page 31: ...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 lo...

Page 32: ...rrect terminals 7 6 Element Replacement l Remove the cover plate over the element tails on top of the oven l Open the door and remove the shelves and the element cover The elements will be directly in front of you l Release the gland nut on the compression fitting holding the element and remove the element l Fit the new element using new olives l Refit the electrical connections and covers 7 7 The...

Page 33: ...duct from the electrical supply and remove the product s access panel The access panel is located at the top of A models and the right hand side of B models Make a note of the wiring 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 the solid state rela...

Page 34: ...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 Amps F1 CDHT 450 3 Phase No Neutral 208V 32 A 8 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 controlled power is...

Page 35: ...here 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 ov...

Page 36: ...10 0 Wiring Diagrams 10 0 Wiring Diagrams For wiring diagrams please contact Carbolite Gero Service Please quote the serial number and model 36 ...

Page 37: ...pacity l Net Weight kg H W D CD Range Ovens for Coal Drying CDHT 450 200 9 610 610 1220 454 400 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 37 11 0 Specifications ...

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Page 39: ...Notes Service Record Engineer Name Date Record of Work ...

Page 40: ... 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...