VERDER CARBOLITE GERO CF 24B, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1200 C Cupellation Furnace CF Model 24B No Controller CF 24B No Controller MEN CF24B 005_NOCTRL 10 07 2020 ...

Page 2: ... CF24 8 2 5 Heating Elements 8 2 6 Baffle 8 2 7 Electrical Connections 8 3 0 Temperature Controller 11 4 0 2132 Over Temperature Controller Description if fitted 12 4 1 Description 12 4 2 Operation 12 4 2 1 Controls 12 4 2 2 Operation 13 4 2 3 Over Temperature Operation 13 4 2 4 Over Temperature Alarm 13 4 2 5 Resetting the Over Temperature Alarm 13 4 2 6 Sensor Break 13 4 3 Audible Alarm 14 4 4 N...

Page 3: ...ower Adjustment 25 8 0 Repairs and Replacements 26 8 1 Safety Warning Disconnection from Power Supply 26 8 2 Safety Warning Refractory Fibre Insulation 26 8 3 Temperature Controller Replacement 26 8 4 Solid State Relay Replacement 27 8 5 Element Fitting and Replacement 28 8 6 Thermocouple Replacement 29 8 7 Fuse Replacement 29 9 0 Fault Analysis 30 A Furnace Does Not Heat Up 30 B Product Overheats...

Page 4: ...12 0 Specifications 37 12 1 Environment 37 4 ...

Page 5: ...ws 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 5 ...

Page 6: ...nd 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 8 2 2 2 Door Counterbalance Door counterbalance are used as handles to open and close the door These may be supplied unfitted If supplie...

Page 7: ...ure 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 disco...

Page 8: ...r element holes Because of different power supplies and national standards the details may differ from the details shown or the terminals may be in reverse order 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 obst...

Page 9: ...nternal 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 rem...

Page 10: ...ral except delta PE Green Yellow to earth ground Technical Notes This model has an electronically controlled power limit Do not attempt to calculate the Amps from the Wattage High break capacity fuses should be used Avoid fast blow fuses and magnetic trip circuit breakers consult Carbolite Gero if in doubt 10 ...

Page 11: ...3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 11 ...

Page 12: ...ch 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 heating element...

Page 13: ...r temperature 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 ...

Page 14: ...tion 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 14 ...

Page 15: ...h can contain a switching time for any or all or the days in a week It is battery backed with approximately 10 years power reserve The shortest switching interval is 1 minute A choice of languages is included There is a real time clock and a choice of daylight saving rules The facia features a digital display and four buttons as shown in the image 15 ...

Page 16: ...the daylight saving rules press the arrow keys to select between six different countries or FREE or FIX DATE or NO SU WI If FREE is chosen a month and date entry sequence is entered follow the display requests Setting a Switch On or Switch Off Time A program entry comprises a function on or off a switching time and the days to which it applies Press MENU PROGRAM is displayed Press OK NEW is displa...

Page 17: ...ime is used for an on as an off off takes priority Overriding the Program To change the present state between on and off press MENU select MANUAL Within the MANUAL choices are PERMANENT ON PERMANENT OFF MANUAL ON TIMER HOLIDAY RANDOM END Avoid random which is irrelevant to furnaces The holiday feature may be left as an exercise for the reader Pulse and Cycle These features are not required and sho...

Page 18: ...ired temperature program in the temperature controller Timer in ON state the program is started Timer in OFF state the program is stopped Set the time switch as required Set the element over temperature controller to approximately 100 C above the maximum or setpoint temperature The element over temperature controller protects the heating elements from excessive temperature and if activated is self...

Page 19: ...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 12 0 towards the back of this manual Lightweight ceramic fibre insulation can easily be marked by accidental contact Some fine cracks may develop in the surface of the insulation due to the progressive shri...

Page 20: ...st the effects of radiated heat when the furnace is open When the product is opened during operation there is considerable radiated heat Do not keep any flammable objects near the product nor objects which could be damaged by radiated heat 6 5 Over Temperature Control if fitted The product may be fitted with a chamber over temperature control if this has been ordered The chamber Over Temperature c...

Page 21: ...the set point on the element over tem perature controller to a lower value than the cur rent displayed temperature on the main controller and ensure the heater lights go out Element Over Temperature Circuit Electrical measurement Over Temperature Safety Circuit if fitted Set an over temperature setpoint lower than the displayed temperature and check for an over tem perature alarm as detailed in th...

Page 22: ...nctions are working normally Operational Check Thorough inspection and report incorporating a test of all functions Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase cir cuit Hearth and Top Element Protection Tiles Visual check for large cracks that could lead to element contamination 22 ...

Page 23: ...e temperature controller set a safe temperature above 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 Maint...

Page 24: ... or a kit of the items most likely to be required Ordering a kit in advance can save time in the event of a breakdown Each kit consists of one thermocouple one sheath one solid state relay one door insulation piece a set of elements a set of element clips and a set of braids and clips Individual spare parts are also available When ordering spare parts please quote the model details as requested ab...

Page 25: ...t making an adjustment If new elements are fitted return the adjustments to the original value A table of standard power limits is given in section 11 0 7 8 Power Adjustment The product s control system incorporates electronic power limiting Power is supplied to the elements in bursts of approximately 0 33 seconds duration This prevents overheating of the elements The power limit is programmed int...

Page 26: ... 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 long sleeved clothing Av...

Page 27: ...e 1 Make a note of the wire connections to the solid state relay then disconnect them 2 Remove the solid state relay from the base panel or aluminium plate 3 Replace and reconnect the solid state relay ensuring that the bottom of it has good thermal contact with the base panel or aluminium plate 4 Replace the access panel 27 ...

Page 28: ...h all element connection braids in position except for 3 off loose braids Insert the elements as explained below and connect the fitted braids to the adjacent element ends Connect the loose braids in pairs to the unconnected ends on the same side of the product as the element power terminals Replacements Replace each element in turn Release the clips using the tool provided Move the braids and car...

Page 29: ...assemble with a new thermocouple observing the colour coding Refit the element access panel 8 7 Fuse Replacement Fuses are marked on the wiring diagram with type codes e g F1 F2 For more information on fuses refer to section 11 0 Depending on model and voltage the different fuse types may or may not be fitted If any fuse has failed it is advisable for an electrician to check the internal circuits ...

Page 30: ...mperature 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 co...

Page 31: ... 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 31 ...

Page 32: ...10 0 Wiring Diagrams 10 1 WA 33 32 Connections below show 3 phase N with indirect safety switches and E temperature control 32 ...

Page 33: ...10 2 WA 33 33 Connections below show 3 phase N with indirect safety switches over temperature and E temperature control 33 ...

Page 34: ...s are in series with the instrument switch 10 4 WS 01 02 The time switch motor circuit is connected to the supply side of the instrument switch The volt free contacts connect to digital inputs on the programmer the programmer is configured to start the program when the time switch comes on and to reset when it goes off 34 ...

Page 35: ...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 CF 24B 1 phase 200 240 100 A CF 24B 3 phase N 380 220 415 240 32 A CF 24B 3 phase Delta 208 240 50 A 11 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures represent th...

Page 36: ...ower Setting Adjustments Date Power Comments Note If a new set of elements are fitted then return the power settings to the original value Please refer to the rating label for product specific information 36 ...

Page 37: ...m Net Weight kg H W D Cupellation Furnaces heated by silicon carbide elements CF 24B 1200 13 200 250 340 306 12 1 Environment The models listed in this manual contain 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 ...

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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...