VERDER CARBOLITE GERO CWF 13/65, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1300 C Chamber Furnace CWF Model 65 Litres No Controller CWF 13 65 No Controller MEN CWF1365 005_NOCTRL 01 08 2019 ...

Page 2: ... 5 2 3 Hearth 6 2 4 Chimney 6 2 5 Electrical Connections 7 2 6 Voltage and Power Limit 8 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...

Page 3: ...emperature Controller Replacement 20 7 4 Solid State Relay Replacement 21 7 5 Thermocouple Replacement 21 7 6 Element Replacement Laboratory Models 22 7 7 Fuse Replacement 22 7 8 Door Plug Replacement 23 8 0 Fault Analysis 24 A Furnace Does Not Heat Up 24 B Product Overheats 25 9 0 Wiring Diagrams 26 9 1 WA 33 30 26 9 2 WA 33 31 27 9 3 WA U3 30 28 9 4 WA U3 31 30 10 0 Fuses and Power Settings 32 1...

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: ... follows remove the nut at the top of the threaded bar cut the straps that hold the bracket to the top of the case and lift off the bracket lift the threaded bar out of the furnace remove the wooden block from inside the chamber 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...

Page 6: ...ct are clear of any obstruction Always ensure all cooling vents and cooling fans if fitted are clear of any obstruction 2 3 Hearth The product is supplied with the hearth tiles supported in place by a timber batten or steel plate held by a jacking bolt fixed through the roof chimney hole Remove the bands holding the frame to the top of the product case Withdraw the bracket with the jacking rod ass...

Page 7: ...star or delta but a product must only be connected to the type and voltage of supply for which it was made If the product is ordered for a single phase supply this may be Live to Neutral reversible or non reversible or Live to Live Check the product rating label before connection The supply voltage should agree with the voltage on the label and the supply capacity should be sufficient for the curr...

Page 8: ...ply Types Live 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 2 or 3 phase L1 Black to phase 1 L2 Black to phase 2 L3 Black to phase 3 except 2 phase N Light Blue to neutral except del...

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: ...ed 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 the controls w...

Page 16: ...heater light goes out Safety 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 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...

Page 17: ...ection and report 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 17 6 0 Maintenance ...

Page 18: ...fe 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 Maintenance Schedule section of this m...

Page 19: ...y 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 Parts Kit Carbo...

Page 20: ... 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 long sleev...

Page 21: ...supply Remove 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 R orange 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...

Page 22: ...may be helpful to feed a flexible plastic or nylon tube with a bore just larger than the element wire through the terminal block into the chamber Fit the element wire into this tube as the tube is withdrawn the element tail can be pulled through the terminal block When both parts of the element are located in the channels gently pull the ends of the element until the first spiral is level with the...

Page 23: ...nd remove the door cover from the plug carrier assembly by loosening the nuts at each side From the front unscrew the self tapping screws which hold the upper door plug retention bracket in place and remove the bracket Remove the old door plug Place the new door plug in position ensuring that the chamfered edge is uppermost Refit the upper bracket and door cover When first heating the furnace afte...

Page 24: ... a low temperature 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 f...

Page 25: ...r 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 25 8 0 Fault Analysis ...

Page 26: ...e filter arrangements ISOLATOR the industrial models have an internal isolator which is not shown in these diagrams 9 1 WA 33 30 Connections below show 3 phase N with indirect safety switches Key F1 F2 F3 Fuses FIL Filter if fitted C Controller TC Control Thermocouple R Relay R1 1 R1 2 R1 3 Relay contactor SW Instrument Switch es SSW Safety Switch EL Element SSR Solid State Relay N Neutral L Live ...

Page 27: ...if fitted C Controller TC Control Thermocouple OT Over Temperature Controller OTC Over Temperature Thermocouple R Relay R1 1 R1 2 R1 3 Relay contactor SW Instrument Switch es SSW Safety Switch EL Element SSR Solid State Relay N Neutral L Live PE Earth Cables BU Blue R Red BL Black GR Y Green Yellow G Grey P Pink 27 9 0 Wiring Diagrams ...

Page 28: ...9 0 Wiring Diagrams 9 3 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 4 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: ... See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating CWF 65 1 phase 220 240 V 63 A CWF 65 1 phase 200 208 V 80 A CWF 65 3 phase N 380 220 415 240 V 25 A ph CWF 65 3 phase delta 220 240 V 40 A ph CWF 65 3 phase delta 200 208 V 40 A ph 10 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures represent...

Page 33: ...kg H W D Chamber furnaces heated by resistance wire resting on refractory formers CWF 13 65 1300 14 280 390 595 65 100 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 Specifications ...

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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...