VERDER CARBOLITE GERO GPC 12/200, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1200 C Chamber Furnace GPC Model 200 Litres No Controller GPC 12 200 No Controller MEN GPC12200 05_NOCTRL 06 08 2019 ...

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

Page 3: ...re Insulation 21 7 3 Temperature Controller Replacement 21 7 4 Solid State Relay Replacement 22 7 5 Thermocouple Replacement 22 7 6 Element Replacement Industrial Models 23 7 7 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 33 30 27 9 2 WA 33 31 28 9 3 WA U3 30 29 9 4 WA U3 31 31 10 0 Fuses and Power Settings 33 10 1 Pow...

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: ...y 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 is resistant to accidental spillage or hot materials The surface on which the equipment is mounted should be stab...

Page 6: ...ng 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 To remove take off the roof panel and unscrew the bracket complete with the jacking rod assembly Fit the product chimney before replacing the roof panel Fit the door counterbalance wei...

Page 7: ...nection by a qualified electrician is recommended The model covered in this manual has three internal circuits and is normally supplied for connection to a three phase power supply This may be either 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...

Page 8: ...e plug should be within reach of the operator and should be easy to remove When connecting the product to an isolating switch ensure that both conductors single phase or on all live conductors three phase and should be within reach of the operator The 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: ...er see the controller instructions and compare it with the data in section 10 0 towards the back of this manual If the power limit setting is incorrect for the voltage of the electrical supply change it This must be done immediately if the setting of OP Hi is higher than it should be 9 2 0 Installation ...

Page 10: ...3 0 Temperature Controller 3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 10 ...

Page 11: ... 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 elements Power is no...

Page 12: ... with the over 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 ...

Page 13: ...top 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 13 4 0 2132 Over Temperature ...

Page 14: ...pplied To turn the product off set the instrument switch to its off position The controller 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 a...

Page 15: ...t saying INERT GAS ONLY In practice inert or oxidising gases may be used but not combustible or toxic gases The chamber is not gas tight the gas usage 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...

Page 16: ...opriate the power limit parameter OP Hi is accessible to the operator but it should not generally 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 o...

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: ... 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 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 Recommende...

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: ...e product from the power supply Remove the appropriate panel 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...

Page 23: ...ng the tube within the chamber and easing the element off it From within the chamber lift the wire element off the hook holding the front end and remove the element through the furnace door Fit the new element At the same time one person should feed the tubes through from the back and the other should feed the wire spirals onto the tube To get the wire ends through correctly it may help to feed a ...

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: ...s 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 PE Earth Cables BU B...

Page 28: ...F3 Fuses FIL Filter 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 28 ...

Page 29: ...9 3 WA U3 30 Connections below show 3 phase N with indirect safety switches 29 9 0 Wiring Diagrams ...

Page 30: ... 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 converted between 208 V...

Page 31: ...9 4 WA U3 31 Connections below show 3 phase N with safety switches and over temperature control 31 9 0 Wiring Diagrams ...

Page 32: ...L2 L3 Live PE Earth 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 ...

Page 33: ...commended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating GPC 12 200 3 phase N 220 240 380 415 V 40 A ph GPC 12 200 3 phase delta 220 240 V 63 A ph 10 1 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 supplied ...

Page 34: ...ity l Net Weight kg H W D Chamber furnaces heated by resistance wire resting on refractory formers GPC 12 200 1200 24 400 500 900 198 518 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 34 ...

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...