VERDER CARBOLITE GERO HRF 7/324, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 750 C Recirculating Air Furnace HRF Model 324 Litres No Controller HRF 7 324 No Controller MEN HRF7324 05_NOCTRL 02 08 2019 ...

Page 2: ...l Connections 6 3 0 Temperature Controller 8 4 0 2132 Over Temperature Controller Description if fitted 9 4 1 Description 9 4 2 Operation 9 4 2 1 Controls 9 4 2 2 Operation 10 4 2 3 Over Temperature Operation 10 4 2 4 Over Temperature Alarm 10 4 2 5 Resetting the Over Temperature Alarm 10 4 2 6 Sensor Break 10 4 3 Audible Alarm 11 4 4 Navigation Diagram 11 5 0 Operation 12 5 1 Operating Cycle 12 5...

Page 3: ...mperature Controller Replacement 18 7 4 Solid state Relay Replacement 19 7 5 Thermocouple Replacement 19 7 6 Element Replacement 19 7 7 Fuse Replacement 20 8 0 Fault Analysis 21 A Furnace Does Not Heat Up 21 B Product Overheats 22 9 0 Wiring Diagrams 23 10 0 Fuses and Power Settings 24 10 1 Fuses 24 10 2 Power Settings 24 11 0 Specifications 25 11 1 Environment 25 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: ...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: ...ling fans if fitted are clear of any obstruction 2 3 Electrical Connections Connection by a qualified electrician is recommended The industrial models are usually supplied for three phase use Access to electrical connections is by removal of the lower right hand panel The industrial models are fitted with an internal isolator cabling should be taken through the mesh base panel directly to the isol...

Page 7: ... internal terminals If the product is to be connected by line plug The 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 Supp...

Page 8: ...3 0 Temperature Controller 3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 8 ...

Page 9: ...s 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 n...

Page 10: ... 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 11: ...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 11 4 0 2132 Over Temperature ...

Page 12: ...g elements are isolated Find and correct the cause before resetting the over temperature controller according to the instructions supplied 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...

Page 13: ...abel near the inlet 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 4 Operator Safety In the industrial models power is cut to the elements and the fan if the door is opened ...

Page 14: ...nt 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 this manual Over Temperature Safety Circuit if fitted Electrical measurement Door Seal Visual inspection checking for splits and fraying Door Seal Replace where necessary Chimney Extraction Check and clean if necessary Electrical...

Page 15: ...cal measurement Power Consumption Measure the current drawn on each phase cir cuit Metal Liner Visual check for fit and damage Circulating Fan With the furnace at ambient open the door and make sure the fan is working 15 6 0 Maintenance ...

Page 16: ...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 17: ...roduct 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 Carbolite Gero can supply individual spare parts 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 solid state relay one door ins...

Page 18: ... 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 19: ...emble the new thermocouple observing the colour coding 3 Refit the element access panel 7 6 Element Replacement See section 7 2 wearing a face mask is required The resistance wire elements are able to withstand temperatures considerably higher than the limit for this furnace and are expected to fail infrequently or not at all In the event of the need for replacement it is recommended that the furn...

Page 20: ...to section 10 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 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 con...

Page 21: ...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 22: ...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 22 ...

Page 23: ...9 0 Wiring Diagrams For wiring diagrams please contact Carbolite Gero Service Please quote the serial number and model 23 9 0 Wiring Diagrams ...

Page 24: ...f cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating HRF 7 324 3 phase N 220 240 380 415 40 A ph HRF 7 324 3 phase Delta 220 240 63 A ph 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 controlled power is supplied to the elements D...

Page 25: ...ght kg H W D Recirculating Air Furnace heated by mineral insulated elements HRF 7 324 750 24 600 600 900 324 1000 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 25 11 0 Specifications ...

Page 26: ......

Page 27: ...Notes Service Record Engineer Name Date Record of Work ...

Page 28: ... 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...