VERDER CARBOLITE GERO HRF 7/45, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 750 C Recirculating Air Furnace HRF Model 45 Litres No Controller HRF 7 45 No Controller MEN HRF7045 05_NOCTRL 06 08 2019 ...

Page 2: ...ey 6 2 4 Electrical Connections 7 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 Alarm 12 4 4 Navigation Diagram 12 5 0 Operation 13 5 ...

Page 3: ...ler Replacement 19 7 4 Solid state Relay Replacement 20 7 5 Thermocouple Replacement 20 7 6 Element Replacement 20 7 7 Fuse Replacement 21 8 0 Fault Analysis 22 A Furnace Does Not Heat Up 22 B Product Overheats 23 9 0 Wiring Diagrams 24 9 1 WA 11 00 H 24 9 2 WA U3 00 25 10 0 Fuses and Power Settings 26 10 1 Fuses 26 10 2 Power Settings 26 11 0 Specifications 27 11 1 Environment 27 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: ...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 stable and not subject to movement or vibrations The hei...

Page 6: ...nts 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 obstruction 2 3 Chimney The chimney is a length of tubing If it is supplied unfitted then fit it through the hole in the top of the case If the product is to be used to heat substances that emit fumes a fume extraction duct of approximately 75 mm 150 mm inlet diame...

Page 7: ...s also given towards the back of this manual When the mains cable is factory fitted internal 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 fuse...

Page 8: ...ive 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 8 ...

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: ...d temperature or a program setpoint Over Temperature option only If the over temperature circuit has tripped an indicator on the over temperature controller flashes and the heating 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 controll...

Page 14: ...ber empty to burn away the soot 5 3 Atmospheres When an optional gas inlet is fitted there is a label 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 Operato...

Page 15: ... 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 Safety external Visual check of external cables and plugs Electrical Safety internal Physically check all connections and cleaning of the power plate area...

Page 16: ...6 0 Maintenance 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 16 ...

Page 17: ...e 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 of this manua...

Page 18: ...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 10 0 for details of power limit settings 18 ...

Page 19: ...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 20: ...pe K green negative white 1 Disconnect the thermocouple to be replaced from its terminal block and withdraw it 2 Re assemble 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 mineral insulated type of element consists of a resistance wire which is centered in a metal tube by a compressed pow...

Page 21: ... Note on 208 V elements these elements are marked 240 V 2000 W These elements correctly give 1500 W when used at 208 V 7 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 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 c...

Page 22: ... 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 23: ...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 23 8 0 Fault Analysis ...

Page 24: ... Wiring Diagrams 9 0 Wiring Diagrams 9 1 WA 11 00 H Note before serial no 20 301901 fan connected on live side of instrument switch 20 3 1901 onwards fan connected on switched side of instrument switch 24 ...

Page 25: ...fer 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 phase Please contact Carbolite Gero Service for details 25 9 0 Wiring Diagrams ...

Page 26: ...ting label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating HRF 7 45 1 phase 208 32 A HRF 7 45 1 phase 220 240 10 A HRF 7 45 3 phase Delta 220 16 A HRF 7 45 3 phase N 380 415 10 A 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...

Page 27: ...ight kg H W D Recirculating Air Furnace heated by mineral insulated elements HRF 7 45 750 6 0 295 265 560 45 110 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 27 11 0 Specifications ...

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Page 29: ...Notes Service Record Engineer Name Date Record of Work ...

Page 30: ... 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...