VERDER CARBOLITE GERO PF 200, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 300 C Peak Fan Convection Oven PF Model 200 Litres No Controller PF 200 No Controller MEN PF200 006_NOCTRL 06 08 2019 ...

Page 2: ...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 Alarm 13 4 4 Navigation Diagram 13 5 0 Operation 14 5 1 Operating Cycle 14 5 2 Over Temperature Control if fitted 14 ...

Page 3: ... Fibre Insulation 22 7 3 Panel Removal 23 7 3 1 Side Panel 23 7 3 2 Internal Element Cover 23 7 4 Temperature Controller Replacement 24 7 5 Solid State Relay Replacement 24 7 6 Thermocouple Replacement 24 7 7 Element Replacement 24 7 8 Fuse Replacement 25 8 0 Fault Analysis 26 A Oven Does Not Heat Up 26 B Oven Overheats 26 9 0 Wiring Diagrams 27 9 1 WV 11 00 27 9 2 WS 02 06 Variable Speed Fan 28 9...

Page 4: ...ight switch is operated the interior light illuminates Solenoid valve if fitted see section 5 8 for full details Variable speed fan if fitted see section 5 9 for full details Exhaust fan if fitted see section 5 10 for full details Stoving and curing if fitted see section 5 11 for full details 1 2 General Warnings DANGER Electric shock Read any warning printed next to this symbol WARNING Risk of fa...

Page 5: ... 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 1 0 Symbols and Warnings ...

Page 6: ... when removing packing materials Locate the shelves and runners as required 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 ...

Page 7: ...bstruction Always ensure all cooling vents and cooling fans if fitted are clear of any obstruction The ends of the runners should be inserted into the vertical columns of holes simultaneously at the front and the back The bar should then be rotated through 90 in a downwards direction to secure it in place The shelves slide onto the runners such that the spurs on the lower side of the shelf are und...

Page 8: ...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 removed and connections made to the internal terminals If the product is to be connected by line plug The plug should be with...

Page 9: ...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 delta PE Green Yellow to earth ground 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: ... to the instructions supplied To switch the product off turn off the instrument switch If the product is to be left unattended isolate the electricity supply DO NOT switch off if the temperature is above 100 C damage could be caused to the fan and motor Adjust the controller to allow the temperature to fall 5 2 Over Temperature Control if fitted The over temperature controller should typically be ...

Page 15: ...itted 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 7 Interior Light if fitted If fitted the interior light is operated using the panel moun...

Page 16: ...unt of energy wasted in heating air 5 11 Stoving and Curing if fitted The stoving and curing option adds an explosion relief panel and a powered exhaust fan With this option the exhaust fan operates continuously when the product is switched on A pressure switch detects that there is sufficient air flow through the chamber If the pressure switch does not detect sufficient air flow a fault light ill...

Page 17: ...ted If ordered the door switch will isolate the heating elements and circulation fan The door switch is operated when the door is opened causing the heating elements and air circulation fan to be switched off 17 5 0 Operation ...

Page 18: ...nt 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 Seal Visual inspection check for splits or fray ing Door Seal Replacement Air Vent Check and clean if necessary Electrical Safety external Visual check of external cables and plugs Electrical Safety internal Physically chec...

Page 19: ...Fan if fitted Visual check to see if it is running Circulating Fan if fitted Check bearings and replace if necessary Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase circuit Shelves Visual check for fit and damage 19 6 0 Maintenance ...

Page 20: ...nce 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 man...

Page 21: ...ge 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 21 6 0 Maintenance ...

Page 22: ...in any significant level of airborne dust from these materials but much 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 respirator...

Page 23: ...ottom edge of the panel remains in contact with the main cas ing carefully lower the panel downwards to expose the products electrical com ponents Note Make a note of all connections before disconnecting any wiring 7 3 2 Internal Element Cover To gain access to the heating element thermocouple and fan 1 Open the oven door The internal element cover is situated on the right hand side of the oven ch...

Page 24: ...ouple connections Make a note of the thermocouple connections Thermocouple cable colour codings are Thermocouple Leg Colour positive type 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 7 Element Replacement l Remove the side panel and the in...

Page 25: ...uses and control circuit fuses may be mounted in their own holders or may be on a circuit board that contains an EMC filter The fuses are marked with their ratings Take care not to disconnect the wires leading from the EMC filter without first recording their positions they must be reconnected to the correct terminals 25 7 0 Repairs and Replacements ...

Page 26: ...faulty controller There are no lights glowing on the controller The controller may be faulty or not receiving a supply due to a faulty switch or a wiring fault B Oven Overheats 1 Oven only heats up when the instrument switch is ON The controller shows a very high temperature The controller is faulty The controller shows a low temperature The thermocouple may have been shorted out or may have been ...

Page 27: ... 11 00 Key F1 F2 Fuses FIL Filter SW Instrument Switch FM Fan Motor Fan Models Only C Temperature Controller TC Thermocouple SSR Solid State Relay EL Element s L Live N Neutral PE GR Y Earth Green Yel low 27 9 0 Wiring Diagrams ...

Page 28: ...n Motor POT Potentiometer A Supply from Instrument Switch B 3 Core 1 5mm2 Screened Cable L Live N Neutral E Earth Potentiometer may be mounted on the control panel for customer adjustment or fitted inside and the fan speed pre set Cables BRN Brown BLU Blue G Y Green Yellow 28 ...

Page 29: ...trument Switch FSC Fan Speed Controller FM Fan Motor L Live N Neutral The variable speed control is wired in series with the fan The fan activates when the instrument switch is turned on Control Circuit 29 9 0 Wiring Diagrams ...

Page 30: ...hases Volts Supply Fuse Control Fuse PF 200 1 phase 110 120 V 16 A 2 A PF 200 1 phase 220 240 V 12 A 2 A 208 V models may have a higher fuse rating check the rating label Stoving and Curing and possibly moisture extraction option models may have a higher fuse rating check the rating label 10 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures ...

Page 31: ...x Capacity l Net Weight kg H W D Peak Range Ovens with fans PF 200 300 2 7 750 590 520 230 90 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 31 11 0 Specifications ...

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Page 33: ...Notes Service Record Engineer Name Date Record of Work ...

Page 34: ... 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...