Installation, Operation &

Maintenance Instructions
Ovens & Incubators
Peak Series

This manual is for the guidance of operators of the above Carbolite products
and should be read before the oven is connected to the electricity supply.

CONTENTS
Section Page

1.0 Symbols & Warnings 1

2.0 Installation 3
3.0 Operation 5
4.0 Maintenance 8
5.0 Repairs & Replacements 9
6.0 Fault Analysis 11
7.0 Circuit Diagrams 12
8.0 Fuses & Power Settings 15
9.0 Specifications 16

Manuals are supplied separately for the temperature controller

(and overtemperature controller when fitted).
Please read the controller manuals before operating the oven.
1.0

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SYMBOLS & WARNINGS

1.1 Switches and Lights

Supply Light: when the oven is connected to the electrical supply the light
in the adjacent switch glows

1.2 Warning Symbols

DANGER of electrical shock– read any warning printed by this symbol.

DANGER – hot surface. Read any warning printed by this symbol.

WARNING: all surfaces of an oven may be hot.

DANGER – read any warning printed by this symbol.

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2.0 INSTALLATION
2.1 Unpacking & Handling
Remove the shelves and runners from the packaging before attempting to move the equipment.
Lift the unit by its base. The door should not be used to support the equipment when moving it.
Use two people to carry the oven where possible. Remove any packing material from the inner
chamber before use.
2.2 Siting & Setting Up
Place the oven on a level surface. If overtemperature protection is not fitted, ensure that the unit
can be directly observed.
Ensure that there is at least 50mm free space behind and around the oven. There are vents in the
back that must not be obstructed. Some models have protruding fan motor housings: these
housings must be in an area of good ventilation.
Ensure that the oven is placed in such a way that it can be quickly switched off or disconnected
from the electrical supply - see below.
Except 800 litre models: 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 under the bar at the back; this prevents the shelf
from tilting forwards when partially withdrawn.

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2.3 Electrical Connections

Connection by a qualified electrician is recommended.
All ovens covered by this manual may be ordered for single phase A.C. supply, which may be
Live to Neutral non-reversible, Live to Neutral reversible or Live to Live. Model PF400 can be
supplied for use on two phases out of a three phase with neutral supply - one phase is left unused.
Model PF800 can be supplied for use on a three phase supply.
Check the oven rating label before connection. The supply voltage should agree with the voltage
on the label, and the supply capacity should be sufficient for the amperage on the label.
The supply should be fused at the next size equal to or higher than the amperage on the label. A
table of the most common fuse ratings is also given in section 8.1 of this manual. Where a supply
cable is present there are internal supply fuses; customer fusing is preferred but not essential.
Oven with supply cable: either wire directly to an isolator or fitted with a line plug.
Oven without supply cable: a permanent connection to a fused and isolated supply should be made
to the internal terminals after temporary removal of the back panel.
Connection by line plug: the plug should be within reach of the operator, and should be quickly
removable.
Connection to isolating switch: this should operate on 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).
CONNECTION DETAILS supply type
Supply Terminal label Cable colour Live-Neutral Reversible or Live-Live
1-phase L Brown To live to either power conductor
N Blue To neutral to the other power conductor
PE Green/Yellow To earth (ground) to earth (ground)
2- or 3-ph 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)

DO NOT connect an oven ordered for three phase use to a single phase supply or to the wrong
type of three phase supply.

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3.0 OPERATION
The instructions for operating the temperature controller are given in a separate manual.
If the oven is fitted with a time switch, see also the supplementary manual MS03.
If cascade control is fitted, see the supplementary manual MS07.
If the oven has variable speed fan, air extraction or stoving and curing options, please also see the
appropriate section on the next page of this manual.
3.1 Operating Cycle
The oven is fitted with a combined Supply light and Instrument switch. The light is on whenever
the oven is connected to the supply. The switch cuts off power to the controller(s).
If the oven has fan-assisted circulation, the fan operates when the instrument switch is switched
on.
Connect the oven to the electrical supply. The Supply light should glow.
Operate the instrument switch to activate the temperature controller; the O position is off, the
I position on. The controller becomes illuminated and goes through a short test cycle.
Adjust the temperature controller – see the controller manual.
Overtemperature option - Hydraulic thermostat. Set the rotary dial to the desired protection
temperature.
Overtemperature option - Digital. If the overtemperature controller has not yet been set as
required, set it and activate it according to the instructions in the appropriate manual.
Unless a time switch is fitted and is off, the oven starts to heat up according to the controller set
point or program.
To switch the oven off, set the Instrument switch to O. If the oven is to be left off, isolate it from
the electrical supply.
3.2 Overtemperature Control (if fitted)
The overtemperature controller should typically be set at 15°C above the main controller. If an
overtemperature condition occurs, always investigate the possibility that the main control system
has failed.
An overtemperature condition always cuts off power to the heating elements. To reset the
condition, first either allow the oven to cool, or increase the overtemperature setting.
Hydraulic thermostat. If the overtemperature trip operates then a click occurs and a warning light
near the thermostat lights up; the reset button on the thermostat pops out. Reset by pressing the
button. In some models the reset button is directly accessibly. In others it is necessary to turn the
thermostat dial till the hole lines up with the reset button and press it using a small diameter rod.
Digital. A light in the overtemperature controller flashes. Reset the overtemperature controller
according the instructions in the appropriate manual.
3.3 Vents
On the back of the unit are two vents, inlet and exhaust. The inlet vent is covered by a baffle that
should be left in place.
The exhaust vent is closed by a butterfly valve that can be controlled from the front panel. Rotate
the knob clockwise to open the vent, anticlockwise to close.
In non-fan models there is only a small flow of air through the chamber. With fan versions, fumes
are pushed out through the exhaust vent by fan action, and drawn in through the inlet vent.

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3.4 Temperature Uniformity

Where accurate temperature control of the load is important, use the central part of the chamber
and place or distribute the load to allow free air circulation. Do not place loads on the chamber
floor: use the bottom shelf.
3.5 Explosive Vapours
The standard models are not suitable for drying or heat treatment applications where vapours are
released that are combustible or that can form explosive mixtures with air. For such applications
only use models supplied with the stoving and curing option.
3.6 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 oven
chambers are not gas tight, so it should be understood that gas usage may be high, and that the
chamber is likely always to contain some air. Residual oxygen levels of 1% are to be expected.
3.7 Variable Speed Fan Option
When this is ordered, a variable speed control is fitted in the fan circuit. Operation of the control is
self-explanatory.
Please note that there is a minimum setting at which the fan motor starts up when the oven is
switched on. Find this setting by experiment, and mark the position on the control or front panel.
It is unlikely that a control setting of less than 50% would ever be required, as there would be very
little air flow inside the oven.
3.8 Fan Exhaust and Moisture Extraction Options
When one of these options is fitted a vent duct at the back adds 45mm to the unit depth. 25mm
free space should be left behind the vent to prevent damage. The motor and fan box and outlet
vent are on the top of the unit, adding 270mm height. The outlet vent is a 64mm o/d tube to which
suitable ducting can be connected if required.
Please note that the heater element power rating may be increased; check the oven rating label for
power and fuse requirements.
Start the extraction unit using the amber switch on the control panel; this is only functional when
the instrument switch is on.
The amount of air exhaust can be controlled by adjusting the vent control knob on the control
panel.
When the unit is turned on, there may be a drop in internal temperature before the oven recovers
to the setpoint value.
3.9 Stoving and Curing Option
The oven is fitted with an explosion relief panel and a powered exhaust fan. The exhaust fan is
physically similar to that described above.
With this option the fan runs all the time that the oven is switched on.
A pressure switch detects that there is sufficient air flow through the chamber, and prevents the
oven from heating if the exhaust fan is not working correctly. If the pressure switch does not
detect sufficient air flow, a fault light comes on and the oven is prevented from heating up.
At least 200mm free space must be left at the back and side of the oven to allow the explosion
relief panel to break out if there is a rapid build up of pressure inside the chamber.

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3.10 Cooled Incubator Models

The incubator is designed to run at a constant temperature; the cooling system is not designed for
cooling the chamber down from high temperatures.
Select the desired temperature on the temperature controller. If this is below 45°C switch on the
cooling unit using the switch marked “*“ on the front panel. If the desired temperature is above
45°C the cooling facility is normally not required and may be switched off.
When switched on, the cooling unit is designed to run all the time, and the heaters are used to
balance the cooling load and maintain a stable temperature.
The optional defrost timer (when fitted) is a 2-hour time clock set to switch off the cooling system
for at least quarter of an hour every 24 hours. This allows the cooling unit to defrost regularly.

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4.0 MAINTENANCE
4.1 General Maintenance
No routine maintenance is required other than the occasional replacement of consumable items.
The oven outer surface may be cleaned with a damp cloth. Do not allow water to enter the interior
of the case. Do not clean with organic solvents.
Fan models: the motor is sealed for life; no lubrication is required.
4.2 Calibration
After prolonged use the controller and/or thermocouple could require recalibration. This would be
important for processes that require accurate temperature readings. A quick check using an
independent thermocouple and temperature indicator should be made from time to time to
determine whether full calibration is required.
For a quick check of the temperature shown by the control thermocouple and oven controller, a
portable temperature indicator and probe thermocouple may be used. Carbolite can supply these
items.
Depending on the controller, the controller manual may contain calibration instructions.
4.3 After Sales Service
Carbolite’s service division (Thermal Engineering Services) has a team of Service Engineers
capable of repair, calibration and preventive maintenance of furnace and oven products at our
customers’ premises throughout the world. We also sell spares by mail order. A telephone call or
fax often enables a fault to be diagnosed and the necessary spare part despatched.
Each oven has its own record card at Carbolite. In all correspondence please quote the serial
number, model type and voltage given on the rating label of the oven. The serial number and
model type are also given on the front of this booklet when supplied with an oven.
To contact Thermal Engineering Services or Carbolite see the back page of this manual.
4.4 Recommended Spares Kits
Carbolite can supply individual spares, 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 comprises a thermocouple, a
solid state relay, an instrument switch, an element or set of elements, and a door seal; for fan
models the kit includes a fan and motor assembly. Individual spares are also available.
When ordering spares please quote the model details as requested above.
4.5 Power Adjustment
The control system incorporates electronic power limiting, but in these models the power limit is
set to 100%. The power limit parameter OP.Hi may be accessible to the operator, but should not
generally be altered.
Rarely, in the case of uncommon voltages (e.g. outside the range 220-240V 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 8.2 for details of any power limit settings.
Occasionally the power limit is set to zero to permit demonstration of the controls without the
heating elements taking power. In this case the power limit is accessible to the operator and may
be reset to its standard value, usually 100: see section 8.2.

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5.0 REPAIRS & REPLACEMENTS

5.1 Safety Warning – Disconnection from Supply
Always ensure that the oven is disconnected from the supply before repair work is
carried out.
5.2 Safety Warning - Refractory Fibrous Insulation
This oven contains refractory fibres in its thermal insulation. These materials may
be in the form of fibre blanket or felt, vacuum formed board or shapes, mineral
wool slab or loose fill fibre.
Normal use of the oven does not result 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, we strongly recommend that safety
precautions are taken whenever the materials are handled.
Exposure to dust from fibre that has been used at high temperatures may cause
respiratory disease.
When handling fibre always use an approved mask, eye protection, gloves and long
sleeved clothing.
Avoid breaking up waste material. Dispose of waste fibre in sealed containers.
After handling rinse exposed skin with water before washing gently with soap (not
detergent). Wash work clothing separately.
Before commencing any major repairs we recommend reference to the European Ceramic Fibre
Industry Association Bulletin No. 11 and the UK Health and Safety Executive Guidance Note
EH46.
We can provide further information on request. Alternatively our service division can quote for
any repairs to be carried out at your premises or ours.
5.3 Panel Removal
Disconnect the oven from the electrical supply.
Control panel. Open the door and remove two screws located in recesses on the left side of the
control panel (these screws are covered with plastic caps). Lift the panel, pull forward the bottom
of the panel, and lower the panel to disengage it from the top of the body. Note that the panel
remains connected by wiring. Do not disconnect any wiring without first making a careful note of
all the connections.
Internal Element Cover. Open the door. Side cover (fan models): remove any screws holding the
panel. Bottom cover (non-fan): no screws; the panel clips into place. Remove the cover.
5.4 Temperature Controller Replacement
200 & 201. These controllers are fitted to the back of the control panel, which can be removed as
given above.
Before handling the controller: wear an anti-static wrist strap or otherwise avoid any possibility
of damage to the unit by static electricity.
Refer to the instructions supplied with the replacement controller.
2132, 2416, 2408 etc. Ease apart the two lugs at the side; grip the instrument and withdraw it from
its sleeve; push in the replacement.

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5.5 Hydraulic Thermostat Replacement (if fitted)

Remove the control panel as given above. Also remove the internal element cover.
Pull off the knob from the thermostat. Remove the fixing screws. Disconnect any fixing clips or
screws inside the oven chamber, and ease out the capillary tube. Remove the thermostat.
Replace by reversal of the procedure.
5.6 Solid-state Relay Replacement
Remove the control panel as given above. Make a note how the wires are connected to the solid
state relay, and disconnect them.
Remove the solid state relay from the aluminium plate.
Replace and reconnect the solid state relay ensuring that the heat-conducting thermal pad is
sandwiched between the relay and the base panel or aluminium plate. Alternatively a thin layer of
white, heat-conducting silicon paste may be applied between the new relay and the plate.
The new solid state relay contains a built-in MOV which protects it from short periods of excess
voltage. If the old relay had a separate disc-shaped "MOV" connected between the high voltage
terminals of the old relay, discard the old MOV.
Replace the removed panel.
5.7 Thermocouple Replacement
Remove the control panel and the internal cover as given above.
Make a note of the thermocouple connections, and how the thermocouple is placed and fixed.
Colour codings are:
negative positive (type K)
white green
Disconnect the thermocouple from its controller terminals or terminal block.
Re-assemble with the new thermocouple observing the colour coding.
5.8 Element Replacement
Remove the control panel and the internal cover as given above. The element terminals are low
down in the side compartment.
Disconnect the wires from the element terminals. Remove any starlock washers - these may need
to be cut with wire cutters. Remove any clips holding the element inside the chamber, and
withdraw the element.
Reverse the procedure with the new element.
Run the oven at a low temperature and check that it is controlling properly, to find out whether the
element failure was caused by a fault in the control circuit.
5.9 Fuse Replacement
Models up to 200 litre: remove the smaller of the two back panels. Larger models: remove the side
panel of the control compartment.
Depending on the model, supply fuses 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.

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6.0 FAULT ANALYSIS

A. Oven Does Not Heat Up

1. The SUPPLY light is Æ No power from the Æ Check the fuses in the supply
OFF supply line
2. The SUPPLY light is Æ The controller shows a Æ The thermocouple has broken
ON very high temperature or has a wiring fault
or a code such as S.br
Æ The controller shows a Æ The SSR could be failing to
low temperature switch on due to internal
failure, faulty logic wiring
form the controller, or faulty
controller
Æ There are no lights Æ The controller may be faulty or
glowing on the not receiving a supply due to a
controller faulty switch or a wiring fault
B. Oven Overheats
1. Oven only heats up Æ The controller shows a Æ The controller is faulty
when the instrument very high temperature
switch is ON
Æ The controller shows a Æ The thermocouple may have
low temperature been shorted out or may have
been moved out of the oven
Æ The thermocouple may be
mounted the wrong way round
Æ The controller may be faulty
2. Oven heats up when Æ The SSR has failed Æ Check for an accidental wiring
the instrument switch “ON” fault that could have
is OFF overloaded the SSR

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7.0 CIRCUIT DIAGRAMS

7.1 Single Phase (overtemperature control: none or hydraulic thermostat)
F1 Filter
N
L
PE F2 Reset
button
Supply light Hydraulic
Instrument Switch thermostat Hydraulic e
t/stat o/temp l
only e
Warning light m
Fan models e
only n
t
Fan motor (s)

temperature SSR
controller
thermocouple
Note on Hydraulic Thermostat. When used over 16 Amps or in a 2- or 3-phase
model, the oven is fitted with a contactor, with the hydraulic thermostat in the coil
circuit – similar to 7.2.

7.2 Single Phase (overtemperature control: digital)

F1 Filter
N
L
F2 relay or
PE contactor
Supply light
Instrument Switch e
l
e
Fan models m
only e
n
Fan motor t
coil (s)

overtemp.
controller
thermocouple
temperature SSR
controller
thermocouple

7.3 Two-phase with Neutral

As 3-phase with neutral (7.4), but with phase L3 not present, and with two SSRs and element
circuits.

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7.4 Three Phase with Neutral

Filter
N
F1
L3
L2 e e e
L1 l l l
e e e
PE F2 contactor m m m
if fitted e e e
Supply light n n n
Instrument Switch t t t
(s) (s) (s)
instrument and fan
circuit as above SSR

SSR

SSR

Note on 3-phase. Depending on filter(s) fitted, there may 3 separate

neutral wires from the elements to the neutral supply.

7.5 Three Phase without Neutral (delta e.g. 208-240V)

Filter
F1
L3
L2 e e e
L1 l l l
e e e
PE F2 contactor m m m
if fitted e e e
Supply light n n n
Instrument Switch t t t
(s) (s) (s)
SSR

instrument and fan

circuit as above SSR

SSR

7.6 Three phase without Neutral (star – e.g. 380-415V)

The circuit is similar to 7.4, but the “neutral” ends of the elements are not connected to a neutral
terminal block.
The control circuit contains an isolating transformer to reduce
the control voltage to 240V or similar. F2

7.7 Higher Voltages (e.g.254V) transformer

The control circuit contains an isolating transformer to reduce

the control voltage to 240V or similar. F2
Supply light &
Instrument Switch

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7.8 Stoving & Curing

The following addition is made to the circuit.
element circuit
Relay or Contactor

control circuit

Fan Motor
exhaust Fan

Fault light
o/temp if
fitted
COIL
Pressure
Switch

7.9 Cooled Incubator (PIC models)

The following addition is made to the circuit.
F1

F2
Defrost timer
(only if
ordered)

supply light
and cooling
instrument switch
switch and
light
To control circuit

condensing unit

internal
thermostat

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8.0 FUSES & POWER SETTINGS

8.1 Fuses
F1-F2: Refer to the circuit diagrams.
F1 Internal supply Fitted if supply cable fitted. on-board and up to 16 Amps: 32mm
fuses Fitted on board to some types of EMC filter. x 6mm type F
other: GEC Safeclip
F2 Auxiliary circuit Fitted on board to some types of EMC filter. 2 Amps glass type F
fuses May be omitted up to 25Amp/phase supply On board: 20mm x 5mm
rating. Other: 32mm x 6mm
Customer fuses Required if no supply cable fitted. See rating label for amperage; see
Recommended if cable fitted. table below for fuse rating.
Model phases Volts Supply Volts Supply Control
Fuse Fuse Fuse
PIN30, PIF30 1-phase 220-240 5A 110-120 5A 2A
PN30,PIC30 1-phase 220-240 5A 110-120 7A 2A
PF30 1-phase 220-240 5A 110-120 10A 2A
PIN60 1-phase 220-240 5A 110-120 5A 2A
PIF60 1-phase 220-240 5A 110-120 7A 2A
PN60, PIC60 1-phase 220-240 5A 110-120 10A 2A
PF60 1-phase 220-240 7A 110-120 12.5A 2A
PIN120, PIF120 1-phase 220-240 5A 110-120 7A 2A
PN120, PIC120 1-phase 220-240 7A 110-120 12.5A 2A
PF120 1-phase 220-240 10A 110-120 20A 2A
PIN200, PIF200 1-phase 220-240 5A 110-120 10A 2A
PIC200 1-phase 220-240 7A 110-120 15-16A 2A
PN200 1-phase 220-240 10A 110-120 20A 2A
PF200 1-phase 220-240 12.5A 110-120 25A 2A
PIF400 1-phase 220-240 10A 5A
PF400 1-phase 220-240 30-32A 5A
PF400 2-phase+N 380/220-415/240 15-16A 5A
PIF800 1-phase 220-240 20A 5A
PF800 1-phase 220-240 40A 5A
PF800 3-phase+N 380/220-415/240 15-16A 5A

208V models may have a higher fuse rating: check the rating label.

8.2 Power Settings

All models are designed for a power limit (OP.Hi) of 100% with the following exceptions to date:
- any model on 254V: 89%
- PN200 on 110V: 89%; on 120V: 75%
- PF120 on 208V: 89%
- PF200 on 120V: 90%

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 Thank you for reading this data sheet.

For pricing or for further information, please contact us at our UK Office, using the details
below.

UK Office
Keison Products,
P.O. Box 2124, Chelmsford, Essex, CM1 3UP, England.
Tel: +44 (0)330 088 0560
Fax: +44 (0)1245 808399
Email: sales@keison.co.uk

Please note - Product designs and specifications are subject to change without notice. The user is responsible for determining the
suitability of this product.