Carbolite Gero EVZ 12/450B, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1200 C Tube Furnace 3 zone EVZ Model 450mm No Controller EVZ 12 450B No Controller MEN EVZ12450B 16_NOCTRL 02 08 2019 ...

Page 2: ...ting the furnace onto the vertical stand 9 2 3 4 Figure Tube furnace positioned horizontally on the stand 10 2 3 5 Figure Tube support 11 2 3 6 Figure Tube support assembled 11 2 3 7 Figure Tube support and end seal 12 2 3 8 Figure Tube support and end seal assembly 12 2 3 9 Figure View showing how to support the work tube in a vertical ori entation 13 2 4 Setting Up Without a Stand 13 2 4 1 Figur...

Page 3: ...Disconnection from Power Supply 27 6 2 Safety Warning Refractory Fibre Insulation 27 6 3 Temperature Controller Replacement 27 6 4 Solid state Relay Replacement 28 6 5 Thermocouple Replacement 28 6 6 Element Replacement 28 6 7 Fuse Replacement 29 7 0 Fault Analysis 30 A Furnace Does Not Heat Up 30 B Product Overheats 31 8 0 Wiring Diagrams 32 8 1 WC 13 70 32 8 2 WC 13 71 33 9 0 Fuses and Power Set...

Page 4: ...d to the elements Heat switch the switch disconnects power to the heating elements unless this switch is OFF there is a danger of electric shock when inserting objects into the product 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 ...

Page 5: ...work tube adaptors or it could be possible for an operator to access electrically live element coils that could cause serious injury or death 8 Warning label Switch off the furnace before loading and unloading The furnace heaters must be switched OFF using the heater switch item 2 in figure 1 3 1 when the furnace is being loaded or unloaded The work tube can become electrically conductive at high ...

Page 6: ...er ON and OFF to the furnace heating ele ments 3 Heater ON light indicates that the furnace heating elements are energized 4 Product rating label indicating the product serial number and electrical inform ation 5 Access holes to front panel fixing screws 6 Warning label Disconnect the mains supply before removing this cover 7 Warning label Do not operate without a work tube 8 Warning label Switch ...

Page 7: ...al spillage or hot materials The surface on which the equipment is mounted should be stable and not subject to movement or vibrations The height of the mounting surface is important to avoid operator strain when loading and unloading samples Unless otherwise stated elsewhere in this manual ensure that there is at least 150 mm of free space around the back and sides of the product Clear space is re...

Page 8: ...bling the stand and mounting the furnace Tools required 4 mm Allen key The assembly of the vertical stand is as follows with reference to 2 3 1 2 3 2 and 2 3 3 Place the vertical stand base item 1 on the floor or bench on which it is to be assembled l Position the vertical stand upright 2 on the stand base in line with the fixing holder l Secure the stand upright to the base using the 6 x M6 dome ...

Page 9: ...mbling the stand Index to numbered items in Figure 2 3 2 and Figure 2 3 3 1 Vertical stand base 2 Vertical stand upright 3 Fixing screws M6 x 16 dome cap screw 4 Washer M6 5 Tube furnace 6 M6 screw knob 2 3 3 Figure Mounting the fur nace onto the vertical stand 9 2 0 Installation ...

Page 10: ...it the work tube with the furnace in the horizontal position as shown in figure 2 3 4 To fit the work tube in a vertical orientation follow the steps below Omit the use of the end seal if not required The same tube support design will work with or without the tube end seal in place WARNING If clamps are used without an end seal care should be taken not to over tighten on to a bare tube especially ...

Page 11: ...5 using item 6 until the tube is secure enough for use in a vertical arrangement Fitting arrangement is shown in figure 2 2 l Figure 2 2 shows an exploded view of all the required parts l Figure 2 2 shows the assembled parts as they would be used 2 3 5 Figure Tube support 2 3 6 Figure Tube support assembled 11 2 0 Installation ...

Page 12: ...n 2 3 7 Figure Tube support and end seal 2 3 8 Figure Tube support and end seal assembly For extra stability of the tube repeat the assembly instructions above as shown in figure 2 3 8 on the other end of the tube 12 ...

Page 13: ...mounting frame It is the customer s responsibility to carry out a risk assessment on the siting and mounting of the furnace and to ensure that it is operated in a safe manner see section 2 2 for the recommended siting instructions The fitting of the work tube is covered in the previous section 2 4 1 Figure Tube furnace shown without a stand for customers own mounting as an example Index to numbere...

Page 14: ...ation shields is similar to that of insulation plugs see figure C If a metal work tube is being used in the furnace ensure that it is earthed See the safety warning in section 4 6 Figure A Cross section view showing standard length work tube insulation plug fitted Figure B Cross section view showing extended work tube insulation plug fitted Figure C Cross section view showing an extended length wo...

Page 15: ...ternal supply fuses in which case customer fusing is preferred but not essential See section 9 0 for furnace rating power current and fusing information The external connection should be either a permanent connection to a fused isolator supply or to a socket on a fused isolator supply the isolating switch must operate on both conductors Make sure that the isolator switch is within easy reach of th...

Page 16: ...3 0 Temperature Controller 3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 16 ...

Page 17: ...or 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 switch off power to the heating elements use the heater switch To switch the product off use both the heater switch and the instrument switch If the product is to be left switched off and unattended...

Page 18: ... coils that could cause serious injury of death Switch off the furnace before loading and unloading The furnace elements must be switched off using the heater switch item 2 in Warning Labels when the furnace is being loaded or unloaded The work tube can become electrically conductive at high temperatures If an element has failed and collapsed onto the work tube the work tube will become live causi...

Page 19: ... zone controllers try to compensate for this by switching on the end zone elements preventing the furnace from cooling B Retransmission of Setpoint Three independent thermocouples are connected to three controllers The three controllers are linked together and the centre zone controller communicates the desired setpoint to the end zone controllers If the centre zone controller is set to a setpoint...

Page 20: ...l Operating Advice 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 and in section 10 0 towards the back of this manual Lightweight ceramic fibre insulation can easily be marked by accidental contact Some fine cracks may develop in the surface of the insulation due to t...

Page 21: ...ting and cooling rate 4 8 Pressure Work tubes are not able to accept high internal pressure When gas seals or similar fittings are in use the gas pressure should be restricted to a maximum of 0 2 bar 3 psi A pressure of approximately half of that should normally be sufficient to achieve the desired flow rate The operator must ensure that the exhaust path from the tube is not blocked so that excess...

Page 22: ...4 0 Operation than inert gases such as nitrogen 22 ...

Page 23: ...tted Electrical measurement Safety Switch Function split models only Set a safe temperature above ambient and open the furnace to see if the heater light goes out Safety Switch Function split models only Electrical measurement Electrical Safety external Visual check of external cables and plugs Electrical Safety internal Physically check all connections and cleaning of the power plate area Functio...

Page 24: ...ted Check all seals and O rings and clamps Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase circuit Cooling Fans if fitted Check whether the cooling fans are work ing 24 ...

Page 25: ...erature controller set a safe 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...

Page 26: ...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 manual when supplied with the product Carbolite Gero Service and Carbolite Gero contact information can be found on the ...

Page 27: ...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 28: ...le connections Thermocouple cable colour codings are thermocouple leg colour positive type N pink negative white Disconnect the thermocouple from its terminal block Carefully withdraw the thermocouple from the product and remove any broken bits of thermocouple Bend the new thermocouple carefully to match the shape of the original working from the terminal end Should the length differ from that of ...

Page 29: ... 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 control box back panel to gain access to the fuses 29 6 0 Repairs and Replacement...

Page 30: ... 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 31: ...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 31 7 0 Fault Analysis ...

Page 32: ...fety Switch A A 2 pole Heater Switch is fitted directly in the element circuit in models up to 16 A rating Safety Switch B A door switch is fitted into the contactor coil circuit Above 16 A a 1 pole Heater Switch is fitted into the same circuit in series 32 ...

Page 33: ...8 2 WC 13 71 Connections below show single phase with indirect safety switches and over temperature control 33 8 0 Wiring Diagrams ...

Page 34: ...ype F fitted on EMC filter circuit board s F2 Auxiliary Circuit Fuses Fitted on board to some types of EMC filter May be omitted up to 25 Amp phase supply rating 2 Amps glass type F On board 20 mm x 5 mm Other 32 mm x 6 mm Customer Fuses Required if no supply cable fitted Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating ...

Page 35: ... refer to the Changing the Maximum Output Power of the control section of the manual All standard models covered by this manual are fitted with elements designed for use over the range of voltages 100 V 120 V and 200 V 240 V the power limit parameter is set according to the table below The power limit depends on the voltages follows Voltage 200 V 208 V 220 V 230 V 240 V Percentage 100 100 89 82 77...

Page 36: ...lite Gero for work tubes with outside diameters of 32 mm 46 mm and 60 mm 10 1 Environment The furnaces contain electrical parts and should be stored and used in indoor conditions as follows Ambient temperature working range Temperature 5 C to 40 C Note when operating the furnace at temperatures close to the maximum and the ambient temperature is above 30 C the allowed external temperature defined ...

Page 37: ...lation procedure see section 2 1 Step 3 After reading the controller operation instructions heat the furnace following the temperature profile given below This will need to be done manually on furnaces with basic control option or programmed into the controller if an advanced control option is fitted l Ramp the setpoint temperature 2 C minute to 100 C and dwell for 2 hours l Ramp the setpoint temp...

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Page 39: ...Notes Service Record Engineer Name Date Record of Work ...

Page 40: ... 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...