VERDER CARBOLITE GERO EZS-3G 12/600, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions 1200 C Tube Furnace 3 zone EZS 3G Model 600mm No Controller EZS 3G 12 600 No Controller MEN EZS3G12600 10_NOCTRL 02 08 2019 ...

Page 2: ...ting 7 2 3 Setting Up 8 2 4 Electrical Connections 15 3 0 Temperature Controller 16 4 0 Operation 17 4 1 Operating Cycle 17 4 2 Control Method 17 4 3 Safe Operation of the Furnace 17 4 4 3 G Control Methods 18 4 4 1 Independent Control 18 4 5 General Operating Advice 18 4 6 Operator Safety 19 4 7 Tube Life 19 4 8 Pressure 19 4 9 Gas Tightness 20 5 0 Maintenance 21 5 1 General Maintenance 21 5 2 Ma...

Page 3: ...cement 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 01937 5001 32 9 0 Fuses and Power Settings 33 9 1 Fuses 33 9 2 Power Settings 33 User Power Setting Adjustments 34 10 0 Specifications 35 10 1 Environment 35 Furnace drying out process 36 3 ...

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: ... a work tube fitted before being used The diameter of the work tube is a customer order option and therefore varies between tube furnaces Note If a metal work tube is being used in the furnace ensure that it is earthed See 4 6 Under no circumstances should any objects be placed on top of the product Always ensure that any vents on the top of the product are clear of any obstruction Always ensure a...

Page 9: ... tube into the bottom half of the furnace in the tube adaptors between the work tube end stops 5 Note that the work tube might be a tight fit when it is new and may need to be twisted backwards and forwards slightly as it is placed l Lower the lid by the handle and refasten the clips l Note in Figure 2 3 1 the right hand furnace end guard 8 is not shown so that the end adaptor 3 and tube end stop ...

Page 10: ...The guards and brackets should then be refitted l Fit the tube support bracket see 5 figure 2 3 5 Use the M6 button head screws and washers supplied l Fit the extended work tube guard see 4 figure 2 3 6 Use the M6 button head screws and washers supplied l Re fit furnace end guards see 3 figure 2 3 7 Use the M6 button head screws and supplied washers l If supplied fit the optional tube end seal ass...

Page 11: ...Figure 2 3 3 Figure 2 3 4 Figure 2 3 5 Figure 2 3 6 11 2 0 Installation ...

Page 12: ...2 0 Installation Figure 2 3 7 Figure 2 3 8 Figure 2 3 9 Figure 2 3 10 Tube support assembled 12 ...

Page 13: ...support and end seal Figure 2 3 12 Tube support and end seal assembly Index to numbered items in Figure 2 3 3 2 3 12 1 Tube support bracket 2 Tube support collar 3 End guard 4 Extended work tube guard 13 2 0 Installation ...

Page 14: ...either horizontally or vertically the insulation plug hooks onto the end seal hook see figure B Alignment of radiation 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...

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: ...ram 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 switch off power to the heating elements use the heater switch To switch the product off use both the ...

Page 18: ...ents 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 causing serious injury or death 4 4 3 G Control Methods 4 4 1 Independent Control The three controllers are completely in...

Page 19: ...ld be of low thermal mass and should have feet to reduce the contact with the tube fig 4 Key A Tube B Crucible Fig 4 Avoidance of thermal contact Do not set too high a heating or cooling rate As tubes are susceptible to thermal shock and may break Tubes which extend beyond the heated part of the furnace are more at risk A general rule for maximum heating or cooling rate is 400 internal diameter in...

Page 20: ...e closed to create a sealed volume A sealed work tube should not be heated from cold due to the pressure increase caused by the trapped air or gas expanding during the heating process 4 9 Gas Tightness Work tubes of IAP material are impervious Sillimanite may look similar but is porous Ensure that the correct tube material is in use before connecting and using gases other than inert gases such as ...

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

Page 23: ...ay 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 check all connections and cleaning of the power plate area Function Temperature Calibration Tested using certified equipment fre quency dependent on the standard required Operational Check Check that all functions are working ...

Page 24: ...5 0 Maintenance Power Consumption Measure the current drawn on each phase circuit Shelves Visual check for fit and damage 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: ...8 0 Wiring Diagrams 8 0 Wiring Diagrams 8 1 01937 5001 32 ...

Page 33: ...f cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Fuse Rating Amps F1 EZS 3G 12 600 1 phase 200 208 16 A EZS 3G 12 600 1 phase 220 240 16 A 9 2 Power Settings The power limit settings OP Hi for this model is as follows The figures represent the maximum percentage of time that controlled power is supplied to the elements Do not attempt to improve ...

Page 34: ...9 0 Fuses and Power Settings User Power Setting Adjustments Date Power Comments Note If a new set of elements are fitted then return the power settings to the original value 34 ...

Page 35: ...ork 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 in EN 61010 1 2...

Page 36: ... Complete the Installation 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 Ra...

Page 37: ...Notes Service Record Engineer Name Date Record of Work ...

Page 38: ... 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...