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Summary of Contents for VERDER CARBOLITE GERO EZS-3G 12/600
- 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...
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Page 2: Table Of Contents
Contents This manual is for guidance on the use of the Carbolite Gero product specified on the front cover. This manual should be read thoroughly before unpacking and using the furnace or oven. The model details and serial number are shown on the back of this manual. - Page 3 Safety Warning - Refractory Fibre Insulation Temperature Controller Replacement Solid-state Relay Replacement Thermocouple Replacement Element Replacement Fuse Replacement 7.0 Fault Analysis Furnace Does Not Heat Up Product Overheats 8.0 Wiring Diagrams 01937-5001 9.0 Fuses and Power Settings Fuses Power Settings User Power Setting Adjustments 10.0 Specifications 10.1...
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Page 4: Symbols And Warnings
1.0 Symbols and Warnings 1.0 Symbols and Warnings Switches and Lights Instrument switch: when the instrument switch is operated the temperature control circuit is energised. Heat light: the adjacent light glows or flashes to indicate that power is being supplied to the elements. Heat switch: the switch disconnects power to the heating elements;... -
Page 5: Warning Labels
1.0 Symbols and Warnings Caution – Double Pole/Neutral Fusing Warning Labels On the front control panel there are 2 warning labels as shown in figure 1.3.1; they are numbered 7 and 8. These warnings must be followed for the safe operation of this furnace. - Page 6 1.0 Symbols and Warnings Figure 1.3.1 - Control Box layout and warning Figure 1.3.2- Back of control box showing labels. mains lead socket Index to numbered items in Figure 1.3.1 and 1.3.2 1. Electrical supply switch - switches electrical power ON and OFF to the furnace. 2.
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Page 7: Installation
2.0 Installation 2.0 Installation If the product has been transported or stored in humid conditions it must be dried out completely before operating the furnace. Contact Carbolite Gero Service for instructions. Unpacking and Handling When unpacking or moving the product, always lift it by its base or both ends of the main body. -
Page 8: Setting Up
2.0 Installation If the product is to be used in a process which could liberate hazardous gases, then it should be installed together with a suitable fume extraction system. Ensure that the product is placed in such a way that it can be quickly switched off or disconnected from the electrical supply. - Page 9 2.0 Installation The fitting of the work tube is as follows with reference to figure 2.3.1. Please note that standard length work tubes are also referred to as tubes suitable for working in air. They are 150 mm longer than the heated length of the furnace (see the table in section 10.0).
- Page 10 2.0 Installation Figure 2.3.2 - Close-up view of the tube end stop for a standard length work tube on the split tube furnace. Note that the right hand furnace end guard (8) has been removed from the view for clarity to show the end adaptor and tube end stop.
- Page 11 2.0 Installation Figure 2.3.3 Figure 2.3.4 Figure 2.3.5 Figure 2.3.6...
- Page 12 2.0 Installation Figure 2.3.7 Figure 2.3.8 Figure 2.3.9 Figure 2.3.10- Tube support assembled...
- Page 13 2.0 Installation Figure 2.3.11- Tube 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...
- Page 14 2.0 Installation 5. End adaptor 6. Fluted grip knob Fitting the Optional Insulation Plugs and Radiation Shield For optimum temperature uniformity, insulation plugs or radiation shields should be placed in the work tube ends as shown below. With a standard work tube, the insulation plug must be fitted as shown in figure A.
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Page 15: Electrical Connections
2.0 Installation Electrical Connections Connection by a qualified electrician is recommended. All furnaces in the range are single-phase and operate over the voltage ranges 100 to 110 volts or 200 - 240 volts. Check the rating label before connection, see "Warning Labels"... -
Page 16: Temperature Controller
3.0 Temperature Controller 3.0 Temperature Controller If this product is fitted with a temperature controller, instructions are provided separately. -
Page 17: Operation
4.0 Operation 4.0 Operation Operating Cycle This product is fitted with an instrument switch which cuts off power to the control circuit. Connect the product to the electrical supply. Turn on the instrument switch to activate the temperature controllers. The controllers illuminate and go through a short test cycle. -
Page 18: 3-G Control Methods
4.0 Operation Explosive Materials The furnace must not be used to heat materials which could explode, or which could emit gases that could form explosive mixtures. If the safe heating of a material is dependent on its temperature, only heat these type of materials if the furnace has the optional over-temperature protection device fitted. -
Page 19: Operator Safety
4.0 Operation Operator Safety The ceramic materials used in the product manufacture become electrically conductive to some extent at high temperatures. DO NOT use any conductive tools within the product without isolating it. If a metal work tube is used, it must be earthed (grounded). Switch off the heater switch whenever loading or unloading the product. -
Page 20: Gas Tightness
4.0 Operation It is recommended that a pressure relief system should be used to avoid an over pressurisation of the work tube. Please note: A product should not be heated up if any valves that have been fitted are 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. -
Page 21: Maintenance
5.0 Maintenance 5.0 Maintenance General Maintenance Preventive rather than reactive maintenance is recommended. The type and frequency depends on the product use; the following are recommended. Maintenance Schedule CUSTOMER QUALIFIED PERSONNEL DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically qualified personnel should attempt these maintenance procedures. - Page 22 5.0 Maintenance Seals (if fitted) Check all seals and O-rings and clamps Performance Element Circuit Electrical measurement Measure the current drawn on each Power Consumption phase / circuit Check whether the cooling fans are work- Cooling Fans (if fitted)
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Page 23: Maintenance Schedule
5.0 Maintenance Maintenance Schedule CUSTOMER QUALIFIED PERSONNEL DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically qualified personnel should attempt these maintenance procedures. Frequency Maintenance Method Procedure Daily Weekly Monthly Annually Annually Safety Set an over-temperature setpoint lower Over-Temperature Safety Circuit than the displayed temperature and (if fitted) check for an over-temperature alarm as... - Page 24 5.0 Maintenance Measure the current drawn on each Power Consumption phase / circuit Shelves Visual check for fit and damage...
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Page 25: Cleaning
5.0 Maintenance 5.3.1 Cleaning The product's outer surface may be cleaned with a damp cloth. Do not allow water to enter the interior of the case or chamber. Do not clean with organic solvents. 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. -
Page 26: After-Sales Service
5.0 Maintenance thermocouple and temperature indicator should be made from time to time to determine whether full calibration is required. Carbolite Gero can supply these items. Depending on the controller fitted, the controller instructions may contain calibration instructions. After-Sales Service Carbolite Gero Service has a team of Service Engineers who can offer repair, calibration and preventive maintenance of furnace and oven products both at the Carbolite Gero factory and at customers’... -
Page 27: Repairs And Replacements
6.0 Repairs and Replacements 6.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Immediately switch the product off in the event of unforeseen circumstances (e.g. large amount of smoke). Allow the product to return to room temperature before inspection. Always ensure that the product is disconnected from the electrical supply before repair work is carried out. -
Page 28: Solid-State Relay Replacement
6.0 Repairs and Replacements Solid-state Relay Replacement Disconnect the product from the power supply and remove the appropriate cover as given above. 1. Make a note of the wire connections to the solid state relay, then disconnect them. 2. Remove the solid state relay from the base panel or aluminium plate. 3. -
Page 29: Fuse Replacement
6.0 Repairs and Replacements Fuse Replacement Fuses are marked on the wiring diagram with type codes, e.g. F1, F2. For more information on fuses refer to section 9.0. 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 check the internal circuits. -
Page 30: Fault Analysis
7.0 Fault Analysis 7.0 Fault Analysis Furnace Does Not Heat Up The HEAT The heating element Check also that the SSR is working light is ON has failed correctly The controller shows a The HEAT The thermocouple has broken or has very high temperature light is OFF a wiring fault... -
Page 31: Product Overheats
7.0 Fault Analysis Product Overheats Product only heats up The controller when the instrument shows a very high The controller is faulty switch is ON temperature The thermocouple may be The controller faulty or may have been shows a low removed out of the heating temperature chamber... -
Page 32: Wiring Diagrams
8.0 Wiring Diagrams 8.0 Wiring Diagrams 01937-5001... -
Page 33: Fuses And Power Settings
9.0 Fuses and Power Settings 9.0 Fuses and Power Settings Fuses F1 - F2: Refer to the circuit diagrams. GEC Safeclip of the type shown Fitted if supply cable fitted. Internal (glass type F up to 16 A) Supply Fitted on board to some types 38 mm x 10 mm type F fitted on Fuses of EMC filter. -
Page 34: User Power Setting Adjustments
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. -
Page 35: Specifications
10.0 Specifications 10.0 Specifications Carbolite Gero reserves the right to change the specification without notice. All models have cylindrical elements with wire mounted in the surface of the insulation material. All models can accept work tubes up to a maximum outside diameter of 60 mm. All models have a maximum operation temperature of 1200°C (1100°C continuous). -
Page 36: Furnace Drying Out Process
10.0 Specifications Furnace drying out process Step 1. Before the furnace is connected to the electrical supply, remove the back panel and check for signs of moisture on the electrical circuits. If visible signs of moisture are present then allow it to dry out in ambient temperature for at least 24 hours. If the problem persists ensure that the furnace is isolated and contact Carbolite Gero Service for more information. - Page 37 Notes Service Record Engineer Name Date Record of Work...
- Page 38 The products covered in this manual are only a small part of the wide range of ovens, chamber furnaces and tube furnaces manufactured by Carbolite Gero for laboratory and industrial use. For further details of our standard or custom built products please contact us at the address below, or ask your nearest stockist.
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