Carbolite Gero EVZ 12/450B Manual

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)

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. Use the product for the purpose for which it is intended.
1.0 Symbols and Warnings 4
1.1 Switches and Lights 4
1.2 General Warnings 4
1.3 Warning Labels 5
2.0 Installation 7
2.1 Unpacking and Handling 7
2.2 Siting 7
2.3 Setting Up 8
2.3.1 Figure - Vertical tube furnace model mounted on its stand. 9
2.3.2 Figure - Assembling the stand. 9
2.3.3 Figure - Mounting 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 Figure - Tube furnace shown without a stand for customers own mount-
ing as an example. 13
2.5 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-Zone Control Methods 18
A. Back-to-Back Thermocouples 19
B. Retransmission of Setpoint 19
C. Independent Control 20
4.5 General Operating Advice 20
4.6 Operator Safety 20
2

4.7 Tube Life 21
4.8 Pressure 21
4.9 Gas Tightness 21
5.0 Maintenance 23
5.1 General Maintenance 23
5.2 Maintenance Schedule 23
5.2.1 Cleaning 25
5.2.2 Safety Switch 25
5.3 Calibration 25
5.4 After-Sales Service 26
5.5 Recommended Spare Parts and Spare Parts Kit 26
6.0 Repairs and Replacements 27
6.1 Safety Warning - 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 Settings 34
9.1 Fuses 34
9.2 Power Settings 35
10.0 Specifications 36
10.1 Environment 36
Furnace drying out process 37
3

1.0 Symbols and Warnings
1.0 Symbols and Warnings
1.1 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;
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 may be hot.
DANGER – Read any warning printed next to this symbol.
4

Caution – Double Pole/Neutral Fusing
1.3 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.
7- Warning label - Do not operate without a work tube.
The furnace must not be operated without the correctly sized work tube
and correspond 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 temperatures,
presenting a possible hazard to the operator. If element failure is left
undetected the element could collapse onto the work tube.
5
1.0 Symbols and Warnings

1.0 Symbols and Warnings
Figure 1.3.1 - Control Box layout and warning
labels.
Figure 1.3.2- Back of control box showing
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. Heater switch - switches electrical power 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 OFF the furnace before loading and unloading.
9. Electrical power lead socket.
10. Back panel fixing screws.
6

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.
2.1 Unpacking and Handling
When unpacking or moving the product, always lift it by its base or both ends of the
main body. Never lift it by the end insulation or by a work tube. It may take 2 or 3
people to lift the furnace, depending on the size and configuration.
NOTE: This product contains Refractory Ceramic Fibre (also known as
Alumino Silicate Wool - ASW). For precautions and advice on handling
this material see section 6.2.
2.2 Siting
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 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 required
above the product to dissipate heat.
Work tubes:
It is recommended that the work tube has either insulation plugs or
radiation shields fitted to minimise heat loss from both ends of the work
tube. If the work tube has open ends, a significant amount of energy
could be radiated from the ends of the work tube. Adjacent surfaces
should always be made from a non-flammable material.
Ensure that the ends of the work tube are positioned at least 500 mm
away from any adjacent surface so that any energy radiated cannot heat
an adjacent surface to a dangerous temperature.
7
2.0 Installation

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.
2.3 Setting Up
The vertical tub furnace models must have their stands assembled, the furnace
mounted on the stand and their work tubes fitted before they can be used.
Assembling 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.
lPosition the vertical stand upright (2) on the stand base in line with the fixing holder.
lSecure the stand upright to the base using the 6 x M6 dome cap screws (4) and wash-
ers (3) supplied.
lPartially screw in the top M6 screw knobs, 2 x (6) into the frame upright as shown in
2.3.3.
lHook the furnace onto the top screw knobs. This may take 2 people to lift the fur-
nace.
lFit the bottom screw knobs x 2 and tighten all four.
8

2.3.1 Figure - Vertical tube furnace model
mounted on its stand.
2.3.2 Figure - Assembling 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

2.0 Installation
Using the tube furnace horizontally
The furnace can be used either with the stand
vertically as shown in 2.3.3 or horizontally as
shown in 2.3.4.
To use horizontally simply tip the stand over
into the horizontal position making sure that
the flexible conduits are not trapped beneath
the frame. This may take 2 people to do on
the largest models.
The position of the furnace on the stand can
be adjusted if necessary.
Note: To prevent injury to the operator and
damage to the furnace this must only be
done when the furnace is switched OFF and is
cold. 2.3.4 Figure -Tube furnace posi-
tioned horizontally on the stand.
Note that the split tube furnace can only be used with the extended length work tube.
Fitting the extended work tube in a furnace
Tools required: 4 mm Allen key
The fitting of the work tube is as follows with reference to Figure 2.3.8. Extended work
tubes are 450 mm longer than the heated length of the furnace (see the table in section
10.0). Read section 6.2 before fitting the work tube.
Note it is easier to fit 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 if the tube is
either quartz or thin wall thickness.
lBefore the extended work tube can be fitted, the work tube end stops for the stand-
ard length work tube must be removed from both ends of the furnace. This is done
by removing the tube furnace end guard (8) and the work tube adaptor brackets (4)
to release the work tube end stop. The guards and brackets should then be refitted.
lFit the tube support bracket, item 15, figure 2.2. Use supplied M6 button head
screws and supplied washers.
lFit the extended work tube guard, item 14, figure 2.2. Use supplied M6 button head
screws and supplied washers.
lRe-fit furnace end guard, item 13, figure 2.2. Use supplied M6 button head screws
and washers.
lFit tube end seal assembly as shown in figure 2.2. refer to manual that was provided
with the replacement end seals or detailed fitting instructions.
10

lFit tube support bracket, item 7, figure 2.2. Use supplied M6 button head screws and
washers.
lFinally, fit tube support collar, (5) using item (6) until the tube is secure enough for
use in a vertical arrangement. Fitting arrangement is shown in figure 2.2.
lFigure 2.2 - shows an exploded view of all the required parts.
lFigure 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

2.0 Installation
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

2.3.9 Figure - View showing how to support the work tube in a vertical orientation.
2.4 Setting Up - Without a Stand
Any of the E-range vertical furnaces can be supplied without a stand for either wall
mounting (using wall bracket option) or installation in customer's test rig/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 numbered items in Figure 2.4.1
1. Control Box
2. Furnace Body
13
2.0 Installation

2.0 Installation
3. Connecting conduit between furnace and control box
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.
If a gas/vacuum end seal is fitted, 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 view showing extended
work tube insulation plug fitted
Figure C- Cross-section view showing an extended length work tube with a radiation shield fitted
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 all cooling vents and cooling fans (if fitted) are
clear of any obstruction.
14

2.5 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" for location of rating label. To check that the OP.Hi setting is correct for the
appropriate voltage, or to change to another setting, follow the instructions in section
0.1.
The electrical supply should be fused at the next standard size equal to or higher than
the design current. Where a supply cable is supplied there are internal 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 the furnace
operator.
Supply Terminal
Label
UK/ Europe
Cable Colour
USA/
Canada
Common
Cable
Colours
Supply Type
Live -
Neutral
Reversible or
Live - Live
1-phase
L Brown Red or
Black To live to either power conductor
N Blue White To neutral to the other power
conductor
PE Green/ Yellow
Green or
Green/
Yellow
To earth
(ground) to earth (ground)
Terminal Connection Details
15
2.0 Installation

3.0 Temperature Controller
3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
16

4.0 Operation
4.1 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.
Over-Temperature option only. If the digital over-temperature option has not yet
been set as required, set and activate it according to the over-temperature controller
instructions.
Switch on the heater switch, located on the instrument panel. Unless a time switch is
fitted and is switched off, the product will start to heat up. The Heat light(s) glow
steadily at first and then flash as the product approaches the desired temperature or a
program 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 heater switch and the instrument switch. If the product is to
be left switched off and unattended, isolate it from the electrical supply.
4.2 Control Method
Set the three temperature controllers to the desired setpoints. The setting and
operation of the end zone controllers depends on the 3-zone control options selected
when the product was ordered. These options are described in the 3-zone control
methods section.
Note: Despite its vertical orientation, the heated zones of the KVZ model are labelled
to correspond with the relevant control module on the CC-T1 touchscreen controller
display (Left, Main, Right).
4.3 Safe Operation of the Furnace
For the safe operation of this furnace the following warnings must be followed:
17
4.0 Operation

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. Ensure that the over-temperature device is
calibrated and set to an over-temperature safety limit that is sufficiently
large as to avoid any hazards. If in doubt, seek expert advice before
proceeding. Customers are responsible for carrying out their own risk
assessments on the heating of materials.
Do not operate without a work tube. The furnace must not be
operated without the correctly sized work tube and correspond work
tube adaptor. Otherwise, an operator can access electrically live
element 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 causing serious injury or death.
4.4 3-Zone Control Methods
There are three different control options (A, B & C).
(A) Back to back thermocouples
(B) Retransmission of Setpoint
(C) Independent control
The models listed in this manual are designed to achieve an extended uniform
temperature zone, through use of three control zones, rather than achieving different
temperatures in each zone.
For A & B, the control zones are linked so that they all follow the centre zone controller
in a master-slave approach
Note:
lOption A is NOT applicable when using the CC-T1 controller
lOption B is NOT applicable when using the Eurotherm 2132 End Zone Controller
18

A. Back-to-Back Thermocouples
This is the most commonly supplied option. The centre zone of the tube furnace is
controlled directly by the centre zone temperature controller. The two end zone
thermocouples are wired in opposition to the centre zone reference thermocouple. If
the temperatures of the centre and end zones are the same then 0°C will be displayed
on the end zone controllers. If the end zone temperatures are either higher or lower
than the centre zone, the end zone controller will display the difference in temperature
(higher = positive value, lower = negative value).
It is best practice to set the setpoint of the two end zone controllers to zero.
Alternatively, a small temperature difference (offset) can be created by setting a non-
zero value, for example to compensate for heat losses at the end or where using a gas
flow. However, the sum of the centre zone controller setpoint and the end zone
controller offset MUST NOT exceed the furnace maximum temperature.
To alter the setpoint with the display showing the Home screen, press Down
or Up once to display the setpoint and then press again or hold down to
adjust it. The display returns to the measured temperature when no key is
pressed for a short period of time.
Sometimes a furnace using this type of control does not cool down because the end
zones lose heat first and therefore the end 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 or
is running a program, the end zone controllers will automatically follow.
For products with the CC-T1 controller, please refer to the separate CC-T1 controller
manual for details on enabling and disabling setpoint retransmission.
For other products, additional communication modules are fitted in the controllers. The
communication between the controllers of the Eurotherm 3000 series is known as
Broadcast communications. It is possible to switch off the linked control and allow the
controllers to work independently. In the level 2 menu of the end zone controllers (see
controller operating instruction), scroll to L-r. Where the end zone controller is a 3216
use the up down buttons and select NO. Where the end zone controller is a 3508
use the up down buttons to select SP1, (SP1 = Local, and SP2 = Remote). There
is no need to alter the centre zone controller.
It is possible to set an offset (local trim) between the centre and end zone controllers.
This can be either a positive or negative difference from the centre zone temperature.
Once entered, this offset will always be added to, or subtracted from, the retransmitted
setpoint temperature.
19
4.0 Operation

4.0 Operation
For products with the CC-T1 controller, please refer to the separate CC-T1 controller
manual for details on how to set an offset trim.
To make this adjustment on other controllers, enter thelevel 2 menu of the end zone
controllers (see controller operating instruction), scroll to LOC.T (local trim) and use the
up down buttons to enter the desired positive or negative value. This will then be
added to, or subtract from, the end zone set temperature. There is no need to alter the
centre zone controller.
C. Independent Control
The three controllers are completely independent. Note that it is not possible to
maintain very different temperatures in the three zones because of heat transfer
between the zones. The models listed in this manual are designed to achieve an
extended uniform temperature zone by the use of three control zones rather than
achieving different temperatures in each zone.
4.5 General 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 the progressive shrinkage of the insulation materials. Cracks are
not usually detrimental to the functioning or the safety of the product.
Clean up any spillages in the insulation, as these can increase the rate of degradation of
the insulation material.
4.6 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.
The elements are isolated when the heater switch is OFF. This switch
cuts both sides of the circuit via a contactor.
20