VERDER CARBOLITE GERO KZS 12/600 Manual

Installation, Operation and Maintenance Instructions
1200°C Large Tube Furnace - KZS Model: 600mm
No Controller
KZS 12/600 + No Controller
MEN-KZS120600-16_NOCTRL (05-08-2019)

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
2.0 Installation 6
2.1 Unpacking and Handling 6
2.2 Siting and Setting Up 6
2.3 Electrical Connections 9
3.0 Temperature Controller 12
4.0 Operation 13
4.1 Operating Cycle 13
4.2 Control Method 13
4.3 3-Zone Control Methods 13
A. Back-to-Back Thermocouples 14
B. Retransmission of Setpoint 14
C. Independent Control 15
4.4 General Operating Advice 15
4.5 Operator Safety 16
4.6 Tube Life 16
4.7 Pressure 16
4.8 Power Adjustment 17
4.9 Running at Low Temperatures 17
5.0 Maintenance 18
5.1 General Maintenance 18
5.2 Maintenance Schedule 18
5.2.1 Cleaning 20
5.2.2 Safety Switch 20
5.3 Calibration 20
5.4 After-Sales Service 21
5.5 Recommended Spare Parts and Spare Parts Kit 21
6.0 Repairs and Replacements 22
6.1 Safety Warning - Disconnection from Power Supply 22
6.2 Safety Warning - Refractory Fibre Insulation 22
2

6.3 Temperature Controller Replacement 22
6.4 Solid-state Relay Replacement 23
6.5 Thermocouple Replacement 23
6.6 Element Replacement 23
6.7 Fuse Replacement 24
7.0 Fault Analysis 25
A. Furnace Does Not Heat Up 25
B. Product Overheats 26
8.0 Wiring Diagrams 27
9.0 Fuses and Power Settings 28
9.1 Fuses 28
10.0 Specifications 29
10.1 Environment 29
Furnace drying out process 29
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
5
1.0 Symbols and Warnings

2.0 Installation
2.0 Installation
2.1 Unpacking and Handling
When unpacking or moving the product always lift it by its base or by both ends of the
main body. Never lift it by its work tube or the surrounding insulation. Use two or more
people to carry the product and control box. Remove any packing material from inside
the product before use.
If an optional or special stand is separately supplied, assemble the product on to it.
Some models may be supplied for customer mounting and may require customer
preparation of mounting components before installation.
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 and Setting Up
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.
6

Ensure that the product is placed in such a way that it can be quickly switched off or
disconnected from the electrical supply.
If the product is supplied with a work tube or any accessories fit these into position.
For optimum temperature uniformity, insulating plugs should be placed in the tube ends
as shown in fig.1. With a long work tube, the stem of the plug assembly should line up
with the end of the tube as in fig.2. Alignment of radiation shields is similar to that of
plugs.
If stainless steel seals with gas inlets are supplied, they are to be fitted as shown in
fig.3; the stem of any insulating plug should touch the seal.
For vertical models with stainless steel seals, a hook and eye arrangement holds the
upper insulating plug assembly.
Horizontal models: if heavy fittings are to be clamped to the end of an extended work
tube they can increase the bending stress at the centre of the tube. Support such
fittings in such a way that expansion of the tube is allowed.
If a metal work tube is being used in the product, ensure that it is earthed for operator
safety.
7
2.0 Installation

2.0 Installation
Fig 1 - Insulating Plug
(standard length tube) Key
A Tube
B Insulating Plug
C Stem
Fig 2 - Insulating Plug
(long work tube)
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Key
A Clamp
B Seal plate
C 'O' Ring seal
D Seal sleeve
E Clamp seal
F End plate
Key
A Clamp
B End plate
CClamp seal (between Seal
sleeve and Clamp
D Seal sleeve
ESeal plate & 'O' Ring seal
(underneath clamp)
F Tube
Fig 3 'Twin Clamp' End Seal
For assembly details refer to the separate work tube end seal manual.
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.
2.3 Electrical Connections
Connection by a qualified electrician is recommended.
9
2.0 Installation

2.0 Installation
The product covered by this manual normally requires a single phase A.C. supply, which
may be Live to Neutral non-reversible, Live to Neutral reversible or Live to Live. Some
models may be ordered for 3-phase use, which may be star or delta.
Check the product rating label before connection. The supply voltage should agree with
the voltage on the label and the supply capacity should be sufficient for the current on
the label.
The supply should be fused at the next size equal to, or higher than the current on the
label. A table of the most common fuse ratings is also given towards the back of this
manual. When the mains cable is factory fitted, internal fuses are also fitted. It is
essential that the operator ensures that the product is correctly fused.
Products with a factory fitted supply cable are designed to be wired directly to an
isolator or fitted with a line plug.
Products without a factory fitted supply cable require a permanent connection to a fused
and isolated supply. The product's electrical access panel should be temporarily
removed, and connections made to the internal terminals.
If the product is to be connected by line plug. The plug should be within reach of the
operator and should be easy to remove.
When connecting the product to an isolating switch ensure that 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).
Supply Terminal Label Cable Colour
Supply Types
Live - Neutral Reversible or Live-
Live
1-phase L Brown to live
to either power
conductor
(For USA 200-240V,
connect L1)
N Blue to neutral
to the other power
conductor
(For USA 200-240V,
connect L2)
PE Green/ Yellow to earth
(ground) to earth (ground)
Electrical Connection Details:
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3-phase L1 Black to phase 1
L2 Black to phase 2
L3 Black to phase 3
N Light Blue to neutral (except delta)
PE Green/ Yellow to earth (ground)
DO NOT connect a product ordered for three phase use to a single
phase supply or to the wrong type of three phase supply.
11
2.0 Installation

3.0 Temperature Controller
3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
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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.
There is also a heater switch which can be used to disconnect power to the elements.
Operate the instrument switch to activate the temperature controller. The controller
becomes illuminated and goes 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.
The product will heat up according to the controller setpoint or program, unless a time
switch is fitted and switched off.
As the product heats up, the heat light glows steadily at first and then flashes as the
product approaches the desired temperature. For more information on temperature
control see the controller instructions.
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 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
13
4.0 Operation

4.0 Operation
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
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
14

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.
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.
4.4 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.
15
4.0 Operation

4.0 Operation
4.5 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.
4.6 Tube Life
A ceramic work tube may crack if work pieces are inserted too quickly or at
temperatures below 900 °C (when the tube is more brittle). Large work pieces
should also be heated slowly to ensure that large temperature differences do not
arise.
Poor thermal contact should be encouraged between the work piece and the tube;
crucibles or boats should 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
mm to give (°C/ min); for 75 mm i/ d tubes this comes to 5 °C per minute. The
controller can be set to limit both the heating and cooling rate.
4.7 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 pressure does not occur.
16

A suitably regulated gas supply should always be used.
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.
4.8 Power Adjustment
The control system incorporates electronic power limiting. The power limit parameter
OP.Hi is accessible to the operator and can be used to adjust the furnace to the actual
supply voltage.
The models covered by this manual are designed for use over the range of voltages 200
V - 250 V (or, if ordered, 100 V - 125 V), and the power limit parameter is set
accordingly. These models may be adjusted to a different voltage within the range: the
power limit should be reset to match OP.Hi, see 9.0
Refer to section 3.0 for power adjustment instructions.
4.9 Running at Low Temperatures
The power limit may be adjusted to a low level in order to achieve better control when
operating the product at a low temperature. Before changing the power limit, record
the default settings for possible future use. Refer to the Power Settings section of this
manual for default power limits. If the product fails to reach the desired temperature,
refer to the Temperature Controller and Fault Analysis sections.
17
4.0 Operation

5.0 Maintenance
5.0 Maintenance
5.1 General Maintenance
Preventive rather than reactive maintenance is recommended. The type and frequency
depends on the product use; the following are recommended.
5.2 Maintenance Schedule
CUSTOMER
QUALIFIED PERSONNEL
DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically
qualified personnel should attempt these maintenance procedures.
Maintenance
Procedure Method
Frequency
Daily Weekly Monthly Bi-
Annually Annually
Safety
Over-Temperature Safety Circuit
(if fitted)
Set an over-temperature setpoint lower
than the displayed temperature and
check for an over-temperature alarm as
detailed in this manual
Over-Temperature Safety Circuit
(if fitted) 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 clean-
ing 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 nor-
mally
Operational Check Thorough inspection and report incor-
porating a test of all functions
Work Tube Position Visually check that the tube is central to
the heated zone (horizontally / vertically)
End Plugs / Radiation Shields Visual check for damage or wear, and cor-
18

rect positioning
Seals (if fitted) 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
19
5.0 Maintenance

5.0 Maintenance
5.2.1 Cleaning
Soot deposits may form inside the furnace, depending on the process. At appropriate
intervals remove these by heating as indicated in the General Operation Notes.
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.
5.2.2 Safety Switch
When correctly functioning, the safety switch will isolate all live conductors (live and
neutral connections) within the heating element circuit(s) when the product door is
opened. The safety switch should be checked regularly to ensure that this occurs.
The safety switch should not fail under normal working conditions, however rough
handling, exposure to corrosive materials/ environments, or exceptionally frequent use,
could compromise the safety system.
Weekly check:
The following check can be carried out by a general operator:
lOn the temperature controller, set a safe temperature above ambient. The heater
lights should illuminate.
lOpen 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 Schedule" section of this manual:
lRemove the element access panel and take a voltage measurement from the heat-
ing element terminals. Do not attempt to take a reading from the heating element
itself as surface oxidation will give an unreliable contact.
lEnsure that power to the heating elements is switched off when the door is opened.
Contact Carbolite Gero Service and discontinue use of the product if it is found that the
heating elements are not fully isolated during these checks.
5.3 Calibration
After prolonged use, the controller and/or thermocouple may require recalibration. This
is important for processes that require accurate temperature readings or for those that
use the product close to its maximum temperature. A quick check using an independent
20