VERDER CARBOLITE GERO KZS 12/600 Handbuch

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

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

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.

Caution – Double Pole/Neutral Fusing

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.

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.

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)

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.

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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