VERDER CARBOLITE GERO TZF 15/90/450 Handbuch

Installation, Operation and Maintenance Instructions

1500 °C Tube Furnace (3-zone) - TZF Model: 450mm

No Controller + 3216 End Zone Controllers

TZF 15/90/450 + No Controller + 3216 End

Zone Controllers

MEN-TZF15450-07_NOCTRL_3216 (19-06-2019)

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 5

1.1 Switches and Lights 5

1.2 General Warnings 5

2.0 Installation 7

2.1 Unpacking and Handling 7

2.2 Siting and Setting Up 7

2.3 Tube Fitting 9

2.4 Heating Elements 11

2.5 Electrical Connections 11

3.0 Temperature Controller 13

4.0 3216 Controller 14

4.1 PID control 14

4.2 3216P1 14

4.3 3216P5 14

4.4 Operation 14

4.4.1 Controller Layout 14

4.4.2 Keys 15

4.5 Quick Start Guide 15

4.5.1 Operation as a simple controller 15

4.5.2 Changing the Setpoint 15

4.5.3 Using the Controller 15

4.5.4 Understanding User Levels 16

4.6 Setting up the Controller 17

4.6.1 Maximum Output Power 17

4.6.2 Customer ID 17

4.6.3 Units 17

4.6.4 Language 17

4.6.5 Scrolling Text 17

4.6.6 Customer Calibration 18

4.6.7 Holdback 18

4.7 Programming 20

4.7.1 Creating a Program 20

4.7.2 Program Number (3216P5 Only) 20

4.7.3 Ramp Units 20

4.7.4 Dwell Units 20

4.7.5 Holdback 20

4.7.6 Ramp Rate 20

4.7.7 Target Setpoint 20

4.7.8 Dwell Time 20

4.7.9 Running a Program 21

4.7.10 Program Status 21

4.7.11 Process Value 21

4.7.12 PSP, Segment Type and Number 21

4.8 Controller Options 24

4.8.1 Digital Communications - RS232 24

4.8.2 Digital Communications - RS485 24

4.8.3 Comms Address 24

4.8.4 Alarm Option 25

4.9 Temperature Controller Replacement 25

4.10 3216 Controller Navigation Diagram 25

5.0 2132 Over-Temperature Controller Description (if fitted) 27

5.1 Description 27

5.2 Operation 27

5.2.1 Controls 27

5.2.2 Operation 28

5.2.3 Over-Temperature Operation 28

5.2.4 Over-Temperature Alarm 28

5.2.5 Resetting the Over-Temperature Alarm 28

5.2.6 Sensor Break 28

5.3 Audible Alarm 29

5.4 Navigation Diagram 29

6.0 Operation 30

6.1 Operating Cycle 30

6.2 Control Method 30

6.3 3-Zone Control Methods 30

B. Retransmission of Setpoint using Broadcast communications 31

C. Independent Control 31

6.4 General Operating Advice 31

6.5 Operator Safety 32

6.6 Tube Life 32

6.7 Pressure 32

7.0 Maintenance 34

7.1 General Maintenance 34

7.2 Maintenance Schedule 34

7.2.1 Cleaning 36

7.3 Calibration 36

7.4 After-Sales Service 36

7.5 Recommended Spare Parts and Spare Parts Kit 36

7.6 Power Adjustment 36

7.7 Element Ageing 37

8.0 Repairs and Replacements 38

8.1 Safety Warning - Disconnection from Power Supply 38

8.2 Safety Warning - Refractory Fibre Insulation 38

8.3 Temperature Controller Replacement 38

8.4 Solid-State Relay Replacement 39

8.5 Thermocouple Replacement 39

8.6 Element Fitting and Replacement 40

Element Fitting - Figures 41

8.7 Fuse Replacement 41

9.0 Fault Analysis 42

A. Furnace Does Not Heat Up 42

B. Product Overheats 43

10.0 Wiring Diagrams 44

10.1 WC-13-31 44

10.2 WC-U3-31 45

10.3 Control by Broadcast Comms (control method B) 46

11.0 Fuses and Power Settings 47

11.1 Fuses 47

11.2 Power Settings 47

User Power Setting Adjustments 48

12.0 Specifications 49

12.1 Environment 49

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.

1.0 Symbols and Warnings

Caution – Double Pole/Neutral Fusing

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 8.2.

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.

2.0 Installation

Depending on the application of the product, it may be appropriate to position it under

an extraction hood. Ensure the extraction hood is switched on during use.

Ensure that the product is placed in such a way that it can be quickly switched off or

disconnected from the electrical supply.

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.

If the product is supplied with a work tube then the holes at the end of the product

chamber should be supplied at the correct size. Carefully line up the tube and ease it

through the chamber.

For a tube of customer supply, ensure that there is approximately 1 mm free play at

each end; if the tube is too tight, it may crack when heated. Increase the diameter of

the hole by rotating the tube, which is abrasive. Remove loose powdered ceramic fibre

with a vacuum cleaner and see section 8.0.

Contact Carbolite Gero if the holes in the product chamber are too large.

Ensure that the tube is centrally placed and reaches to or through the product end

covers, so that there is no access to exposed electrical connections.

2.3 Tube Fitting

Vertical Mode. The product (if a tube is also supplied) has a plate or clip to retain the

tube in position. See fig.1.

Key

A End guard

B Plate

C Standard tube

D Long tube

E Strap

F Ring clip

Fig 1 - Vertical Tube Retention

Key

A Furnace body

B Tube

C Insulating plug

D End guard

E Stem

Fig 2 - Insulating End Plug

Fit any accessories supplied. For optimum temperature uniformity, ceramic insulation

plugs or radiation shields should be placed in the tube ends as shown in fig.2. The ends

of the insulation plugs or radiation shields should not protrude outside of the work tube.

NOTE: Insulation plugs or Radiation shields are strongly recommended

for this product. Contact Carbolite Gero or Carbolite Gero Service for

further information.

2.0 Installation

Expanded View of "Twin Clamp" End Seals:

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 (under-

neath clamp)

F Tube

Fig 3 'Twin Clamp' End Seal

For assembly details refer to separate work tube and end seal manual.

If stainless steel end 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 end plate.

When stainless steel end seals are fitted in the vertical mode, a hook and eye, on the

end of the plate holds the upper insulating plug or radiation shield assembly.

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 the fittings in such a way

that longitudinal expansion of the tube is allowed.

If a metal work tube is being used in the product, ensure that it is earthed (grounded).

There can be leakage of current through ceramic insulation at high temperatures.

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