VERDER TZF 12/75/700 Handbuch

Installation, Operation and Maintenance Instructions

1200 °C Tube Furnace (3-zone) - TZF Model: 700mm

3508 Controller + 3216CC End Zone Controllers

TZF 12/75/700 + 3508 Controller + 3216CC

End Zone Controllers

MEN-TZF12075-09_3508_3216CC (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 7

1.1 Switches and Lights 7

1.2 General Warnings 7

2.0 Installation 9

2.1 Unpacking and Handling 9

2.2 Siting and Setting Up 9

2.3 Electrical Connections 12

3.0 3508 Controller 15

3.1 PID control 15

3.2 3508P1 15

3.3 3508P10 15

3.4 3508P25 15

3.5 Basic Operation 16

3.5.1 Controller Layout 17

3.5.2 Keys 17

3.6 Quick Start Guide 17

3.6.1 Operation as a simple controller 17

3.6.2 Changing the Setpoint 17

3.6.3 Resetting the programmer 18

3.6.4 Understanding User Levels 18

3.7 Setting Up Controller 19

3.7.1 Maximum output power setting 19

3.7.2 Customer ID. 19

3.7.3 Units 20

3.7.4 Language 20

3.8 Programming 20

3.8.1 Programming Notes 20

3.8.2 Holdback 21

3.8.3 Wait Segments 21

3.8.4 Program Cycling 22

3.8.5 Creating a Program 22

3.8.6 Running a Program 23

3.8.7 To pause (hold) a program 24

3.8.8 To stop and reset a program 24

3.8.9 To run a different program (P10 and P25) 24

3.8.10 Program Status 24

3.8.11 Program Hold with Holdback 25

3.8.12 Power Failure Recovery 25

3.8.13 Alarms 25

3.8.14 Program Example 1 26

3.8.15 Program Example 2 28

3.9 Controller Options 30

3.9.1 Digital Communications - RS232 31

3.9.2 Digital Communications - RS485 31

3.9.3 Comms Address 31

3.9.4 Alarm Option 31

3.9.5 Remote Input and Output (Analogue Communications) 32

3.9.6 Program segment output 32

3.10 Temperature Controller Replacement 33

3.11 Controller Navigation Diagrams 33

3.11.1 Operator Level 1 - No Program Running 34

3.11.2 Operator Level 1 - Program Running 35

3.11.3 Supervisor Level 2 36

4.0 3508 Dual Loop Cascade Control (if fitted) 37

4.1 Principle of Cascade Control 37

4.2 Operation of Cascade Control 37

4.3 Bypassing Cascade Control 41

4.4 3508P1 Element Loop (Loop 2) 41

4.5 Caution 41

4.6 Over-Temperature Control 41

5.0 3216CC Controller 42

5.1 3216CC 42

5.2 PID control 42

5.3 Operation 42

5.3.1 Controller Layout 42

5.3.2 Keys 43

5.4 Quick Start Guide 43

5.4.1 Operation as a simple controller 43

5.4.2 Changing the Setpoint 43

5.4.3 Using the Controller 43

5.4.4 Understanding User Levels 44

5.5 Setting up the Controller 45

5.5.1 Setpoint Ramp Rate 45

5.5.1.1 Setting Setpoint Ramp Rate 45

5.5.1.2 Running with Ramp Rate 45

5.5.2 Maximum Output Power 46

5.5.3 Customer ID 46

5.5.4 Units 46

5.5.5 Language 46

5.6 Timer 46

5.6.1 Setting the Timer 46

5.6.2 Dwell Timer 47

5.6.3 Delayed Switch On Timer 47

5.6.4 Soft Start Timer 48

5.7 Running a Timer 48

5.7.1 Dwell Timer 49

5.7.2 Power Failure While Using Dwell Timer 49

5.7.3 Running Dwell Timer with Ramp Rate 50

5.7.4 Running Dwell Timer with Ramp Rate & Threshold 50

5.7.5 Delayed Switch on Timer 50

5.7.6 Running Delay Timer with Ramp Rate 51

5.7.7 Delay timer with ramp rate functions 51

5.7.8 Power Failure While Using Delay Timer 52

5.7.9 Soft start Timer 52

5.7.10 Power Failure While Using Soft Start Timer 52

5.7.11 Ramp Rate with Soft Start Timer 52

5.7.12 Time Remaining 52

5.7.13 Alarms 53

5.8 Controller Options 53

5.8.1 Digital Communications - RS232 53

5.8.2 Digital Communications - RS485 54

5.8.3 Comms Address 54

5.8.4 Alarm Option 54

5.9 3216CC Navigation Diagram 55

6.0 2132 Over-Temperature Controller Description (if fitted) 56

6.1 Description 56

6.2 Operation 56

6.2.1 Controls 56

6.2.2 Operation 57

6.2.3 Over-Temperature Operation 57

6.2.4 Over-Temperature Alarm 57

6.2.5 Resetting the Over-Temperature Alarm 57

6.2.6 Sensor Break 57

6.3 Audible Alarm 58

6.4 Navigation Diagram 58

7.0 Operation 59

7.1 Operating Cycle 59

7.2 Control Method 59

7.3 3-Zone Control Methods 59

A. Back-to-Back Thermocouples 60

B. Retransmission of Setpoint 60

C. Independent Control 61

7.4 General Operating Advice 61

7.5 Operator Safety 61

7.6 Tube Life 62

7.7 Pressure 62

7.8 Power Adjustment 63

7.9 Running at Low Temperatures 63

8.0 Maintenance 64

8.1 General Maintenance 64

8.2 Maintenance Schedule 64

8.2.1 Cleaning 66

8.3 Calibration 66

8.4 After-Sales Service 66

8.5 Recommended Spare Parts and Spare Parts Kit 66

9.0 Repairs and Replacements 67

9.1 Safety Warning - Disconnection from Power Supply 67

9.2 Safety Warning - Refractory Fibre Insulation 67

9.3 Temperature Controller Replacement 67

9.4 Solid-state Relay Replacement 68

9.5 Thermocouple Replacement 68

9.6 Element Replacement 69

9.7 Fuse Replacement 70

10.0 Fault Analysis 71

A. Furnace Does Not Heat Up 71

B. Product Overheats 72

11.0 Wiring Diagrams 73

11.1 WC-13-01 73

11.2 WC-13-31 74

11.3 2- and 3-phase With Neutral 75

11.4 Independent Zones (control method C) 75

11.5 Control by Broadcast Comms (control method B) 75

12.0 Fuses and Power Settings 76

12.1 Fuses 76

12.2 Power Settings 76

User Power Setting Adjustments 77

13.0 Specifications 78

13.1 Environment 78

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 9.2.

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

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.

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