VERDER CARBOLITE GERO TZF 15/90/450 Manual

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
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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
3

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
4

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.
5
1.0 Symbols and Warnings

1.0 Symbols and Warnings
Caution – Double Pole/Neutral Fusing
6

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.
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2.0 Installation

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.
8

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.
9
2.0 Installation

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.
10

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.
2.4 Heating Elements
The silicon carbide elements are VERY FRAGILE and are packed separately. Fit them
accordingly to the instructions in section 8.6.
2.5 Electrical Connections
Connection by a qualified electrician is recommended.
All models covered by this manual may be ordered for single phase A.C. supply, which
may be Live to Neutral non-reversible, Live to Neutral reversible or Live to Live.
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).
11
2.0 Installation

2.0 Installation
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:
2- or
3-phase L1 Black to phase 1
L2 Black to phase 2
L3 Black to phase 3 (except 2-phase)
N Light Blue to neutral (except delta)
PE Green/ Yellow to earth (ground)
DO NOT connect a model ordered for three phase use to a single phase supply or to
the wrong type of three phase supply.
Technical Notes
This model has an electronically controlled power limit. Do not attempt to calculate the
Amps from the Wattage. High break capacity fuses should be used. Avoid fast-blow
fuses and magnetic trip circuit breakers - consult Carbolite Gero if in doubt.
12

3.0 Temperature Controller
If this product is fitted with a temperature controller, instructions are provided
separately.
13
3.0 Temperature Controller

4.0 3216 Controller
4.0 3216 Controller
4.1 PID control
This controller uses PID (Proportional Integral Derivative) temperature control. This
type of control uses a complex mathematical control system to adjust the heating power
and achieve the desired temperature.
4.2 3216P1
The 3216P1 is a digital temperature controller which uses PID algorithms to give
excellent temperature control. This controller can store and operate a single program of
8 ramp/ dwell segments. The 3216P1 can also be used as a simple temperature
controller.
4.3 3216P5
The 3216P5 is a digital temperature controller which uses PID algorithms to give
excellent temperature control. This controller can store up to 5 programs of 8 ramp/
dwell segments. The 3216P5 can also be used as a simple temperature controller.
4.4 Operation
4.4.1 Controller Layout
Key
A Power Output Indicator
B Alarm Indicator
CRemote Indicator
(when configured)
D Page
E Scroll
F Down
G Up
H Run Indicator
I Hold Indicator
JSetpoint Temperature
(SP)
KMeasurement Tem-
perature
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4.4.2 Keys
Page Key The page key is used to access level 2 when held down
for 3 seconds.
Scroll Key The scroll key is used to scroll through parameters.
Ack
Page and
Scroll
+
When pressed simultaneously the ACK function is used
to:
lReturn to the Home Menu
lAcknowledge an alarm if activated.
lReset a program after the program has ended.
Arrow Keys +
The arrow keys are used individually to adjust the
selected parameters and in combinations to operate a
program.
Note: If a parameter is selected and no further action is taken, the display will time
out and revert back to the home display in its working level after approximately 1
minute.
4.5 Quick Start Guide
4.5.1 Operation as a simple controller
When switched on, the controller goes through a short test routine and then shows the
measured temperature (PV = Process Value) in the upper part of the display and below
it, the desired temperature (Setpoint).
4.5.2 Changing the Setpoint
Press Up or Down to select the required SP. If the SP is higher than the measured
temperature, the OP1 indicator will illuminate in the top left corner of the display,
indicating that the controller is calling for power (giving an output).
The controller will immediately attempt to reach the setpoint and then maintain it.
This will cause the product to heat as quickly as possible which may not be appropriate
where the product contains sensitive ceramic components. For products with ceramic
components, e.g. a tube furnaces fitted with a long ceramic work tube, use the ramp
rate feature set with a low heating rate such as 5°C per minute (300°C per hour), to
prevent damage.
4.5.3 Using the Controller
The parameters in the controller are first shown by a short code (mnemonic). After 5
Seconds a description of the parameter will scroll once along the display and then revert
back to the mnemonic. The scrolling text can be interrupted at any time by a single
press of any of the buttons, but will not scroll again until the parameter is returned to.
In this manual the mnemonic will be shown first, followed by the scrolling text in
brackets; e.g. PROG <PROGRAM NUMBER>
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4.0 3216 Controller

4.0 3216 Controller
4.5.4 Understanding User Levels
There are two user levels in the controller; Level 1 (Operator) and Level 2 (Supervisor).
Level 1 (Operator) is for the day to day operation of the controller. These parameters
are not protected by a security code.
Level 2 (Supervisor) provides access to additional parameters. Access to this level
protected by a security code
To Enter Level 2
1. Press and hold the page key for 3 seconds.
2. The display will show LEu 1 GOTO
3. Release the page Key
4. Press the up or down to choose LEu 2 (level 2)
5. Press the up or down to enter the code (Level 2 Code = 9).
If the correct code is entered, PASS should momentarily be displayed and then revert to
the level 2 home display.
If an incorrect code is entered the display reverts back to Level 1 home display.
When level 2 operations have been completed, the supervisor must return to Level 1
either manually or by switching the instrument off and back on. There is no time out
function.
To Return to Level 1
1. Press and hold the page Key
2. Press down to select LEu 1
It is not necessary to enter a code when going from a higher level to a lower level.
When level 1 is selected, the display reverts to the home display (See Controller Layout)
Table showing parameters accessible in level 1 and Level 2
Operator LEVEL 1 Supervisor LEVEL 2
home display home display
Programming Programming
Program Status Program Status
Alarms (if configured)
Current Transformer Input (if configured)
Comms (if configured)
Controller Setup
Customer Calibration
TIP
If while navigating the controller, a parameter has been passed or you need to access
parameters which would be at the end of a scroll list, press and hold scroll and use up
to return to a previous parameter.
16

4.6 Setting up the Controller
Before using the controller (or during its lifetime) certain parameters may have to be
set, depending on specific requirements. To do this the controller must be set to
supervisor level (Level 2).
4.6.1 Maximum Output Power
Press scroll until the display shows OP.HI <OUTPUT HIGH>. Use the up and down
keys to select the output power required as a percentage. Once the setting is made,
turn the instrument switch off and on to power cycle the temperature controller.
Depending on the furnace or oven model, the maximum output power setting OP.Hi
may be accessible or locked.
For silicon carbide heated furnaces, the parameter is accessible to allow compensation
for element ageing.
In many models the maximum output power setting depends on the supply voltage, see
section 11.0.
4.6.2 Customer ID
A furnace or oven identification number can be entered if required. This maybe used to
identify one of many units for production or quality control systems.
Press scroll until the display shows ID <CUSTOMER ID>. Use the up and down
keys to enter your own identification number. This can range from 1-9999.
4.6.3 Units
Press scroll until the display shows UNITS <DISPLAY UNITS>. Use the up or
down keys to select the required units.
Mnemonic Description
NONE No units (Default °C)
°C Celsius
°F Fahrenheit
°K Kelvin
PERC % (shows °C value)
4.6.4 Language
The scrolling text on the 3216 can be shown in different languages, this can only be set
at the factory and therefore must be specified at the time of placing an order.
4.6.5 Scrolling Text
If at any time the scrolling text is not required.
Press and hold the page for three seconds until “GOTO” is displayed.
Press scroll until the display shows. TEXT <ENABLE/ DISABLE SCROLLING TEXT>
Use the up and down keys to select ON or OFF.
17
4.0 3216 Controller

4.0 3216 Controller
4.6.6 Customer Calibration
The 3216 Controller series are calibrated for life at manufacture, there may however be
sensor or other system errors, which affect the accuracy of the measured temperature.
Customer calibration can be used to compensate for these errors.
Dual Offset
Dual point calibration uses two offset values at two corresponding temperatures; this
changes the calibration linearly as the temperature increases or decreases.
Press scroll until the display shows CAL.P (Enter Calibration Code) Use the up
down keys to enter the password code. (Calibration Pass Code = 95). When the
correct password has been entered the display will show PNT.LO. If the wrong pass code
is entered the display will revert to zero pass code, until the correct pass code is
entered.
When the correct pass code is entered and PNT.LO (Adjust Low Point) is displayed. Use
the up and down keys to enter the Low Temperature Point, which you want to
apply an Offset.
Press scroll until the display shows OFS.LO (Adjust Low OFFset). Use the up and
down keys to enter the amount Offset you want to apply to the Low Temperature
Point.
Press scroll until the display shows PNT.HI (Adjust High Point). Use the up and
down keys to enter the High Temperature Point, which you want to apply an Offset.
Press scroll until the display shows OFS.HI (Adjust High OFFset). Use the up and
down keys to enter the amount Offset you want to apply the High Temperature
Point.
Once the calibration details have been entered, press scroll until the display shows
the next required parameter or return to the home list. The calibration data will now be
protected by the pass code. To edit the data the above procedure must be followed.
Single Offset
If a constant offset is required across the temperature range, set the required “High
Point” (PNT.HI) and “Low Point” (PNT.LO) to the required values (not the same), then
set the “low Offset” (OFS.LO) and “High Offset” (OFS.HI) to the same value.
Caution! - Do not make PNT.LO and PNT.HI the same value as the
controller will not work correctly and could cause the product to
overheat.
4.6.7 Holdback
If the temperature ramp rate of the program is quicker than the product can achieve,
the program will wait until the temperature of the product catches up.
18

e.g. If a holdback value of 10 is set and the program is set to ramp to a setpoint of 600
°C, the program will reach 600 °C, then go into a hold state; the hold indicator will light
until the product temperature reaches 590 °C, the program will then continue to control
again.
The holdback will only apply once per segment, therefore when control has been re-
established, the holdback will not apply again to that segment, even if the product
temperature goes outside the holdback band.
Holdback can only be accessed in supervisor level (level 2) by scrolling with the scroll
until the display shows H.BACK <PROGRAM HOLDBACK>: Use the up and down
keys to select the required Holdback value.
If a multi programmer is used, each program can have its own holdback value assigned
to it.
Note: When a holdback is set, each segment used must have a Ramp Rate assigned
to it, in order for it to be recognised by the program.
19
4.0 3216 Controller

4.0 3216 Controller
4.7 Programming
4.7.1 Creating a Program
Programs can be created in level 1 or level 2 of the 3216P1 and 3216P5. Each program
contains 8 Ramp/ Dwell pairs.
Note: A currently active program cannot be altered. Go into 'Reset' mode before
starting to create or modify a program
4.7.2 Program Number (3216P5 Only)
Press scroll until the display shows PROG <PROGRAM NUMBER.> Select the program
number.
4.7.3 Ramp Units
Press scroll until the display shows RAMP.U <Ramp Units>: Use the up down to
select the Ramp Units of Hour, Min or Seconds.
4.7.4 Dwell Units
Press scroll until the display shows DWEL.U <Dwell Units>: Use the up down to
select the Dwell Units of Hour or Min.
4.7.5 Holdback
see section 4.6. Press scroll until the display shows H.BACK <Program Holdback>: If
a holdback value is required, use the up down to enter the required value or
select “OFF” if no holdback is required.
4.7.6 Ramp Rate
Press scroll until the display shows RMP.1 <Ramp Rate 1>: Using the up down
enter the value for the first ramp rate depending on the Ramp Units selected. If the
Ramp segment is not required select “OFF”.
4.7.7 Target Setpoint
Press scroll until the display shows T.SP 1 <Target SP 1>: Enter the temperature
that you want the product to ramp up to using “Ramp rate 1”.
If “Ramp Rate 1” has been set to “OFF”. The product will Heat/ Cool directly to the
Target SP.
4.7.8 Dwell Time
Press scroll until the display shows DWELL. 1 <DWELL TIME 1>: Enter the time to
dwell at “Target SP 1”. If the dwell segment is not required, use the down to select
OFF, which is below the Zero value.
This Process is repeated for each of the 8 segments of the program.
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