VERDER TZF 12/65/550 Manual

Installation, Operation and Maintenance Instructions
1200 °C Tube Furnace (3-zone) - TZF Model: 550mm
301 Controller + 2132 End Zone Controllers
TZF 12/65/550 + 301 Controller + 2132 End
Zone Controllers
MEN-TZF12065-01_301_2132 (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 6
1.1 Switches and Lights 6
1.2 General Warnings 6
2.0 Installation 8
2.1 Unpacking and Handling 8
2.2 Siting and Setting Up 8
2.3 Electrical Connections 11
3.0 301 Controller 14
3.1 PID control 14
3.2 Basic Operation of the 301 Controller 14
3.2.1 Menu System 15
3.2.2 Navigation Diagram 15
3.2.3 Basic Function Guide 17
3.2.4 Home Display 18
3.2.5 Hold Mode 18
3.2.6 Checking the Temperature Setpoint from the Home Display 19
3.2.7 Changing the Temperature Setpoint 19
3.2.8 Changing the Temperature Setpoint Ramp Rate 19
3.2.9 Changing the Timer Time 20
3.3 Advanced Operation 20
3.3.1 Entering the Setup menu 20
3.3.2 Changing the Timer Type 20
3.3.3 Changing the Timer Band 21
3.3.4 Changing the Maximum Output Power 21
3.3.5 Changing the Customer Calibration Type 22
3.3.6 Calibration Password 22
3.4 Temperature Setpoint Ramp Rate 22
3.4.1 Setpoint Ramp Rate 22
3.4.2 Limitations of Setpoint Ramp Rate 22
3.5 The Timer 23
3.5.1 Starting the Timer 23
3.5.2 Checking the Time Remaining 23
3.5.3 Pausing the Timer 23
3.5.4 Resetting the Timer 24
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3.5.5 Timer Function Description 24
3.5.6 The Timer Temperature Band 25
3.5.7 Timer Function Table 26
3.6 Ramp Dwell Programming 27
3.6.1 Setting up a Ramp Dwell program 27
3.7 Maximum Output Setting 29
3.8 Customer Calibration 29
3.8.1 Factory Calibration - FAct 29
3.8.2 Single Point Calibration - C.CL1 30
3.8.3 Changing the Single Point Calibration Offset - OFSt 30
3.8.4 Dual Point Calibration - C.CL2 30
3.8.5 Changing the Calibration, Low Temperature - CAL.L 31
3.8.6 Changing the Calibration, Low Temperature Offset - OFS.L 31
3.8.7 Changing the Calibration, High Temperature - CAL.H 31
3.8.8 Changing the Calibration, High Temperature Offset - OFS.H 32
3.9 Over-Temperature Protection 33
3.9.1 Over-Temperature (O/T) home display 33
3.9.2 Changing the Over-Temperature Limit 34
3.9.3 Checking the Over-Temperature Sensor Temperature 34
3.9.4 Over-Temperature Protection Calibration 35
3.9.5 Over-Temperature Activation 35
3.9.6 Resetting Over-Temperature Activation 36
3.10 RS232 Communication Option 37
3.11 Temperature Controller Replacement 37
3.12 Glossary of Terms 38
3.13 Controller Fault 38
4.0 2132 Controller 39
4.1 Description 39
4.2 2132 Controller Operation 39
4.2.1 Controls 39
4.2.2 2132 Controller Operation 40
4.2.3 Basic Operation 40
4.2.4 Altering the Setpoint 40
4.2.5 Stopping and Starting Control 41
4.2.6 Altering the Ramp Rate 41
4.3 Operating with the Timer 42
4.3.1 Setting the Timer Mode 44
4.3.2 Setting the Time Period 44
4.3.3 Running with the Timer 44
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4.3.4 Stopping the Timer 45
4.3.5 End of Time Period 46
4.3.6 Cancelling the Alarm 46
4.3.7 Program Example 46
4.4 Altering Power Limit 46
4.5 Audible Alarm 49
4.6 Temperature Controller Replacement 49
4.7 Navigation Diagram 50
5.0 Operation 52
5.1 Operating Cycle 52
5.2 Control Method 52
5.3 3-Zone Control Methods 52
A. Back-to-Back Thermocouples 53
B. Retransmission of Setpoint 53
C. Independent Control 54
5.4 General Operating Advice 54
5.5 Operator Safety 54
5.6 Tube Life 55
5.7 Pressure 55
5.8 Power Adjustment 56
5.9 Running at Low Temperatures 56
6.0 Maintenance 57
6.1 General Maintenance 57
6.2 Maintenance Schedule 57
6.2.1 Cleaning 59
6.3 Calibration 59
6.4 After-Sales Service 59
6.5 Recommended Spare Parts and Spare Parts Kit 59
7.0 Repairs and Replacements 60
7.1 Safety Warning - Disconnection from Power Supply 60
7.2 Safety Warning - Refractory Fibre Insulation 60
7.3 Temperature Controller Replacement 60
7.4 Solid-state Relay Replacement 61
7.5 Thermocouple Replacement 61
7.6 Element Replacement 62
7.7 Fuse Replacement 63
8.0 Fault Analysis 64
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A. Furnace Does Not Heat Up 64
B. Product Overheats 65
9.0 Wiring Diagrams 66
9.1 WC-13-01 66
9.2 WC-13-31 67
9.3 2- and 3-phase With Neutral 68
9.4 Independent Zones (control method C) 68
9.5 Control by Broadcast Comms (control method B) 68
10.0 Fuses and Power Settings 69
10.1 Fuses 69
10.2 Power Settings 69
User Power Setting Adjustments 70
11.0 Specifications 71
11.1 Environment 71
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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.
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Caution – Double Pole/Neutral Fusing
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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 7.2.
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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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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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.
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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.
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2.0 Installation

3.0 301 Controller
3.0 301 Controller
Due to the complex nature of the furnace or oven control the use of technical terms
throughout this manual is unavoidable. Explanations of these terms can be found in
the"Glossary of Terms".
3.1 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.
3.2 Basic Operation of the 301 Controller
Key Description
A Display
BOver-Temperature
Key (if fitted)
The Over-Temperature key is used to access the over-
temperature menu. Note: Over-Temperature is an option.
CPage Key The Page key is used to scroll through the parameters and
switch between menus.
DTimer Key The Timer key is used to start, view, pause and reset the
timer.
EArrow Keys The Arrow keys are used to adjust the value of the selected
parameter and pause the output power.
FOver-Temperature
Indicator (if fitted)
The Over-Temperature indicator shows green in normal use.
It flashes red when over-temperature is triggered and is
constantly red when over-temperature is reset and waiting
for the temperature to drop.
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GTimer Indicator The Timer indicator shows when the timer is active.
HOutput Indicator The Output indicator shows when the controller is switching
on the heating elements.
3.2.1 Menu System
The 301 Controller is divided into two menus; the Home Menu and the Setup Menu. The
Home Menu contains all the basic operating controls: setpoint, setpoint ramp rate and
timer time. The Setup menu contains all the set up features: timer type, timer band,
output power and customer calibration. The features available vary depending on
operator input or product specification.
3.2.2 Navigation Diagram
The following diagram details how to navigate to the various menu options within the
301 Controller. At each option, values can be set using the arrow keys.
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3.0 301 Controller

3.0 301 Controller
HM Home Menu Page Key Black = Progress
SM SetupMenu Hold for 1.5 seconds White = Return
OTHM Over-Temperature Home Menu Keep Held
OTSM Over-Temperature Setup Menu Press Page Key multiple times
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Please note that the Over-Temperature Menu is only available when the Over-
Temperature Protection option is fitted.
3.2.3 Basic Function Guide
HOLd Used to pause the current program and set new parameters.
SP"C Used to set the desired temperature (setpoint) of the product
(°C).
SPrr Used to set the heating rate of the product, e.g. increase by
5°C per minute.
t1,t2,t3,t4,t5 Indicates the timer type in use. See section 3.5 for more
details.
t.typ Used to set the timer type.
t.bnd Available when t1 or t4 is in use. Allows the timer to start
the countdown before the desired setpoint is reached.
rSt Used to reset the timer.
OPHi Used to set the maximum output power.
CL.St Used to set the customer calibration type.
FAct Used to select the factory calibration settings.
PASS Flashes when a password is required to access further
options.
C.CL1 Select to access the single point calibration option.
C.CL2 Select to access the dual point calibration options.
OFSt Used to set the single point calibration offset temperature
(°C).
CAL.L Used to set the low temperature point (°C) for dual point
calibration.
CAL.H Used to set the high temperature point (°C) for dual point
calibration.
OFS.L Used to set the offset value for the low temperature point
(°C) for dual point calibration.
OFS.H Used to set the offset value for the high temperature point
(°C) for dual point calibration.
Ot Used to set the Over-Temperature limit (°C).
Ott Displayed when the Over-Temperature protection has been
activated.
PV Displayed before the current temperature when checking the
Over-Temperature sensor temperature.
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3.0 301 Controller

3.0 301 Controller
3.2.4 Home Display
The Home Display is the first display you see when the controller is switched on, it shows
the actual temperature of the product. When entering the menus, the controller will
automatically return to the Home Display if no keys are pressed for 30 seconds.
Finding the Home Display
lTo find the Home Display from the Home Menu, press the
Page key until the current temperature is shown on the
display.
lTo find the Home Display from the Setup Menu, press and
hold the Page key for 1.5 seconds.
3.2.5 Hold Mode
'Hold' mode turns the output off; this allows parameters to be set without the controller
instantly trying to control at the new settings.
When the output indicator is off, the Home Display flashes between the current
temperature and HOLd.
To enter 'Hold' mode:
lStart at the Home Display.
lPress and hold the up and down Arrow keys together for
1.5 seconds
lThe display will flash HOLd to show that 'Hold' mode has
been entered.
To exit 'Hold' mode:
lStart at the Home Display.
lPress and hold the up and down Arrow keys together for
1.5 seconds OR start the timer (See "The Timer ").
lNote: The 'Hold' mode function is disabled when the timer
function is operating.
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3.2.6 Checking the Temperature Setpoint from the Home Display
lStart at the Home Display.
lPress either the up or down Arrow key.
lThe setpoint will show on the display for 3 seconds before
returning to the home display.
3.2.7 Changing the Temperature Setpoint
lStart at the Home Display.
lRepeatedly press the Page key to scroll through the
Home Menu until SP"C is displayed.
lUse the up and down Arrow keys to alter the value.
lA single press of the up or down Arrow key shows the cur-
rent setting.
lTo alter this, either keep the key pressed or press it
again. The value will then be stored without any further
input.
3.2.8 Changing the Temperature Setpoint Ramp Rate
lStart at the Home Display.
lRepeatedly press the Page key to scroll through home
menu until SPrr is displayed.
lUse the up and down Arrow keys to turn off or alter the
value.
lA single press of either the up or down Arrow key shows
the current setting. To alter, either keep pressed or press
again. The value will then be stored without any further
input.
lSee section 3.4 for more information.
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.
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3.0 301 Controller

3.0 301 Controller
3.2.9 Changing the Timer Time
lStart at the Home Display.
lRepeatedly press the Page key to scroll through the
Home Menu until t1,t2,t3,t4 or t5 shows on the dis-
play.
lUse the up and down Arrow keys to turn off, or alter the
value.
lA single press of either the up or down Arrow key shows
the current setting (Hr:Min).
lTo alter this, either keep pressed or press again.The
value will then be stored without any further input.
lSee 3.5 for more information.
3.3 Advanced Operation
3.3.1 Entering the Setup menu
lStart at the Home Display.
lPress and hold the Page key for 1.5 seconds
lThe display will change to the first parameter in the Setup
Menu.
3.3.2 Changing the Timer Type
lStart at the Home Display.
lHold the Page key for 1.5 seconds to enter the set-up
menu.
lOnce entered, repeatedly press the Page key until
t.typis displayed.
lUse the up and down Arrow keys to alter the value.
To alter this, either keep pressed or press again. The value will then be stored
without any further input. A single press of the up or down key shows the current
setting.
Note: This function is disabled when the timer is operating. see section 3.5 for more
information on the timer types and functions.
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