VERDER TZF 12/75/700 Manual

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
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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
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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
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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
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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
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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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1.0 Symbols and Warnings

1.0 Symbols and Warnings
Caution – Double Pole/Neutral Fusing
8

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.
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2.0 Installation

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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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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2.0 Installation

2.0 Installation
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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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:
13
2.0 Installation

2.0 Installation
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.
14

3.0 3508 Controller
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 3508P1
The 3508P1 is a digital temperature controller which uses PID algorithm to give
excellent temperature control when properly set. This controller can store and operate
a single program of up to 20 segments. The 3508P1 can also be used as a simple
temperature controller.
3.3 3508P10
The 3508P10 is a digital controller which uses PID algorithms to give excellent
temperature control when properly set. This controller can store 10 programs of up to
50 segments each. Programs can be operated individually or linked by a Call parameter
as sub-programs or to form single long programs. The 3508P10 can also be used as a
simple temperature controller.
3.4 3508P25
The 3508P25 is a digital temperature controller which uses PID algorithms to give
excellent temperature control when properly set. This controller has a maximum of 500
segments or 25 programs; each program has a maximum of 50 segments. For
example 3508P25 could store 10 programs with 50 segments or 25 programs with 20
segments. Programs can be operated individually or linked by a Call parameter as sub-
programs or to form single long programs. The 3508P25 can also be used as a simple
temperature controller.
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3.0 3508 Controller

3.0 3508 Controller
3.5 Basic Operation
Key
A Alarm Indicator
B Power Output Indicator
C Not Used
D Runs, Holds, Resets the current program
E Page
F Scroll
G Down
H Up
I Power Output Percentage
JProgram Setpoint Temperature (PSP) when a program is
running
K Setpoint Temperature (SP) when basic controlling
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L Measurement Temperature
M Measurement Units
3.5.1 Controller Layout
3.5.2 Keys
A/ Man - Disabled
RUN/ HOLD - Runs, Holds or Resets the current program. Hold down for 3
seconds to Reset.
Page Key Scrolls through the page headings. Hold down for 3 seconds
to access further levels, pass codes are required.
Scroll Key Scrolls through parameters listed on pages.
Arrow Keys +Adjust parameter values.
Page and
Scroll
together +Press together to return to the home display or to
acknowledge an alarm.
Page and Up
together +Press together quickly to scroll back up the page headings.
Scroll and Up
together +Press together quickly to scroll back up a parameter list.
Pressing any other combination of keys together has no effect.
Note: If no keys are pressed for 1 minute, the display returns to Home.
3.6 Quick Start Guide
3.6.1 Operation as a simple controller
When switched on the controller goes through a short test routine and then shows the
measured temperature. Below it, the setpoint temperature (SP) and percentage of
power output.
The controller will immediately attempt to reach the set temperature and 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.
3.6.2 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 at the top of the display, indicating that
the product is heating.
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3.0 3508 Controller

3.0 3508 Controller
The controller will immediately attempt to reach the set temperature and 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.
3.6.3 Resetting the programmer
To reset the programmer to simple controller mode, press RUN/HOLD for 2 seconds.
Operating the current program
• To avoid unwanted heating at the end of a program, set the SP temperature to zero
before operating a program.
• Ensure the programmer is reset to simple controller mode before starting a program
by pressing RUN/HOLD for 2 seconds.
• To start the program, press RUN/HOLD twice, RUN will light up on the display.
The displayed Program Setpoint (PSP) follows ramps, dwells and steps as the program
runs. The SP temperature of the controller does not apply when a program is operating.
• To pause the program, press RUN/HOLD.
• To stop the program and return to simple controlling (reset), press RUN/HOLD for 2
seconds.
When the program ends, the programmer will either:
• Automatically reset to operation as a simple controller.
• Dwell at the last temperature of the program (with the RUN indicator flashing), until
the operator presses RUN/HOLD for 2 seconds to manually reset, or presses RUN/HOLD
once to restart the program.
• Turn power to the elements down to zero.
3.6.4 Understanding User Levels
There are two levels in the controller; Level 1(Operator) and Level 2 (Supervisor).
Level 1 (Operator) is for the day-to-day operation of the controller is not protected by a
security code. There are 3 pages at this level. Page 1, Customer Identity, can only be
altered in level 2. Page 2 shows the current program status. Page 3 is for writing and
viewing programs.
Level 2 (Supervisor) requires a security code to enter, but once enable, provides access
to additional parameters. A further 4 pages are accessible in this level as follows; Home
, Customer identity, Control Output Hi percentage, Units.
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To Enter Level 2:
1. Press and hold page for 3 seconds. The display will show “Access Goto Level
1”
2. Press up to select level 2. After a short pause the display will show “Access
Pass code”.
3. Press up or down to enter the pass code. Pass is momentarily displayed.
After a short pause the display will return to home, the controller is now in level 2.
When Level 2 operations have been completed the supervisor must return to Level
1 manually. It is not necessary to enter a code when going from a higher level to a
lower level.
To Return to Level 1:
1. Press and hold page for 3 seconds. The display will show “Access Goto Level 2.
2. Press down to go to level 1. After a short pause the display will revert to
home, the controller is now in level 1.
3.7 Setting Up 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 2, see "Controller Navigation Diagrams".
3.7.1 Maximum output power setting
Press page until "Control Output Hi" is displayed. Press up or down to adjust
the value.
Depending on the product model, the maximum power output setting may be
accessible or locked.
For silicon carbide heated products the parameter is accessible to allow compensation
for element ageing.
In many models the maximum power output setting depends on the electrical supply
voltage, refer to section 12.0.
3.7.2 Customer ID.
A product identity number can be entered if required. This may be used to identify one
of many units, for production or quality control systems.
Press page until "Customer Identity" is displayed. Press up or down to select a
number.
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3.0 3508 Controller

3.0 3508 Controller
3.7.3 Units
Press page until "Units" is displayed. Press up or down to select:
C Celsius
F Fahrenheit
K Kelvin
3.7.4 Language
The text on the 3508 Controller 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.
3.8 Programming
3.8.1 Programming Notes
Programs can be created in Level 1 or Level 2 of the 3508 Controller.
For the P10 and P25, new programs can be created while the current program is
operating.
To avoid unwanted heating at the end of a program, set the controller setpoint
temperature to zero before operating a program.
All new unused programs show only 1 segment of type 'End'.
The minimum number of segments for a program is 2. The second being an 'End' type.
Ramp-to-setpoint control. To achieve this, create a two segment program. Set the first
segment type as 'Rate' or 'Time'. Set the second segment type 'End' type' Dwell'.
For the P10 and P25, programs can be linked together using a 'Call' segment. However,
a lower number program can not be called and a program can not be ended with a call
segment.
A program can be ended in four ways:
1. With 'End' segment set to S.OP the power to the elements is turned down to 0%,
no matter what the 'Setpoint' temperature is.
2. With 'End' segment set to 'Reset' and the 'Setpoint' temperature turned down to
zero, power to the elements will be 0%. To do this set the 'Setpoint' temperature
to the minimum possible. For type B thermocouples this will be below zero.
3. With the 'End' segment set to 'Reset'. The controller will try to reach and maintain
the 'Setpoint' temperature in place before the program started.
4. With the 'End' segment set to 'Dwell'. The controller will dwell at the 'PSP' of the
last segment ("RUN" indicator flashes), until it is reset.
To reduce the number of segments in a program, change the last required segment to
an 'End' type.
You will be asked to press to cancel or for OK.
To cancel all segments in a program, change the first segment to an 'End' type.
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