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Related Manuals for VERDER CARBOLITE GERO TZF 15/90/610
Summary of Contents for VERDER CARBOLITE GERO TZF 15/90/610
- Page 1 Installation, Operation and Maintenance Instructions 1500 °C Tube Furnace (3-zone) - TZF Model: 610mm No Controller + 3216 End Zone Controllers TZF 15/90/610 + No Controller + 3216 End Zone Controllers MEN-TZF15610-07_NOCTRL_3216 19-06-2019...
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Page 2: Table Of Contents
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. - Page 3 4.7.3 Ramp Units 4.7.4 Dwell Units 4.7.5 Holdback 4.7.6 Ramp Rate 4.7.7 Target Setpoint 4.7.8 Dwell Time 4.7.9 Running a Program 4.7.10 Program Status 4.7.11 Process Value 4.7.12 PSP, Segment Type and Number Controller Options 4.8.1 Digital Communications - RS232 4.8.2 Digital Communications - RS485 4.8.3...
- Page 4 7.0 Maintenance General Maintenance Maintenance Schedule 7.2.1 Cleaning Calibration After-Sales Service Recommended Spare Parts and Spare Parts Kit Power Adjustment Element Ageing 8.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Safety Warning - Refractory Fibre Insulation Temperature Controller Replacement Solid-State Relay Replacement Thermocouple Replacement Element Fitting and Replacement...
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Page 5: Symbols And Warnings
1.0 Symbols and Warnings 1.0 Symbols and Warnings 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;... - Page 6 1.0 Symbols and Warnings Caution – Double Pole/Neutral Fusing...
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Page 7: Installation
2.0 Installation 2.0 Installation 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. - Page 8 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.
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Page 9: Tube Fitting
2.0 Installation 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. A End guard B Plate C Standard tube D Long tube E Strap F Ring clip Fig 1 - Vertical Tube Retention A Furnace body... - Page 10 2.0 Installation Expanded View of "Twin Clamp" End Seals: A Clamp B Seal plate C 'O' Ring seal D Seal sleeve E Clamp seal F End plate A Clamp B End plate Clamp seal (between Seal sleeve and Clamp D Seal sleeve Seal plate &...
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Page 11: Heating Elements
2.0 Installation 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. - Page 12 2.0 Installation Electrical Connection Details: Supply Types Supply Terminal Label Cable Colour Reversible or Live- Live - Neutral Live to either power conductor 1-phase L Brown to live (For USA 200-240V, connect L1) to the other power conductor Blue to neutral (For USA 200-240V, connect L2) to earth...
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Page 13: Temperature Controller
3.0 Temperature Controller 3.0 Temperature Controller If this product is fitted with a temperature controller, instructions are provided separately. -
Page 14: 3216 Controller
4.0 3216 Controller 4.0 3216 Controller 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. 3216P1 The 3216P1 is a digital temperature controller which uses PID algorithms to give excellent temperature control. -
Page 15: Keys
4.0 3216 Controller 4.4.2 Keys The page key is used to access level 2 when held down Page Key for 3 seconds. Scroll Key The scroll key is used to scroll through parameters. When pressed simultaneously the ACK function is used Page and Return to the Home Menu Scroll... -
Page 16: Understanding User Levels
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. -
Page 17: Setting Up The Controller
4.0 3216 Controller 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>. -
Page 18: Customer Calibration
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;... - Page 19 4.0 3216 Controller 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.
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Page 20: Programming
4.0 3216 Controller 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... -
Page 21: Running A Program
4.0 3216 Controller If not all the segments are used for a program, the Ramp & Dwell of each of the subsequent segments should be set to OFF. A program will end in one of two ways, either revert to the control setpoint or dwell at the temperature set in the last segment used. - Page 22 4.0 3216 Controller Working Output Power From the home display, press scroll until the display shows WRK.OP <WORKING OUTPUT POWER>. This shows the power being used as a percentage. Time Remaining Press scroll until the display shows T.REMN <TIME REMAINING>. This shows the dwell time remaining for the current segment.
- Page 23 4.0 3216 Controller Program Example The following sequence of entries creates and runs the program shown graphically below. 1. Press scroll until the display shows RAMP.U <SP RAMP UNITS>. Select MIN. 2. Press scroll until the display shows DWELL.U <DWELL UNITS>. Select MIN. 3.
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Page 24: Controller Options
4.0 3216 Controller RMP.1= 5°C/Min RMP.1= 4°C/Min RMP.1= OFF RMP.1= 3°C/Min RMP.1=5°C T.SP1= 600°C T.SP1= 400°C T.SP1= 600°C T.SP1= 800°C T.SP1= 400°C Dwel.1= 30 Min Dwel.1= 30 Min Dwel.1= 60 Min Dwel.1= OFF Dwel.1= 480 Min Controller Options As options can be ordered in a variety of combinations and for a variety of purposes, exact instructions are not given here. -
Page 25: Alarm Option
4.0 3216 Controller address value, access the level 2 list. In level 2 press the page key until the COMMS parameter is displayed. Press up down to select the address value. 4.8.4 Alarm Option When an alarm board is fitted, which consists of a relay with voltage free contacts, for operator use, the contacts are taken to a panel plug on the control panel, wired as indicated: Temperature Controller... - Page 26 4.0 3216 Controller Hold the Page key for 3 Level 1 Press the Scroll Key seconds Press the Scroll Key multiple Locked - password Level 2 times required Access If configured Unlocked Black = Progress Do not raise the power limit (if Dashed = Through multiple accessible) above the design level Multiple Program Only...
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Page 27: 2132 Over-Temperature Controller Description (If Fitted)
5.0 2132 Over-Temperature 5.0 2132 Over-Temperature Controller Description (if fitted) Description Alarm Light Page Scroll D Down Display This over-temperature controller is fitted and supplied ready to use by Carbolite Gero. It is a digital instrument with a latching alarm, requiring no additional panel controls. The controller features easy setting of over-temperature setpoint and reading of current temperature by the over-temperature sensor. -
Page 28: Operation
5.0 2132 Over-Temperature 5.2.2 Operation When switched on, the controller lights up, goes through a short test routine and then displays the measured temperature or the over-temperature setpoint. The page key allows access to parameter lists within the controller. A single press of the page key displays the temperature units, normally set to °C;... -
Page 29: Audible Alarm
5.0 2132 Over-Temperature Audible Alarm If an audible alarm is supplied for use with the over-temperature controller, it is normally configured to sound on over-temperature condition and to stop sounding when the alarm is acknowledged as given in section 5.2. Note: the alarm may sound during controller start-up. -
Page 30: Operation
6.0 Operation 6.0 Operation Operating Cycle This product is fitted with an instrument switch which cuts off power to the control circuit. Connect the product to the electrical supply. There is also a heater switch which can be used to disconnect power to the elements. Operate the instrument switch to activate the temperature controller. -
Page 31: Retransmission Of Setpoint Using Broadcast Communications
6.0 Operation B. Retransmission of Setpoint using Broadcast communications Three independent thermocouples are connected to three controllers. The three controllers are linked together and the centre zone controller communicates the desired setpoint to the end zone controllers. If the centre zone controller is set to a setpoint or is running a program, the end zone controllers will automatically follow. -
Page 32: Operator Safety
6.0 Operation Operator Safety The ceramic materials used in the product manufacture become electrically conductive to some extent at high temperatures. DO NOT use any conductive tools within the product without isolating it. If a metal work tube is used, it must be earthed (grounded). Switch off the heater switch whenever loading or unloading the product. - Page 33 6.0 Operation A suitably regulated gas supply should always be used. It is recommended that a pressure relief system should be used to avoid an over pressurisation of the work tube. Please note: A product should not be heated up if any valves that have been fitted are closed to create a sealed volume.
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Page 34: Maintenance
7.0 Maintenance 7.0 Maintenance General Maintenance Preventive rather than reactive maintenance is recommended. The type and frequency depends on the product use; the following are recommended. Maintenance Schedule CUSTOMER QUALIFIED PERSONNEL DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically qualified personnel should attempt these maintenance procedures. - Page 35 7.0 Maintenance rect positioning Seals (if fitted) Check all seals and O-rings and clamps Performance Element Circuit Electrical measurement Measure the current drawn on each Power Consumption phase / circuit Check whether the cooling fans are work- Cooling Fans (if fitted)
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Page 36: Cleaning
7.0 Maintenance 7.2.1 Cleaning The product's outer surface may be cleaned with a damp cloth. Do not allow water to enter the interior of the case or chamber. Do not clean with organic solvents. 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. -
Page 37: Element Ageing
7.0 Maintenance Element Ageing Silicon carbide elements gradually increase in resistance with use; a process known as ageing. Their heating power reduces correspondingly. To ensure sufficient power to the product, it may be necessary to adjust the power limit and, ultimately, replace the elements - taking care to readjust the power limit. -
Page 38: Repairs And Replacements
8.0 Repairs and Replacements 8.0 Repairs and Replacements Safety Warning - Disconnection from Power Supply Immediately switch the product off in the event of unforeseen circumstances (e.g. large amount of smoke). Allow the product to return to room temperature before inspection. Always ensure that the product is disconnected from the electrical supply before repair work is carried out. -
Page 39: Solid-State Relay Replacement
8.0 Repairs and Replacements Solid-State Relay Replacement Disconnect the product from the power supply and remove the appropriate cover as given above. Make a note of the wire connections to the solid state relay and disconnect them. Remove the solid state relay from the base panel or aluminium plate. Replace and reconnect the solid state relay ensuring that the bottom of it has good thermal contact with the base panel or aluminium plate. -
Page 40: Element Fitting And Replacement
8.0 Repairs and Replacements Element Fitting and Replacement Replacements: see section 7.7. If at any time the power limit has been increased, reset it to its original value (see section 11.0 at the back of this manual for the original value). New elements must not be mixed with aged elements. -
Page 41: Element Fitting - Figures
8.0 Repairs and Replacements Element Fitting - Figures Fig 1 - Use of Clip Tool Fig 2 - Element Connections - 3 zone models Fuse Replacement Fuses are marked on the wiring diagram with type codes, e.g. F1, F2. For more information on fuses refer to section 11.0. -
Page 42: Fault Analysis
9.0 Fault Analysis 9.0 Fault Analysis Furnace Does Not Heat Up The HEAT The heating element Check also that the SSR is working light is ON has failed correctly The controller shows a The HEAT The thermocouple has broken or has very high temperature light is OFF a wiring fault... -
Page 43: Product Overheats
9.0 Fault Analysis Product Overheats Product only heats up The controller when the instrument shows a very high The controller is faulty switch is ON temperature The thermocouple may be The controller faulty or may have been shows a low removed out of the heating temperature chamber... -
Page 44: Wiring Diagrams
10.0 Wiring Diagrams 10.0 Wiring Diagrams 10.1 WC-13-31 Connections below show single phase with indirect safety switches and over- temperature control. -
Page 45: Wc-U3-31
10.0 Wiring Diagrams 10.2 WC-U3-31 Connections below show 3-phase +N with safety switches and over-temperature control. Products with this wiring arrangement may be converted between the following supply voltages (please refer to the table within section 11.0 for compatible phases with the product): 3-phase + neutral in the range 380/220 V - 415/240 V 3-phase delta in the range 220 V - 240 V... -
Page 46: Control By Broadcast Comms (Control Method B)
10.0 Wiring Diagrams 10.3 Control by Broadcast Comms (control method B) When this is ordered there are three independent thermocouples connected to the three controllers; the controllers are linked together (not shown), and remain “master” and “slave”. The communication between the controllers of the Eurotherm 3000 series is known as Broadcast comms. -
Page 47: Fuses And Power Settings
11.0 Fuses and Power Settings 11.0 Fuses and Power Settings 11.1 Fuses F1-F3: Refer to the circuit diagrams. GEC Safeclip of the type shown Fitted if supply cable fitted. Internal (glass type F up to 16 A) Supply Fitted on board to some types 38 mm x 10 mm type F fitted on Fuses of EMC filter. -
Page 48: User Power Setting Adjustments
11.0 Fuses and Power Settings User Power Setting Adjustments Date % Power Comments Note: If a new set of elements are fitted then return the power settings to the original value. Please refer to the rating label for product specific information. -
Page 49: Specifications
12.0 Specifications 12.0 Specifications Carbolite Gero reserves the right to change the specification without notice. Heated Work Tube Work Tube Model Temp Power Length Weight Bore (mm) Length (mm) (°C) (kW) (mm) (kg) Tube furnaces with a ceramic work tube wound with resistance wire. TZF 15/610 1500 1200-1500... - Page 51 Notes Service Record Engineer Name Date Record of Work...
- Page 52 The products covered in this manual are only a small part of the wide range of ovens, chamber furnaces and tube furnaces manufactured by Carbolite Gero for laboratory and industrial use. For further details of our standard or custom built products please contact us at the address below, or ask your nearest stockist.
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