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8.0 Repairs and Replacements

8.6

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. If a single element fails in an
aged set of elements then replace with a new set. The remaining aged elements can be
used as spare parts in the future.

Disconnect the product from the electrical supply.

Remove the end guards to gain access to the element connections.

Remember that the elements are fragile and expensive and that they can be damaged
by contamination: handle them with care and keep them clean.

Replacements: make a note of the actual braid and cable connections to the elements.
For rod elements disconnect the clips, lift off the braids and carefully withdraw each
element. Refer to the image below.

Carefully insert the new elements into the product. Ensure that the rod elements are
placed centrally: the same length should be outside the insulation at each end.

TZF: The 3 rod elements are connected in series, using braids. The 6 double-spiral
elements are fitted 3 in series at each end, connected by 10 mm cable. See fig. 9. In
the case of 3-phase + neutral, each set of elements is connected to a live from an SSR
at one end, at to neutral at the other. In the case of 3-phase delta (no neutral), each
set of elements is connected to a live from an SSR at one end and a direct live from
another phase at the other. The normal phase connections are A1-C, B1-A, C1-B.

Replace the end guards and connect the product to the electrical supply.

If aged elements have been replaced, reset the products power limit.

If you have any problems with this procedure, please contact the Carbolite Gero service
division.

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Содержание CARBOLITE GERO TZF 15/90/610

Страница 1: ...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 ...

Страница 2: ...p 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 ...

Страница 3: ... 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 ...

Страница 4: ...ibre 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 ...

Страница 5: ...itch 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 an...

Страница 6: ...1 0 Symbols and Warnings Caution Double Pole Neutral Fusing 6 ...

Страница 7: ...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 ...

Страница 8: ...r 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 ...

Страница 9: ...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 Car...

Страница 10: ...itted 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 fitting...

Страница 11: ... 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 directl...

Страница 12: ... 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...

Страница 13: ...3 0 Temperature Controller If this product is fitted with a temperature controller instructions are provided separately 13 3 0 Temperature Controller ...

Страница 14: ...re 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 Control...

Страница 15: ...ct 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 c...

Страница 16: ...k 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 displa...

Страница 17: ... 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 d...

Страница 18: ... 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 T...

Страница 19: ...hed 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 t...

Страница 20: ... 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 S...

Страница 21: ...g Display Current Program state To HOLD a program Press and quickly release Indicator RUN Flashing Scrolling Display Program Hold To RESET a program Press and hold for more than 1 second Indicator RUN OFF Scrolling Display None Program Ended Indicator RUN OFF Scrolling Text Program End To RESET a program after it has completed Press and hold for more than 1 second or press and quickly release Ack ...

Страница 22: ...mperature has not caught up with the program Power Failure If there is a power failure while the program is operating and the power is subsequently restored the scrolling text will read POWER FAIL PROGRAM RESET Press the ACK function to acknowledge this message press the ACK function again to reset the program Alarms Alarms are used to alert the operator when a pre set level has been exceeded or a...

Страница 23: ...play shows DWEL 2 DWELL TIME 2 Select 30 9 Press scroll until the display shows RMP 3 RAMP RATE 3 Select OFF 10 Press scroll until the display shows T SP3 TARGET SP 3 Select 600 11 Press scroll until the display shows DWEL 3 DWELL TIME 3 Select 60 12 Press scroll until the display shows RMP 4 RAMP RATE 4 Select 3 13 Press scroll until the display shows T SP4 TARGET SP 4 Select 800 14 Press scroll ...

Страница 24: ...ter PC using a straight through cable as follows the linked pins at the computer end are recommended but may not be necessary The cable is usually 9 pin at the furnace end and 9 pin at the computer but other alternatives are shown in parentheses Product end of cable female 25 pin 9 pin RS232 Cable product to PC Computer end of cable 9 pin 25 pin male Rx 2 3 _________________ 3 2 Tx Tx 3 2 ________...

Страница 25: ...ding on the circuit due to high voltage The instrument configuration and parameters available to the operator depend on the customer requirements 4 9 Temperature Controller Replacement Before handling the controller wear an anti static wrist strap or otherwise avoid any possibility of damage to the unit by static electricity Refer to the detailed instructions supplied with the replacement controll...

Страница 26: ... seconds L2 Level 2 Press the Scroll Key multiple times Locked password required A Access If configured Unlocked Do not raise the power limit if accessible above the design level for the product Multiple Program Only Black Progress Dashed Through multiple menus White Return 26 ...

Страница 27: ... off power to the controller and other parts of the control circuit To operate the controller power must be supplied to the product and the instrument switch must be on If a time switch is included in the product circuit this must be in the ON position When an over temperature condition occurs the controller cuts the power to a contactor which in turn cuts power to the heating elements Power is no...

Страница 28: ... with the over temperature set at 15 C above the furnace or oven maximum working temperature Press scroll twice view the present temperature as measured by the over temperature controller Press it twice the first press shows the temperature units C 5 2 4 Over Temperature Alarm If an over temperature condition occurs the OP2 indicator flashes and an alarm message 2FSH also flashes alternating with ...

Страница 29: ...top sounding when the alarm is acknowledged as given in section 5 2 Note the alarm may sound during controller start up 5 4 Navigation Diagram HL Home List Page Key Black Progress OTSP Over Temperature Setpoint Scroll Key Dashed Through to other options AL Access List For factory access to list and parameters not available to the operator 29 5 0 2132 Over Temperature ...

Страница 30: ...an indicator on the over temperature controller flashes and the heating elements are isolated Find and correct the cause before resetting the over temperature controller according to the instructions supplied To switch off power to the heating elements use the heater switch To switch the product off use both the heater switch and the instrument switch If the product is to be left switched off and ...

Страница 31: ... the retransmitted setpoint temperature unless edited To make this adjustment enter level 2 menu of the end zone controllers see controller operating instruction scroll to LOC T local trim and use the up down to enter the desired positive or negative value This will then be added to or subtract from the end zone set temperature There is no need to alter the centre zone controller C Independent Con...

Страница 32: ...iece and the tube crucibles or boats should be of low thermal mass and should have feet to reduce the contact with the tube fig 4 Key A Tube B Crucible Fig 4 Avoidance of thermal contact Do not set too high a heating or cooling rate As tubes are susceptible to thermal shock and may break Tubes which extend beyond the heated part of the furnace are more at risk A general rule for maximum heating or...

Страница 33: ...d 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 A sealed work tube should not be heated from cold due to the pressure increase caused by the trapped air or gas expanding during the heating process 33 6 0 Operation ...

Страница 34: ...ure Safety Circuit if fitted Electrical measurement Safety Switch Function split models only Set a safe temperature above ambient and open the furnace to see if the heater light goes out Safety Switch Function split models only Electrical measurement Electrical Safety external Visual check of external cables and plugs Electrical Safety internal Physically check all connections and clean ing of the...

Страница 35: ...ck all seals and O rings and clamps Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase circuit Cooling Fans if fitted Check whether the cooling fans are work ing 35 7 0 Maintenance ...

Страница 36: ... offer repair calibration and preventive maintenance of furnace and oven products both at the Carbolite Gero factory and at customers premises throughout the world A telephone call or email often enables a fault to be diagnosed and the necessary parts to be despatched In all correspondence please quote the serial number and model type given on the rating label of the product The serial number and ...

Страница 37: ... date of the adjustment in section 11 0 Increase the power limit in steps of 5 until the product regains its original performance If the power limit is set to 100 a new set of heating elements is required Please note it is not possible to use the cold resistance of the element as a measure of ageing as the cold resistance is not an accurate indicator of hot resistance Hot resistance is used to cal...

Страница 38: ... higher levels may be encountered during maintenance or repair Whilst there is no evidence of any long term health hazards it is strongly recommended that safety precautions are taken whenever the materials are handled Exposure to fibre dust may cause respiratory disease When handling the material always use approved respiratory protection equipment RPE eg FFP3 eye protection gloves and long sleev...

Страница 39: ...y Remove terminal cover to gain access to the thermocouple connections Make a note of the thermocouple connections Thermocouple cable colour codings are Thermocouple leg Colour positive type R orange negative white Disconnect the thermocouple from its terminal block and withdraw the thermocouple from its sheath by bending the metal tag or releasing the screw to release It is also advisable to remo...

Страница 40: ...nts disconnect the clips lift off the braids and carefully withdraw each element Refer to the image below Carefully insert the new elements into the product Ensure that the rod elements are placed centrally the same length should be outside the insulation at each end TZF The 3 rod elements are connected in series using braids The 6 double spiral elements are fitted 3 in series at each end connecte...

Страница 41: ... and voltage the different fuse types may or may not be fitted If any fuse has failed it is advisable for an electrician to check the internal circuits Replace any failed fuses with the correct type For safety reasons do not fit larger capacity fuses without first consulting Carbolite Gero The fuses are located at the cable entry point Remove the back panel or control box back panel to gain access...

Страница 42: ... a low temperature The door switch es if fitted may be faulty or need adjustment The contactor relay if fitted may be faulty The heater switch if fitted may be faulty or need adjustment The SSR could be failing to switch on due to internal failure faulty logic wiring from the controller or faulty controller There are no lights glowing on the controller Check the supply fuses and any fuses in the f...

Страница 43: ...r shows a low temperature The thermocouple may be faulty or may have been removed out of the heating chamber The thermocouple may be connected the wrong way around The controller may be faulty 2 Product heats up when the instrument switch is OFF The SSR has failed ON Check for an accidental wiring fault that could have overloaded the SSR 43 9 0 Fault Analysis ...

Страница 44: ...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 44 ...

Страница 45: ...supply voltages please refer to the table within section 11 0 for compatible phases with the product l 3 phase neutral in the range 380 220 V 415 240 V l 3 phase delta in the range 220 V 240 V l Single phase in the range 220 V 240 V l 208 V model can be converted between 208 V delta and 208 V 1 phase Please contact Carbolite Gero Service for details 45 10 0 Wiring Diagrams ...

Страница 46: ...hree 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 The wiring connections between the controllers are as follows 46 ...

Страница 47: ...Recommended if cable fitted See rating label for current See table below for fuse rating Model Phases Volts Supply Rating TZF 15 610 1 phase 200 240 63 A TZF 15 610 3 phase Delta 200 240 40 A TZF 15 610 3 phase N 380 415 25 A 11 2 Power Settings The power limit settings parameter OP Hi for this model are voltage dependant The figures represent the maximum percentage of time that controlled power i...

Страница 48: ...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 48 ...

Страница 49: ...ork tube wound with resistance wire TZF 15 610 1500 8 90 1200 1500 610 70 Note Weights are approximate for horizontal models and do not include fittings or vertical stands 12 1 Environment The models listed in this manual contains electrical parts and should be stored and used in indoor conditions as follows Temperature 5 C 40 C Relative humidity Maximum 80 up to 31 C decreasing linearly to 50 at ...

Страница 50: ......

Страница 51: ...Notes Service Record Engineer Name Date Record of Work ...

Страница 52: ... us at the address below or ask your nearest stockist For preventive maintenance repair and calibration of all furnace and oven products please contact Carbolite Gero Service Telephone 44 0 1433 624242 Fax 44 0 1433 624243 Email ServiceUK carbolite gero com Carbolite Gero Ltd Parsons Lane Hope Hope Valley S33 6RB England Telephone 44 0 1433 620011 Fax 44 0 1433 621198 Email Info carbolite gero com...

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