VERDER HZS 12/900 Manual

Installation, Operation and Maintenance Instructions

1200°C Split Tube Furnace - HZS Model: 900mm

3508 Controller + 2132 End Zone Controllers

HZS 12/900 + 3508 Controller + 2132 End

Zone Controllers

MEN-HZS120900-08_3508_2132 (02-08-2019)

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 3508 Controller 14

3.1 PID control 14

3.2 3508P1 14

3.3 3508P10 14

3.4 3508P25 14

3.5 Basic Operation 15

3.5.1 Controller Layout 16

3.5.2 Keys 16

3.6 Quick Start Guide 16

3.6.1 Operation as a simple controller 16

3.6.2 Changing the Setpoint 16

3.6.3 Resetting the programmer 17

3.6.4 Understanding User Levels 17

3.7 Setting Up Controller 18

3.7.1 Maximum output power setting 18

3.7.2 Customer ID. 18

3.7.3 Units 19

3.7.4 Language 19

3.8 Programming 19

3.8.1 Programming Notes 19

3.8.2 Holdback 20

3.8.3 Wait Segments 20

3.8.4 Program Cycling 21

3.8.5 Creating a Program 21

3.8.6 Running a Program 22

3.8.7 To pause (hold) a program 23

3.8.8 To stop and reset a program 23

3.8.9 To run a different program (P10 and P25) 23

3.8.10 Program Status 23

3.8.11 Program Hold with Holdback 24

3.8.12 Power Failure Recovery 24

3.8.13 Alarms 25

3.8.14 Program Example 1 25

3.8.15 Program Example 2 27

3.9 Controller Options 29

3.9.1 Digital Communications - RS232 30

3.9.2 Digital Communications - RS485 30

3.9.3 Comms Address 30

3.9.4 Alarm Option 30

3.9.5 Remote Input and Output (Analogue Communications) 31

3.9.6 Program segment output 31

3.10 Temperature Controller Replacement 32

3.11 Controller Navigation Diagrams 32

3.11.1 Operator Level 1 - No Program Running 33

3.11.2 Operator Level 1 - Program Running 34

3.11.3 Supervisor Level 2 35

4.0 3508 Dual Loop Cascade Control (if fitted) 36

4.1 Principle of Cascade Control 36

4.2 Operation of Cascade Control 36

4.3 Bypassing Cascade Control 40

4.4 3508P1 Element Loop (Loop 2) 40

4.5 Caution 40

4.6 Over-Temperature Control 40

5.0 2132 Controller 41

5.1 Description 41

5.2 2132 Controller Operation 41

5.2.1 Controls 41

5.2.2 2132 Controller Operation 42

5.2.3 Basic Operation 42

5.2.4 Altering the Setpoint 42

5.2.5 Stopping and Starting Control 43

5.2.6 Altering the Ramp Rate 43

5.3 Operating with the Timer 44

5.3.1 Setting the Timer Mode 46

5.3.2 Setting the Time Period 46

5.3.3 Running with the Timer 46

5.3.4 Stopping the Timer 47

5.3.5 End of Time Period 48

5.3.6 Cancelling the Alarm 48

5.3.7 Program Example 48

5.4 Altering Power Limit 48

5.5 Audible Alarm 51

5.6 Temperature Controller Replacement 51

5.7 Navigation Diagram 52

6.0 2132 Over-Temperature Controller Description (if fitted) 54

6.1 Description 54

6.2 Operation 54

6.2.1 Controls 54

6.2.2 Operation 55

6.2.3 Over-Temperature Operation 55

6.2.4 Over-Temperature Alarm 55

6.2.5 Resetting the Over-Temperature Alarm 55

6.2.6 Sensor Break 55

6.3 Audible Alarm 56

6.4 Navigation Diagram 56

7.0 Operation 57

7.1 Operating Cycle 57

7.2 Control Method 57

7.3 3-Zone Control Methods 58

A. Back-to-Back Thermocouples 59

B. Retransmission of Setpoint 59

C. Independent Control 60

7.4 General Operating Advice 60

7.5 Operator Safety 60

7.6 Tube Life 61

7.7 Pressure 61

7.8 Power Adjustment 62

7.9 Running at Low Temperatures 62

8.0 Maintenance 63

8.1 General Maintenance 63

8.2 Maintenance Schedule 63

8.2.1 Cleaning 65

8.2.2 Safety Switch 65

8.3 Calibration 65

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 Fuse Replacement 68

9.7 Element Replacement 69

10.0 Fault Analysis 70

A. Furnace Does Not Heat Up 70

B. Product Overheats 71

11.0 Wiring Diagrams 72

11.1 WC-13-70 72

11.2 WC-13-71 73

11.3 2- and 3-phase With Neutral 74

11.4 Independent Zones (control method C) 74

11.5 Control by Broadcast Comms (control method B) 74

11.6 Three-phase without neutral (star - e.g. 380-415 V) 74

11.7 Higher Voltages 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

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.

Caution – Double Pole/Neutral Fusing

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 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.

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.

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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