: Monitoring and Control EUROTHERM : “of Heat Treatment Furnaces - CONTROLS oe ‘The Carburizing Process SL PUBNESI TABLE OF CONTENTS 4L_INTRODUGTION. 2 Section F 5 2. TYPES OF CARBURIZING FURNACES 00002 Section fi 5 3 ELEMENTS OF CONTROL ZONE. 2 Section H 5 4, ZIRCONIA SENSOR THEORY... 3 Section | 5 5_ TYPICAL FUBNACE CONTROLS : Section J Ss Section A 4 Section k ieee 5 Section B 4 Section L 6 Section C 4 Section M. 6 Section D 4 6 SUMMARY 6 Section 5S1. INTRODUCTION Although heat treating of metals has been around tor many years, improvements ig methods and perfor- ‘mance continue, either by introducing new atmosphere {gases or by maintaining tighter control of the process, Although the purpose of heat treating metals has re- mained much the same over time (to alter a motafs hhardness), the method has changed significantly with the invention cf more capable and accurate process controls. A heat treater, whether commercial or captive, must be equipped with modem technology and equipment to operate competitively in today’s heat treat market ‘This includes not only the correct types of furnaces, but the proper controls that run the furnace heat treat cycle. 2, TYPES OF CARBUBIZING FURNACES ‘The heat treating industry employs many different types of carburizing furnaces. These may be broadly Givided into "laboratory’ and "industrial" categories. ‘The focus of this technical note is on the industria car- burzing furnaces where most applications. reuiring carbon potential controllers are found, ‘There aro several different types of industrial carburiz Ing furnaces. Among these are integral quench batch, continuous, and vacuum furnaces. These types of fur- rnaces share many similar zones to control 3. ELEMENTS OF CONTROL ZONE ‘As with any closed foop control zone, four major com- ponents are required, These components are: + the controller, + the power control switch or val the heating load, and the sensor These components are illustrated in Figure 7 and Figure 2, oe I Figure 1. Components of a closed loop ‘eontrol zone. ‘Though temperature is probably the most commonly controlled variable, carbon potential is also very impor- tent. A reliable controller to property contre! carbon potential is essential, The control manufacturer's repu- tation and their ability to provide service are Key con- siderations. As there are several diferent manufactur- fers trom which to choose, roliabilty and modem features should not be overlooked. \Noxt, a reliable carbon potential sonsor, often referred to as an oxygen probe of zirconia prove, is required. Since there are several manufacturers of zirconia ‘probes, a carbon potential controller that can be con- figured to accept input signals from probes of varying characteristics is desireable. In addition to the controller and sensor, a means by which the level of carbon nich atmosphere in the fur- nace can be adjusted, is necessary, This can be per- tormed by cortroliing the addition of more carbon with ‘one valve and dilution of the actual furnace carbon po- tential by controlling another valve Proper placement of the zirconia probe, location of at mosphere adtition/dilution valves, and proper recircu lation of the furnace atmosphere are essential for opti mum performance and measurement of carbon diffusing into the load. In the event this proper place ment is not possible, any modem carbon potential con: troller should have the means to perform process value adjustments. pt Ny Figure 2. Typical carbon control system showing ‘elements of a control zone.4. ZIRCONIA SENSOR THEORY Carton/axygeruzirconia probes are used extensively in moder control of heat treatment furnace atmosphere and carbon potential control. This sensor. technology has become mote and more prevalent and accepted over the past 20 years. Although stil considered by some to be a new technology, it is now well proven and widely accepted. ‘The zirconia probe generates 2 milivolt signal based onthe ratio of oxygen concentrations between the ret erence alr side of the probe and the amount of oxygen actually inside the turace (see Figure 3), This mil volt signal is sent to the carbon potential controller. A builtin thermocouple sensor is used to measure the temperature at the tip of the zirconia probe, This tem- perature signal is also sent to the carbon potential con troller. Together, these signals are used to calculate the actual percentage of carbon in the furnace atmcs- phere. With these two varables, the carbon potential can be found in a published look up table (see Allachment 1) 5. TYPICAL FURNACE CONTROLS Having reviewed the basic principals, the complement of controls typically found on heat treatment furnaces must be considered. The number of controls vary with the size and/or type cf furnace. The type of controllers generally cemains the same. The most obvious control is the furnace temperature controller, which may vary by manufacturer, DIN size, and functionally. This controller may even vary in the method of control output(s) (current proportioning, valve positioning, onioff, time proportioning), alarms (high, low, deviation, . . .}, rampidwell programming, program events, ete. 2D N ead | For batch type fumaces, rampidwell programming is generally required for standard toustilluse oycles (see Figure 4). For continuous type carourlaing fur haces, rampidwell programming Is seldom used and the controller typically holds a constan: setpoint value. eno. Figure 4. Typical heat treat furnace cycle. Equally important as temperature control is the furnace carbon potential control. Although many manufactur- ers can provide basic temperature control instruments, the ability to supply precision carson potential control 'simtea When choosing the proper carbon potential controller, there are many features to consider, Accuracy and re. Peatability aro no longer the sole tems to consider Depending on the requirements or specifications of the parts running in the furnace, some o! the following fea- ture may also be important. A —ovrensszcrco ACCUCARB Probe Schematic Figure 3. Typical zirconia probe schematic.A. The ability to configure to a variety of manulac~ turer's zirconia probes. As with any sensor, zirconia probes are subject to ‘wear and subsequent failure, To get a furnace running again as quickly as possible may mean locating and installing a different manutacturer’s zirconia probe. it the carbon potential controller is limited to one manu factuter, the down time is denendent on that sole sup: pliers ability to provide @ replacement. ‘This may not always occur in the time frame required. tt is much saler to specity a contraller with added flexibility 8. The ability to provide concise operator information. Display technology has evolved and contro! manutac: turers have had to Keep pace with incorporating this, technology in their products. For example, the Euro: therm 900EPC Series controller/programmer incorpo. rates a high density dot matrix display. This type of display not only allows easy viewing of standard infor mation such as satpoinis and actual process values, but also allows visual graphies of process data Graphic display of the furnace program (also called a mimic), the current running cycle, output bar graph dis: plays, and deviation from setpoint bar graphs can be seen, Better displays are important as operator efficiency is heavily influenced by the quality of information avaita- ble at the instrument level. For oxample, Figure 5 shows the furnace operator the actual percent carbon process value, the zirconia probe milivotts, the zirco- nla probe temperature, and the gas correction value. {In this case, the gas correction represents CO gas tor accurately calculating the percent carbon, in genera. ior dew point applications, this would represent the percent hydrogen Figure 5. Instrument display. ©. The ability to contro! furnace temperature or carbon potential in one instrument as well as in one easy-to-use package. Coordinating the program timing between percent carbon and temperature is critical. The temperature protile should not be running # the carban profiles not ready, and vice versa. Any dual-loop programmer for this application should run off a single internal clock, so that f one loop is held, both loops are held from ad- vvancing. When the process deviation is corrected and the program is ready to run again, both loops slay synchronized from start to finish. {In the past, controllers relied on external digitat signals to start and stop at the same time, This functionality is ‘now built into the instrument as the watchdog, allowing the fumace controller to run and advance the tumace cycle without the nead for external wiring schemas or operator intervention, Frequenily, this feature is re- ferred to as "holdback.” D. The ability to initiate @ routine zirconia probe burnout oyele. By design, some zirconia probes do not require a burn- ‘out (like the Accucarb probe manufactured by Furnace Control Corporation). However, the majority of zirco- nia probes on the market do require a routine burnout to operate effectively. In the past, this routine burnout was either not performed or was accommodated by using a series of external devices (relays and timers}. When bumouts are not performed, the actual carbon process measured value may not be accurate. This, ean result in parts not being processed within speciti cations. The carbon controller must be able to initiate a probe bumout cycle. The Eurotherm S00EPC pro- vides this probe bumout cycle (or “purging” of the zie Conia probe} in two ways. First, through an automatic sequence timer that may bbe set by the operator, the controller energizes an ‘output. This allows air to pass through to the tp of the Zirconia probe and causes a flame to bum out the ‘carbon soot buildup deposited during previous cycles. This frequency timer is user adjustablo to fit the exact requirements, To ensure the probe is cleaned thor- oughly, the probe bumout output remains energized for another user-adjustable period of time. ‘The second way to accommadate a zirconia probe: ‘eumout cycle is by manual intervention. For example, when the furnace inner door opens to transter loads, the controller initiates a burnout eycle so the probe is, ‘back to optimum operating condition before processing the next batch of parts. This can be initiated by the op-erator through a push button if t is suspected that the probe needs cleaning. Performing a probe burnout ‘causes a flame to burn down the sheath of the probe, which can deliver excessive heat to the delicate zirco- nia sensor. tis bast fo wait a minimum of 30 minutes between bumout cycles. The automatic bumout rou- tine is more appropriate for continuous vacuum funac- ‘es, whereas the manual routine fs more appropriate for ‘quench batch type applications. During probe burn out, the zirconia probe temporaniy sees excessive oxygen at the tip of the sensor. Since the differential of oxygen has changed, this would nor- mally cause the measured value to fluctuate, provoke the control outputs to react, and initiate the process alarms. To prevent this, the present process value is locked info memory during the probe bumout penod, ‘causing the process outputs to remain in position and process alarms not to change state. For optimum affi- cleney, any carbon potential controller considered today should offer both methods of probe burnout as found in the S00EPC. E. Once the probe has been through a burnout cycle, the zirconia probe's ability to resume normal measurement of the furnace carbon poten- tial should be checked before proceeding. Eurotherm calls this "probe health." At the completion of a bumout cycie, the instrument monitors the time It takes for the zirconia probe to return to 95 percent of the last operating milivott value, During commission ing of the controller, the furnace operator or supersor can set a time limit for the probe to recover—generally several seconds. If this time is not exceeded, itis pre: ‘sumed the probe is healthy. 1 this time limit is exceed: fd, it is presumed to be a sign of failure. Note the probe did not fail, but this health indication is to warn ff imminent failure and allow sufficient time to replace the aging zirconia probe. The controller will also enun ‘late a catastrophic failure, if one occurs. F. Capable of alarming on a sooting condition. {A sooting condition is the point where too much carbon In the almosphere or too low a temperature causes soot deposits. Under these conditions, the parts cannet absorb as much carbon as is allowed to enter the furnace. As this can happen oiten in carburizing, the Eurotherm 900EPC has alarm strategies built-in to natty the operator of this condition. One strategy is to initiate a probe burnout if the sooting condition persists {or a time period set in minutes. This prevents the zir conia probe from sooting and eliminates the need to ‘conduct an expensive, time-consuming operation to remove and replace it G. The instrument should have bullt-in totalizers and timers. Totalizers and timers track the time the zitconia probe is exposed to temperatures above x degrees. This feature allows @ maintenance stat! to plan for replace- ments rather than react when replacement consitions bocome serious. H. The capability tor a remote input from a gas analyzer. ‘The remote input from a gas analyzer corrects chang: es in CO gas. Using the correct CO gas correction value is essential for calculating an accurate carbon potential 1. In many heat treat facilities, the quality lab peri odically runs shim stock samples to verity the ac- curacy between the carbon potential controls and the actual work samples that have been metallurgl- cally tested. Hf the shim stocks do not match the process, the con- troller must have the capability to compensate for this difference, For example, the Eurotherm S00EPC, refers to this as the “zone factor” which can be used to cetfactively compensate for the differance. It is possi- bie, through a simple chart, 10 offset the instrument to ‘match the shim stack samples as tested. J. The capability to control generator dew point. For maximum tlexibiity, the instrument should also be capable of controlling the generator dew point so an in- ventory of multiple spare controllers for similar applica tions is not necessary. For example, the same Euro- therm 900EPC can be easily configured for either percent carbon, dew point control, or oxygen control K. The capability of controlling all associated variables. The fumace carbon and temperature controliet/ programmer should have the means to transfer the load on a batch fumace to the quench upon comple- tion of the ramp/dwell program. Rather than set a digi tal event output during each program (something that ‘can be easily overlooked) the Eurotherm 900EPC has. a “program complete status" output. When the pro- gram is complete, the load is automatically transferred to the quench. Additional outputs may be used for such items as ammonia addition dunng a particular program segment,L. In batch furnace application, ramp/dwell pro gramming Is usually needed. ‘The question then arises as to how many programs or segments is enough? Experience shows between 20, and 80 programs are adequate. Many heat treaters seldom use more than 450 individual program seg ments, Beyond this point, personal computers are used to manage and edit fumace programs. Look for support software from the manufacturer that allows this capability More and more, support software is supplied which allows entire instrument sotuns to be saved to a disk. These disk.files then become available in case a re: placement or spare instrument must be utilized. Hard ware is easily replaceable, but the time-consuming task of re-entering hundreds or thousands of individual parameters becomes the real chore. When a spare ‘controller must be used, all instrument parameters can be downloaded to this new controller with minimal downtime and lost production within minutes, M. As process controllers have advanced over the years, the real intent has been to make the job of running equipment easier and taster. Momentary power outages resulted in manually re- starting a furnace (or worse, multiple furnaces, as older controls did not have this capability). New pro- cess controls can now do this automatically. For ex: ample, should the program continue, run, oF reset? A time deviation test enables the program to reset if the power was out for more than x minutes. A process value deviation test enables the program to reset if the Geviation is more than x units. If neither time nor pro- cess value deviation is exceeded, the controller can servo and continue, Servo is a means by which the programmer ramps ‘back to the setpoint and resumes the remainder of the dwell tine after power retums. For example, if you were four hours into a six hour dwell and power failed, even just momentarily, the servo feature would auto- matically ramp the temperature and carbon back to the desired seipoint and finish out the two hours re- maining on dwell ime. This feature can save a com. pany trom possibly scraping a salvageable load when the instrument can make a simple process decision. (Other furnace equipment found on most heat treat fur: aces are chart recorders which can log process data for long-term traceability. Optionally, many heat treat- ‘ers log this vital data to personal computers for fast land accurate access for long-term historical replay Standard communication protocols. suchas. MODBUS™ should be available ‘The last control component found on a typical heat treat furnace includes some sort of over-temperature protection for emergency shut down. Typically re- ferred to as a “policeman,” this controllers sole pur- pose Is to shut off the fumace in case of a runaway temperature condition. This may include opening elec- trical power contactors or shutting down main gas valves. Many of these devices carry safety approvals such as Factory Mutual (FM). Typically, this device uilizes its own Independent thermocouple sensor- ccheck with local codes and ordinances for compliance. 8. SUMMARY ‘There are two main furnace types for carburizing metals—hatch and continuous—both have similar types of parameters to control. The primary parame- ters to control are temperature and carbon. ‘The tour main components in any closed loop contro! system are power switch (or valve), load, and sensor. Zirconia probes are used in carburizing furnaces to measure and calculate the actual percentage ot carbon in the furnace atmosphere and send these sig- nals to the carbon potential controller. Instruments that control temperature and carbon potential must have a complete suite of sophisticated features and software algorithms to improve process results and make the job of heat treating easier and faster. The Eurotherm 900EPC controller meets all these modem requirements for suocesstul contro! of a batch or con: tinuous type of carburizing fumace.FURNACE CARBON POTENTIAL) Attachment 1 8816 Nowth 124th Stret, Suite R_ Brookfild, Wisconsin 63005. (414) 788-7525 FAX {41d} 1837977 ACCUCARB® PROBE OUTPUT IN MILLIVOLTS* FOR VARIOUS COMBINATIONS FURNACE TEMPERATURE AND CARBON POTENTIAL elelele 172 bs fe ie ee os | 1a [FURNACE TEMPERATURE *P “DATA VALIO WITH CARRIER GAS COMPOSITION CO + CO, = 20% ANG AIS 1010 STEEL Te ow0108Monitoring and Gontrol of Heat Treatment Furnaces Presented at: ‘The Institute of Motals and Materials: AAIEE Exhibiton May 28, 1996 Written and Presented by: Steve Rakers ‘Subjoct to change without nace. © 1996 Eurotherm Controls Ine © EUROTHERM CONTROLS INC 41485 Sunset Hills Road, Reston, VA 20190-5206 eusorwerm TELEPHONE: 703-471-4870, FAX: 703-787-3496, BBS: 709-787-0484 CONTROLS WWW htipu/vnwweurotherm.comFax-On-Demanc: 708-767-3441