FURNACE & ASSAY 168 Manual

ABN: 68 606 541 468 Email: info@fandasupplies.com 1

168 Place Cupellation Furnace

Operation & Maintenance Manual

Tel: +61 8 9399 9299

E-mail: info@fandasupplies.com

Website: fandasupplies.com/

FURNACE & ASSAY

——S U P P L I E S—––

Fuel Source:

LPG

Manufacturing

Date

Electrical:

220-240V

Working Area

● 650mm Deep

● 650mm Wide

● 220mm High

Combustion

Chamber

Volume:

0.19

Swept Volume:

0.2

ABN: 68 606 541 468 Email: info@fandasupplies.com 2

Manual Index

System Overview 3-4

Safety Devices 5 - 6

Spare Parts List 7 - 8

Installation Procedure 9

Warm-up/ Curing Procedure 10

Operating Instructions 11

Weekly Check Sheet 12

Commissioning procedure 13 - 20

Gas Submission 21

Operational Flowchart 22

Fuel Schematic 30

Maintenance 31 - 44

Contact Details 45

Troubleshooting Guide 23 - 28

Electrical Schematic 29

ABN: 68 606 541 468 Email: info@fandasupplies.com 3

Please note you will require a minimum of 1 metre clearance around the furnace.

 Base construction uses high-quality 100 x

100 RHS.

 Furnace body construction is durable 5mm

laser-cut plate

 High quality refractory brick and insulation

 Bolt holes in base plates of all 4 legs for

individual adjustment on uneven surfaces

 Pneumatic door controls with hand

valve—optional foot pedal available

 Port viewing window installed in door

 Vent Tube height 1115mm

Construction

 ISPM 15 Heat

treated export

crates

Length 1690mm

Width 1690mm

Height 2230mm

Weight 1550KG

1400 mm

INSPECTION

HOLE

1830mm 1170 mm

ELECTRICAL BOX

250 mm

875 mm

2135 mm

1170 mm

930 mm

1125 mm

VENT TUBE

BURNER

1490 mm

AVERAGE BURNER EQUIPMENT DEPTH

* Dimensions are approximate only and may vary slightly with each furnace.

ABN: 68 606 541 468 Email: info@fandasupplies.com 4

168 Place Cupellation Furnace

240V-FAS-180

Power Requirements

 Volts

 Phase

 Kilowatts

240V

Fuel Type LPG

Gas Consumption 280MJ Per Hour

Operating Pressure 140 KPA

Gas Pressure Requirements

Minimum Inlet Pressure

Maximum Inlet Pressure

2.5KPA

140KPA

Safety Devices Installed

UV Flame Detection

System Overview:

This furnace has a fan forced single burner system, with an automatic ignition system. It can

be swapped between NG and LPG (propane) to suit varying site requirements, with just a

few simple adjustments performed on-site involving a minimum of downtime and

associated costs.

Temperature is monitored and modulated automatically by a Type K thermocouple system and

Omron temperature controller, pre-set for a maximum temperature of 1100 degrees Celsius.

This controller is simple to operate, and has a 2-level display (PV and SV), that shows actual

temperature as well as the temperature the furnace is set to.

The door has a pneumatic ram opening system with an easy to use foot pedal control or

optional hand valve that allows you to open the door part-way so that you can check inside with

minimal temperature loss.

ABN: 68 606 541 468 Email: info@fandasupplies.com 5

Safety Devices

The Safety Features on this Furnace are:

UV FLAME DETECTION:

1/.A UV flame detection unit is installed which monitors burner flame. It checks that

there is no flame present at start up of furnace. If there is then furnace will not start.

This will only happen if the unit can detect either residual flame inside furnace or flame

from another source.

2/. During second purge cycle and after pilot ignition it will do a check 5 seconds after

ignition. If no flame detected then controller will lock out. Also if UV flame detector is

faulty controller will lock out.

3/. A UV amp meter is fitted to the front of the electrical box to monitor the

performance of the UV flame detector. Good flame detection will indicate between 0.5-

0.8 m amps. If the reading falls below 0.2 m amps then either the flame detector unit is

aging and needs replacing or the holder that houses the unit needs correct alignment

with the flame.

ABN: 68 606 541 468 Email: info@fandasupplies.com 6

Recommended 12 Months Consumables

Recommended Spare Parts

Parts List for FAS-180-INLPG2

168 Place Cupellation Furnace, 240v Inspirated LPG

Recommended Critical Spare Parts

FAS Part# FAS Description Qty

FAS-206 Muffle #8 to suit 168PCF 6

FAS-212 Vent Slotted #5 to suit E100PCF & 100PCF & 168PCF 5

FAS-304 Floor Tile 650x650x25mm to suit 168PCF 6

FAS-409 Thermocouple Inner Sheath 300x10mm 5

FAS-410 Thermocouple Outer Sheath 300x15mm 5

FAS-603 Ceramic Anchor, (Complete) 3" 18

FAS-605 Thermocouple Element, type K. 310mm 6

FAS-803 Isowool Blanket (Kaowool) 160kg x 25mm 1

FAS-1008 Refractory Mortar 2 KG 2

FAS Part# FAS Description Qty

FAS-180-DOOR 168PCF Door, factory lined (No Hinges or pins) 1

FAS-411 Porcelain 2-way Element Connectors 1

FAS-509 Door Switch, OMRON D4D-1121N 1

FAS-608 Thermocouple Wire 4

FAS-612 U.V. Ammeter 0-1Ma 48x48mm 1

FAS-654 Air Hose, Double Insulated 4

FAS-657 Festo, Foot Pedal 1

FAS-680 LPG Gas Filter 1

FAS-802 Isowool Blanket (Kaowool) 128kg x 50mm 2

FAS Part# FAS Description Qty

FAS-609 Thermocouple 1/2" Head 1

FAS-611 U.V. Cell Flame Detector QRA.2 4

FAS-615 Flame Controller, LGB41

FAS-620A Dual Ignition Transformer TQO31A2750 1

FAS-622 Igniter Rod 2

FAS-623 Solenoid Valve (Complete) 1430k 2

FAS-626 U.V. Amplifier, AGQ1.1A27 1

FAS-627 Ignition Lead (Copper Cord) 3

FAS-627A Ignition Boot and Connector 1

FAS-648 Temperature Controller, Omron E5CC-RX2ASM-800 (Relay) 1

FAS-678 Ignition Electrode 2

ABN: 68 606 541 468 Email: info@fandasupplies.com 7

Associated Spare Parts

For pictures, data sheets and more info on spare parts please go to products

tab on our website http://www.fandasupplies.com/products

Parts List for FAS-180-INLPG2

168 Place Cupellation Furnace, 240v Inspirated LPG

FAS Part# FAS Description

FAS-180-SHL 168PCF New Body and Bricks

FAS-180-BRNINLPG 168PCF Burner Equipment lpg Inspirated 240v

FAS-180-DHP 168PCF Door and Hinge with Pneumatics

FAS-180-EXT 168PCF Back Extraction Piece

FAS-180-BKT 168PCF Refractory Reline Kit (no muffle/vent/tile)

FAS-628 Toggle Switch ( on/off, high/low )

FAS-643 LPG Gas Train

FAS-644 Two Stage Regulator

FAS-647 Gas Gauge

FAS-655 Pneumatic Cylinder

FAS-656 Pneumatic Cylinder set

FAS-657A Festo 3 way hand valve

FAS-659 Pneumatic Regulator

FAS-670 5AMP Control Fuse

FAS-674 Plug in 6mm Air Fitting

FAS-675 LPG High Pressure Test Point Assembly

FAS-681 Surge Protector *240V*

FAS-801 Isowool Blanket (Kaowool) 128kg x 25mm

FAS-1001 Flue Block - Large 50PFF

FAS-1003A Burner Port Round Hole 230x250mm

FAS-1004 Refractory Mortar 25kg Drum

FAS-1006 Refractory Castable 25kg Bag

ABN: 68 606 541 468 Email: info@fandasupplies.com 8

Installation Procedure

*Unpack furnace from crate and store in dry area. The furnace usually

has timber supports installed inside for transport. Remove before

operation.

*Remove Furnace Manual from inside of furnace chamber.

*Furnace requires a min of 1 metre space around it to carry out main-

tenance / repairs.

*Install fuel supply. This must be carried out by a qualified technical

person. Refer to furnace gas requirements to size inlet line correctly.

*For door operation air is required to run the pneumatics. Connect air

supply to the filter on the furnace.

*Electrical box is fitted with 3 core flex. If power socket is available

connect correct type plug and turn on. If not then an electrician is to

either install correct socket or hard wire furnace to power supply.

*NOTE THIS FURNACE USES SINGLE PHASE POWER WITH A

NEUTRAL WIRE AND EARTH.

*BEFORE STARTING CHECK THAT ALL EXHAUST DUCTING IS IN

PLACE.

ABN: 68 606 541 468 Email: info@fandasupplies.com 9

First Time Start Up

A new furnace will still have moisture trapped within the roof and requires curing

over a period of a few days to strengthen the refractory.

Always start on low fire and run for half hour on then half hour off. Continue this

procedure for a minimum. of 6 hours. Once completed then leave on low fire for at

least 24 hours.

Keep a close eye on any cracks that may develop on front of refractory indicated by

moisture seeping through refractory. If you see this then maintain temperature until

moisture clears.

After around 30 hours you will notice that the furnace temperature is running

around 650degC. You can now turn furnace to high fire and set the controller

100degC above the real temperature. Let the furnace modulate on this temperature

for an additional 1hour.

Keep a close eye on any cracks that may develop on front of refractory indicated by

moisture seeping through refractory. If you see this then maintain temperature until

moisture clears.

1. Increase set point in 100degC increments every hour until desired temperature

is reached.

CURING PROCEDURE

ABN: 68 606 541 468 Email: info@fandasupplies.com 10

Starting Furnace shut down for more than 36 Hours

When furnace has been shut down for a period of time then you will need to

start up the furnace slowly.

Keep a close eye on any cracks that may develop on front of refractory indicated by

moisture seeping through refractory. If you see this then maintain temperature until

moisture clears.

1. Leave on low fire or 250°C / 480°F for minimum of two hours.

2. Increase set point to 500°C / 930°F and leave for minimum of one hour.

3. Continue to increase to required temperature.

Starting Furnace with new muffle chamber installed

For LPG, NG and Diesel Furnaces:

1. Turn Furnace onto low fire for 15 mins, turn off for 15 mins, repeat for 1

hour with door open.

2. Shut furnace door and start on low fire, run until reaches 500°C /930°F.

3. Hold 500°C / 390°F for minimum of 1 hour.

4. Increase temperature 100°C/ 210°F every hour up to normal running

conditions.

Keep a close eye on any cracks that may develop, this is indicated by moisture

seeping through refractory. If you see this then maintain temperature until

moisture clears.

Furnace warm up procedure

Tabla de contenidos

Otros manuales de Horno de FURNACE & ASSAY

FURNACE & ASSAY

FURNACE & ASSAY FAS-130EAF Manual

FURNACE & ASSAY

FURNACE & ASSAY LPG Manual

Manuales populares de Horno de otras marcas

Armstrong

Armstrong EG7H SERIES Manual de usuario

Payne

Payne PG92ESA Guía

SUPREME

SUPREME FEM10-M2301CM-A Instrucciones de montaje

Ingersoll-Rand

Ingersoll-Rand S9V2B080D4VSAC/D Instrucciones de montaje

Johnson Controls

Johnson Controls TM9T Guía

Fluke

Fluke 9118A Manual de usuario

Lennox

Lennox EL195UHE Elite Series Manual de instalación y operación

Intertherm

Intertherm M7RL Series Manual de usuario

HDG

HDG Pelletmaster 15 Manual de usuario

Pinnacle

Pinnacle Aero Bella AB-716C-QH Manual

Nortek

Nortek MG2S Series Manual de usuario

VERDER

VERDER CARBOLITE GERO ABF 8/28 Manual

Goodman

Goodman GMV9 Manual

SUPREME

SUPREME SUP10-M2301C Instrucciones de montaje

Dettson

Dettson AMT400B34-SM1PMA Instrucciones de montaje

Evcon

Evcon DGD 60 MBH Manual de usuario

Trane

Trane S8B1A026M2PSAB Instrucciones de montaje

Hart Sceintific

Hart Sceintific 9113 Manual de usuario