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Carbolite CAF DIGITAL IMAGING Installation, Operating, & Maintenance Instructions

Coal ash fusion test furnace
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Installation, Operating &
Maintenance Instructions
Coal Ash Fusion Test Furnace
CAF DIGITAL IMAGING
This manual is for the guidance of operators of the CAF Digital furnace and should be read
before the furnace is connected to the electricity and gas supplies. It contains information
required for safe and trouble-free furnace operation. If, however, any questions remain
unanswered please contact our service division at the address at the end of this manual.
MF36-3.05

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Summary of Contents for Carbolite CAF DIGITAL IMAGING

  • Page 1 Maintenance Instructions Coal Ash Fusion Test Furnace CAF DIGITAL IMAGING This manual is for the guidance of operators of the CAF Digital furnace and should be read before the furnace is connected to the electricity and gas supplies. It contains information required for safe and trouble-free furnace operation.

  • Page 2: Table Of Contents

    Caf Digital Imaging CONTENTS page 1.0 Safety Information. General. Carbon Monoxide Warning. Hydrogen And Carbon Dioxide Warning. Refractory Fibrous Insulation Warning. Viton ‘O’ ring Seals Warning 2.0 Models Covered By This Manual. 3.0 Installation Instructions. Unpacking And Handling. Packing List.
  • Page 3 Caf Digital Imaging 10.0 Appendix. 31 - end Fig 1. Element wiring and positions. Fig 2. Work tube and back plug assembly. Fig 3. Front tube seal assembly. Fig 4. Door arm assembly. Fig 5a. Camera mounting bracket. Fig 5b. Standard lens & camera assembly.

  • Page 4: Safety Information

    Caf Digital Imaging AFETY NFORMATION General. Please read all of this section first. Please look through the complete manual before connecting the furnace. In particular read through the section on installation and observe section 3.6 about supply voltage. This furnace must be earthed (grounded).

  • Page 5: Hydrogen And Carbon Dioxide Warning

    Caf Digital Imaging To minimise the risks associated with CO it is most important that the furnace is installed and operated in accordance with this instruction manual. If the furnace operator experiences any of the effects listed above, the furnace must be isolated from the gas and electricity supplies immediately and expert advice sought.

  • Page 6: Viton 'O' Ring Seals Warning

    Caf Digital Imaging Before commencing any major repairs we recommend reference to the European Ceramic Fibre Industry Association Bulletin No. 11 and the UK Health and Safety Executive Guidance Note EH46. We can provide further information on request, alternatively our service division can quote for any repairs to be carried out at your premises or ours.

  • Page 7: Installation Instructions

    Caf Digital Imaging NSTALLATION NSTRUCTIONS The furnace 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 40°C Unpacking & Handling.
  • Page 8 Caf Digital Imaging 3.3. Assembly Of The Furnace. 3.3.1. Element Fitting. Ensure that the furnace is isolated from the mains supply. Remove the back panel from the furnace unit. Note: The heating elements are fitted at the factory to test the furnace but are removed for transit.
  • Page 9 Caf Digital Imaging Tighten the six socket screws evenly in the sequence as shown by numbers 1 to 6 in fig 8. Ensure that the work tube sealing ring is held firmly against the end of the work tube and is evenly spaced from the work tube ring about its circumference.

  • Page 10: Positioning The Furnace

    Caf Digital Imaging Due to the high work tube temperatures used during CAF testing the tube ‘O’ ring seals will deteriorate with time. The furnace work tube also has a finite life and may eventually crack due to normal wear and tear. It is necessary to conduct a pressure test of the work tube assembly at regular intervals during normal use of the furnace to ensure integrity of the work tube and ‘O’...

  • Page 11: Voltage Level & Power Limit Settings

    Caf Digital Imaging the operator. Unless a supply cable is fitted the supply connections are to be made to terminals mounted inside back of the furnace, accessed by removing the furnace back panel. The terminals are marked according to the power supply, connect as shown in table 2. The supply must incorporate an earth (ground).

  • Page 12: Gas Connection

    Caf Digital Imaging Note: It is important that the vents are not restricted in any way, do not use tube of less than 6mm diameter for the safety pressure relief vent connection and 12mm for the main vent connection. Check regularly that the main and safety pressure relief vents are clear from obstructions.

  • Page 13: Camera Mounting & Connections - Standard Lens

    Caf Digital Imaging 3.9. Camera Mounting And Connections – Standard Lens. Fit the camera mounting bracket onto the door arm as shown in fig 5c and 5d. Note that the camera shown in fig 5c and 5d is not fitted for this operation.

  • Page 14: 3.11. Computer Connections

    Unpack the computer from its transit boxes and assemble in accordance with the manufacturers instructions provided. Insert the Carbolite hardware lock (dongle) into the printer port on the back of the computer. Connect the camera video extension cable from the phono socket on the back of the furnace case to the Video Card phono socket on the back of the computer.

  • Page 15: Operating Instructions

    Computer Start-up. The computer is set up by Carbolite to run the following software: Microsoft Windows 2000 (earlier models: Windows 98). Carbolite Coal Ash Fusibility Test software: protected by a hardware lock (dongle).

  • Page 16: Loading Samples Into The Work Tube

    Switch on the computer and monitor, and double click on the Carbolite icon displayed on the start up screen. The ‘Carbolite Coal Ash Fusibility Test’ software initiation screen will be displayed followed by the main test screen. The Carbolite logo will be displayed in the centre of the blank image screen.

  • Page 17: Running A Coal Ash Fusion (Caf) Test

    Caf Digital Imaging Running A Coal Ash Fusion (CAF) Test. 4.5.1 Setting the Target Temperature. Note: Avoid operating the furnace at unnecessarily high temperatures as this will reduce the life of the elements, furnace insulation and tube end seals. Set the target temperature as low as possible (depending on your application) to gain the most economical use from your furnace.
  • Page 18 4.5.4.2 Select ‘Setup’ and ‘Sample Codes’ at the top left corner of the screen and the ‘Sample codes’ window will appear. Up to 15 sample codes can be entered, though Carbolite do not recommend analysing more than 12 samples per test. Select the number of samples required and enter the identification code (less than 8 characters) for each sample and click OK.
  • Page 19 Caf Digital Imaging Selecting ‘Record’ will automatically set the furnace controller to ‘Run’ and start the furnace program. The yellow ‘test in progress’ light will illuminate on the control panel. The green Standby Mode indicator will go out. Note: Do not open the furnace door when the ‘test in progress’ light is illuminated. See section 1.1.
  • Page 20 The control panel can be left running if required. When the analysis is complete select ‘OK’ to accept the results. Select ‘File’ and ‘Save’ to save the results to your file directory under ‘Carbolite\Images\DSHF’ as ‘.tif’ files and ‘Data’ as ‘.dat’ files.
  • Page 21 Caf Digital Imaging A computer print out can be obtained by selecting ‘File’ and ‘Print, the results are presented as a report sheet as shown in fig 18. The ‘.tif’ image files can be imported into Microsoft Word or Excel for inclusion in test reports etc.

  • Page 22: Maintenance And Calibration

    There is a feature in the furnace controller which allows the power to the elements to be turned down, this ‘power limit’ is pre-set at Carbolite. As the element performance declines the available power can be increased to compensate. The maximum power figure available is 100 (%), if the furnace performance is still poor when the power is set to 100 (%) the elements must be replaced.

  • Page 23: Furnace Calibration

    CAF Digital furnace. The furnace is calibrated prior to leaving the factory, but both ASTM and BS standards call for regular checks on calibration. Carbolite recommend that calibration checks are conducted in accordance with these instructions, if the furnace is found to be out of calibration then the control instrument must be adjusted (see section 5.4.5).
  • Page 24 Caf Digital Imaging Four pieces of each wire type are required, the samples are prepared as follows: Cut a piece of wire 30mm in length. Using a pair of pin nose pliers, form one end of the wire into a coil so that when standing on a flat surface it supports a 12mm vertical column of wire.
  • Page 25 5.4.5. If the spread lies outside the permissible limit, then the furnace will require rectification of its temperature uniformity; contact Carbolite for further advice. Any servicing or modifications to the furnace or controls may affect the calibration of the furnace and will require a re-test.
  • Page 26 Caf Digital Imaging Note: Following alteration the ‘Adj’ value will lock after aproximately 2 seconds. If you pause when entering the new value the ‘Adj’ feature may lock, indicated by the ‘Adj’ value changing to ---- whenever the Up or Down buttons are pressed. If this happens exit to the ‘iP LiSt’ by pressing the Page button (2) and re-access ‘Adj’...

  • Page 27: Circuit Diagrams

    Caf Digital Imaging IRCUIT IAGRAMS Please see the separate enclosure or request a diagram from Carbolite if one is not supplied. MF36 page 27...

  • Page 28: Fault Analysis

    Caf Digital Imaging AULT NALYSIS A general fault analysis chart can be seen below; see section 4.0: Operating Instructions, for more detailed fault analysis of the control system. A. Furnace Does Not Heat Up à An ohm meter applied à A heating element has failed...

  • Page 29: After Sales Service

    To contact Thermal Engineering Services or Carbolite see the back page of this manual. Recommended Spares & Consumables. Carbolite can supply individual spares, or a kit of the items most likely to be required. Ordering a kit in advance can save time in the event of a breakdown. Each kit comprises one thermocouple, one solid state relay, a set of elements and braids, one of each type of internal fuse, window glass gasket, work tube gasket and door/window ‘O’...

  • Page 30: Specifications

    Caf Digital Imaging PECIFICATIONS Carbolite reserves the right to change specifications without notice. Maximum external cabinet dimensions: Height 700mm Width 505mm Case depth 625mm Overall depth 1070mm Work tube dimensions: Internal diameter 79mm Length 650mm Material Mullite page 30 MF36...
  • Page 31 Caf Digital Imaging 10.0 A PPENDIX The figures referred to in the previous text are listed below. Fig 1. Element wiring and positions. Work tube back support Rear seal assembly Work Tube Insulating collar Fig 2. Work tube and back plug assembly.
  • Page 32 Caf Digital Imaging Tube ‘O’ ring Work tube gasket Swing bolt Socket screws Work tube ring Work tube sealing ring Gas inlet fitting Fig 3. Front tube seal assembly. Door plug ring Viewing window Door arm Door plug Camera assembly...
  • Page 33 Caf Digital Imaging Fig 5a. Camera mounting bracket. 49-55mmStep up ring Lens heat Camera shield 49mm UV filter 43-49mmStep up ring Video socket Shutter switch Power socket Auto iris socket 5mm spacer ring Standard auto iris lens Fig 5b. Standard lens & camera assembly.
  • Page 34 Caf Digital Imaging Fig 5c. Sliding the camera mounting bracket assembly onto the door arm. (note: the camera is not fitted during this operation.) Fig 5d. Securing the camera mounting bracket assembly to the door arm. (note: the camera is not fitted during this operation.)
  • Page 35 Caf Digital Imaging Fig 5e. Mounting the standard lens & camera assembly. Fig 5f. Standard lens & camera assembly in position. MF36 page 35...
  • Page 36 Caf Digital Imaging Screw Fixing Locking screw Ball joint 70-210mm Lens clamp Close up 52-49mm zoom lens +1 filter step ring Lens mounting 20mm spacer tube Aperture ring Lens operating ring Fig 5g. Zoom lens assembly & lens clamp. Fig 5h.
  • Page 37 Caf Digital Imaging Fig 5j. Mounting the lens heat shield. Fig 5k. Mounting the zoom lens & bracket assembly. MF36 page 37...
  • Page 38 Caf Digital Imaging Fig 5l. Zoom lens in position. Fig 5m. Adjusting the position of the zoom lens & camera assembly. page 38 MF36...
  • Page 39 Caf Digital Imaging Fig 5n. Releasing lens clamp screw to rotate camera & lens assembly. Fig 5p. Storing the zoom lens & carrier. MF36 page 39...
  • Page 40 Caf Digital Imaging Work tube insulating collar Furnace case Brick box Work tube back support Rear support fixing posts Thermocouple Thermocouple connecting Vent tube fitting terminals Fig 6. Rear view of furnace showing brick box assembly. page 40 MF36...
  • Page 41 Caf Digital Imaging See note Socket screws Tube ‘O’ ring (compressed) Work tube gasket Work tube Work tube sealing ring Note: Position ‘O’ ring 7 mm from end of tube. Work tube ring Fig 7. Front tube seal position. Swing bolts Gas inlet fitting Fig 8.
  • Page 42 Caf Digital Imaging Work tube Tube guard Work tube front support adjustment Work tube front support Fig 9. Work tube front support. Door arm assembly (Door in open position) Door slide shaft Fig 10. Fitting the door arm assembly. page 42...
  • Page 43 Caf Digital Imaging Remove back screws only before fitting the door arm assembly to the door slide shaft. Door arm assembly. Door slide shaft Loosen front and back screws to adjust the door arm assembly position. Fig 10a Adjusting the door arm assembly.
  • Page 44 Caf Digital Imaging Forced air extraction ducted out of the building Furnace front Furnace side Wall Bench Bench Fig 12. Positioning the furnace. Sample tile Ash cone Sample carrier Fig 13a. Positioning samples on the sample carrier page 44 MF36...
  • Page 45 Caf Digital Imaging Fig 13b. Loading samples into the mouth of the work tube. Fig 13c. Loading samples into the work tube. MF36 page 45...
  • Page 46 Caf Digital Imaging Fig 14. Set-up options. Fig 15a. Enter file name and sample identifier. page 46 MF36...
  • Page 47 Caf Digital Imaging Carbolite your file name.log your file name Contains the log file of this test. A text file, showing date of test, image no., time and temperature Contains a dat file if the results Data window was used and the file saved.
  • Page 48 Caf Digital Imaging Door plug ring Window glass Window retaining ring Door plug Door ‘O’ ring Window ‘O’ ring Door arm Window glass gasket Door handle Fig 17. Door arm assembly exploded view. page 48 MF36...
  • Page 49 Caf Digital Imaging Coal Ash Fusibility Test Results Date of test: Thursday, January 22, 1998 Record start time: 17:15 Date of analysis Thursday, February 05, 1998 Time of print: 16:30 Test reference: USA TYPE F Sample Position Identifier Au-Pd Au-Pd...
  • Page 50 Caf Digital Imaging 12mm Plan view Side view Fig 19. Formed wire sample. Fig 20. Sample carrier, sample tiles and sample positions. page 50 MF36...
  • Page 51 Thank you for reading this data sheet. Please contact us for a quotation: Head Office (UK) Switzerland Office P.O. Box 2124 Zugerstrasse 46 Chelmsford 6314 Unterägeri Essex CM1 3UP England Switzerland Tel: +44 (0)1245 600 560 Tel: +41 41 541 5877 Fax: +44 (0)1245 600 030 Fax: +41 41 541 5878 Email:...

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