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VERDER CARBOLITE GERO CAF G5 Installation, Operation And Maintenance Instructions

1600c coal ash fusion furnace
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Installation, Operation and Maintenance Instructions
1600°C Coal Ash Fusion Furnace - CAF G5
CAF G5
MEN-CAFG5-001_3508
17-09-2020
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Summary of Contents for VERDER CARBOLITE GERO CAF G5

  • Page 1 Installation, Operation and Maintenance Instructions 1600°C Coal Ash Fusion Furnace - CAF G5 CAF G5 MEN-CAFG5-001_3508 17-09-2020...

  • Page 2: Table Of Contents

    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.
  • Page 3 4.3.1 Communication Failure: Gas Set-Up 4.4.1 Gas Flow Rates 4.4.2 Carbon Monoxide Sensor Loading Samples into the Work Tube Introduction to the CAF Test Software 4.6.1 CAF Interface Operation of CAF Software 4.7.1 Process Tabs 4.7.2 Configure 4.7.2.1 Test Results Folder 4.7.2.2 Temperature Settings 4.7.2.3...
  • Page 4 4.7.4.11 File Formats Post-Operation Cooling 5.0 Maintenance General Maintenance Maintenance Schedule 5.2.1 Cleaning Element Ageing Checking and Replacing the Door 'O' Ring Seal Cleaning the Viewing Window 5.5.1 To remove the viewing window for cleaning or replacement: 5.5.2 Cleaning the Window 5.5.3 When Replacing the Window Furnace Calibration...
  • Page 5 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. Fig 5c. Sliding the camera mounting bracket assembly onto the door arm. Securing the camera mounting bracket assembly to the door arm.

  • Page 6: Safety Information

    1.0 Safety Information General Please read all of this section first. Please look through the complete manual before connecting the furnace. In particular read through the section 3.6. This furnace must be earthed (grounded). Do not operate the furnace at temperatures above 815 °C (1500 °F) with the door open.

  • Page 7: Carbon Monoxide Warning

    Carbon Monoxide Warning Operation of the CAF furnace involves the use of carbon monoxide. Carbon monoxide is a product of reaction of H and CO Carbon monoxide (CO) is a colourless, odourless, tasteless and inflammable gas which is acutely toxic. CO is introduced into the blood stream through the lungs and binds with the haemoglobin preventing it from carrying oxygen around the body.

  • Page 8: Hydrogen And Carbon Dioxide Warning

    Hydrogen and Carbon Dioxide Warning Applicable for furnaces constructed to use H and CO test gases with CO 'Purge' gas. can form explosive gas mixtures, take precautions to avoid leakage of H and CO can react to form CO. see section 1.2. Carbon dioxide (CO ) is a colourless, odourless and tasteless gas that is an asphyxiant.

  • Page 9: Viton 'O' Rings - Warning

    Further information can be provided on request. Alternatively, Carbolite Gero Service can quote for any repairs to be carried out either on site or at the Carbolite Gero factory. Viton 'O' Rings - Warning The ‘O’ ring seals used in the CAF G5 furnace work tube assembly are manufactured from Viton.

  • Page 10: Installation

    3.0 Installation Unpacking and Handling When unpacking and handling the product, always lift it by its base. Do not use the door or any other projecting cover or component to support the equipment when moving it. Use two or more people to carry the product where possible. Carefully remove any packing material from inside and around the product before use.

  • Page 11: Assembly Of The Furnace

    1 off Furnace Assembly 1 off Work tube and back seal assembly, see fig 2. 1 off Work tube front insulating collar. 1 off Work tube gasket. 1 off Front tube seal assembly, see fig 3. 1 off Door arm assembly (without door plug), see fig 4. 1 off Door plug, see fig 4.

  • Page 12: Installing The Work Tube And Rear Seal Assembly

    Note: The heating elements are fitted at the factory to test the furnace but are removed for transit. These elements are extremely fragile, and can be damaged by contamination: handle them with care and keep them clean. Avoid touching the heating part.

  • Page 13: Fitting The Work Tube Front Seal Assembly

    3.3.3 Fitting the Work Tube Front Seal Assembly Slide the work tube front insulating collar over the front protruding part of the work tube until it is in contact with the front face of the heating chamber. Dismantle the front tube seal assembly by removing the six socket screws. See fig 3. Slide the work tube ring over the front of the work tube with the internal chamfer facing towards the front.

  • Page 14: Pressure Testing Of The Work Tube Assembly

    Carefully swing the door arm in a clockwise direction (view from front) to its stop position, ensuring that the door plug does not touch tube end guard. The door plug should be clear of the furnace in its fully withdrawn position. It should not be possible to push the door arm in towards the furnace until the door arm is rotated fully clockwise (view from front) and the door plug is in line with the work tube front aperture.

  • Page 15: Positioning The Furnace

    Under no circumstances should any objects be placed on top of the product. Always ensure that any vents on the top of the product are clear of any obstruction. Always ensure all cooling vents and cooling fans (if fitted) are clear of any obstruction.

  • Page 16: Voltage Level And Power Limit Settings

    The voltage or range of voltages on which the furnace may be operated is given on the furnace rating label. See fig 11a. Check that the electrical supply voltage is compatible with the voltage on the label, and that the current capacity is sufficient for the maximum current on the label before connection to the electrical supply.

  • Page 17: Exhaust Vent Connections

    If the actual supply voltage is higher than the voltage on the rating label (or the voltage for which the furnace was last set), immediately after switch-on set the temperature setpoint to zero, to prevent heating and drawing excessive current. First select user level 2.

  • Page 18: Gas Connections

    Gas Connections 3.8.1 Furnaces for CO/ CO and Air Test Gases with N Purge Gas See below if a mixer box for separate CO & CO inputs is supplied. Note: The gas supply pressure required is 4 psi (0.276 bar) and must not exceed this. There are three gas connections on the side of the furnace, CO/ CO pre mixed 'reducing' atmosphere gas, Air 'oxidising' gas and N...

  • Page 19: Fitting Type 1 - Bayonet

    Fitting Type 1 - Bayonet Mount the lens and camera assembly (fig 5b) onto the camera mounting bracket as shown in fig 5e and 5f. Rotate the lens and camera assembly anti-clockwise to locate in position. The socket head screws are fixed in position and do not require tightening. Ensure that the camera is in a horizontal position.

  • Page 20: Adjusting The Lens

    to 1200 °C, the aperture can be set to a suitable position to maximise the exposure range e.g. f8. 3.9.2 Adjusting the Lens. To adjust the lens for the ideal image quality the furnace and computer must be connected, see section 3.10 and the software must be running in configure mode see section 4.7.2.

  • Page 21: Operating Instructions

    4.0 Operating Instructions Furnace Start-Up This furnace is available with either of two gas options (These cannot be converted - see section 2.0 for more details): Type 1/ Reducing Gas Type 2 Rear lighting version available. Oxidising Gas Purge Gas Compatible with both: ASTM D1857/ D1857M - 04 (2010) Standard Test Method for Fusibility of Coal and Coke Ash...

  • Page 22: Eurotherm Controller

    control panel. See fig 11a. This alarm will continue until the furnace is turned off and the 'purge' gas supply is restored. While the alarm is activated the control sys- tem will not allow introduction of 'reducing' gas. 3. Switch on the furnace electrical supply, the cooling fans will run. Operate the instru- ment switch to activate the control system, the furnace will begin to heat up to the start temperature and the work tube will be purged with 'Purge' gas for 5 minutes.

  • Page 23: Communication Failure

    Note: Carbolite Gero accept no responsibility for any damage to software loaded onto the computer by the operator and accept no responsibility for damage to the computer or its software resulting from the use of any software or hardware not supplied by Carbolite Gero.

  • Page 24: Gas Flow Rates

    The desired test gas is selected using the 'oxidising' - 'reducing' gas selector switch on the front of the furnace control panel. See fig 11a. The test gas will flow for the duration of the controller program. 4.4.1 Gas Flow Rates To set the gas flow rates please refer to the following guidance notes: BS ISO 540: 2008 Reducing Atmosphere...

  • Page 25: Carbon Monoxide Sensor

    Note: In the event of a power failure during the program the 'purge' gas will flow continually until the power is restored. When the furnace mains supply is turned off the gas supply must also be turned off. When the power is restored the 'Purge' gas timer will run for 5 minutes after which the system will go into 'standby' mode and the green 'standby' indicator will illuminate.

  • Page 26: Introduction To The Caf Test Software

    After about one minute slowly slide the samples into the tube at a rate of about 25 mm per minute to make contact with the control thermocouple sheath. See fig 13c. Once the sample is in position allow a couple of minutes for the cones to burn off before closing the door, this will allow any vapours given off by the cones to dis- sipate out of the tube and reduce contamination of the rear end plug and the view- ing window.
  • Page 27 Automatic Analysis. Each of the samples is identified by placing a numbered grid over each individual sample. The operator then has the option to activate the auto- matic analysis mode. When activated the system will identify the sample profile and its position within its own grid boundary.

  • Page 28: Caf Interface

    4.6.1 CAF Interface Operation of CAF Software Switch on the furnace and the computer, and load the test samples as described in sections 4.1 to 4.5 Proceed as follows to run a CAF test: Sample Window Once the samples have been loaded into the furnace and the camera is positioned correctly a live image of the samples will be displayed in the sample window if sufficient light is available in the tube.

  • Page 29: Process Tabs

    Window Zoom The image can be manipulated in the sample window by the controls in the lower right hand side of the sample window. The image can be zoomed in and out with the + and - buttons. Note: the image can also be zoomed by double clicking a position in the sample window (this must be outside the sample grid area).

  • Page 30: Configure

    4.7.2 Configure Select the 'Configuration' tab to set up the test parameters. 4.7.2.1 Test Results Folder Selecting the text box or the ellipsis (square box with three dots) at the end of the test results folder box, will open the file browser where the folder location can be specified and new folders can be created.
  • Page 31 temperatures as outlined in the relative standard. Users can set their own test parameter as described below. Start Image Capture Temperature - Select the temperature at which the software starts to record images. It is advisable to start recording at a temperature that is as close as possible the first sample melt point as this will reduce the number of stored images.

  • Page 32: Test Piece Identification

    4.7.2.3 Test Piece Identification Click the 'Test Piece Identification' button to open this window. Adjust the quantity and description of test pieces. Maximum number of 8 samples to be used for automatic analysis. Clear Test - This can be used to reset the test piece descriptions to the default values e.g.

  • Page 33: Analysis Grids

    4.7.2.4 Analysis Grids The analysis grids are an integral part of the automatic analysis program and must be set up before the test is started if the 'Auto Analysis' option is selected, see section 4.7.3.4 where automatic analysis is to be carried out after the furnace has finished its test cycle.

  • Page 34: User Settings

    4.7.2.5 User Settings Clicking the 'User Settings' button will open this window. The Temperature Settings, Test Identifications Settings and the Analysis Grid Settings can be stored in one unique file. Save Settings - Once the Temperature Settings, Test Identification Settings and the Analysis Grid Settings have been adjusted the value can be saved to a custom file name in a folder location of the users choice.

  • Page 35: Test

    4.7.3 Test Select the 'Test' tab to set up the test identification parameters and start a test. Select the 'Test' tab to set up the test references and run the test. 4.7.3.1 Test Results Folder The 'Test Results Folder' box may already be populated with the correct folder if set up previously in the Configure tab, see section 4.7.2.

  • Page 36: Test Reference

    4.7.3.3 Test Reference A test reference can be entered into the 'Test Reference' text box. This may be a specific sample number, batch number or a LIMS related reference if required. 4.7.3.4 Auto Analysis Selection When this is selected the auto analysis will be carried out straight after the heat up cycle is completed and all the deformation images have been captured, hence the whole test from heat up through to analysis is one continuous process.

  • Page 37: Test Results Folder

    Select the 'Analysis' tab to open previous test images and store the identified deformation points by using automatic or manual analysis methods. 4.7.4.1 Test Results Folder The "Test Results Folder" box may already be populated with the correct folder if set up previously in the Configure tab, see section 4.7.2.

  • Page 38: Automatic Analysis

    4.7.4.3 Automatic Analysis If the Automatic Analysis option was chosen before the test was started see section 4.7.3.4. If the 'Auto Analysis' option was not selected before the start of the test, the automatic analysis can be started at any time as long as the test sequence has been completed, or a previous test reference can be selected for the analysis.

  • Page 39: Running With Automatic Analysis

    shown as 15% in some standards). The operator has the option to change this ratio between 0.5% and 20.0%. 4.7.4.5 Running with Automatic Analysis Once the above parameters have been selected the automatic process can be started. Start - Selecting 'Start' will activate the automatic analysis process. Abort - Selecting 'Abort' will cancel the test that is being analysed.

  • Page 40: Automatic Entry Of Test Results

    The results form show the Identity number and description of the test pieces to be analysed. These are initially set up using 'Test Piece Identification' command. See section 4.7.2.3. Analysis of CAF test results stored images. The four columns headed DT, ST, HT, FT for coal ash or SST, DT, HT, FT for Biomass refer to the temperatures at which the characteristic changes of shape occur: Coal Ash: DT = Deformation Temperature...

  • Page 41: Analysis Graph Form

    No test results can be added or removed from the automatically generated results form. If manual analysis is to be carried out the manual analysis results table should be used, see section 4.7.4.9. A test piece number row can be activated by selecting the corresponding grid number. When the grid is selected it will highlight in red and the corresponding item number row on the results table will be highlighted in blue.

  • Page 42: Manual Entry Of Analysis Results

    Sample Reference Information - The upper part of this area shows the test details such as 'Test Name', 'Test Reference', 'Acquisition date/time' and 'Analyse Date/ Time'. The lower section controls the test piece identity number and the image number and/ or temperature of the 'Current Selected Temperature Point' (this is shown by a green line headed 'Current').

  • Page 43: File Folders

    Dragging the scroll bar situated in the lower part of the Analysis tab window. Selecting the arrows on the end of the scroll bar Entering a sequence number into the 'Image in Sequence' box. Entering a temperature into the 'Temperature' box. Scrolling through images with a wheel mouse.

  • Page 44: File Formats

    Images folder. This folder is created when a test is run and images are captured. This folder contains all the captured test images in the format 'Date-Time-Temperature- SequenceNumber.tif'. 4.7.4.11 File Formats There are several files created when running the CAF software: .tiff Image Files.

  • Page 45: Post-Operation Cooling

    Post-Operation Cooling After the completion of testing, the furnace must be allowed to cool gradually. Ceramic work tubes are subject to thermal expansion when heated to high temperatures, increasing in both length and diameter. Rapid changes in temperature can cause stress upon the work tube material which may cause it to break; a process known as thermal shock.

  • Page 46: Maintenance

    5.0 Maintenance General Maintenance Preventive rather than reactive maintenance is recommended. The type and frequency depends on the product use; the following are recommended. Maintenance Schedule CUSTOMER QUALIFIED PERSONNEL DANGER! ELECTRIC SHOCK. Risk of fatal injury. Only electrically qualified personnel should attempt these maintenance procedures. Frequency Maintenance Method...
  • Page 47 Performance Element Circuit Electrical measurement Measure the current drawn on each phase / cir- Power Consumption cuit Visual check for fit and damage, and correct pos- Tube Insulation Collars itioning...

  • Page 48: Cleaning

    5.2.1 Cleaning Soot deposits may form inside the furnace, depending on the process. At appropriate intervals remove these by heating as indicated in the General Operation Notes. The product's outer surface may be cleaned with a damp cloth. Do not allow water to enter the interior of the case or chamber.

  • Page 49: Checking And Replacing The Door 'O' Ring Seal

    Save Settings To save the calibration settings, the save button must first be activated by entering a password of 525 in the password box. The word 'Activated' will be displayed if the correct password is entered and the save button will be highlighted. Select the save button to save the settings.

  • Page 50: Cleaning The Window

    5.5.2 Cleaning the Window When cleaning the window, use a suitable cleaning agent. Alternatively an optician equipped with re-polishing machines can restore the clarity of the windows. 5.5.3 When Replacing the Window Ensure that the glass is clean and free from dust, grit, chips, scratches and cracks. If the glass is damaged replace it, a faulty window glass can cause leakage of carbon monoxide during testing.

  • Page 51: Test Procedure

    Four pieces of each wire type are required, the samples are prepared as follows: Cut a piece of wire 30 mm 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 12 mm vertical column of wire.

  • Page 52: Deviations From Limits

    Furnace in °C Furnace in °F Actual Gold Melt (ball) temp 1063 °C 1945 °F Min. permissible Gold Melt (ball) temp 1057.5 °C 1935 °F Max. permissible Gold Melt (ball) temp 1068.5 °C 1955 °F Actual Palladium Melt (ball) temp 1554 °C 2829 °F Min.
  • Page 53 Calculate the upper calibration temperature (displayed Palladium melt tem- perature) correction factor: Calculate the Palladium mid melt temperature from the results obtained, as given in section 5.6.4. Calculate the upper calibration temperature correction factor as the difference between the Palladium actual melt temperature and the Palladium mid melt tem- perature: Palladium: actual melt temperature - mid melt temperature = upper calibration temperature...
  • Page 54 Lower Calibration Temperature Adjustment: From your previous calculations enter the lower mid melt temperature calculated into the 'Low Temperature Value' box e.g. 1060 °C. Enter the lower calibration temperature correction factor into the 'Low Temperature Offset Box' e.g. 3. Once saved the correction value will now be 1060 + 3 = 1063 Upper Calibration Temperature Adjustment: From your previous calculations enter the upper mid melt temperature calculated into the 'Low Temperature Value' box e.g.

  • Page 55: After-Sales Service

    After-Sales Service Carbolite Gero Service has a team of Service Engineers who can 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.

  • Page 56: Fault Analysis

    6.0 Fault Analysis A general fault analysis chart can be seen below; see section 4.0; for a more detailed fault analysis of the control system. Furnace Does Not Heat Up The HEAT lamp/ s Check that the SSRs are working A heating element has failed is/ are...

  • Page 57: Furnace Overheats

    Furnace Overheats The HEAT light goes OFF when The controller instrument shows a very The controller is faulty switch is high switched temperature OFF. When switched back ON. The controller The thermocouple may have been shows a low shorted out or may have been moved temperature out of the heating chamber The thermocouple may be mounted the...

  • Page 58: Rear Internal Lighting

    Rear Internal Lighting Rear The 'Back light is off Increase the 'Back light off lighting temperature' is lower than temperature' to a value greater does not the standby temperature than the standby temperature illuminate when instrument Allow the furnace to cool below switch is the 'Back light off temperature' on and the...

  • Page 59: Gas System

    Gas System Control system will This alarm will continue until the activate an alarm furnace is turned off and the 'purge' buzzer and gas supply is restored. While the alarm illuminate a is activated the control system will not warning light on the allow introduction of 'reducing' gas.

  • Page 60: Internal Carbon Monoxide Sensor

    Internal Carbon Monoxide Sensor Fumes from Press the CO alarm reset switch during the the insulation first heating cycle. The CO warning light will binders during remain on during this period. When the first heating furnace has completed its initial heating cycle may cycle turn the instrument switch off then cause alarm...

  • Page 61: Wiring Diagrams

    7.0 Wiring Diagrams For wiring diagrams, please contact Carbolite Gero Service. Please quote the serial number and model. 8.0 Specifications Carbolite Gero reserves the right to change the specification without notice. Maximum external cabinet dimensions: Height 804 mm Width 505 mm Case Depth 625 mm Overall Depth...

  • Page 62: Appendix

    9.0 Appendix The figures referred to in the previous text are listed below. Fig 1. Element Wiring and Positions Fig 2. Work Tube and Back Plug Assembly...
  • Page 63 Fig 3. Front Tube Seal Assembly Fig 4. Door Arm Assembly...
  • Page 64 Fig 5a. Camera Mounting Bracket Fig 5b. Lens and Camera Assembly...
  • Page 65 Fig 5c. Sliding the Camera Mounting Bracket Assembly onto the Door Arm...
  • Page 66 Fig 5d. Securing the Camera Mounting Bracket Assembly to the Door Arm...
  • Page 67 Fig 5e. Mounting the Lens and Camera Assembly...
  • Page 68 Fig 5f. Lens and Camera Assembly in Position...
  • Page 69 Fig 6a. Rear View of the Standard CAF G5 Furnace Showing Brick Box Assembly...
  • Page 70 Fig 6b. Rear View of the CAF G5 Biomass Furnace with Rear Illumination Showing Brick Box Assembly...
  • Page 71 Fig 7. Front Tube Seal Position...
  • Page 72 Fig 8. Tube End Seal Assembly Tightening Sequence Fig 9. Work Tube Front Support...
  • Page 73 Fig 10. Fitting the Door Arm Assembly Fig 10a. Adjusting the Door Arm Assembly...
  • Page 74 Fig 11a. Furnace Case and Controls...
  • Page 75 Fig 11b. Gas Inlet Pipe Fig 12. Positioning the Furnace...
  • Page 76 Fig 13a. Positioning Samples on the Sample Carrier Fig 13b. Loading Samples into the Mouth of the Work Tube...
  • Page 77 Fig 13c. Loading Samples into the Work Tube...
  • Page 78 Fig 16. File Folder...
  • Page 79 Fig 17. Door Arm Assembly Exploded View...
  • Page 80 Ash Fusibility Results Date of Test: 01 April 2015 Test Start Time: 15:03 Date of Analysis: 23rd April 2015 Time of Analysis: 16:01 Test Name: Carbolite Gero Biomass Test Reference: ESG Ash Wood Identity Description test piece 1 1209 1230 1242 1251 test piece 2...
  • Page 81 Date of Test: 01 April 2015 Test Start Time: 15:03 Date of Analysis: 23 April 2015 Time of Analysis: 16:01 Test Name: Carbolite Gero Biomass Test Reference: Ash Wood Identity Description test piece 1 1209 1230 1242 1251...
  • Page 82 Fig 18. Report Sheet Page 2 Side View Plan View Fig 19. Formed Wire Sample...
  • Page 83 Fig 20. Sample Carrier, Sample Tiles and Sample Positions...
  • Page 84 Fig 21a. Coal and Coke Test Piece Mould Fig 21b. Biomass Test Piece Mould and Hand Press...
  • Page 85 Fig 22. Sample Loading Tool Fig 23. Camera Ethernet Connection...
  • Page 86 Fig 24. LED Driver Connection...
  • Page 87 Notes Service Record Engineer Name Date Record of Work...
  • Page 88 The products covered in this manual are only a small part of the wide range of ovens, chamber furnaces and tube furnaces manufactured by Carbolite Gero for laboratory and industrial use. For further details of our standard or custom built products please contact us at the address below, or ask your nearest stockist.

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