FURNACE & ASSAY 168 Operation & Maintenance Manual
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FURNACE & ASSAY 168 Operation & Maintenance Manual

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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
FURNACE & ASSAY
——
168 Place Cupellation Furnace
Operation & Maintenance Manual
E-mail: info@fandasupplies.com
Website: fandasupplies.com/
—––
S U P P L I E S
Tel: +61 8 9399 9299
Email: info@fandasupplies.com
1

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Summary of Contents for FURNACE & ASSAY 168

  • Page 1 Fuel Source: FURNACE & ASSAY —— —–– S U P P L I E S Manufacturing 168 Place Cupellation Furnace Date Operation & Maintenance Manual Electrical: 220-240V Working Area ● 650mm Deep ● 650mm Wide ● 220mm High Combustion Chamber Volume: 0.19...

  • Page 2: Manual Index

    Manual Index System Overview Safety Devices 5 - 6 Spare Parts List 7 - 8 Installation Procedure Warm-up/ Curing Procedure Operating Instructions Weekly Check Sheet Commissioning procedure 13 - 20 Gas Submission Operational Flowchart Troubleshooting Guide 23 - 28 Electrical Schematic Fuel Schematic Maintenance 31 - 44...
  • Page 3 Construction 1170 mm 875 mm  Base construction uses high-quality 100 x 100 RHS.  Furnace body construction is durable 5mm laser-cut plate  High quality refractory brick and insulation  VENT TUBE Bolt holes in base plates of all 4 legs for 2135 mm individual adjustment on uneven surfaces BURNER...
  • Page 4 168 Place Cupellation Furnace 240V-FAS-180 System Overview: It can This furnace has a fan forced single burner system, with an automatic ignition system. 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.

  • Page 5: Safety Devices

    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.

  • Page 6: Recommended Spare Parts

    Parts List for FAS-180-INLPG2 168 Place Cupellation Furnace, 240v Inspirated LPG Recommended 12 Months Consumables FAS Part# FAS Description FAS-206 Muffle #8 to suit 168PCF FAS-212 Vent Slotted #5 to suit E100PCF & 100PCF & 168PCF FAS-304 Floor Tile 650x650x25mm to suit 168PCF...
  • Page 7 Parts List for FAS-180-INLPG2 168 Place Cupellation Furnace, 240v Inspirated LPG Associated Spare Parts FAS Part# FAS Description 168PCF New Body and Bricks FAS-180-SHL FAS-180-BRNINLPG 168PCF Burner Equipment lpg Inspirated 240v 168PCF Door and Hinge with Pneumatics FAS-180-DHP 168PCF Back Extraction Piece...

  • Page 8: Installation Procedure

    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.
  • Page 9 CURING PROCEDURE 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.
  • Page 10 Furnace warm up procedure 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.

  • Page 11: Shutdown Procedure

    Operating Instructions 1-Turn on Fuel Supply 2-Turn on Main Switch. 3-Set to required temperature. (See warm up procedure for instructions on starting a cold furnace) 4-Turn on Burner Switch (Burners will take approximately 70 seconds to fire) 5- Set High \ Low Switch TO High. Burners will modulate between on and off to maintain the set temperature.
  • Page 12 Gas Submission FAS-180-INSLPG2 116 Place Cupellation Furnace, 240v Inspirated LPG Fuel: LPG Fuel Usage: MAX. 280MJ/HR NOMINAL 200MJ/HR Operating Pressure: 140Kpa Max inlet: 140Kpa Min Inlet: 2.5 Kpa Combustion Chamber Volume: 0.19M3 Swept Volume: 0.2 M3 Air Supply for door operation: Minimum 3 cfm @ 350 Kpa Electrical: 220-240 volt 50 Hz 4 amps 1 phase Door Operation: Pneumatic Ram ABN: 68 606 541 468...

  • Page 13: Troubleshooting

    Trouble Shooting By knowing the start up cycle of the furnace, you can isolate any problems that may arise. Also by setting up an operating register (weekly check sheet) you can monitor the operation of your furnace. Keeping these records will assist in isolating any problems you are experiencing with the furnace.
  • Page 14 Operational Troubleshooting Flow Chart Power On Pre Purge No power:  Not plugged in  Surge Protector Faulty Alarm light on:  Reset Burner Control Pre Purge Ignition Transformer Engages No Ignition:  Faulty spark plug Clean or replace  Faulty Boot or Connector Repair ...
  • Page 15 Operational Troubleshooting Flow Chart Set desired Temperature on temperature controller and set to high fire. The Temperature Controller regulates High/Low flame. Flame is Going out when switches to high fire  Gas pressure set too high Lower gas pressure (140kpa) ...

  • Page 16: Weekly Check List

    Weekly Check List FURNACE TYPE: FUEL: FURNACE NUMBER: Pressure Uv Cell readings Inspections Value Clean Burner Date Low Gas Hi Gas Flues Gear Door Blanket Mil amps Deterioratin 5Kpa 140Kpa Clear Clean Example ABN: 68 606 541 468 Email: info@fandasupplies.com...

  • Page 17: Commissioning Procedure

    Commissioning Procedure 168 Place Cupellation Furnace, 240v INSP Electrical Box Layout Burner Control & UV Amplifier Toggle Amp meter Under burner controller Alarm Button switches Surge Alarm Ignition Temperature light Controller Transformers Protector ABN: 68 606 541 468 Email: info@fandasupplies.com...
  • Page 18 168 Place cupellation Furnace, 240v Inspirated LPG Burner Equipment overview Burner Ignition boot Pressure gauge Ignition Gas Train Gas Inlet UV Cell lead ABN: 68 606 541 468 Email: info@fandasupplies.com...
  • Page 19 Burner Equipment close up Pressure Gauge High fire Burner Ignition Rod LPG Jet Low Fire Uv Cell LPG Gas Low Fire Adjustment Orifice Filter ABN: 68 606 541 468 Email: info@fandasupplies.com...
  • Page 20 Commissioning Procedure Turn gas on slowly Check for leaks (use soapy water) Check supply pressure (140KPA) Open Furnace Door Turn power on and make sure furnace is set to Low fire. (Toggle switches located on front of electrical box) Amp Meter High/Low Switch On/Off Switch Alarm Light...
  • Page 21 Commissioning Procedure Check all gas Ball Valves are in the open position Push burner control button if alarm light is on Wait for Burner control to go through its stages Spark plug (ignition rod) clicks over 10. Pilot Solenoid valve on burner opens , once established low fire opens. 11.

  • Page 22: Electrical Schematic

    Electrical Schematic SURGE PROTECTOR ON - OFF 220-240 VOLT 50-60 HZ SUPPLY HIGH FIRE VALVES Contoller No.1 HIGH - LOW IGNITION TRANSFORMER LOW FIRE VALVES BLACK BLUE BROWN BLACK UV Meter BLUE Flame Failure UV Amplifier AGQ FLAME SENSOR Alarm Light Therminal blocks in electical Box BURNER CONTROL SIEMANS LGB41...
  • Page 23 Fuel Schematic ABN: 68 606 541 468 Email: info@fandasupplies.com...

  • Page 24: Maintenance

    Maintenance Regular maintenance is required to make sure furnace is running correctly. It is important to keep the flue areas clean and regularly change floor tile. A good clean combustion chamber will allow the furnace to run efficiently. Check that muffle chamber has no cracks and if so then seal with some Refractory cement.
  • Page 25 If blocked Pb will stick to the walls of the chamber reducing the life of the Muffle. This also increases the density of the chamber. The furnace will then need to use additional power to maintain temperature of the chamber and will have longer cupelling times. Your muffle chamber will also last longer if you keep everything clean.
  • Page 26 Keep the floor areas around the furnace clean and free of dirt, as it will layer onto the transformer and control equipment. This chokes the equipment, making it run hotter and it may over heat. Remember a Muffle is a consumable item in a furnace. You must change a muffle out at least 2 –...
  • Page 27 You will also need to ream out the inside of the Flues. Make sure it is completely clear from the rim of the flu at the top to the bottom. The best way to tell is shine a torch down each flue to make sure it is clear. Regularly change / clean the floor tiles along with the bone ash for collection of spills.
  • Page 28 Installing Muffle Chamber When replacing a muffle remove old muffle and vent. Ensure that all debris is re- moved. Before installing new muffle you must make sure that the back wall, back ledge and front ledge are clean and smooth. Also while the Muffle is out it is a good time to clean out any build up in the Burner Port.
  • Page 29 Installation of muffle chamber remove thermocouple first remove rear extraction if fitted Slide muffle chamber into position check that muffle is positioned correctly slide in vent tube from rear ABN: 68 606 541 468 Email: info@fandasupplies.com...
  • Page 30 Using strips of ceramic fibre seal around front of chamber and rear vent Seal front and back of muffle and vent with thin layer of refractory cement. This will help to protect the ceramic fibre during operation. Note: if seal has been damaged then replace as soon as possible. Place some magnisite powder on floor (about 15-20mm) thick then install floor tile Re-install Thermocouple and Lead extractor.
  • Page 31 Installing Floor Tiles This method can apply to all fusion and cupel furnaces . Reason: To stop the tile from sticking to the furnace or muffle floor so it can be easily removed when needs to be replaced. If tile does not crack it is also possible to reuse the tile on the opposite side. Each time you replace a tile you must scrape out the old mabor powder (or bone ash) and replace with new.
  • Page 32 Step 4 Sprinkle a little powder on top of tiles ready for the first pour. If a spillage occurs then scrape out to the front of the furnace and sprinkle powder back on the floor. By following this practice your tiles will last longer and the furnace will stay clean. Summary A good clean combustion chamber will allow the furnace to run efficiently.
  • Page 33 Door Re-packing First, second and third layer Cut 3 x 25mm Kaowool (or 1 x 50mm & 1 x 25mm kaowool) to 740mm long x 600mm (roll width) wide. Cut out slots for the door hinges to sit into. ABN: 68 606 541 468 Email: info@fandasupplies.com...
  • Page 34 Fourth Layer Cut 25mm Kaowool to 710mm long x 540mm. Fit Kaowool to inside lip. Final layer Cut 25mm Kaowool to 780mm x 610mm (roll width) and place so that a 20mm overhang of kaowool is present on the edges as shown. ABN: 68 606 541 468 Email: info@fandasupplies.com...
  • Page 35 Using a guide like a screw driver, push up through the existing anchor holes in the door’s body, keeping the guide straight until it comes through top layer of kaowool. Once guide is through wiggle around to make a slightly bigger hole. Place a screwdriver through the hole (kaowool side up) then the cutter over the screwdriver (a piece of pipe with a circumference of about 25mm by 100mm long with a mark about 50mm up).
  • Page 36 6.Screw anchors into holes cut out by cutter in kaowool until the bolts come through the pre drilled anchor holes in the door’s body. Once bolt is through secure with a wing nut. Once all anchors have been installed, use a straight edged, flat piece of wood and a sharp knife to cut off overhanging kaowool.
  • Page 37 Replacing thermocouple Parts PART NUMBERS FOR COMPONENTS: Thermocouple head- FAS –609: Inner Sheath FAS-409 Outer Sheath FAS-410: Thermocouple Type K - FAS –605, Thermocouple sheath adaptor FAS-610 Once steel sheath adaptor has been removed from TC head replace inner and outer sheath . Insert thermocouple into sheath and guide TC ends into TC Head connections.

  • Page 38: Contact Details

    Contact Details FURNACE & ASSAY —— —–– S U P P L I E S 54 Owen road, Kelmscott, Western Australia, Australia Phone +61 8 9399 9299 +61 8 9399 9288 Email Info@fandasupplies.com www.fandasupplies.com ABN: 68 606 541 468 Email: info@fandasupplies.com...

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