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Fuel Source:
LPG
Electrical:
220-240V
Working Area
● 560mm Deep
● 480mm Wide
● 190mm High
Combustion
Chamber
Volume:
0.17
Swept Volume:
0.18
E-mail: Info@fandasupplies.com
FURNACE & ASSAY
——
100 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
ABN: 68 606 541 468
Website: www.fandasupplies.com
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Table of Contents
Related Manuals for FURNACE & ASSAY LPG
Summary of Contents for FURNACE & ASSAY LPG
- Page 1 FURNACE & ASSAY Fuel Source: —— —–– S U P P L I E S 100 Place Cupellation Furnace Electrical: Operation & Maintenance Manual 220-240V Working Area ● 560mm Deep ● 480mm Wide ● 190mm High Combustion Chamber Volume: 0.17 Swept Volume: 0.18 Tel: +61 8 9399 9299...
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Page 2: Manual Index
Manual Index System Overview Safety Devices Spare Parts List Installation Procedure Warm-up Procedure 9-10 Operating Instructions Operational Flowchart Gas Submission Weekly Check Sheet Troubleshooting Guide 15-17 Commissioning procedure 18-23 Electrical Schematic Fuel Schematic Maintenance 26-38 Contact E-mail: Info@fandasupplies.com Website: www.fandasupplies.com... - Page 3 Construction 1030 mm 860 mm Base construction uses high-quality 75 x 75 RHS. Furnace body construction is durable 2mm laser-cut plate High quality refractory brick and insulation Bolt holes in base plates of all 4 legs for individual adjustment on uneven surfaces 2070 mm ...
- Page 4 100 Place Cupellation Furnace LPG - FAS-170-INLPG System Overview: This furnace has a Long Pattern Inspirator burner system, with an automatic Ignition System. 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.
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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-170-INLPG2 100 Place Cupellation Furnace, 240v Inspirated LPG Recommended 12 Months Consumables FAS Part# FAS Description FAS-202 Muffle #5 to suit E100PCF & 100PCF FAS-212 Vent Slotted #5 to suit E100PCF & 100PCF & 168PCF FAS-302 Floor Tile 560x480x25mm to suit E100PCF & 100PCF & E20PFF... - Page 7 Parts List for FAS-170-INLPG2 100 Place Cupellation Furnace, 240v Inspirated LPG Associated Spare Parts FAS Part# FAS Description 100PCF New Body and Bricks FAS-170-SHL FAS-170-BRNINLPG 100PCF Burner Equipment LPG Inspirated 110/240v 100PCF Door and Hinge with Pneumatics FAS-170-DHP 100PCF Back Extraction Piece...
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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 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.
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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 and set to Low Fire (Burners will take approximately 70 seconds to fire) 6- Set HIGH \ LOW SWITCH To HIGH. -
Page 12: Operational Flow Chart
Pre purge cycle Burner (63 sec) Ignition Transformer engages Pilot solenoid opens Flame established After 5 seconds UV flame detection Low fire valve opens if additional Temperature required high fire Solenoid opens on burner This furnace is run on LPG Only E-mail: Info@fandasupplies.com Website: www.fandasupplies.com... - Page 13 Gas Submission FAS-170-INSLPG2 100 Place Cupellation Furnace, 240v Inspirated LPG Fuel: LPG Fuel Usage: MAX. 270MJ/HR NOMINAL 200MJ/HR Operating Pressure: 140Kpa Pilot Operating Pressure 2.5 - 2.75 kpa Producing 12mj hr Max inlet: 140Kpa Min Inlet: 2.5 Kpa Combustion Chamber Volume: 0.17M3 Swept Volume: 0.18 M3...
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Page 14: 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 E-mail: Info@fandasupplies.com Website: www.fandasupplies.com... -
Page 15: 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 16 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 17 Operational Troubleshooting Flow Chart UV flame detection low fire Solenoid opens No Flame: Faulty/Blocked Solenoid Replace/ Clean Gas Bottle Empty Check at test point for flow. Change/fill bottle Low gas pressure Check supply pressure at test point. Must be 140KPA. If not then may be faulty Regulator.
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Page 18: Commissioning Procedure
Commissioning Procedure Electrical Box Layout Burner Control Burner Control Amp meter Alarm Button Toggle Temperature Surge Ignition switches Controller Transformer Protector E-mail: Info@fandasupplies.com Website: www.fandasupplies.com... - Page 19 Commissioning Procedure 100 Place cupellation Furnace, 240v Inspirated LPG Burner Equipment overview Ignition boot Inspirator (Spark plug located Burner UV Cell under ignition boot) Ignition Pressure Gas Inlet Gas Train Lead Gauge E-mail: Info@fandasupplies.com Website: www.fandasupplies.com...
- Page 20 Commissioning Procedure Burner Equipment close up Pressure Gauge High fire Burner Pilot Burner LPG Jet Low Fire Pilot LPG Gas Low Fire Pilot 2 stage regulator Orifice solenoid Filter E-mail: Info@fandasupplies.com Website: www.fandasupplies.com...
- Page 21 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 22 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 23 Terminal blocks in electical Box BURNER CONTROL SIEMENS LFL1.635 240v TEMPERATURE CONTROL OMRON E5CC-RX2ASN-800 Terminals in contollers FLAME SENSOR SIEMANS QRA2 IGNITION TRANSFORMER BRAHMA TC1LVCA ELECTRICAL SCHEMATIC Single Burner Assay Furnace LPG Single Phase 240 volt, 50-60 hz E-mail: Info@fandasupplies.com Website: www.fandasupplies.com...
- Page 24 Fuel Schematic E-mail: Info@fandasupplies.com Website: www.fandasupplies.com...
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Page 25: 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 26 Maintenance 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 27 Maintenance 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 28 Maintenance 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 29 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 30 Installing Muffle Chamber 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 E-mail: Info@fandasupplies.com Website: www.fandasupplies.com...
- Page 31 Installing Muffle Chamber 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.
- Page 32 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 AB powder (or bone ash) and replace with new.
- Page 33 Installing Floor Tiles 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 34 100 PCF 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. E-mail: Info@fandasupplies.com Website: www.fandasupplies.com...
- Page 35 100 PCF Door Re-packing 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. E-mail: Info@fandasupplies.com Website: www.fandasupplies.com...
- Page 36 100 PCF Door Re-packing 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.
- Page 37 100 PCF Door Re-packing 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.
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Page 38: Contact Details
Contact Details FURNACE & ASSAY —— —–– S U P P L I E S 54 Owen Road Kelmscott, 6111 Western Australia, Australia Phone +61 8 9399 9299 +61 8 9399 9288 Email Info@fandasupplies.com www.fandasupplies.com E-mail: Info@fandasupplies.com Website: www.fandasupplies.com...
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