Carbolite CAF DIGITAL IMAGING, Installation, Operating, & Maintenance Instructions

Page 1: ...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 ...

Page 2: ...st Vent Connections 11 3 8 Gas Connection 12 3 9 Camera Mounting Connections Standard Lens 13 3 10 Camera Mounting Connections Zoom Lens 13 3 11 Computer Connections 14 4 0 Operating Instructions 15 4 1 Furnace Start Up 15 4 2 Eurotherm Controller 15 4 3 Computer Start Up 15 4 4 Loading Samples Into The Work Tube 16 4 5 Running A Coal Ash Fusion CAF Test 17 5 0 Maintenance and Calibration 22 5 1 G...

Page 3: ...osition Fig 5m Adjusting the position of the zoom lens camera assembly Fig 5n Releasing lens clamp screw to rotate camera lens assembly Fig 5p Storing the zoom lens carrier Fig 6 Rear view of furnace showing brick box assembly Fig 7 Front tube seal position Fig 8 Tube end seal assembly tightening sequence Fig 9 Work tube front support Fig 10 Fitting the door arm assembly Fig 10a Adjusting the door...

Page 4: ...rate the furnace with the door or window O ring seals removed or exposure to carbon monoxide may result See section 1 2 Carbon Monoxide Warning A regular work tube pressure test must be conducted to ensure integrity of the work tube and O ring seals See section 3 3 5 Pressure testing of the Work Tube Assembly To avoid fire do not expose combustible materials to heat from the open door Do not use t...

Page 5: ...dioxide CO2 is a colourless odourless and tasteless gas that is an asphyxiant Rapid unconsciousness occurs at levels above 11 levels of 20 30 are immediately hazardous to life Information extracted from Croner Publications Ltd Substances Hazardous To Health To minimise the risks associated with CO2 it is most important that the furnace is installed and operated in accordance with this instruction ...

Page 6: ... highly corrosive Although these seals should not be exposed to elevated temperatures during normal use the following precautions should be taken Wear neoprene gloves while handling the seals Dispose according to local regulations Landfill is recommend Burning is not recommended except by an approved or licensed incineration agent 2 0 MODELS COVERED BY THIS MANUAL Two basic furnace options are ava...

Page 7: ...sket 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 1 off Flexible gas pipe 1 off Camera mounting bracket see fig 5a 1 off Standard lens and camera assembly see fig 5b 1 off Zoom lens assembly and lens clamp see fig 5g if supplied 1 off Zoom lens mounting bracket if supplied 6 off Panel hole blanking plugs 5 off Cable ties 1 o...

Page 8: ... tube insulating collar is in contact with the back face of the furnace heating chamber the work tube back support is located over the fixing posts and the thermocouple sheath is at the top above the vent tube fitting Secure the work tube back support in position using the fixings provided See fig 6 Note Take care not to stress the work tube The work tube back support must be parallel to the back ...

Page 9: ...out some clearance is required in the door mechanism consequently there is a small radial movement in the door slide arm when the door arm is pushed in towards the work tube Because of this radial movement it is possible for the door plug to contact the work tube front seal assembly if the door handle is lifted as the door arm is pushed inwards take care to avoid this happening Carefully swing the...

Page 10: ...l operation but incorrect installation or component failures due to misuse or wear and tear could give rise to a high presence of carbon monoxide To minimise risk to the user in the event of a high presence of carbon monoxide the furnace must be installed under a suitable forced air extraction hood An example is shown in fig 12 The extraction hood must be ducted out of the building and must be ope...

Page 11: ...igh is displayed Press Down q or Up p once to display the value of OP Hi it is good practice to write down the original value To alter the parameter use Down q or Up p Correct values for the OP Hi parameter with new elements are 200V 208V 220V 380V 230V 400V 240V 415V 79 74 65 60 55 See also the section on element ageing section 5 2 3 7 Exhaust Vent Connections Note Significant amounts of carbon m...

Page 12: ...ors suitable for connecting 6mm copper tube Separate CO and CO2 supplies If a mixer box is supplied then separate input connections of CO and CO2 may be made to the lower connections at the back of the box A pipe from the upper connection is to be taken to the CO CO2 inlet on the furnace The box is fitted with two flowmeters which may be adjusted to ensure that equal mixtures of CO and CO2 are sup...

Page 13: ...n option It shares the camera and lens heat shield assembly used with the standard lens See fig 5g showing the zoom lens assembly and lens clamp 3 10 1 Assembly of the zoom lens Disconnect the auto iris plug from the camera and unscrew the camera from the standard lens It is not necessary to remove the 5mm spacer ring from the rear of the standard lens see fig 5b Screw the camera onto the rear of ...

Page 14: ...the door using the swing bolts Mount the zoom lens and camera assembly to the door arm as described in section 3 10 2 When the furnace has reached 815 C there should be sufficient light in the work tube to allow an image to be captured With the test software in test grabber mode release the ball swivel locking screw and move the lens and camera assembly to display an image of the test sample in th...

Page 15: ...uminate and the cooling fans will run Operate the instrument 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 The start temperature is adjustable using the Up and Down buttons qp on the controller depending on your requirements For furnaces constructed to use CO CO2 and Air test gases with N2 Purge gas ...

Page 16: ...mples Into The Work Tube Use the sample carrier and sample tiles provided Arrange the samples as shown in fig 13a 4 4 1 When the furnace has reached its start temperature open the furnace door and swing it clear of the work tube to allow access Load the samples into the mouth of the work tube to warm up using the Sample Loading Tool provided See fig 13b Note Do not operate the furnace at temperatu...

Page 17: ...ges from the video camera mounted on the front of the furnace and store them in sequential order Each image displays the date time and temperature at which the image was recorded and an optional sample identification Images are stored under a file name of your choice which is entered at the start of the test and are played back for analysis of the test samples Analysis of the results is aided by t...

Page 18: ...e work tube will increase slightly in length causing the camera focus to alter it may be necessary to re focus the camera during the initial Coal Ash Fusion test run Once the camera is focused the focus ring can be locked in position using the locking screw unless the camera is disturbed it should not require re focusing during subsequent tests During the test the image displayed in the image wind...

Page 19: ...e program press the Run Hold button l on the front of the controller the word RUN will illuminate at the side of the button to signify that the program is running To stop the program hold down the Run Hold button l on the front of the controller until both the words RUN and HOLD at the side of the button are not illuminated 4 5 5 Gas Set Up The gas sequence is started automatically by the furnace ...

Page 20: ...perature FT Flow fluid temperature Using the scroll bar or Shift or Shift keys scroll through the stored images until the relevant deformation temperature for a sample is reached Each image has a black text box across the top showing the date time and temperature at which the image was captured and a test identification When the relevant image is displayed eg a sample showing the deformation simpl...

Page 21: ...imit an overtemperature controller automatically shuts down the furnace and the over temperature warning light illuminates on the furnace control panel See fig 11 The over temperature controller is mounted inside the furnace case and is not accessible to the operator Turning the instrument switch off and then on again once the furnace has cooled down will reset the overtemperature control Note The...

Page 22: ...nt or furnace life For standard values of the parameter as factory set with new elements see section 3 6 5 3 Checking And Replacing The Door O Ring Seal Wear neoprene gloves before handling the O ring seals see section 1 5 Regularly check the condition of the door O ring seal see fig 17 The O ring seal is a push fit into the groove in the door plug ring carefully remove it by hand do not use sharp...

Page 23: ...uum cleaner is the best method of removing the dust and grit Take care not to damage the back face of the door plug during cleaning Fit a new window glass gasket if this gasket is not fitted the window glass will break when the window retaining ring is tightened Fit the window O ring seal onto the window retaining ring Place the window glass in position in the door plug ring and re fit the window ...

Page 24: ...e digital image software to record at 1 C 2 F temperature intervals starting at 20 C 35 F below the expected Gold melt point and finishing at 1600 C 2912 F see section 4 5 5 4 4 Interpretation Of Results 5 4 4 1 Definitions The individual melt temperature of a wire sample is the temperature at which the wire sample having fallen over onto the sample tile melts and forms one or more stable balls of...

Page 25: ...e 1063 C from table mid melt temperature 1060 C calculated from test lower calibration temperature correction factor 1063 C 1060 C 3 5 4 5 2 Calculate the upper calibration temperature displayed Palladium melt temperature correction factor Calculate the Palladium mid melt temperature from the results obtained as given in section 5 4 4 Calculate the upper calibration temperature correction factor a...

Page 26: ... qp Press Scroll Q to display the Adj value this is the upper calibration value Subtract the lower calibration temperature correction factor from the Adj value then add the upper calibration temperature correction factor enter the new value using the Up and Down buttons qp For example if the lower calibration temperature correction factor is calculated as 3 the upper calibration temperature correc...

Page 27: ...Caf Digital Imaging MF36 page 27 6 0 CIRCUIT DIAGRAMS Please see the separate enclosure or request a diagram from Carbolite if one is not supplied ...

Page 28: ...oken or has a wiring fault There are no lights glowing on the controller à The SUPPLY light is ON à The controller may be faulty or not receiving a supply due to a faulty switch or a wiring fault à The SUPPLY light is OFF à Check the supply fuses and any fuses in the furnace control compartment B Furnace Overheats 1 The HEAT light goes OFF with the instrument switch à The controller shows a very h...

Page 29: ...g Services or Carbolite see the back page of this manual 8 1 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 g...

Page 30: ...TIONS 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 31: ...page 31 10 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 Work Tube Rear seal assembly Work tube back support Insulating collar ...

Page 32: ...ront tube seal assembly Fig 4 Door arm assembly Work tube ring Tube O ring Work tube gasket Work tube sealing ring Gas inlet fitting Socket screws Swing bolt Door plug ring Viewing window Door arm Handle Camera assembly fixing nuts Door plug ...

Page 33: ...a Camera mounting bracket Fig 5b Standard lens camera assembly Lens heat shield 49 55mmStep up ring 49mm UV filter 43 49mmStep up ring Camera Video socket Power socket Shutter switch Auto iris socket 5mm spacer ring Standard auto iris lens ...

Page 34: ...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 MF36 page 35 Fig 5e Mounting the standard lens camera assembly Fig 5f Standard lens camera assembly in position ...

Page 36: ...Zoom lens assembly lens clamp Fig 5h Fitting the camera to the zoom lens Screw Fixing Ball joint 70 210mm zoom lens Locking screw Lens clamp Lens mounting 20mm spacer tube Aperture ring Lens operating ring 52 49mm step ring Close up 1 filter ...

Page 37: ...Caf Digital Imaging MF36 page 37 Fig 5j Mounting the lens heat shield Fig 5k Mounting the zoom lens bracket assembly ...

Page 38: ...Caf Digital Imaging page 38 MF36 Fig 5l Zoom lens in position Fig 5m Adjusting the position of the zoom lens camera assembly ...

Page 39: ...Caf Digital Imaging MF36 page 39 Fig 5n Releasing lens clamp screw to rotate camera lens assembly Fig 5p Storing the zoom lens carrier ...

Page 40: ...40 MF36 Fig 6 Rear view of furnace showing brick box assembly Furnace case Brick box Work tube back support Thermocouple Vent tube fitting Thermocouple connecting terminals Rear support fixing posts Work tube insulating collar ...

Page 41: ...l position Fig 8 Tube end seal assembly tightening sequence Work tube Tube O ring compressed Work tube ring Socket screws Work tube gasket Work tube sealing ring See note Note Position O ring 7 mm from end of tube 1 3 5 4 6 Swing bolts Gas inlet fitting 2 ...

Page 42: ...ng page 42 MF36 Fig 9 Work tube front support Fig 10 Fitting the door arm assembly Work tube Tube guard Work tube front support Work tube front support adjustment Door slide shaft Door arm assembly Door in open position ...

Page 43: ...or arm assembly position Door slide shaft Door arm assembly Door arm Gas inlets and safety vent Gas outlet Test gas flow meters Instrument switch Heater lights Gas selector switch Eurotherm controller Test in progress warning light Standby mode indicator Camera and standard lens Door assembly Tube guard Swing bolts Rating label Overtemperature warning light Purge gas fail warning light Camera 12V ...

Page 44: ...page 44 MF36 Fig 12 Positioning the furnace Fig 13a Positioning samples on the sample carrier Bench Bench Wall Forced air extraction ducted out of the building Furnace front Furnace side Sample carrier Sample tile Ash cone ...

Page 45: ...Caf Digital Imaging MF36 page 45 Fig 13b Loading samples into the mouth of the work tube Fig 13c Loading samples into the work tube ...

Page 46: ...Caf Digital Imaging page 46 MF36 Fig 14 Set up options Fig 15a Enter file name and sample identifier ...

Page 47: ...ur file name log 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 window was used and the file saved A text file Contains all the images of a test Contains the images specified in the results window if the file is saved ...

Page 48: ...Caf Digital Imaging page 48 MF36 Fig 17 Door arm assembly exploded view Door plug ring Door plug Door O ring Door arm Door handle Window glass gasket Window O ring Window retaining ring Window glass ...

Page 49: ...6 30 Test reference USA TYPE F Sample Position 1 2 3 4 5 6 7 8 9 Identifier Au Au Pd Au Pd Au DT ST HT FT 1946 2632 2632 1940 Sample Position 10 11 12 13 14 15 Identifier Au Au Pd Au Pd Au DT ST HT FT 1942 2638 2634 1942 Temperature scale Fahrenheit DT Initial deformation temperature ST Sphere softening temperature HT Hemisphere temperature FT Flow fluid temperature Fig 18 Report sheet ...

Page 50: ...Caf Digital Imaging page 50 MF36 Fig 19 Formed wire sample Fig 20 Sample carrier sample tiles and sample positions 12mm Side view Plan view ...

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