FURNACE & ASSAY 168, Operation & Maintenance Manual

Page 1: ...Operation Maintenance Manual Tel 61 8 9399 9299 E mail info fandasupplies com Website fandasupplies com FURNACE ASSAY S U P P L I E S 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 ...

Page 2: ... Spare Parts List 7 8 Installation Procedure 9 Warm up Curing Procedure 10 Operating Instructions 11 Weekly Check Sheet 12 Commissioning procedure 13 20 Gas Submission 21 Operational Flowchart 22 Fuel Schematic 30 Maintenance 31 44 Contact Details 45 Troubleshooting Guide 23 28 Electrical Schematic 29 ...

Page 3: ... 4 legs for individual adjustment on uneven surfaces Pneumatic door controls with hand valve optional foot pedal available Port viewing window installed in door Vent Tube height 1115mm Construction ISPM 15 Heat treated export crates Length 1690mm Width 1690mm Height 2230mm Weight 1550KG 1400 mm INSPECTION HOLE 1830mm 1170 mm ELECTRICAL BOX 250 mm 875 mm 2135 mm 1170 mm 930 mm 1125 mm VENT TUBE BUR...

Page 4: ... propane to suit varying site requirements with just a few simple adjustments performed on site involving a minimum of downtime and associated costs 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 This controller is simple to operate and has a 2 level display PV and SV th...

Page 5: ...flame from another source 2 During second purge cycle and after pilot ignition it will do a check 5 seconds after ignition If no flame detected then controller will lock out Also if UV flame detector is faulty controller will lock out 3 A UV amp meter is fitted to the front of the electrical box to monitor the performance of the UV flame detector Good flame detection will indicate between 0 5 0 8 ...

Page 6: ... Mortar 2 KG 2 FAS Part FAS Description Qty FAS 180 DOOR 168PCF Door factory lined No Hinges or pins 1 FAS 411 Porcelain 2 way Element Connectors 1 FAS 509 Door Switch OMRON D4D 1121N 1 FAS 608 Thermocouple Wire 4 FAS 612 U V Ammeter 0 1Ma 48x48mm 1 FAS 654 Air Hose Double Insulated 4 FAS 657 Festo Foot Pedal 1 FAS 680 LPG Gas Filter 1 FAS 802 Isowool Blanket Kaowool 128kg x 50mm 2 FAS Part FAS De...

Page 7: ...ics FAS 180 EXT 168PCF Back Extraction Piece FAS 180 BKT 168PCF Refractory Reline Kit no muffle vent tile FAS 628 Toggle Switch on off high low FAS 643 LPG Gas Train FAS 644 Two Stage Regulator FAS 647 Gas Gauge FAS 655 Pneumatic Cylinder FAS 656 Pneumatic Cylinder set FAS 657A Festo 3 way hand valve FAS 659 Pneumatic Regulator FAS 670 5AMP Control Fuse FAS 674 Plug in 6mm Air Fitting FAS 675 LPG ...

Page 8: ...pply This must be carried out by a qualified technical person Refer to furnace gas requirements to size inlet line correctly For door operation air is required to run the pneumatics Connect air supply to the filter on the furnace Electrical box is fitted with 3 core flex If power socket is available connect correct type plug and turn on If not then an electrician is to either install correct socke...

Page 9: ...ndicated by moisture seeping through refractory If you see this then maintain temperature until moisture clears After around 30 hours you will notice that the furnace temperature is running around 650degC You can now turn furnace to high fire and set the controller 100degC above the real temperature Let the furnace modulate on this temperature for an additional 1hour Keep a close eye on any cracks...

Page 10: ...point to 500 C 930 F and leave for minimum of one hour 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 2 Shut furnace door and start on low fire run until reaches 500 C 930 F 3 Hold 500 C 390 F for minimum of 1 hour 4 Increa...

Page 11: ...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 Shutdown Procedure 1 Turn off Burner Switch 2 Isolate Gas Supply ...

Page 12: ...e 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 ...

Page 13: ...auge or gas filter B High Low Pressures are Increasing This will tell you that the burner nozzle or gas filter needs cleaning C The UV Reading on the Amp meters are decreasing You may need to check the alignment of the UV Cells there may be a build up of dust on the globe of the UV cells or the cell itself may be wearing out Other checks will also assist in the efficient operation of the Furnace C...

Page 14: ...place Ignition Transformer Engages 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 Blocked Gas Filter Remove and Clean Blocked Inspirator jet Remove and Clean low fire Solenoid opens UV Flame detection Flame ...

Page 15: ...ill cold Let furnace hear up on low fire for half hour If not going to High Flame Temperature controller set too low Check that Set Point is correct required temperature and is above actual reading SEER Error shown on Temperature controller Check Thermocouple Replace Thermocouple wire connections High Fire Solenoid not opening Check for blockages replace solenoid Not Enough Gas pressure Check Gas ...

Page 16: ...fandasupplies com 16 Weekly Check List FURNACE TYPE FUEL FURNACE NUMBER Pressure readings Inspections Uv Cell Value Date Low Gas Hi Gas Flues Clean Burner Gear Door Blanket Mil amps Example 5Kpa 140Kpa Clear Clean Deterioratin g 1ma ...

Page 17: ...Commissioning Procedure 168 Place Cupellation Furnace 240v INSP LPG Electrical Box Layout Burner Control Alarm Button Amp meter Toggle switches Temperature Controller Ignition Transformers Surge Protector UV Amplifier Under burner controller Alarm light ...

Page 18: ...BN 68 606 541 468 Email info fandasupplies com 18 Burner UV Cell Ignition boot Ignition lead Gas Inlet Pressure gauge Gas Train 168 Place cupellation Furnace 240v Inspirated LPG Burner Equipment overview ...

Page 19: ...ABN 68 606 541 468 Email info fandasupplies com 19 Burner Equipment close up Burner LPG Jet LPG Gas Filter Low Fire High fire Low Fire Orifice Pressure Gauge Uv Cell Air Adjustment Ignition Rod ...

Page 20: ... gas on slowly 2 Check for leaks use soapy water 3 Check supply pressure 140KPA 4 Open Furnace Door 5 Turn power on and make sure furnace is set to Low fire Toggle switches located on front of electrical box Amp Meter On Off Switch High Low Switch Temperature Controller Alarm Light ...

Page 21: ...et Furnace warm up slightly If the furnace is cold it may have issues switching to high fire 12 Put temp above set point 13 Make sure it swaps to high fire on its own 14 Check for gas leaks on Inspirator 15 Check amp meter should be on 0 4m amp or better 16 Furnace should swap to low fire when it hits set temperature 17 Check U V cells are working correctly Put hand over UV cell holder Flame shoul...

Page 22: ... PROTECTOR ON OFF N 7 4 9 6 12 5 2 1 3 HIGH LOW IGNITION TRANSFORMER Contoller No 1 UV Amplifier AGQ TEMPERATURE CONTROL BURNER CONTROL FLAME SENSOR SIEMANS LGB41 SIEMANS QRA2 ELECTRICAL SCHEMATIC Singel Burner Assay Furnace INSP LPG OMRON E5CC RX2ASM 800 Single Phase 240 volt 50 60 hz Therminal blocks in electical Box Therminals in contollers GAS VALVES STAIGER MA232 INGITION TRANSFORMER BRAHMA T...

Page 23: ...kPa Minimum for high fire MANUAL ISOLATION VALVE SUPPLY PRESSURE STAIGER 1 4 MA 232 007 P 240V HIGH FIRE VALVE LOW FIRE VALVE LOW FIRE VALVE PRESSURE GUAGE H P Size 51 Size 66 STAIGER 1 4 MA 232 007 P 240V STAIGER 1 4 MA 232 007 P 240V STAIGER 1 4 MA 232 007 P 240V 40MM LONG PATTERN I N SPIRATOR FR NOZZLE BURNER TEST POINT TEST POINT ...

Page 24: ...rnace to run efficiently Check that muffle chamber has no cracks and if so then seal with some Refractory cement The life of the chamber depends on several factors A Keeping the rear vent clean If blocked then Pb will stick to the walls of the chamber thus increasing the density of the chamber The furnace then needs to use additional gas to maintain temperature of the chamber and will have longer ...

Page 25: ...e of the chamber and will have longer cupelling times Your muffle chamber will also last longer if you keep everything clean To do this you will need a vent cleaning tool or a piece of metal or jimmy bar to ream the vent out Make sure the vent has been cleaned all the way through not just at the front You may need to shine a torch into the vent to see your progress Regularly change or clean the fl...

Page 26: ...over heat Remember a Muffle is a consumable item in a furnace You must change a muffle out at least 2 3 times a year if looked after correctly If little or no maintenance is done on a furnace the chamber can last as little as 1 month If the muffle is left unchanged the brick work of the furnace will be eaten away This will severely Spills clogging the burner port due to poor maintenance Failing to...

Page 27: ...ake its way into the blower motor or Inspirator and reduce air flow Keep all the burner equipment clean and free of dirt so that the equipment does not over heat Schedule regular pressure readings to develop a history of furnace operation It is a good idea to dedicate a log book for this purpose Important readings to monitor are the air pressure Low fire gas pressure and high fire pressure and UV ...

Page 28: ...stalling 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 Note If the back wall back ledge and front ledge are not cleaned properly the muffle will not sit correctly meaning the muffle will not work correctly and will not last as long ...

Page 29: ...il info fandasupplies com 29 Installation of muffle chamber remove thermocouple first remove rear extraction if fitted Slide muffle chamber into position slide in vent tube from rear check that muffle is positioned correctly ...

Page 30: ... 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: ... 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 Mabor powder is used to soak up any spills you have during fusion or cupellation processes The following is a tile install for a Cupellation furnace Step 1 Shovel Mabor powder or similar product onto the floor Step 2 Using a flat edge flatten off so that powder is about 1 2 ...

Page 32: ...ficiently To do this and to extend the life of your muffle and your furnace regularly check that muffle chamber has no cracks if so then seal with some refractory cement Make sure a floor tile is always installed with about 15mm of Bone Ash underneath it Keep the back Vent clean and clear and change it when needed Regularly scrape and clean the floor tile If there is build up on one side flip the ...

Page 33: ...468 Email info fandasupplies com 33 First second and third layer 1 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 Door Re packing ...

Page 34: ...dasupplies com 34 Fourth Layer Final layer 2 Cut 25mm Kaowool to 710mm long x 540mm Fit Kaowool to inside lip 3 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 ...

Page 35: ... is through wiggle around to make a slightly bigger hole 5 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 Keeping the cutter at 90 deg cut down to marked line in cutter 50mm and pull out Knock out kaowool stuck in cutter Once cutter is pulled out there is a hole big...

Page 36: ... off overhanging kaowool Make sure the straight edge is lined up flush with the outer lip of furnace door top and bottom Push straight edge down firmly and cut off excess kaowool 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 ...

Page 37: ...m TC head replace inner and outer sheath Insert thermocouple into sheath and guide TC ends into TC Head connections Take note which side red is marked as this is the neg connection for controller Wind in steel collar and adjust sheath for a good fit Make sure that TC is inside sheath all the way to bottom Tighten up connection screws and then trim off excess wire Once completed check that locking ...

Page 38: ...mail info fandasupplies com 38 Contact Details FURNACE ASSAY S U P P L I E S 54 Owen road Kelmscott Western Australia Australia Phone 61 8 9399 9299 Fax 61 8 9399 9288 Email Info fandasupplies com Web www fandasupplies com ...