Carbolite CAF DIGITAL IMAGING Assembly instructions

MF36-3.05
Installation, Operating &
Maintenance Instructions
CoalAshFusionTestFurnace
CAFDIGITALIMAGING
This manualis fortheguidance ofoperators oftheCAFDigitalfurnace andshould beread
before thefurnace is connected to theelectricityand gas supplies. Itcontains information
required forsafeand trouble-freefurnaceoperation. If, however, anyquestions remain
unanswered pleasecontactourservicedivision attheaddress attheend ofthis manual.

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CONTENTS.
page
1.0 SafetyInformation. 4
1.1 General.4
1.2 Carbon MonoxideWarning.4
1.3 Hydrogen And Carbon DioxideWarning.5
1.4 RefractoryFibrous Insulation Warning.5
1.5 Viton ‘O’ ringSeals Warning 6
2.0 Models CoveredByThis Manual.6
3.0 Installation Instructions. 7
3.1 UnpackingAnd Handling.7
3.2 PackingList.7
3.3 AssemblyOfTheFurnace.7
3.4 PositioningTheFurnace.10
3.5 ElectricalConnections. 10
3.6 VoltageLevel&PowerLimit Settings11
3.7 ExhaustVentConnections. 11
3.8 Gas Connection.12
3.9 Camera Mounting&Connections – StandardLens13
3.10 Camera Mounting&Connections – ZoomLens13
3.11 Computer Connections. 14
4.0 OperatingInstructions. 15
4.1 Furnace Start-Up.15
4.2 EurothermController15
4.3 Computer Start-Up. 15
4.4 LoadingSamplesInto TheWork Tube.16
4.5 RunningACoalAsh Fusion (CAF)Test.17
5.0 Maintenance and Calibration. 22
5.1 GeneralMaintenance.22
5.2 ElementAgeing.22
5.3 CheckingAnd Replacing TheDoor‘O’ RingSeal.22
5.4 CleaningTheViewingWindow.22
5.5 Furnace Calibration.23
6.0 Circuit Diagrams.27
7.0 Fault Analysis.28
8.0 After Sales Service.29
8.1 Recommended Spares And Consumables. 29
9.0 Specifications.30

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10.0 Appendix.31 -end
Fig1.Elementwiringand positions.
Fig2.Work tubeand back plug assembly.
Fig3.Fronttubesealassembly.
Fig4.Doorarmassembly.
Fig5a.Camera mountingbracket.
Fig5b.Standard lens &camera assembly.
Fig5c.Slidingthecameramountingbracketassemblyonto thedoorarm.
Fig5d.Securingthecamera mountingbracketassemblyto thedoorarm.
Fig5e.Mountingthestandard lens &camera assembly.
Fig5f.Standard lens &camera assemblyin position.
Fig5g.Zoomlens assembly&lens clamp.
Fig5h.Fittingthecamerato thezoomlens.
Fig5j.Mountingthelens heatshield.
Fig5k.Mountingthezoomlens &bracketassembly.
Fig5l.Zoomlens in position.
Fig5m.Adjustingtheposition ofthezoomlens &camera assembly.
Fig5n.Releasinglens clamp screwto rotatecamera&lens assembly.
Fig5p.Storingthezoomlens &carrier.
Fig6.Rear viewoffurnace showingbrick boxassembly.
Fig7.Fronttubesealposition.
Fig8.Tubeend sealassemblytighteningsequence.
Fig9.Work tubefrontsupport.
Fig10.Fittingthedoorarmassembly.
Fig10a.Adjustingthedoorarmassembly.
Fig11.Furnace caseand controls.
Fig12.Positioningthefurnace.
Fig13a.Positioningsamples on thesamplecarrier.
Fig13b.Loadingsamples into thework tube.
Fig13c.Loadingsamples into thework tube.
Fig14.Set-up options.
Fig15a.Filenameand sampleidentifier.
Fig16.Filedirectory.
Fig17.Doorarmassemblyexploded view.
Fig18.Reportsheet.
Fig19.Formed wiresample.
Fig20.Samplecarrier, sampletiles and samplepositions.
Fig21.Routeofcameravideo cables.

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1.0 SAFETY INFORMATION.
1.1 General.
Pleaseread all ofthis section first.
Pleaselook through thecompletemanualbefore connectingthefurnace.In
particular read through thesection on installation and observesection 3.6
aboutsupplyvoltage.
This furnacemustbeearthed (grounded).
Do notoperatethefurnaceattemperatures above815°C(1500°F)with thedooropen.
Thefurnace doormustnotbeleftopen longer than is necessaryto loadand unload samples from
thework tube.
Thefurnace doormustbeclosed and secured usingthetwo swingbolts before commencinga
CoalAsh Fusion test.Itis importantthattheswingbolts aretightened evenlyto createagas tight
sealbetween thedoorflanges. When acoalash fusion testis runningtheyellowTestIn Progress
lightilluminates on thecontrolpaneland thegreen StandbyModelightgoes out. Do notopen
thefurnace doorwhen theTestIn Progress lightis illuminated orexposure to carbon monoxide
mayresult. See section 1.2:Carbon MonoxideWarning.
DuringatestonlytheyellowTestIn Progress lightshould beilluminated. Ifanyoftheother
three lightsare illuminated (see fig11)then thereis afault: do notuse thefurnaceuntil thefault
is rectified.
DuringStandbyModeonlythegreen StandbyModelightshould beilluminated. Ifthere are no
lights illuminated, orifanyoftheother threelights are illuminated (seefig11)includingthe
green StandbyModelight, then there is afault: do notuse thefurnaceuntil thefault is rectified.
Do notoperatethefurnacewith thedoororwindow‘O’ ringseals removedorexposure to
carbon monoxidemayresult. See section 1.2:Carbon MonoxideWarning.
Aregular work tubepressure testmustbeconducted to ensure integrityofthework tubeand ‘O’
ringseals. See section 3.3.5:Pressure testingoftheWork TubeAssembly.
To avoid fire, do notexposecombustiblematerials to heatfromtheopen door.
Do notusethefurnace inthepresence ofinflammableorcombustiblechemicals:fire or
explosion mayresult. Do notplace thefurnaceon an inflammablesurface.
When operatingthefurnace wear appropriatesafetyclothing, includingeyeprotection and
gloves.
Isolatethefurnacefromtheelectricaland gas supplyand ensure thatthefurnace iscold before
changingelements, thermocouples orundertakingother routinemaintenance.
1.2 CarbonMonoxideWarning.
Operation oftheCAFDigitalfurnaceinvolves theuseofcarbon monoxide.
When testingin accordance with ASTM:D1857-87 (1994)Carbon
monoxideisintroduced as a‘reducing’atmospheregas and carbon
monoxideis produced as aby-productwhen testingin accordance with
BS1016:Part113:1995 ISO540:1995 and ASTM:D1857-87 (1994).
Carbon monoxide(CO) is acolourless, odourless, tasteless and inflammable
gaswhich is acutelytoxic. COis introduced into theblood streamthroughthelungs and binds
with thehaemoglobin preventingit fromcarrying oxygenaround thebody.This can result in
rapid damageto bodytissues dueto oxygen starvation. Since COis an accumulatingtoxin it can
bedangerous even whenpresentin quitelowconcentrations over longperiods oftime.
Individuals varyconsiderablyin theirreactions to concentrations oftoxicgases;table1 shows
thetypicaleffects ofcumulativeCOexposure.

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To minimisetherisks associated with COit is mostimportantthatthefurnace is installed and
operated in accordancewith this instruction manual.Ifthefurnace operatorexperiences anyof
theeffects listed above, thefurnace mustbeisolated fromthegasand electricitysupplies
immediatelyand expertadvice sought. Forsafetyguidelines seek thegas manufacturersadvice.
Table1. Carbon monoxidein air:
Information extracted fromGuidance NoteEH43 (1996)fromtheHealth and SafetyExecutive.
Partsper
million Effect.
50 Recommended Exposure Limit (8 hours time weighted average concentration).
200 Headache afterabout7 hours ifrestingorafter2 hoursexertion.
400 Headache with discomfortwith possibilityofcollapse after2 hoursatrestor45
minutesexertion.
1200 Palpitationsafter30 minutesatrestor10 minutesexertion.
2000 Unconsciousafter30 minutesatrestorup to 10 minutesexertion.
Forfurther information refer to:
-Guidance NoteEH43 (1996)fromtheHealth and SafetyExecutive. ISBN0 11 883597 1
-EH40/97 OccupationalExposureLimits 1997. ISBN0 7176 1315 1
1.3 Hydrogenand CarbonDioxideWarning.
Applicablefor furnaces constructed to useH2and CO2testgases withCO2
‘Purge’ gas.
H
2
can formexplosivegas mixtures, takeprecautions to avoid leakageof
H2. H2and CO2can reactto formCO. See section 1.2:Carbon Monoxide
Warning.
Carbon dioxide(CO2)isacolourless, odourless and tasteless gas thatis an
asphyxiant. Rapid unconsciousness occursatlevels above11%, levels of20 -30%are
immediatelyhazardous to life.
Information extracted fromCroner Publications Ltd. Substances Hazardous To Health.
To minimisetherisks associated with CO2it is mostimportantthatthefurnace is installed and
operated in accordancewith this instruction manual.Ifthefurnace operatorexperiences anyof
theeffects listed above, thefurnace mustbeisolated fromthegasand electricitysupplies
immediatelyand expertadvice sought. Forsafetyguidelines seek thegas
manufacturers advice.
1.4 RefractoryFibrous InsulationWarning.
This furnacecontains refractoryfibres in its thermalinsulation. These
materials maybein theformoffibre blanketorfelt, vacuumformed board
orshapes, mineralwoolslab orloosefill fibre.
Normaluseofthefurnacedoes notresult in anysignificantlevelof
airbornedustfromthesematerials, butmuch higher levels maybe
encountered duringmaintenance orrepair.
Whilstthere is no evidence ofanylongtermhealth hazards, westronglyrecommend thatsafety
precautions are taken whenever thematerialsare handled:
Exposureto dustfromfibrethathas beenused athightemperatures maycauserespiratory
disease.
Whenhandling fibrealways useanapproved mask, eye protection, gloves and long sleeved
clothing.
Avoid breaking up wastematerial. Disposeofwastefibreinsealed containers.
After handlingrinseexposed skinwith water beforewashing gentlywithsoap (notdetergent).
Washwork clothing separately.

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Before commencinganymajorrepairswerecommend reference to theEuropean CeramicFibre
IndustryAssociation Bulletin No. 11 and theUK Health and SafetyExecutiveGuidance Note
EH46. Wecan providefurther information on request, alternativelyourservice division can
quoteforanyrepairs to becarried outatyourpremises orours.
1.5 Viton‘O’ring Seals -Warning.
The‘O’ ringseals used in theCAFDigitalfurnacework tubeassemblyare
manufactured fromViton. Viton is combustibleand decomposition occurs
atelevated temperatures. Decomposition products includeHydrogen
Fluoride, fluorinated hydrocarbons, Carbon Monoxideand Carbonyl
Fluoride. Hydrogen Fluorideis highlycorrosive.
Although theseseals should notbeexposed to elevated temperatures
duringnormaluse, thefollowingprecautions should betaken:
· Wear neoprenegloves whilehandlingtheseals.
· Disposeaccordingto localregulations. Landfill is recommend. Burningisnotrecommended
exceptbyanapproved orlicensed incineration agent.
2.0 MODELS COVEREDBY THIS MANUAL.
Two basicfurnaceoptions are available, which differ onlyin thegases usedto createthe
‘oxidising’and ‘reducing’atmosphere and thecontrolofthosegases.
Option 1. CO/CO2‘reducing’gas and Air‘oxidising’gas with N2‘Purge’ gas.
Compatiblewith -ASTM D1857-87 Standard TestMethod forFusibilityofCoal
and CokeAsh.
Option 2. H
2
and CO2‘reducing’gases and CO2‘oxidising’gaswith CO2‘Purge’ gas.
Compatiblewith -BS1016 :Part113 :1995 ISO540 :1995 Methods for
Analysis and TestingofCoaland Coke. Part113. Determination ofAsh
Fusibility.

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3.0 INSTALLATION INSTRUCTIONS.
Thefurnace contains electricalparts and should bestored and used in indoorconditions as
follows:
temperature:5°C-40°C
relativehumidity:maximum80%up to 31°Cdecreasinglinearlyto50%at40°C
3.1 Unpacking &Handling.
This furnaceis heavy, takeappropriateprecautions when liftingormovingit and useasufficient
number ofpeople.
When unpackingormovingthefurnace always liftit byits base. Never liftitbyanyattachments
orprotrudingparts. Avoid applyingforce to internalcomponents such as thework tubeor
insulation.
3.2 Packing List.
Thepackagingshouldcontain thefollowingcomponents:
1 off Furnace assembly.
1 offWork tubeand back sealassembly, see fig2.
1 offWork tubefrontinsulatingcollar.
1 offWork tubegasket.
1 offFronttubesealassembly,see fig3.
1 offDoorarmassembly(withoutdoorplug), see fig4.
1 offDoorplug, see fig4.
1 offFlexiblegas pipe.
1 offCamera mountingbracket, see fig5a.
1 offStandard lens and cameraassembly, see fig5b.
1 offZoomlens assemblyand lens clamp, see fig5g. if supplied
1 offZoomlens mountingbracket.if supplied
6 offPanelholeblankingplugs.
5 offCableties.
1 offSampleCarrier.
100 offSampletiles.
1 offSampleloadingtool.
1 off‘Windowretainingring’spanner.
1 offConemould.
1 off 150mm length ofGold wire (1063°Cfusewire).
1 off150mm length ofPalladiumwire (1554°Cfusewire).
1 offCarbon Monoxidemonitor.
1 offRS 232 Interfacecable.
1 offCamera videoextension cable.
1 offComputer.
1 off Monitor.
1 offKeyboard.
1 offMouse.
1 offCarbolitesoftware protection dongle.
2 offComputer power cables.
1 offSet-Troubleshootingdiscs.
1 offSet-Computer operating instructions.
1 offInstallation, Operating&Maintenance Instructions fortheCAFTestFurnace.

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3.3. Assembly OfTheFurnace.
3.3.1. ElementFitting.
Ensure thatthefurnaceis isolated fromthemains supply. Removethebackpanelfromthe
furnaceunit.
Note:Theheatingelements are fitted atthefactoryto testthefurnacebutare removed fortransit.
Theseelements are extremelyfragile, and can bedamaged bycontamination:handlethemwith
care and keep themclean. Avoid touchingtheheatingpart.
Slideoneinsulatingcollarover eachelement, thengentlyslidetheelementinto its holein the
furnaceuntil thetip oftheelementlocates in thefrontinsulation, see fig1. Iftheelementdoes
notslidein freelycheck thatyou are holdingit in linewith thehole;it mayhelp to rotatethe
elementwhilstslidingit in. Onlylightfinger pressure should berequired. When theelementis in
position slidetheinsulatingcollarup againstthefurnace back insulation.
Usethebraids to link theelements and connectthemto theterminalposts as shown in fig1.
Makesure thebraids do nottouch anyother component, oreach other.
3.3.2. InstallingTheWorkTubeAnd RearSealAssembly
Ensure thatthefurnaceis isolated fromthemains supply, removethebackpaneland frontpanel
fromthefurnace unit.
Removethefixingnutand onewasherfromeachofthework tubeback supportfixingpillars on
theback ofthefurnace. See fig6.
Carefullyinserttheworktubeand back sealassemblyinto thefurnace fromtheback and slideit
through thefurnace until thework tubeis protrudingfromthefront. Thework tubeis correctly
positioned when:thework tubeinsulatingcollar isin contactwith thebackface ofthefurnace
heatingchamber, thework tubeback supportis located overthefixingposts and the
thermocouplesheath is atthetop abovetheventtubefitting. Secure thework tubeback support
in position usingthefixings provided. Seefig6.
Note:Takecarenotto stress thework tube. Thework tubeback supportmustbeparallelto the
back ofthefurnace heatingchamber and it should notbenecessaryto bendtheback support
fixingposts to locateit.
Connectthenumbered thermocoupleleads to thethermocoupleconnectingterminals mounted on
thework tubeback support. Ensure correctpolarity, thenegativelegs ofthethermocoupleare
marked blue, compensatingcablecolourcodingis:Negative=white. Positive=orange.
Makesure theelementbraids do nottouch anymetalcomponents oftheback tubesealassembly.
3.3.3. Fitting TheWorkTubeFrontSealAssembly.
Slidethework tubefrontinsulatingcollar over thefrontprotrudingpartofthework tubeuntil it
is in contactwith thefrontface oftheheatingchamber.
Dismantlethefronttubesealassemblybyremovingthesixsocketscrews. See fig3.
Slidethework tuberingover thefrontofthework tubewith theinternalchamfer facingtowards
thefront. See fig7.
Fit thetube‘O’ ringoverthefrontofthework tubeand position it uniformly7.0mm fromthe
frontedgeofthework tube. See fig7.
Fit thework tubegasketto thework tubesealingringasfig7, position thework tubesealingring
on thefrontend ofthework tubeand looselysecure to thework tuberingusingthesixsocket
screws provided.
Rotatethefrontsealassemblyso thattheswingbolts are positioned horizontallyand thegas inlet
fixingis atthelower leftsideofthework tube. Seefig8.

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Tighten thesixsocketscrews evenlyin thesequence as shown bynumbers1 to 6 in fig8. Ensure
thatthework tubesealingringis held firmlyagainsttheend ofthework tubeand is evenly
spaced fromthework tuberingaboutits circumference.
Fit thefurnace frontpanelin position and adjustthework tubefrontsupportbracketto support
theweightofthework tubeassembly. See fig9.
Note: Do notstress thework tube. With thework tubefrontsupportcorrectlyadjusted there
should beaslightgaparound thecircumference ofthetubewithin theaperture ofthefurnace
heatingchamber. This can betested forbyliftingthework tubeupwards fromthesupport
bracket, onlyaslightgapshould beobserved between thework tubeand thesupportbracket
when thework tubeis lifted as far as possible.
3.3.4. Fitting And Adjusting TheDoorArmAssembly.
Note: therefractorydoorplugis fragile:handlewith care.
Thedoorplugis supplied separatefromthedoorarmassemblyto avoid transit damage.Fit the
doorplugto thedoorarmassemblybefore fittingthedoorassemblyto thefurnace. Refer to
section 5.4.
Pull outthedoorslideshaftto its full extension and rotateit fullyanti clockwise(viewfrom
front). Thedoorslideshaftwill onlyrotatewhen it is fullyextended.
Removethefoursocketscrewsfromtheback ofthedoorarmassemblymountingblock only;do
notremovethefrontfixingscrews, which arefactorysetto position thedoorarm. See fig10a.
Slidethedoorarmassemblyonto theend ofthedoorslideshaftand securefirmlyin thedoor
open position shown in fig10. usingthefoursocketscrews. Takecareto tighten thesocket
screwsevenlyto avoid anydistortion in thedoorarmassembly.
Caution: To allowthedoorsideshaftto slidein and out, someclearanceis required in thedoor
mechanism; consequentlythereis asmall radialmovementin thedoorslidearmwhen thedoor
armis pushed in towardsthework tube.Becauseofthis radialmovementit is possibleforthe
doorplugto contactthework tubefrontsealassemblyifthedoorhandleis lifted as thedoorarm
is pushed inwards:takecare to avoid this happening.
Carefullyswingthedoorarmin aclockwisedirection (viewfromfront)to its stop position,
ensuringthatthedoorplugdoes nottouch tubeend guard. Thedoorplugshould beclear ofthe
furnacein its fullywithdrawn position. Itshould notbepossibleto push thedoorarmin towards
thefurnace until thedoorarmis rotated fullyclockwise(viewfromfront)and thedoorplugis in
linewith thework tubefrontaperture.
Attached to thedoorarmassemblyis aconduit carryingthevideo and power cables forthe
camera. Pass thewires through theconduit plateaperture in theleft-hand sideofthefurnacecase
and connectthecamera power cableconnectorsituated justinsidetheconduit plateaperture.
Routethecameravideo cableas shown in fig. 21 and tieinto theexistingwiringatsuitable
points usingthecableties provided.
Note: takecare to routethecableawayfromsharp edges and hotsurfaces.
Fit thecamera videocablephono socketinto theholeadjacentto thecomms socketin thebottom
flangeattherearofthefurnace case. Secureusingthefixings provided.
Fit thefurnace casebackpanel.
Carefullyslidethedoorpluginto thework tubeensuringthatit is clearofthefrontseal
assembly.Ifthedoorplugis misaligned, adjustmentofits position in relation to thework tube
can beachieved byslackeningthefrontand backdoorarmfixingscrews and rotatingthedoor
armaboutthedoorslideshaftaxis. See fig10a.
3.3.5. Pressure Testing oftheWorkTubeAssembly.
Note: To ensure thatthework tubeassemblyhasbeen correctlyinstalled itis necessaryto
pressure testthefurnace priorto use.

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Dueto thehighwork tubetemperatures used duringCAFtestingthetube‘O’ ringseals will
deterioratewith time. Thefurnace work tubealso has afinitelife and mayeventuallycrack due
to normalwear and tear.Itis necessarytoconductapressuretestofthework tubeassemblyat
regular intervals duringnormaluseofthefurnaceto ensure integrityofthework tubeand ‘O’
ringseals. Thefollowing procedureapplies:
Connectoneend oftheflexiblegas inletpipe(normallyconnected betweenthebulkhead
connection on thefrontofthefurnace caseand thework tubefrontsealassembly)to thework
tubefrontsealassembly.See fig11. Connecttheother end to an adjustablecompressed airtest
lineorinertgas supplycapableofdeliveringup to 4 psi. Check all air/gasconnections forleaks,
anyleakagefromtheair/gas supplylinemayaffectthepressure testresults.
Closethedoorassemblyand clamp in position usingtheswingbolts.
Securelyblock theworktubeventattheback ofthefurnace usingabungorblankingplug.
Pressurisethework tubeassemblyviatheflexiblegas inletpipeto 3 psi ±1psiusing
compressed airorinertgas, and check thatthework tubeassemblydoes notleak.
Followingsuccessfulpressure testingoftheworktubeassembly,connecttheflexiblegas inlet
pipeto thebulkhead connection on thefrontofthefurnace case. Check all externalgas
connections and venttubes forleaks priorto using thefurnace.
3.4. Positioning TheFurnace.
Significantamounts ofcarbon monoxidemaybeexhausted fromthework
tubeduringtheuseofthis furnace. Carbon monoxideis toxicand
inflammable(see section1.2:Carbon MonoxideWarning.)and mustbe
ducted outofthebuilding. See also section 3.6:ExhaustVentConnections.
Thefurnace is designed to begas tightduringnormaloperation, butincorrect
installation orcomponentfailures dueto misuseorwear and tearcouldgive
riseto ahigh presence ofcarbon monoxide. To minimiserisk to theuser in
theeventofahigh presence ofcarbon monoxidethefurnace mustbeinstalled under asuitable
forcedairextraction hood. An exampleis shown in fig12. Theextraction hood mustbeducted
outofthebuildingand mustbeoperatingwheneverthefurnace is in use. Theroommustbewell
ventilated and the‘fresh airin’ventilation should exceed thehood extraction to ensure that
fumes do notescapeinto theroom.
As aprecaution thefurnace is supplied with acarbon monoxidedetector.IftheCOdetectoris
correctlyinstalled it will alertthefurnaceoperatorin theeventofaleak ofcarbon monoxidethat
is notremoved byextraction.
Note: TheCOdetectormustbepositioned and installed in accordance with themanufacturer’s
instructions supplied. In theeventofaCOdetectoralarmevacuatetheareaimmediatelyand
seek expertadvice.Isolated thefurnace fromthegas and electricitysupplyonlyifit is safe to do
so.
Ensure thatthefurnaceis installed in such awaythattheelectricalsupplyand thegas supplycan
bequicklyswitched off in theeventofanemergencywithoutanydanger to theoperator.
Ensure thatthereis aminimumfree spaceof100mmaround thefurnace anddo notobstructany
ofthevents in thecaseasthesearerequired to keep internalcomponents cool.
3.5. ElectricalConnections. Connection bya qualified electrician is recommended.
Thevoltageorrangeofvoltages on which thefurnace maybeoperated isgiven on thefurnace
ratinglabel. See fig11. Check thatthesupplyvoltageis compatiblewith thevoltageon thelabel,
and thatthecurrentcapacityis sufficientforthemaximumcurrenton thelabelbeforeconnection
to thesupply.
Thefurnace should bepermanentlyconnected to thecorrectsupplythrough awall mounted
isolatingswitch oraneasilyremovableplug.Theswitch orplugshould bewithin easyreach of

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theoperator.Unless asupplycableis fitted thesupplyconnections areto bemadeto terminals
mounted insideback ofthefurnace,accessed byremovingthefurnace back panel.
Theterminals aremarked accordingto thepower supply, connectas shownin table2. The
supplymustincorporatean earth(ground).
Table2. Electricalconnections: Supplytype
SupplyTerminallabelCable colour Live-Neutral Reversible orLive-Live
1-phase LorL1Brown orBlackto liveto eitherpowerconductor
NorL2Blue orBlackto neutralto the otherpowerconductor
PEGreen/Yellowto earth (ground)to earth (ground)
SupplyTerminallabelCable colour
2-phase L1Blackto phase 1
L2Blackto phase 2
NLightBlue to neutral
PEGreen/Yellowto earth (ground)
3.6. VoltageLevel&Power LimitSettings.
Check thefurnace ratinglabelvoltage.Iftheactualsupplyis notthesameas thevoltageon the
label, then thecontroller power limit should beadjusted as follows.
Iftheactualsupplyvoltageis higher than thevoltageon therating label(or thevoltagefor
which thefurnace was lastset), then immediatelyafter switch-on setthetemperaturesetpointto
zero to preventheating and drawing excessive current.
Press Page /until oP (outputlist)is displayed. Press Scroll Quntil OP.Hi (OutputHigh)is
displayed. Press Down qorUp ponce to displaythevalueof OP.Hi (it is good practice to
writedown theoriginalvalue). To altertheparameter useDown qorUp p.
Correctvaluesforthe OP.Hi parameter, with newelements, are:
200V208V220V/380V230V/400V240V/415V
79%74%65%60%55%
See also thesection on elementageing– section 5.2.
3.7. ExhaustVentConnections.
Note: Significantamounts ofcarbon monoxidemaybeexhausted fromthe
work tubeduringtheuseofthis furnace. Carbon monoxideistoxicand
inflammable(see section1.2:Carbon MonoxideWarning.)it is
recommended thattheventtubeis routed outofthebuilding. Thefurnace
mustalways bepositioned as recommended in section 3.4:PositioningThe
Furnace.
Thefurnace has two exhaustvents, themain ventattheback oftheheating
chamber and asafetypressure relief ventatthesideofthefurnace. Thepurposeofthesafety
ventis to preventdangerous pressure build up as thefurnace warms up ifthemain venttube
becomes blocked.
Themain ventand thesafetypressurereliefventmustbeconnected to separateventruns and
routed outofthebuilding.
With theback panelremoved access isgained to themain venttubefittingsituated on thework
tubeback sealassemblybelowthethermocouples. Themain venttubefittingis a12mm x3/8”
BSP adapter suitableforconnecting12mm diameter coppertube. See fig6.
Thesafetypressurereliefventtubefittingis a6mmx1/8”BSP adapter suitableforconnecting
6mm copper tube. See fig11.

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Note: Itis importantthatthevents are notrestricted in anyway, do notusetubeofless than
6mm diameter forthesafetypressure relief ventconnection and 12mm forthemain vent
connection.
Check regularlythatthemain and safetypressure relief vents are clear fromobstructions.
3.8. Gas Connection.
3.8.1. Furnaces forCO/CO2and AirTestGases withN2 PurgeGas.
See nextpageif a mixerboxfor separateCO&CO2inputs is supplied.
Note: Thegas supplypressure required is 4 psi(0.276 bar) and mustnotexceed this.
There are three gas connections on thesideofthefurnace, CO/CO2pre mixed ‘reducing’
atmosphere gas, Air‘oxidising’gasand N2‘Purge’ gas. See fig 11. Itis recommended thatthe
gases aresupplied to thefurnaceviaseparateisolation valves thatcan bequicklyswitched off in
theeventofanemergencyorpotentialhazard withoutdanger to theoperator. See section 1.2:
Carbon MonoxideWarning.
The‘Purge’ gas lineis pre-setto allowaflowofN2into thework tubeequalto 6 litre/min, the
‘oxidising’and ‘reducing’atmosphere gases haveadjustableflowviatheflowmeters on the
frontofthefurnace. See fig11. Thegas supplyfittings are6mm x1/8”BSP adaptors suitablefor
connecting6mm copper tube.
SeparateCOand CO2supplies.
Ifa mixer boxis supplied, then separateinputconnections ofCOand CO2maybemadeto the
lower connections attheback ofthebox. A pipefromtheupper connection is to betaken to the
CO/CO2inleton thefurnace.
Theboxis fitted with twoflowmeters which maybeadjusted to ensurethatequalmixtures ofCO
and CO2aresupplied. Theboxalso contains two non-return valves to ensurethatneither gas
can flowback outofeither inletconnection.
3.8.2. Furnaces forH2 and CO2 TestGases withCO2 PurgeGas.
Note: Thegas supplypressure required is 4 psi(0.276 bar) and mustnotexceed this.
There are three gas connections on thesideofthefurnace, CO2‘oxidising’atmosphere gas, H2
(mixed with CO2in thework tube) ‘reducing’atmosphere gasand CO2‘Purge’gas. See fig11. It
is recommended thatthegases aresupplied to thefurnaceviaseparateisolation valves thatcan
bequicklyswitched off in theeventofanemergencyorpotentialhazard withoutdanger to the
operator. Seesection 1.3:Hydrogen and Carbon DioxideWarning.
The‘Purge’ gas lineis pre-setto allowaflowofCO2into thework tubeequalto 6 litre/min, the
‘oxidising’and ‘reducing’atmosphere gases haveadjustableflowviatheflowmeters on the
frontofthefurnaceSee fig11. Thegas supplyfittings are6mm x1/8”BSP adaptors suitablefor
connecting6mm copper tube.

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MF36 page13
3.9. CameraMounting AndConnections – StandardLens.
Fit thecamera mountingbracketonto thedoorarmas shown in fig5cand5d. Notethatthe
camerashown in fig5cand 5d is notfitted forthis operation.
Mountthestandard lens and camera assembly(fig5b)onto thecamera mountingbracketas
shown in fig5eand 5f. Rotatethelens and camera assemblyanti-clockwiseto locatein position.
Thesockethead screws are fixed in position and do notrequire tightening.Ensure thatthe
camerais in ahorizontalposition. To rotatethecamera independentlyofthelens hold thelens
firmlyin position, push thecamera towards thelens and rotateit in thedesired direction.
Thecamera power cableis secured to therear ofthecamera byasecuritybracket. Do not
removethis bracket. Connectthecamera power cableto the12VDCcamerasupplysocketon
thefrontofthedoorarm.See fig11.
Connectthecamera video cablefromthefrontofthedoorarmto the‘video out’socketon the
back ofthecamera.
3.9.1. Camera and lens settings.
Thecamera and lens arepre-adjusted togivethebestqualitypicture. Thefollowingsettings have
been made.
· Theshutter switch on therear ofthecameramustbesetto OFFwhen usingthestandard
auto-iris lens.
· Thestandardauto-iris lens has two adjustmentscrews on thelens body. Thescrewmarked
ALCis setto A(fullyclockwise). ThescrewmarkedLEVELis settoL(fully
anticlockwise).
3.10. CameraMounting &Connections – ZoomLens.
Thezoomlens is supplied as an option. Itshares thecamera and lens heatshield assemblyused
with thestandard lens. See fig5gshowingthezoomlens assemblyand lens clamp.
3.10.1. Assembly ofthezoomlens.
Disconnecttheauto-iris plugfromthecamera and unscrewthecamera fromthestandard lens. It
is notnecessaryto removethe5mm spacerringfromtherear ofthestandard lens (see fig5b).
Screwthecameraonto therearofthezoomlens assembly(see fig5h).
Unscrewthelens heatshield assemblyfromthefrontofthestandard lens. Itis notnecessaryto
removethe43-49mm step up ringfromthefrontofthestandard lens (see fig5b).
Screwthelens heatshield assemblyonto thefrontofthezoomlens assembly(seefig5j).
3.10.2. Zoomlensmounting.
Note:Thezoomlens andcameraassemblymustberemovedfromthedoorarmbeforeopening
thedoor. Thedoorslidemechanismis notdesigned to carrytheextra weightofthezoomlens
assemblywhen thedoorarmis fullyextended. Theswingbolts which secure thedoorcannotbe
swungclear ofthedoorwhen thezoomlens mountingbracketis in position;onlymountthe
zoomlens bracketwhen thedooris closed and theswingbolts aresecured.
Thezoomlens and camera assemblycan beconvenientlystored between tests bystandingit on
its end as shown in fig5p.
Secure thezoomlens andcameraassemblyto thezoomlens mountingbracketusingthescrew
fixingin thetop oftheball joint. Removethestandard camera mountingbracketfromthedoor
arm; see fig5cand 5d. Mountthezoomlens and bracketonto thedoorassemblybyslidingthe
bracketonto thethree fixingscrews on thefrontofthedoorassembly;see fig5k. Thesocket
head screws are fixed in position and do notrequire tightening.

CafDigitalImaging
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Thecamera power cableis secured to theback ofthecamera byasecuritybracketwhich should
notberemoved. Connectthecamerapowercableto the12v-dccamera supplysocketon the
frontofthedoorarm. Seefig11. Connectthecamera video cablefromthefrontofthedoorarm
to theVideo Outsocketon theback ofthecamera.
3.10.3. Camera and Lens Settings.
To givethebestqualitypicture thefollowingsettings are required.
Theshutter switch on theback ofthecamera mustbesetto ON when using thezoomlens.
Setthezoomlens aperture to f22. This givesan imageat815°Csufficientto adjustthelens
position before atest.Ifnecessary, ahigheraperture settingcan beused atlower temperatures to
giveabrighter imageduringtestsetup.
Do notsetthelens aperture higher thanf22 during atest: theimagewill burn outathigh
temperatures.
3.10.4. Adjusting theLens.
Thetestsoftwaremustberunning in “testgrabber”modeto performthis operation. See section
4.5.4.
With thelens atits maximumusablezoommagnification, a3mm wideand3mm high objectwill
bedisplayed in theviewingwindowofthemonitoras an imageapproximately110mm wideand
110mm high. Reducingthezoommagnification reduces thesizeorthedisplayed image.Itis not
possibletoo focus theimageover thefull zoomrangeofthelens.
Load thetestsamples into thework tube(see section 4.4)and securelyclosethedoorusingthe
swingbolts. Mountthezoomlens and camera assemblyto thedoorarmasdescribed in section
3.10.2.
When thefurnacehas reached 815°Cthere shouldbesufficientlightin thework tubeto allowan
imageto becaptured. With thetestsoftware in “testgrabber” modereleasetheball swivel
lockingscrew and movethelens and camera assemblyto displayan imageofthetestsamplein
theviewingwindowofthemonitor. See fig5m. Once an imageis displayed correctly, lock the
lens in position usingtheball swivellockingscrew.
Iftheimageis difficult to see, adjustingthelens aperture mayimproveit. Remember to setthe
apertureback to f22 after settingthelens position, ortheimagewill burn out.
Focus theimageand adjustits sizeusingthelens operatingring.Itmaybenecessaryto rotatethe
lens and camera assemblyto leveltheimageon themonitor;to do this, releasethelens clamp
screwas shown in fig5n.
As thefurnace heats up thework tubewill increaseslightlyin lengthand somemovementofthe
testsamplemayoccur.Itmaybenecessaryto refocus thecamera duringtheinitialCAFtestrun.
3.11. Computer Connections.
Unpack thecomputer fromits transit boxes and assemblein accordancewith themanufacturers
instructions provided.
InserttheCarbolitehardware lock(dongle) into theprinter porton theback ofthecomputer.
Connectthecamera video extension cablefromthephono socketon theback ofthefurnacecase
to theVideo Card phono socketon theback ofthecomputer.
Connectthecomms leadfromthe‘Comms Port’on theback ofthefurnace to thecomms porton
theback ofthecomputer.

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4.0 OPERATING INSTRUCTIONS.
4.1 Furnace Start-up.
This furnaceis availablein two options:
Option 1. CO/CO2 ‘reducing’gas and Air‘oxidising’gas with N2 ‘Purge’gas.
Compatiblewith -ASTM D1857-87.
Option 2. H2 and CO2 ‘reducing’gases and CO2 ‘oxidising’gaswith CO2 ‘Purge’ gas.
Compatiblewith -BS1016 :Part113 :1995 ISO540.
Theprincipleofoperation is thesameforboth options. Thefurnace is normallysupplied
programmed to operatebetweenapre-determinedsetpoint(starttemperature) and 1500°C
(2732°F)ataramprateof7°C/min. (12.6°F/min.). Thetargettemperatureis setto 1500°C
(2732°F)to avoid operatingthefurnace athigh temperatures unnecessarily. See section 4.5.1.
Thefollowingtextdescribes howto usethefurnacewith this program.
4.1.1. Open thefurnacedoortocheck thatthesilica windowis clean. Anyslighthazeshould be
removed before use.Ifneglected this hazequicklythickens and becomes impossibleto remove.
See section 5.4. forinstructions on howto removeand clean theviewingwindow.
4.1.2. Turn on the‘oxidising’, ‘reducing’and ‘purge’ gas supplies. Ifthe‘purge’ gas is notpresent
when thefurnaceelectricalsupplyand instrumentswitch are on thecontrolsystemwill activate
an alarmbuzzer and illuminateawarninglighton thecontrolpanel. See fig11. This alarmwill
continueuntil thefurnaceis turned off and the‘purge’ gas supplyis restored. Whilethealarmis
activated thecontrolsystemwill notallowintroduction of‘reducing’gas.
4.1.3. Switch on thefurnaceelectricalsupply, theinstrumentswitch will illuminateand thecooling
fans will run. Operatetheinstrumentswitch to activatethecontrolsystem, thefurnace will begin
to heatup to thestarttemperatureand thework tubewill bepurged with ‘Purge’ gas. Thestart
temperatureis adjustableusingtheUpand Downbuttons (qp)on thecontroller dependingon
yourrequirements:
Forfurnaces constructedto useCO/CO2and Airtestgases with N2‘Purge’gas(compatible
with ASTM D1857-87. Thestarttemperature is adjustablefrom400°C(752 °F).
Forfurnaces constructedto useH2and CO2testgases with CO2‘Purge’ gas(compatiblewith BS
1016 :Part113 :1995 ISO540. Thestarttemperature is adjustablefrom815°C(1499°F).
To switch thefurnace off, settheinstrumentswitch to off. Thecasecooling fans remain on.
Leavethefans on until thefurnace cools to below300°C.Ifthefurnace is to beleftoff, isolateit
fromtheelectricalsupply.
Note: Itis notrecommended to operatethefurnacecontinuouslyattemperatures above1000°C
(1832°F). Thefurnaceis designed to operateto aprogrammed ramp;continuous operation at
elevated temperatures will shorten thelife oftheelements, insulation and tubeend seals.
4.2 EurothermController.
TheEurothermcontrolleris configured to controlthefurnace and providetheother signals
necessaryto switchgas flows and communicatewith theCAFTestSoftware. Thefollowing
sections describehowto adjustthecontroller as necessaryto achievecorrectoperation ofyour
furnace.
4.3 Computer Start-up.
Thecomputer is setup byCarboliteto run thefollowingsoftware:
MicrosoftWindows 2000 (earliermodels:Windows 98).
CarboliteCoalAsh FusibilityTestsoftware:protected byahardware lock (dongle).
Although thesoftware isalreadyinstalled, installation CDs are supplied forsystemsupport.

CafDigitalImaging
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Note: Carboliteacceptno responsibilityforanydamageto software loaded onto thecomputer by
theuser and acceptno responsibilityfordamageto thecomputer orits software resultingfrom
theuseofanysoftwareorhardware notsupplied byCarbolite.
Switch on thecomputer and monitor, and doubleclick on theCarboliteicon displayed on the
startup screen. The‘CarboliteCoalAsh FusibilityTest’softwareinitiation screenwill be
displayedfollowed bythemain testscreen. TheCarbolitelogo will bedisplayed in thecentreof
theblank imagescreen.
Note: This software is Windows 2000 compatible;all normalWindows 2000 functions apply
(earliermodels:Windows 98).
Ifthesoftware fails to load, thefollowingmessages mayappear:
4.3.1 “Communication failure”-“Pleasecheck seriallineand selectretry”
Selectingthe“cancel”button will onlyallowtheCarbolitesoftware to beused in analysis mode.
Check thattheComms lead is correctlyconnectedatboth theback ofthefurnace and theback of
thecomputer. See section 3.11.
Check thatthefurnace power supplyand instrumentis switch are turned on. When correct
communication is established the‘process value’temperature(thetop temperatureofthetwo
temperatures displayed on thefurnace controller) will bedisplayed on thelefthand sideofthe
computer screen belowthetimeand date.
4.4.2. “Donglenotfound”-“Continuingin analysis mode”
Selectingthe“OK”button will allowtheCarbolitesoftware to load, buttherecordfunction is
disabled and thesoftwarecan onlybeusedforanalysingstored images. To record images the
dongle(hardware lock)mustbeinstalled and the‘CAFTest’softwarere started.
4.4 LoadingSamples Into TheWorkTube.
Usethesamplecarrier and sampletiles provided. Arrangethesamples as shown in fig13a.
4.4.1 When thefurnacehas reached its starttemperatureopen thefurnace doorand swingit clearof
thework tubeto allowaccess. Load thesamples into themouth oftheworktubeto warmup,
usingtheSampleLoadingToolprovided. Seefig13b.
Note: Do notoperatethefurnaceattemperaturesabove815°C(1499°F)with thedooropen.
Thefurnace doormustnotbeleftopen longer than is necessaryto loadand unload samples from
thework tube.
Note: ifusingthezoomlens and camera kit, removeit before openingthedoor.
After aboutoneminuteslowlyslidethesamples into thetubeatarateofabout25mm per minute
to makecontactwith thecontrolthermocouplesheath. See fig13c.
Note: Itis possibleto crack thework tubebyinsertingsamples too quickly.Work tubefailures
are notcovered byCarbolite'sguarantee.
Warning: Do notusethefurnaceifthework tubeis cracked as thereis arisk ofexposure to
carbon monoxidegas. Seesection 1.2:Carbon MonoxideWarning.
4.4.2 Closethefurnacedoorand secure usingthetwo swingbolts. Itis importantthattheswingbolts
are tightenedevenlyto createagas tightsealbetween thedoorflanges.
Caution: To allowthedoorsideshaftto slidein and out, someclearanceis required in thedoor
mechanism; consequentlythereis asmall radialmovementin thedoorslidearmwhen thedoor
armis pushed in towardsthework tube.Becauseofthis radialmovementit is possibleforthe
doorplugto contactthework tubefromsealassemblyifthedoorhandleis lifted as thedoorarm
is pushed inwards:takecare to avoid this happening.
Warning: Do notoperatethefurnace with thedoororwindow‘O’ringseals removed. See fig
20. This will result in high levels ofcarbon monoxideleakingfromthework tube. See section
1.2:Carbon MonoxideWarning.

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4.5 Running ACoalAshFusion(CAF)Test.
4.5.1 Setting theTarget Temperature.
Note: Avoid operatingthefurnace atunnecessarilyhigh temperaturesas this will reduce thelife
oftheelements, furnaceinsulation and tubeend seals. Setthetargettemperature as lowas
possible(dependingon yourapplication)togain themosteconomicalusefromyourfurnace.
Themaximumtargettemperatureis 1600°C. Adjustthefurnacecontroller ramp target
temperatureas follows:
UsethePageButton (2)on thecontroller to selectthe‘ProGLiSt’. Repeatedlypress theScroll
Button (Q)to select‘tGt’in SEG.n 2, then usetheUp and Down buttons (qp)to selectthe
desired ramp targettemperature. Thecontroller will return to its homepageautomaticallyafter a
fewseconds.
4.5.2 Setting a Controller RampRate.
Note: Avoid operatingthefurnace atunnecessarilyfastramp rates as theymaycausepremature
failure ofthework tube.Setthecontroller ramprateas slowas possible(dependingon your
application)to gain themosteconomicalusefromyourfurnace. Thecontroller is factorysetto
givearamp of7°C/min. (12.6°F/min.). Adjustthefurnacecontrollerramprateas follows:
UsethePageButton (2)on thecontroller to selectthe‘ProGLiSt’. Repeatedlypress theScroll
Button (Q)to select‘rAtE’in SEG.n 2, then usetheUp and Down buttons(qp)to selectthe
desired ramprate. Thecontroller will return to its homepageautomaticallyafter afew seconds.
4.5.3 Introductionto theCAFTestSoftware.
TheCAFTestSoftware is designed tocapture imagesfromthevideo cameramounted on the
frontofthefurnaceand store themin sequentialorder. Each imagedisplaysthedate, time, and
temperatureatwhich theimagewas recorded and an optionalsampleidentification. Imagesare
stored under afilenameofyourchoice, which isenteredatthestartofthetest, and are played
back foranalysis ofthetestsamples.
Analysis oftheresults is aided bytheuseofa‘Results’chart, which enables thecritical
deformation temperatures to beenteredalongwith individualsampleidentification. Theresults
chartcan then besaved and printed outin reportform. Thesoftware automaticallystarts and
stops thefurnacecontroller, thestarttemperatureand intervalbetween images are adjustableto
suit yourrequirements.
Thesoftwareis designedprimarilyto beused with amouse, however mostoperations are
selectablefromthekeyboard ifnecessaryand are as follows:
· Buttons and themain menu bar atthetop leftofthescreen areactivated usingthe‘Alt’key
togetherwith theletter underlined in thecaption. Fordrop down menus press theunderlined
character withoutusingthe‘Alt’key.
· When usingthe‘playback’facilitytheimages canbescrolled back and forth bydraggingthe
scroll bar, orusingtheleftand right‘arrow’ keys.When theresults windowis activethe<
and >keys togetherwiththeshiftkeywill scroll theimages.
· When the‘Results’windowis open the‘arrow’ keys movethecursoraround thechartin the
appropriatedirection. Pressingthe‘space’bar withthecursorin avalid result boxwill cause
thetemperaturecorrespondingto thecurrentlydisplayed imageto beentered into thebox. If
an incorrectvalueis entered into oneboxsimplyre-enterthevaluewhen thecorrectimageis
displayed.

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4.5.4 OperationoftheCAFTestSoftware.
Switch on thefurnaceand thecomputer, and loadthetestsamples as described in sections 4.1. to
4.4. Proceed asfollows to run aCAFtest:
4.5.4.1 Select‘Setup’and ‘Hardware’atthetop leftcorner ofthescreen, and the‘Set-up options’
windowwill appear.Aselection ofcamera formats is available, thecamerasupplied is aCCIR,
768 x576, 8 bits, 14.8 MHz. Selectthis option ifitis notalreadydisplayed. See fig14.
Enter therequired ‘Temperatureinterval’. This is theintervalatwhich thesoftware will record
and store an imagefromthevideo camera.Forexample, if10°Cis enteredan imagewill be
recorded every10°Ctemperatureriseabovethestarttemperature.
Note: Onlywholenumbers can beused, thesmallestnumber thatcan beentered is ‘1’, the
largestis 100. Themaximumnumber ofimages thatcan berecorded foreach separatetestis
1500, each stored imagerequiring437KBofdiscspace so it is advisabletouselargetemperature
intervals whenever possible.
Setthe‘Startrecording’temperatureto startrecordingand storingimagesatthedesired
temperature. Tryto startrecordingas closeto theexpected criticaltemperatures as possibleto
minimisethenumber ofstored images;remember thateach stored imagerequires 437KBofdisc
space.
Select‘Testgrabber’, this enablesyou to displayarealtimeimageofthesamples in thework
tubebeforestartingatestsequence.
Note: An imagewill notappear in theimagewindowuntil around 800°C(1472°F);at
temperatures belowthis there is insufficientlightwithin thetube.
When usingthestandardlens adjustthecamerafocus to obtain thebestviewofthesamples. As
thefurnace warms up thework tubewill increaseslightlyin length causing thecamerafocus to
alter, it maybenecessaryto re-focus thecamera duringtheinitialCoalAshFusion testrun.
Once thecamerais focused thefocus ringcan belocked in position usingthelockingscrew,
unless thecamerais disturbed it should notrequirere-focusingduringsubsequenttests. During
thetesttheimagedisplayed in theimagewindowis arealtimeimage, so thecamera focus can
easilybere-adjusted.
Refer to section 3.10.4 forsettingup thezoomlens.
Once you havesettherelevantparameters selectOK to saveyoursettings.The‘Set-up options’
windowwill disappear, if‘Testgrabber’ has beenselected afrozen imagewill remain in the
imagewindow.
4.5.4.2 Select‘Setup’and ‘SampleCodes’atthetop leftcorner ofthescreen and the‘Samplecodes’
windowwill appear.Up to 15 samplecodes can beentered, though Carbolitedo notrecommend
analysingmorethan 12 samples per test. Selectthenumber ofsamples required and enterthe
identification code(less than 8 characters)foreach sampleand click OK.This automaticallysets
thesizeoftheresults windowand enters thesampleidentification codes into theresults column.
4.5.4.3 Enter thedesired filenamein the‘FileName’ box, see fig15a, this nameforms therootofthe
filenames under which theimages arestored. Ifno filenameis entered thedefault name‘temp’
will beused.
The‘SampleIdentification’is optional, ifno identification is entered theidentifier is setto
‘Noneentered’.This ‘SampleIdentification’is displayed on each recordedimage.
Invalid filenamecharacters arefiltered outautomatically, both the‘FileName’ and ‘Sample
identification’boxes are disabled once recordinghas started.
4.5.4.4 Whenyou aresatisfied thattheinformation you haveentered is correct, select‘Record’to run a
CAFtest. The‘Record’and ‘Play’buttons will fadeto greyand agreen ‘Recording’boxwill
appear.

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Selecting‘Record’will automaticallysetthefurnace controllerto ‘Run’and startthefurnace
program. Theyellow‘testin progress’lightwill illuminateon thecontrolpanel. Thegreen
StandbyModeindicatorwill go out.
Note: Do notopen thefurnace doorwhen the‘testin progress’lightis illuminated. See section
1.1.
Thefurnace will dwell atits currentsetpoint(starttemperature)for5 minutes then ramp to the
selected targettemperature atthepre-selected ramp rate.
Note: Avoid operatingthefurnace atunnecessarilyhigh temperaturesand ramp rates. See
sections 4.5.1 and 4.5.2.
When thefurnacereaches thepre-selected ‘Startrecording’temperature, images will besavedat
thepre-selected‘Temperature interval’up to theramp targettemperature.As theimages are
stored theblack textboxwill flash across thetop oftheimagewindow.
When thefurnacehas reached theselected targettemperatureit will dwell for1 minutethen the
controller will switch off allowingthefurnace to coolnaturallyto its setpoint(start
temperature). Thesoftware will stop recordingimages when thefurnace temperature stops rising,
selectthe‘Stop’button to exit record mode. Alternativelythecontroller, and imagerecording,
can bestoppedatanytimeduringthetestbyselectingthe‘Stop’button.
Note: Periodicallyaredboxcontainingthewords‘Communication failure’mayappearabove
the‘SampleIdentification’box, this occurs when thecomputer is busywith another task during
communication with thefurnacecontrollerand should onlyappear momentarily.
4.5.4.5 Thefurnace controller programcanalso bestartedand stopped independentlyoftheCAFtest
software:
To starttheprogram: press theRun/Hold button (l)on thefrontofthecontroller, theword RUN
will illuminateatthesideofthebutton to signifythattheprogramis running.
To stop theprogram: hold down theRun/Hold button (l)on thefrontofthecontroller until both
thewords RUN and HOLDatthesideofthebutton are notilluminated.
4.5.5 Gas Set-Up.
Thegas sequence is started automaticallybythefurnace controller. Thegas sequence isas
follows:
When theinstrumentswitch is turned on thecontrolsystemwill open the‘purge’ gas solenoid
valveand purgetheworktubeforaduration of5 minutes.
When thecontroller programis initiated the‘purge’ gas solenoid valvewill open and purgethe
work tubefor5 minutes (duringthe5 minutedwell period oftheprogram).After the5 minute
purgethe‘purge’ gas is turned off and thetestgassolenoid valveis opened.
Note: Ifthe‘purge’ gas supplyis interruptedatthestartofthetestorduringthetestanalarm
buzzer will sound and awarninglightwill illuminateon thecontrolpanel.See fig11. This alarm
will continueuntil thefurnace is turned off and the‘purge’ gas supplyis restored. Whilethe
alarmis activated thecontrolsystemwill notallowintroduction of‘reducing’gas. See also
section 4.1.2
Note: Duringthetesttheyellow‘testin progress’lightwill illuminateon thecontrolpaneland
thegreen StandbyModeindicatorwill go out. Donotopen thefurnace doorwhen the‘testin
progress’lightis illuminated. See section 1.1.
Thedesired testgas is selected usingthe‘oxidising’-‘reducing’gas selectorswitch on thefront
ofthefurnace controlpanel. See fig11. Thetestgas will flowfortheduration ofthecontroller
program.
Attheend ofthecontroller programoriftheprogramis interrupted (manualintervention)the
‘reducing’gas is turned off and the‘purge’ gas solenoid valvewill open topurgethework tube
foraduration of5 minutes.

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Note: In theeventofapower failure the‘purge’ gaswill flowcontinuallyuntil thepower is
restored. When thefurnace mains supplyis turnedoff thegas supplymustalso beturned off.
4.5.6 Analysing TheResults.
DuringtheCAFtestimagesare stored in theformof‘Yourfilename’.tiffiles in the‘Images’
directory. Theseimagesare viewed byopeningthe‘yourfilename’.logfile(see section 4.5.7.).
Thefiledirectoryis constructed as shown in fig16.
When theCAFtestis completethestored imagescan bereplayedforanalysis ofthetest
samples.
4.5.7 Analysis ofCAFTestresults storedimages.
Stored imagesare playedback as follows:Select‘File’ then ‘Open’atthetop leftofthescreen
and open the‘your filename’filefollowed bythe‘your filename.log’fileyou wish to playback.
Thefilenamewill appearin the‘FileName’ box.
Selectthe‘Play’button, ascroll bar will appear belowthe‘Record’‘Stop’and ‘Play’buttons.
Usethescroll barto scroll through thestored images, alternativelytheleftand rightarrowkeys
on thekeyboardcan beused.
4.5.7.1 Record thecharacteristicdeformation temperatures duringanalysis oftheresults usingthe
‘Results’windowduringplayback:
Select‘Results’atthetop leftofthescreen to open the‘Results’window.Thewindowcan be
moved, resized orminimised to revealtheimagebeneath.
In theresults window‘Identifier’ refers toyourown identification codeofthesamples on the
samplecarrier. Theseareentered usingthe‘samplecodes’window;see section 4.5.4.2
DT, ST, HT and FTreferto thetemperatures atwhich thecharacteristicchanges ofshapeoccur:
DT =Deformation temperature.
ST =Sphere/softeningtemperature.
HT =Hemisphere temperature.
FT =Flow/fluid temperature.
Usingthescroll bar or‘Shift+>orShift+<’keys scroll through thestored images until the
relevantdeformation temperatureforasampleis reached. Each imagehasablack textboxacross
thetop showingthedate,timeand temperatureatwhich theimagewas captured and atest
identification. When therelevantimageis displayed (eg. asampleshowing thedeformation)
simplyclick in therelevantboxbeneath thatsampleidentification in the‘Results’windowusing
themousepointer. Therelevanttemperature will beentered automatically.Alternativelyusethe
‘arrow’ keys on thekeyboard to movethecursoraround theresults chart, thespace bar enters the
imagetemperaturewhenthecursoris in therelevantbox. Ifthewrongtemperatureis entered
into thewrongboxlocatethecorrectimageand re-click in therelevantboxto over writethetext
orhighlightand deletethetext. Notethattheshift+<and shift+>keysareonlyfunctional
when theresults windowis active.
4.5.7.2 Agrid featureis availableto assistin analysis oftestsamples. Selecting‘grid’atthetop left
corner ofthescreen opens up atransparentgrid overlayand controlpanel.Thegrid sizecan be
altered and rows and columns added and deleted to suit yourrequirements.Position thegrid over
therelevantsampleimagebydraggingit usingthemousepointer. Fineadjustments can bemade
usingthecontrolpanel.
Ifthegrid is notvisibleafter selecting GRID fromthemenu, left-clickthemouseanywherein the
imagewindowand thegrid will appear attheselected point.
Once setup, thegrid canbeturned on and off usingthe‘On/Off’button on thecontrolpanel.
Thecontrolpanelcan beleftrunningifrequired.
When theanalysis is completeselect‘OK’ to accepttheresults. Select‘File’and ‘Save’to save
theresults toyourfiledirectoryunder‘Carbolite\Images\DSHF’as ‘.tif’ files and ‘Data’ as‘.dat’
files.