FURNACE & ASSAY 168 Manual

ABN: 68 606 541 468 Email: [e-mail] 1
168 Place Cupellation Furnace
Operation & Maintenance Manual
Tel: [phone]
E-mail: [e-mail]
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

ABN: 68 606 541 468 Email: [e-mail] 2
Manual Index
System Overview 3-4
Safety Devices 5 - 6
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

ABN: 68 606 541 468 Email: [e-mail] 3
Please note you will require a minimum of 1 metre clearance around the furnace.
 Base construction uses high-quality 100 x
100 RHS.
 Furnace body construction is durable 5mm
laser-cut plate
 High quality refractory brick and insulation
 Bolt holes in base plates of all 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
BURNER
1490 mm
AVERAGE BURNER EQUIPMENT DEPTH
* Dimensions are approximate only and may vary slightly with each furnace.

ABN: 68 606 541 468 Email: [e-mail] 4
168 Place Cupellation Furnace
240V-FAS-180
Power Requirements
 Volts
 Phase
 Kilowatts
240V
1
1
Fuel Type LPG
Gas Consumption 280MJ Per Hour
Operating Pressure 140 KPA
Gas Pressure Requirements
Minimum Inlet Pressure
Maximum Inlet Pressure
2.5KPA
140KPA
Safety Devices Installed
UV Flame Detection
System Overview:
This furnace has a fan forced single burner system, with an automatic ignition system. It can
be swapped between NG and LPG (propane) to suit varying site requirements, with just a
few simple adjustments performed on-site involving a minimum of downtime and
associated costs.
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), that shows actual
temperature as well as the temperature the furnace is set to.
The door has a pneumatic ram opening system with an easy to use foot pedal control or
optional hand valve that allows you to open the door part-way so that you can check inside with
minimal temperature loss.

ABN: 68 606 541 468 Email: [e-mail] 5
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.
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 m amps. If the reading falls below 0.2 m amps then either the flame detector unit is
aging and needs replacing or the holder that houses the unit needs correct alignment
with the flame.

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Recommended 12 Months Consumables
Recommended Spare Parts
Parts List for FAS-180-INLPG2
168 Place Cupellation Furnace, 240v Inspirated LPG
Recommended Critical Spare Parts
FAS Part# FAS Description Qty
FAS-206 Muffle #8 to suit 168PCF 6
FAS-212 Vent Slotted #5 to suit E100PCF & 100PCF & 168PCF 5
FAS-304 Floor Tile 650x650x25mm to suit 168PCF 6
FAS-409 Thermocouple Inner Sheath 300x10mm 5
FAS-410 Thermocouple Outer Sheath 300x15mm 5
FAS-603 Ceramic Anchor, (Complete) 3" 18
FAS-605 Thermocouple Element, type K. 310mm 6
FAS-803 Isowool Blanket (Kaowool) 160kg x 25mm 1
FAS-1008 Refractory 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 Description Qty
FAS-609 Thermocouple 1/2" Head 1
FAS-611 U.V. Cell Flame Detector QRA.2 4
FAS-615 Flame Controller, LGB41
FAS-620A Dual Ignition Transformer TQO31A2750 1
FAS-622 Igniter Rod 2
FAS-623 Solenoid Valve (Complete) 1430k 2
FAS-626 U.V. Amplifier, AGQ1.1A27 1
FAS-627 Ignition Lead (Copper Cord) 3
FAS-627A Ignition Boot and Connector 1
FAS-648 Temperature Controller, Omron E5CC-RX2ASM-800 (Relay) 1
FAS-678 Ignition Electrode 2
1

ABN: 68 606 541 468 Email: [e-mail] 7
Associated Spare Parts
For pictures, data sheets and more info on spare parts please go to products
tab on our website http://www.fandasupplies.com/products
Parts List for FAS-180-INLPG2
168 Place Cupellation Furnace, 240v Inspirated LPG
FAS Part# FAS Description
FAS-180-SHL 168PCF New Body and Bricks
FAS-180-BRNINLPG 168PCF Burner Equipment lpg Inspirated 240v
FAS-180-DHP 168PCF Door and Hinge with Pneumatics
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 High Pressure Test Point Assembly
FAS-681 Surge Protector *240V*
FAS-801 Isowool Blanket (Kaowool) 128kg x 25mm
FAS-1001 Flue Block - Large 50PFF
FAS-1003A Burner Port Round Hole 230x250mm
FAS-1004 Refractory Mortar 25kg Drum
FAS-1006 Refractory Castable 25kg Bag

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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.
*Install fuel supply. 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 socket or hard wire furnace to power supply.
*NOTE THIS FURNACE USES SINGLE PHASE POWER WITH A
NEUTRAL WIRE AND EARTH.
*BEFORE STARTING CHECK THAT ALL EXHAUST DUCTING IS IN
PLACE.

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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. of 6 hours. Once completed then leave on low fire for at
least 24 hours.
Keep a close eye on any cracks that may develop on front of refractory indicated 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 that may develop on front of refractory indicated by
moisture seeping through refractory. If you see this then maintain temperature until
moisture clears.
1. Increase set point in 100degC increments every hour until desired temperature
is reached.
CURING PROCEDURE

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Starting Furnace shut down for more than 36 Hours
When furnace has been shut down for a period of time then you will need to
start up the furnace slowly.
Keep a close eye on any cracks that may develop on front of refractory indicated by
moisture seeping through refractory. If you see this then maintain temperature until
moisture clears.
1. Leave on low fire or 250°C / 480°F for minimum of two hours.
2. Increase set 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. Increase temperature 100°C/ 210°F every hour up to normal running
conditions.
Keep a close eye on any cracks that may develop, this is indicated by moisture
seeping through refractory. If you see this then maintain temperature until
moisture clears.
Furnace warm up procedure

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Operating Instructions
1-Turn on Fuel Supply
2-Turn on Main Switch.
3-Set to required temperature.
(See warm up procedure for instructions on starting a cold furnace)
4-Turn on Burner Switch
(Burners will take approximately 70 seconds to fire)
5- Set High \ Low Switch TO High.
Burners will modulate between on and off to maintain
the set temperature.
Shutdown Procedure
1-Turn off Burner Switch
2-Isolate Gas Supply

ABN: 68 606 541 468 Email: [e-mail] 12
Gas Submission
FAS-180-INSLPG2
116 Place Cupellation Furnace, 240v Inspirated LPG
Fuel: LPG
Fuel Usage: MAX. 280MJ/HR NOMINAL 200MJ/HR
Operating Pressure: 140Kpa
Max inlet: 140Kpa
Min Inlet: 2.5 Kpa
Combustion Chamber Volume: 0.19M3
Swept Volume: 0.2 M3
Air Supply for door operation: Minimum 3 cfm @ 350 Kpa
Electrical: 220-240 volt 50 Hz 4 amps 1 phase
Door Operation: Pneumatic Ram

ABN: 68 606 541 468 Email: [e-mail] 13
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. E.g., any changes in one or more of these readings will be your
first indication that something may be wrong. Have a look at the problems below
and the possible causes:
A) High/Low Fire Pressures are Decreasing.
This will tell you that something may be blocking up before the pressure gauge,
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.
Clean Burner equipment: - Dirt acts as an insulator, causing motors and solenoid
coils to heat up. If this is left too long, eventually your equipment will fail.
Check Flues:- Blocked flues are the biggest cause of furnace break-down. Left
unchecked, the operation of the furnace will quickly deteriorate. Some signs of
blocked flues are:
A) Flame shooting out of the top of the furnace.
B) Flame licking outside of rear burners.
C) Flame coming out of the door.

ABN: 68 606 541 468 Email: [e-mail] 14
Operational Troubleshooting Flow Chart
Power On Pre Purge
No power:
 Not plugged in
 Surge Protector Faulty
Alarm light on:
 Reset Burner Control
Pre Purge Ignition Transformer Engages
No Ignition:
 Faulty spark plug Clean or replace
 Faulty Boot or Connector Repair
 Damaged Ignition cord Replace
 Faulty Transformer Replace
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 Ignites but goes out:
 Ignites for 5 seconds and goes out Check Uv Cell alignment to pilot flame
Check Uv Cell Globe for dust build up
Replace Uv Cell, may be faulty

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Set desired Temperature on temperature controller and set to high fire.
The Temperature Controller regulates High/Low flame.
Flame is Going out when switches to high fire
 Gas pressure set too high Lower gas pressure (140kpa)
 Furnace just started and is still 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 Supply
Refer to operational log book for normal High/Low settings
Operational Troubleshooting Flow Chart

ABN: 68 606 541 468 Email: [e-mail] 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

ABN: 68 606 541 468 Email: [e-mail] 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

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Burner
UV Cell
Ignition boot
Ignition
lead
Gas Inlet
Pressure gauge
Gas Train
168 Place cupellation Furnace, 240v Inspirated LPG
Burner Equipment overview

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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

ABN: 68 606 541 468 Email: [e-mail] 20
Commissioning Procedure
1. Turn 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