FURNACE & ASSAY FAS-130EAF Manual

ABN: 68 606 541 468 Email: [e-mail] 1
Tel: [phone]
E-mail: [e-mail]
Website: fandasupplies.com/
Electric Ashing Furnace
Operation & Maintenance Manual
Electrical:
240V
Working Area
3 Shelves each
● 350mm Deep
● 350mm Wide
● 150mm High
Power
Requirements
 240 Volts
 1 Phase
 3.5 Kilowatt
FURNACE & ASSAY
——S U P P L I E S—––

ABN: 68 606 541 468 Email: [e-mail] 2
Manual Index
System Overview 3
Spare Parts List 4
Installation Procedure 5
Installing Elements 9-11
Furnace Start-up 12
Electrical Schematic 13
Troubleshooting 14-15
Maintenance 16
Contact Details 17

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System Overview
System Overview:
The Ashing furnace has an easy to use on/off toggle switch.
It is heated by 2 elements mounted in the side walls.
Temperature is monitored and modulated automatically by a Type K thermocouple
system and Omron temperature controller, pre-set for a maximum temperature of
1000 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 micro switch installed that will automatically cut power to the heating
elements when the door is opened.

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Recommended 12 Months Consumables
Recommended Spare Parts
Parts List for FAS-130EAF
Electric Ashing Furnace, Single Phase 3.5kw
Recommended Critical Spare Parts
FAS Part# FAS Description Qty
FAS-406 Thermocouple Cupellation 230mm plus 75mm bend 3
FAS-407 Thermocouple Inner Sheath 250x10mm 3
FAS-408 Thermocouple Outer Sheath 250x15mm 3
FAS-603 Ceramic Anchor, (Complete) 3" 12
FAS-703 Ceramic Tube, 30mm EAF Vent 1
FAS-704 Ashing furnace Element Set 2
FAS-1007 Refractory Mortar 1KG 1
FAS Part# FAS Description Qty
FAS-506 Element Tail Porcelain Tubes, 15 x 50mm 2
FAS-507 Porcelain 3-way Element Connectors 1
FAS Part# FAS Description Qty
FAS-411 Porcelain 2-way Element Connectors 1
FAS-608 Thermocouple Wire 3
FAS Part# FAS Description
FAS-513 Contactor, ABB A30-30-10
FAS-514 Solid State Relay , G3PB-235B/VD
FAS-628 Toggle Switch ( on/off, high/low )
FAS-648R Omron E5CC-RX2ASM-800 Temp Controller
FAS-701 Trays for Ashing Furnace
FAS-702 Micro Door Switch Z15GQB
FAS-801 Isowool Blanket (Kaowool) 128kg x 25mm
FAS-1004 Refractory Mortar 25kg Drum
FAS-1008 Refractory Mortar 2 KG
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

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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.
*Furnace requires a min of .5 metre space around it to carry out main-
tenance / repairs.
*Install fuel supply. This must be carried out by a qualified technical
person.
*Electrical connection is single phase with Earth.
*Before connecting power supply make sure ALL electrical connections
are tight, and have not become loose in transit.
*BEFORE STARTING CHECK THAT ALL EXHAUST DUCTING IS IN
PLACE.

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REPLACING ASHING ELEMENTS
When to change an Ashing Furnace element.
If a break in an element is visible, one side of an element is not heating up
(glowing) or the furnace is not getting to temperature, chances are an element
will need changing.
Below are some pictures of element breaks; some are easily visible, others are
a little harder to spot.

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REPLACING ASHING ELEMENTS
How to change an Ashing Furnace element.
First Isolate Power Supply
To remove back panel, firstly unscrew
the bolt holding vent tube in place.
Then unscrew the four mounting bolts on
the back panel.
Once removed locate where the old
elements are connected to.
Loosen the screw in the connection
to the element.
Straighten element tails and pull out
ceramic tubes covering the
elements. Keep these to cover the
new elements.
Once elements are free, move to the front of the
furnace.

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REPLACING ASHING ELEMENTS
Carefully remove old elements. Slowly pull out of grooves,
making sure not to damage the brick work as you go.
One element may come out in several pieces.
Take note of how they come out. This will help you to understand how to install the
new elements into the grooves in the furnace. Once old elements are out, make
sure to vacuum all grooves out as dust, parts of an old element and any other build
up will shorten the life span of the new elements.
Lay new elements out and make
sure they are not tangled. Pick up by
the element tail and thread into the
hole through the bricks and out the
back of the furnace.
There will be one of these holes
top and bottom of each wall.

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Carefully place elements into grooves trying not to force the elements in too much,
as this may break the bricks.
REPLACING ASHING ELEMENTS

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Once both sides of elements are in place
and sitting in grooves, move to the back of
the furnace.
If you are having issues with getting the
elements to sit in the grooves, you can pin
elements back. If you do not have any
element pins then elements may fall into
place when elements are Annealing in the
first hour of start up. If they are still not
sitting correctly you will need to source
some element pins or use excess element
tails (see below) to make some element
pins.
REPLACING ASHING ELEMENTS
Slide ceramic tube back over the
element tails top and bottom.
Push into place, leaving about 5-10mm
out, and silicon around to keep in place.

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REPLACING ASHING ELEMENTS
Once Silicon has dried, using two sets of pliers
bend tails towards the centre of the furnace.
You will need to bend to just over 90 Deg.
Measure 50mm from centre of bend
and cut excess tail off.
NOTE: if you unwind the excess wire
from the tails into two single bits of
wire, you can use this to make ele-
ment pins if having issues with ele-
ments sitting flat. Bend to a U shape
pin about 30mm long.
Reinstall element tails into porcelain connectors.
Once all have been reinstalled (before attaching
back panel to furnace) turn on the furnace for
one hour to anneal elements.
Once elements have been annealed, check to
see if elements are sitting correctly in grooves.
Isolate power and check tightness of element
tails in porcelain connectors, as the wire can be-
come loose as it softens.
Once this has been checked replace back cover.

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STARTING UP FURNACE
Micro
Switch
Temperature Controller
Temp Display
Temp
Down
Temp
Up
1. Connect Power
2. Turn Furnace on at toggle Switch
3. Once door is closed, the furnace will start.
If the door is open the power to the furnace is cut by the
Micro Door Switch.
Set Temperature controller to desired temperature.
Front Panel
Toggle
Switch

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Electrical Schematic
C O M P O N E N T S
T E M P E R A T U R E
C O N T R O L L E R
D O O R
S W I T C H
+
-
5
2
9
11
10
12
6
1
TEMPERATURE CONTROL
HEATING ELEMENTS 13g Wire wound
ELECTRICAL SCHEMATIC
EAF
Omron E5CC-RX2ASM-800
DOOR SWITCH OMRON D4D-1121N
ABB A30-30-11 - 240v ALARM CONTACTOR
Draw By MB 2011
MAIN CONTACTOR S S Relay G3PB
THERMOCOUPLE TYPE K 280 + 75MM
T H E R M O C O U P L E
N
-
+
C O N T R O L
S W I T C H
A1
A2
A1
A2
Contactor
S S
Relay
L1 L2 L3
T1 T2 T3
L1
T1
3.5 kw Wire wound
Elements
240 single phase power
R1
SSR

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FAULT:
Furnace Not Turning on.
Make sure the furnace is connected to power.
Make sure the furnace door is closed, as it has a safety door switch to cut power
when the door is open.
FAULT:
The Error shown below in the picture is coming up on the temperature controller.
This is a thermocouple circuit error.
It could be a few things, the most common is the thermocouple is broken and
needs changing.
If you still have this error after changing out the thermocouple it could be because
a wire has become loose in the circuit. Try and tighten all wire connections from
thermocouple head to temp controller.
If you still have no luck then check the thermocouple wire has not been melted/
damaged. If it has, then replace it.
If all this fails, you may need to replace the temp controller.
Troubleshooting

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Troubleshooting
FAULT:
The furnace door is not closing properly or is not sealing.
Over time the Kaowool in the door may become compacted slightly.
This may stop the door from sealing properly when
closed due to the micro door switch that is installed.
If this happens you can simply screw the connection
bolt in more to allow the door to seal correctly.
If this is done test the door switch is still working
correctly.
If the door is open, the power should cut from the
furnace.
When the door is shut the power will return.
FAULT:
The Furnace is not heating up or one side of elements is not heating up.
Shut furnace down and check elements for breaks.
If breaks present replace affected element. (See instructions above)
If none seen remove back panel and check the element connections are tight.
If issues continue replace element as a break sometimes is not visible.

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Maintenance
Do not place anything closer than 0.5 of a metre to the furnace
as this may damage the item or cause damage to the furnace.
It is important to keep the bench clean and clear around the furnace.
Once every few months or when the furnace is shut down and cool, vacuum out
the furnace and the element grooves.
This will help the elements to last longer.
Seal any cracks in bricks with refractory mortar.
Note: keep mortar away from element grooves.

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Contact Details
FURNACE & ASSAY
——S U P P L I E S—––
54 Owen Road,
Kelmscott, 6111
Western Australia, Australia
Phone
[phone]
Fax
[phone]
Email
[email protected]m
Web
www.fandasupplies.com