FURNACE & ASSAY LPG Manual

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100 Place Cupellation Furnace
Operation & Maintenance Manual
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ABN: 68 606 541 468
FURNACE & ASSAY
——S U P P L I E S—––
Fuel Source:
LPG
Electrical:
220-240V
Working Area
● 560mm Deep
● 480mm Wide
● 190mm High
Combustion
Chamber
Volume:
0.17
Swept Volume:
0.18

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Manual Index
System Overview 3-4
Safety Devices 5
Spare Parts List 6-7
Installation Procedure 8
Warm-up Procedure 9-10
Operating Instructions 11
Operational Flowchart 12
Gas Submission 13
Weekly Check Sheet 14
Troubleshooting Guide 15-17
Commissioning procedure 18-23
Electrical Schematic 24
Fuel Schematic 25
Maintenance 26-38
Contact 39

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1230 mm
1760mm 990 mm
ELECTRICAL
BOX
250mm
2070 mm
1030 mm
1400 mm
AVERAGE BURNER EQUIPMENT DEPTH
860 mm
Please note you will require a minimum of 1 metre clearance around the furnace.
 Base construction uses high-quality 75 x 75
RHS.
 Furnace body construction is durable 2mm
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
 Optional port viewing window in door
 Vent Tube height 1110mm
Construction
 ISPM 15 Heat treated
export crates
Shipping
Length 1540mm
Width 1490mm
Height 1980mm
Weight 1080KG
* Dimensions are approximate only and may vary slightly with each furnace.

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100 Place Cupellation Furnace
LPG - FAS-170-INLPG
Safety Devices Installed
UV Flame Detection
Pilot Gas Start
Power Requirements
 Volts
 Phase
 Kilowatts
240V
1
1
Fuel Type LPG (Propane)
Gas Consumption 270MJ Per Hour
Operating Pressure 140KPA
Gas Pressure Requirements
Minimum Inlet Pressure
Maximum Inlet Pressure
0KPA
140KPA
System Overview:
This furnace has a Long Pattern Inspirator burner system, with an automatic Ignition
System.
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.
Please note: this type of equipment is not suitable for altitudes above 1000 metres .

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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-170-INLPG2
100 Place Cupellation Furnace, 240v Inspirated LPG
Recommended Critical Spare Parts
FAS Part# FAS Description Qty
FAS-202 Muffle #5 to suit E100PCF & 100PCF 5
FAS-212 Vent Slotted #5 to suit E100PCF & 100PCF & 168PCF 5
FAS-302 Floor Tile 560x480x25mm to suit E100PCF & 100PCF & E20PFF 6
FAS-406 Thermocouple Cupellation 230mm plus 75mm bend 6
FAS-407 Thermocouple Inner Sheath 250x10mm 5
FAS-408 Thermocouple Outer Sheath 250x15mm 5
FAS-603 Ceramic Anchor, (Complete) 3" 18
FAS-803 Isowool Blanket (Kaowool) 160kg x 25mm 1
FAS-1008 Refractory Mortar 2 KG 2
FAS Part# FAS Description Qty
FAS-611 U.V. Cell Flame Detector QRA.2 4
FAS-616 Burner Controller, LFL1.1635 1
FAS-620A Dual Ignition Transformer 1
FAS-623 Solenoid Valve (Complete) 1430k 2
FAS-627 Ignition Lead (Copper Cord) 3
FAS-627A Ignition Boot and Connector 1
FAS-639 Spark Plug UY6 Igniter 2
FAS-648R Temperature Controller, Omron E5CC-RX2ASM-800 (Relay) 1
FAS Part# FAS Description Qty
FAS-170-DOOR 100PCF 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-680 LPG Gas Filter 1
FAS-802 Isowool Blanket (Kaowool) 128kg x 50mm 2

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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-170-INLPG2
100 Place Cupellation Furnace, 240v Inspirated LPG
FAS Part# FAS Description
FAS-170-SHL 100PCF New Body and Bricks
FAS-170-BRNINLPG 100PCF Burner Equipment LPG Inspirated 110/240v
FAS-170-DHP 100PCF Door and Hinge with Pneumatics
FAS-170-EXT 100PCF Back Extraction Piece
FAS-170-BKT 100PCF 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-658A Pneumatic Hand Kit (inc cylinders, hand valve, mounting brackets and fittings)
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-1002 Flue Block - Small
FAS-1003A Burner Port Round Hole 230x250mm
FAS-1004 Refractory Mortar 25kg Drum
FAS-1006 Refractory Castable 25kg Bag
FAS-657 Festo Foot Pedal
FAS-640 Gas Pilot Burner LPG

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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.
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 and set to Low Fire
(Burners will take approximately 70 seconds to fire)
6- Set HIGH \ LOW SWITCH To HIGH.
Burners will modulate between high and low to
maintain the set temperature.
Shutdown Procedure
1-Turn off Burner Switch OFF.
2-Isolate Gas Supply

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Operational Flow Chart
Power on via ON/OFF switch
Pre purge cycle Burner (63 sec) Ignition Transformer engages
Pilot solenoid opens Flame established
After 5 seconds UV flame detection Low fire valve opens if additional
Temperature required high fire Solenoid opens on burner
This furnace is run on LPG Only

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Gas Submission
FAS-170-INSLPG2
100 Place Cupellation Furnace, 240v Inspirated LPG
Fuel: LPG
Fuel Usage: MAX. 270MJ/HR NOMINAL 200MJ/HR
Operating Pressure: 140Kpa
Pilot Operating Pressure 2.5 - 2.75 kpa Producing 12mj hr
Max inlet: 140Kpa
Min Inlet: 2.5 Kpa
Combustion Chamber Volume: 0.17M3
Swept Volume: 0.18 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

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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

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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.

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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 Pilot Established
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/Pilot burner Remove and Clean
Pilot Flame Established 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
Note: Refer to operation log book for any changes in UV meter readings. If they have
been low then replace UV Cell.

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UV flame detection 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 Inspirator jet Remove and Clean
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

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Commissioning Procedure
Electrical Box Layout
Burner Control
Alarm Button
Amp meter Burner Control
Toggle
switches
Temperature
Controller
Ignition
Transformer
Surge
Protector

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Commissioning Procedure
100 Place cupellation Furnace, 240v Inspirated LPG
Burner Equipment overview
UV Cell
Ignition boot
(Spark plug located
under ignition boot)
Gas Train
Gas Inlet
Inspirator
Burner
Pressure
Gauge
Ignition
Lead

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Commissioning Procedure
Burner Equipment close up
Burner
LPG Jet
LPG Gas
Filter
Low Fire
High fire
Low Fire
Orifice
Pressure
Gauge
Pilot
solenoid
Pilot 2 stage
regulator
Pilot Burner