VERDER CARBOLITE GERO CAF G5 Manual

Installation, Operation and Maintenance Instructions
1600°C Coal Ash Fusion Furnace - CAF G5
CAF G5
MEN-CAFG5-001_3508 (17-09-2020)

Contents
This manual is for guidance on the use of the Carbolite Gero product specified on the
front cover. This manual should be read thoroughly before unpacking and using the
furnace or oven. The model details and serial number are shown on the back of this
manual. Use the product for the purpose for which it is intended.
1.0 Safety Information 6
1.1 General 6
1.2 Carbon Monoxide Warning 7
1.3 Hydrogen and Carbon Dioxide Warning 8
1.4 Safety Warning - Refractory Fibre Insulation 8
1.5 Viton 'O' Rings - Warning 9
2.0 Models Covered by this Manual 9
3.0 Installation 10
3.1 Unpacking and Handling 10
3.2 Packing List 10
3.3 Assembly of the Furnace 11
3.3.1 Element Fitting 11
3.3.2 Installing the Work Tube and Rear Seal Assembly 12
3.3.3 Fitting the Work Tube Front Seal Assembly 13
3.3.4 Fitting and Adjusting the Door Arm Assembly 13
3.3.5 Pressure Testing of the Work Tube Assembly 14
3.4 Positioning the Furnace 15
3.5 Electrical Connections 15
3.6 Voltage Level and Power Limit Settings 16
3.7 Exhaust Vent Connections 17
3.8 Gas Connections 18
3.8.1 Furnaces for CO/ CO2 and Air Test Gases with N2 Purge Gas 18
3.8.2 Furnaces for H2 and CO2 Test Gases with CO2 Purge Gas. 18
3.9 Camera Mounting and Connections 18
Fitting Type 1 - Bayonet 19
Fitting Type 2 - Screw 19
3.9.1 Camera and Lens Settings 19
3.9.2 Adjusting the Lens. 20
3.10 Computer Connections 20
4.0 Operating Instructions 21
4.1 Furnace Start-Up 21
4.2 Eurotherm Controller 22
4.3 Computer Start-Up 22
2

4.3.1 Communication Failure: 23
4.4 Gas Set-Up 23
4.4.1 Gas Flow Rates 24
4.4.2 Carbon Monoxide Sensor 25
4.5 Loading Samples into the Work Tube 25
4.6 Introduction to the CAF Test Software 26
4.6.1 CAF Interface 28
4.7 Operation of CAF Software 28
4.7.1 Process Tabs 29
4.7.2 Configure 30
4.7.2.1 Test Results Folder 30
4.7.2.2 Temperature Settings 30
4.7.2.3 Test Piece Identification 32
4.7.2.4 Analysis Grids 33
4.7.2.5 User Settings 34
4.7.2.6 Factory Reset 34
4.7.2.7 Backlight Intensity (If Available) 34
4.7.3 Test 35
4.7.3.1 Test Results Folder 35
4.7.3.2 New Test Name 35
4.7.3.3 Test Reference 36
4.7.3.4 Auto Analysis Selection 36
4.7.3.5 Start Test 36
4.7.3.6 Start/ Stop the Program 36
4.7.4 Analysis: Automatic and Manual 36
4.7.4.1 Test Results Folder 37
4.7.4.2 Test Name 37
4.7.4.3 Automatic Analysis 38
4.7.4.4 Automatic Analysis Thresholds 38
4.7.4.5 Running with Automatic Analysis 39
4.7.4.6 Results Form 39
4.7.4.7 Automatic Entry of Test Results 40
4.7.4.8 Analysis Graph Form 41
4.7.4.9 Manual Entry of Analysis Results 42
4.7.4.10 File Folders 43
3

4.7.4.11 File Formats 44
4.8 Post-Operation Cooling 45
5.0 Maintenance 46
5.1 General Maintenance 46
5.2 Maintenance Schedule 46
5.2.1 Cleaning 48
5.3 Element Ageing 48
5.4 Checking and Replacing the Door 'O' Ring Seal 49
5.5 Cleaning the Viewing Window 49
5.5.1 To remove the viewing window for cleaning or replacement: 49
5.5.2 Cleaning the Window 50
5.5.3 When Replacing the Window 50
5.6 Furnace Calibration 50
5.6.1 Sample Carrier Tiles 50
5.6.2 Sample Preparation 50
5.6.3 Test Procedure 51
5.6.4 Interpretation of Results 51
5.6.4.1 Definitions: 51
5.6.4.2 Documentation of Results 51
5.6.4.3 Temperature Limits 51
5.6.4.4 Deviations from Limits 52
5.7 Instrument Calibration Adjustment 52
5.8 After-Sales Service 55
5.9 Recommended Spare parts and Consumables 55
6.0 Fault Analysis 56
A. Furnace Does Not Heat Up 56
B. Furnace Overheats 57
C. Rear Internal Lighting 58
D. Computer Software 58
E. Gas System 59
F. Internal Carbon Monoxide Sensor 60
7.0 Wiring Diagrams 61
8.0 Specifications 61
8.1 Environment 61
9.0 Appendix 62
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Fig 1. Element wiring and positions.
Fig 2. Work tube and back plug assembly.
Fig 3. Front tube seal assembly.
Fig 4. Door arm assembly.
Fig 5a. Camera mounting bracket.
Fig 5b. Standard lens & camera assembly.
Fig 5c. Sliding the camera mounting bracket assembly onto the door arm.
Fig 5d. Securing the camera mounting bracket assembly to the door arm.
Fig 5e. Mounting the lens & camera assembly.
Fig 5f. Lens & camera assembly in position.
Fig 6. Rear view of furnace showing brick box assembly.
Fig 7. Front tube seal position
Fig 8. Tube end seal assembly tightening sequence
Fig 9. Work tube front support.
Fig 10. Fitting the door arm assembly.
Fig 10a. Adjusting the door arm assembly.
Fig 11a. Furnace case and controls.
Fig 11b. Gas Inlet Pipe
Fig 12. Positioning the furnace.
Fig 13a. Positioning the samples on the sample carrier.
Fig 13b. Loading samples into the work tube.
Fig 13c. Loading samples into the work tube.
Fig 14. Set-up options.
Fig 15a. File name and sample identifier
Fig 16. File folder
Fig 17. Door arm assembly exploded view.
Fig 18. Report sheet.
Fig 19. Formed wire sample.
Fig 20. Sample carrier, sample tiles and sample positions.
Fig 21a. Coal and Coke Test Piece Mould.
Fig 21b. Biomass Test Piece Mould and Hand Press.
Fig 22. Sample loading tool.
Fig 23. Camera Ethernet Connection.
Fig 24. LED Driver Connection.
5

1.0 Safety Information
1.1 General
Please read all of this section first.
Please look through the complete manual before connecting the
furnace.
In particular read through the section 3.6.
This furnace must be earthed (grounded).
Do not operate the furnace at temperatures above 815 °C (1500 °F) with the door
open.
The furnace door must not be left open longer than is necessary to load and unload
samples from the work tube.
The furnace door must be closed and secured using the two swing bolts before
commencing a Coal Ash Fusion test. It is important that the swing bolts are tightened
evenly to create a gas tight seal between the door flanges. When a coal ash fusion test
is running the yellow Test In Progress light illuminates on the control panel and the
green Standby Mode light goes out. Do not open the furnace door when the Test In
Progress light is illuminated or exposure to carbon monoxide may result. See section
1.2.
During a test only the yellow Test In Progress light should be illuminated. If any of the
other three lights are illuminated (see fig 11a) then there is a fault: do not use the
furnace until the fault is rectified.
During Standby Mode only the green Standby Mode light should be illuminated. If there
are no lights illuminated, or if any of the other three lights are illuminated (see fig 11a)
including the green Standby Mode light, then there is a fault: do not use the furnace
until the fault is rectified.
Do not operate the furnace with the door or window ‘O’ ring seals removed or exposure
to carbon monoxide may result. See section 1.2.
A regular work tube pressure test must be conducted to ensure integrity of the work
tube and ‘O’ ring seals. See section 3.3.5.
To avoid fire, do not expose combustible materials to heat from the open door.
Do not use the furnace in the presence of inflammable or combustible chemicals: fire or
explosion may result. Do not place the furnace on an inflammable surface.
When operating the furnace wear appropriate safety clothing, including eye protection
and gloves.
Isolate the furnace from the electrical and gas supply and ensure that the furnace is
cold before changing elements, thermocouples or undertaking other routine
maintenance.
6

1.2 Carbon Monoxide Warning
Operation of the CAF furnace involves the use of carbon monoxide.
Carbon monoxide is a product of reaction of H2and CO2.
Carbon monoxide (CO) is a colourless, odourless, tasteless and inflammable gas which
is acutely toxic. CO is introduced into the blood stream through the lungs and binds with
the haemoglobin preventing it from carrying oxygen around the body. This can result in
rapid damage to body tissues due to oxygen starvation. Since CO is an accumulating
toxin it can be dangerous even when present in quite low concentrations over long
periods of time. Individuals vary considerably in their reactions to concentrations of
toxic gases; table 1 shows the typical effects of cumulative CO exposure.
Information extracted from Guidance Note EH43 (1996) from the Health and
Safety Executive.
To minimise the risks associated with CO it is most important that the furnace is
installed and operated in accordance with this instruction manual. If the furnace
operator experiences any of the effects listed above, the furnace must be isolated from
the gas and electricity supplies immediately and expert advice sought. For safety
guidelines seek the gas manufacturers advice.
Table 1. Carbon monoxide in air:
Parts per
million Effect
50 Recommended Exposure Limit (8 hours time weighted average
concentration)
200 Headache after approximately 7 hours if resting or after 2 hours
exertion
400 Headache with discomfort with possibility of collapse after 2 hours at
rest or 45 minutes exertion.
1200 Palpitations after 30 minutes at rest or 10 minutes exertion.
2000 Unconscious after 30 minutes at rest or up to 10 minutes exertion.
For further information refer to:
lGuidance Note EH43 (1996) from the Health and Safety Executive. ISBN 0 11
883597 1
lEH40/ 2005 Workplace Exposure Limits 2011. ISBN 978 0 7176 6446 7
7

1.3 Hydrogen and Carbon Dioxide Warning
Applicable for furnaces constructed to use H2and CO2test gases with CO2'Purge' gas.
H2can form explosive gas mixtures, take precautions to avoid leakage
of H2.
H2and CO2can react to form CO.
see section 1.2.
Carbon dioxide (CO2) is a colourless, odourless and tasteless gas that is an asphyxiant.
Rapid unconsciousness occurs at levels above 11%, levels of 20 - 30% are immediately
hazardous to life.
Information extracted from Croner Publications Ltd. Substances Hazardous To
Health.
To minimise the risks associated with CO2it is most important that the product is
installed and operated in accordance with this instruction manual. If the product
operator experiences any of the effects listed above, the product must be isolated from
the gas and electricity supplies immediately and expert advice sought. For safety
guidelines seek the gas manufacturers advice.
1.4 Safety Warning - Refractory Fibre Insulation
Insulation made from High Temperature Insulation Wool
Refractory Ceramic Fibre, better known as (Alumina silicate
wool - ASW).
This product contains alumino silicate wool products in its thermal insulation. These
materials may be in the form of blanket or felt, formed board or shapes, slab or loose
fill wool.
Typical use does not result in any significant level of airborne dust from these materials,
but much higher levels may be encountered during maintenance or repair.
Whilst there is no evidence of any long term health hazards, it is strongly recommended
that safety precautions are taken whenever the materials are handled.
Exposure to fibre dust may cause respiratory disease.
When handling the material, always use approved respiratory protection
equipment (RPE-eg. FFP3), eye protection, gloves and long sleeved clothing.
Avoid breaking up waste material. Dispose of waste in sealed containers.
After handling, rinse exposed skin with water before washing gently with soap
(not detergent). Wash work clothing separately.
Before commencing any major repairs it is recommended to make reference to the
European Association representing the High Temperature Insulation Wool industry
(www.ecfia.eu).
8

Further information can be provided on request. Alternatively, Carbolite Gero Service
can quote for any repairs to be carried out either on site or at the Carbolite Gero
factory.
1.5 Viton 'O' Rings - Warning
The ‘O’ ring seals used in the CAF G5 furnace work tube assembly are
manufactured from Viton. Viton is combustible and decomposition
occurs at elevated temperatures.
Decomposition products include Hydrogen Fluoride, fluorinated hydrocarbons, Carbon
Monoxide and Carbonyl Fluoride. Hydrogen Fluoride is highly corrosive.
Although these seals should not be exposed to elevated temperatures during normal
use, the following precautions should be taken:
lWear neoprene gloves while handling the seals.
lDispose according to local regulations. Landfill is recommended. Burning is not
recommended except by an approved or licensed incineration agent.
2.0 Models Covered by this Manual
Three furnace options are available, These differ in the type of gases that are used to
create the ‘oxidising’ and ‘reducing’ atmosphere and the control of those gases and the
option of rear lighting particularly for lower temperature analysis, such as Biomass.
Type
1.
CO/ CO2‘reducing’ gas and Air ‘oxidising’ gas with N2‘Purge’ gas. With no
rearlighting. Compatible with both:
ASTM D1857 / D1857M – 04 (2010) Standard Test Method for Fusibility of Coal
and Coke Ash
& BS ISO 540 : 2008 Hard coal and coke. Determination of Ash Fusibility.
Type
2.
Rear Lighting option with CO/CO2‘reducing’ gas and Air ‘oxidising’ gas with N2
‘Purge’ gas. Compatible with:
DDCEN/TS 15370-1:2006 Solid biofuels-Method for determination of as
melting behaviour.
& PD CEN/TR 15404:2002 Solid recovered fuels-Methods for the
determination of ash melting behaviour by using characteristic temperatures.
& ASTM D1857 / D1857M – 04 (2010) Standard Test Method for Fusibility of
Coal and Coke Ash
& BS ISO 540 : 2008 Hard coal and coke. Determination of Ash Fusibility.
Type
3.
H2and CO2‘reducing’ gases and CO2‘oxidising’ gas with CO2‘Purge’ gas. With
no rear lighting.
Compatible with - BS ISO 540 : 2008 Hard coal and coke. Determination of
Ash Fusibility.
9

3.0 Installation
3.1 Unpacking and Handling
When unpacking and handling the product, always lift it by its base. Do not use the door
or any other projecting cover or component to support the equipment when moving it.
Use two or more people to carry the product where possible.
Carefully remove any packing material from inside and around the product before use.
Avoid damaging the surrounding insulation when removing packing materials.
Avoid applying force to internal components such as the work tube or insulation.
3.2 Packing List
The packaging should contain the following components:
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1 off Furnace Assembly
1 off Work tube and back seal assembly, see fig 2.
1 off Work tube front insulating collar.
1 off Work tube gasket.
1 off Front tube seal assembly, see fig 3.
1 off Door arm assembly (without door plug), see fig 4.
1 off Door plug, see fig 4.
1 off Flexible gas pipe.
1 off Camera mounting bracket, see fig 5a.
1 off Lens and camera assembly, see fig 5b.
6 off Panel hole blanking plugs.
1 off Sample Carrier.
1 off Sample Loading Tool, see fig 21.
100 off Sample tiles.
1 off 'Window retaining ring' spanner.
1 off Cone mould.
1 off 1.25 mm Allen key
1 off 150 mm length of Gold wire (1063 °C fuse wire).
1 off 150 mm length of Palladium wire (1554 °C fuse wire).
1 off Carbon Monoxide monitor
1 off RS232 Interface cable.
1 off Ethernet connection cable, Furnace/ Computer.
1 off Computer.
1 off Monitor.
1 off Keyboard.
1 off Mouse.
1 off Memory Stick - containing a copy of the software and operation manual.
2 off Computer power cable.
1 off Installation, Operation and Maintenance Instructions for the CAF Test
Furnace.
3.3 Assembly of the Furnace
3.3.1 Element Fitting
Ensure that the furnace is isolated from the mains supply. Remove the back panel from
the furnace unit.
11

Note: The heating elements are fitted at the factory to test the furnace but are
removed for transit. These elements are extremely fragile, and can be damaged by
contamination: handle them with care and keep them clean. Avoid touching the heating
part.
Slide one insulating collar over each element, then gently slide the element into its hole
in the furnace until the tip of the element locates in the front insulation, see fig 1. If the
element does not slide in freely check that you are holding it in line with the hole; it may
help to rotate the element whilst sliding it in. Only light finger pressure should be
required. When the element is in position slide the insulating collar up against the
furnace back insulation.
Use the braids to link the elements and connect them to the terminal posts as shown in
fig 1. Make sure the braids do not touch any other component, or each other.
3.3.2 Installing the Work Tube and Rear Seal Assembly
Ensure that the furnace is isolated from the mains supply, remove the back panel and
front panel from the furnace unit.
Remove the fixing nut and one washer from each of the work tube back support fixing
pillars on the back of the furnace. See fig 6a, 6b.
Take the rear insulation assembly. See Fig 2.
Carefully insert the work tube and back seal assembly into the furnace from the back
and slide it through the furnace until the work tube is protruding from the front. The
work tube is correctly positioned when: the work tube insulating collar is in contact with
the back face of the furnace heating chamber, the work tube back support is located
over the fixing posts and the thermocouple sheath is at the top above the vent tube
fitting. Secure the work tube back support in position using the fixings provided. See fig
6.
Note: Take care not to stress the work tube. The work tube back support must be
parallel to the back of the furnace heating chamber and it should not be necessary to
bend the back support fixing posts to locate it.
Connect the numbered thermocouple leads to the thermocouple connecting terminals
mounted on the work tube back support. Ensure correct polarity, compensating cable
colour coding is:
thermocouple leg colour
negative white
positive orange
Rear Lighting Option.
If the rear lighting option is fitted connect the 6 way socket and plug that connects the
LED lights to the LED Driver positioned in the bottom right of the case looking at the
rear of the unit, see fig 23.
Make sure the element braids do not touch any metal components of the back tube seal
assembly.
12

3.3.3 Fitting the Work Tube Front Seal Assembly
Slide the work tube front insulating collar over the front protruding part of the work
tube until it is in contact with the front face of the heating chamber.
Dismantle the front tube seal assembly by removing the six socket screws. See fig 3.
Slide the work tube ring over the front of the work tube with the internal chamfer facing
towards the front. See fig 3 and See fig 7.
Fit the tube ‘O’ ring over the front of the work tube and position it uniformly 7.0 mm
from the front edge of the work tube. See fig 7.
Fit the work tube gasket to the work tube sealing ring as fig 7, position the work tube
sealing ring on the front end of the work tube and loosely secure to the work tube ring
using the six socket screws provided.
Rotate the front seal assembly so that the swing bolts are positioned horizontally and
the gas inlet fixing is at the lower left side of the work tube. See fig 8.
Tighten the six socket screws evenly in the sequence as shown by numbers 1 to 6 in fig
8. Ensure that the work tube sealing ring is held firmly against the end of the work tube
and is evenly spaced from the work tube ring about its circumference.
Fit the furnace front panel in position and adjust the work tube front support bracket to
support the weight of the work tube assembly. See fig 9.
Note: Do not stress the work tube. With the work tube front support correctly adjusted
there should be a slight gap around the circumference of the tube within the aperture of
the furnace heating chamber. This can be tested for by lifting the work tube upwards
from the support bracket, only a slight gap should be observed between the work tube
and the support bracket when the work tube is lifted as far as possible.
3.3.4 Fitting and Adjusting the Door Arm Assembly
Note: the refractory door plug is fragile: handle with care.
The door plug is supplied separate from the door arm assembly to avoid transit
damage. Fit the door plug to the door arm assembly before fitting the door assembly to
the furnace. Refer to section 5.4.
Pull out the door slide shaft to its full extension and rotate it fully anti clockwise (view
from front). The door slide shaft will only rotate when it is fully extended.
Remove the four socket screws from the back of the door arm assembly mounting block
only; do not remove the front fixing screws, which are factory set to position the door
arm. See fig 10a.
Slide the door arm assembly onto the end of the door slide shaft and secure firmly in
the door open position shown in fig 10. using the four socket screws. Take care to
tighten the socket screws evenly to avoid any distortion in the door arm assembly.
Caution: To allow the door side shaft to slide in and out, some clearance is required in
the door mechanism; consequently there is a small radial movement in the door slide
arm when the door arm is pushed in towards the work tube. Because of this radial
movement it is possible for the door plug to contact the work tube front seal assembly if
the door handle is lifted as the door arm is pushed inwards: take care to avoid this
happening.
13

Carefully swing the door arm in a clockwise direction (view from front) to its stop
position, ensuring that the door plug does not touch tube end guard. The door plug
should be clear of the furnace in its fully withdrawn position. It should not be possible to
push the door arm in towards the furnace until the door arm is rotated fully clockwise
(view from front) and the door plug is in line with the work tube front aperture.
The door arm assembly has an Ethernet cable running through it for the camera. The
cable has a connector at each end. One end of the cable comes out of the conduit cable
through the conduit plate and is connected to the Ethernet connector inside the aperture
in the left hand side of the furnace case see fig. 22. Once the cable is connected
carefully insert the connector into the aperture and fix the conduit plate into position.
Note: take care to keep the cable away from sharp edges.
If no other options are to be added to the rear of the unit i.e. rear lighting option, the
back panel can be replaced, ensuring that the earth tag and fan connections are
securely fitted.
Carefully slide the door plug into the work tube ensuring that it is clear of the front seal
assembly. If the door plug is misaligned, adjustment of its position in relation to the
work tube can be achieved by loosening the front and back door arm fixing screws and
rotating the door arm about the door slide shaft axis. See fig 10a.
3.3.5 Pressure Testing of the Work Tube Assembly
Note: To ensure that the work tube assembly has been correctly installed it is necessary
to pressure test the furnace prior to use.
Due to the high work tube temperatures used during CAF testing the tube ‘O’ ring seals
will deteriorate with time. The furnace work tube also has a finite life and may
eventually crack due to normal wear and tear. It is necessary to conduct a pressure test
of the work tube assembly at regular intervals during normal use of the furnace to
ensure integrity of the work tube and ‘O’ ring seals. The following procedure applies:
Connect one end of the flexible gas inlet pipe (normally connected between the
bulkhead connection on the front of the furnace case and the work tube front seal
assembly) to the work tube front seal assembly. See fig 11b. Connect the other end to
an adjustable compressed air test line or inert gas supply capable of delivering up to 4
psi. Check all air/ gas connections for leaks, any leakage from the air/ gas supply line
may affect the pressure test results.
Close the door assembly and clamp in position using the swing bolts.
Securely block the work tube vent at the back of the furnace using blanking plug.
Pressurise the work tube assembly via the flexible gas inlet pipe to 3 psi ± 1 psi using
compressed air or inert gas.
Once the furnace gas system is pressurised to 3 psi ±1 turn off the air supply, the gas
system should stay pressurised to 3 psi ±1 for 5 minutes.
Following successful pressure testing of the work tube assembly, connect the flexible gas
inlet pipe to the bulkhead connection on the front of the furnace case. Check all external
gas connections and vent tubes for leaks prior to using the furnace.
14

Under no circumstances should any objects be placed on top of the product.
Always ensure that any vents on the top of the product are clear of any
obstruction. Always ensure all cooling vents and cooling fans (if fitted) are
clear of any obstruction.
3.4 Positioning the Furnace
Significant amounts of carbon monoxide may be exhausted from the
work tube during the use of this furnace. Carbon monoxide is toxic and
inflammable (see section 1.2) and must be ducted out of the building.
See also section 3.7.
The furnace is designed to be gas tight during normal operation, but incorrect
installation or component failures due to misuse or wear and tear could give rise to a
high presence of carbon monoxide. To minimise risk to the operator in the event of a
high presence of carbon monoxide the furnace must be installed under a suitable forced
air extraction hood. An example is shown in fig 12. The extraction hood must be ducted
out of the building and must be operating whenever the furnace is in use. The room
must be well ventilated and the ‘fresh air in’ ventilation should exceed the hood
extraction to ensure that fumes do not escape into the room.
As a precaution the furnace is supplied with a carbon monoxide detector. If the CO
detector is correctly installed it will alert the furnace operator in the event of a leak of
carbon monoxide that is not removed by extraction.
Note: The CO detector must be positioned and installed in accordance with the
manufacturer’s instructions supplied. In the event of a CO detector alarm evacuate the
area immediately and seek expert advice. Isolate the furnace from the gas and
electricity supply only if it is safe to do so.
Ensure that the furnace is installed in such a way that the electrical supply and the gas
supply can be quickly switched off in the event of an emergency without any danger to
the operator.
Ensure that there is a minimum free space of 100 mm around the furnace and do not
obstruct any of the vents in the case as these are required to keep internal components
cool.
Under no circumstances should any objects be placed on top of the product.
Always ensure that any vents on the top of the product are clear of any
obstruction. Always ensure all cooling vents and cooling fans (if fitted) are
clear of any obstruction.
3.5 Electrical Connections
Connection by a qualified electrician is recommended.
15

The voltage or range of voltages on which the furnace may be operated is given on the
furnace rating label. See fig 11a. Check that the electrical supply voltage is compatible
with the voltage on the label, and that the current capacity is sufficient for the maximum
current on the label before connection to the electrical supply.
The furnace should be permanently connected to the correct supply through a wall
mounted isolating switch or an easily removable plug. The switch or plug should be
within easy reach of the operator. Unless a supply cable is fitted the electrical supply
connections are to be made to terminals mounted inside back of the furnace, accessed
by removing the furnace back panel.
The terminals are marked according to the power supply, connect as shown in the table
below. The electrical supply must incorporate an earth (ground).
Supply Terminal Label Cable Colour
Supply Types
Live - Neutral Reversible or Live-
Live
1-phase L1 Brown to live
to either power
conductor
(For USA 200-240V,
connect L1)
N / L2 Blue to neutral
to the other power
conductor
(For USA 200-240V,
connect L2)
PE Green/ Yellow to earth
(ground) to earth (ground)
Electrical Connection Details:
2-phase L1 Black to phase 1
L2 Black to phase 2
N Light Blue to neutral
PE Green/ Yellow to earth (ground)
3.6 Voltage Level and Power Limit Settings
Check the furnace rating label voltage. If the actual supply is not the
same as the voltage on the label, the controller power limit should be
adjusted as follows. The power limit can also be changed through the
software if connected, see section 5.3.
16

If the actual supply voltage is higher than the voltage on the rating label (or the voltage
for which the furnace was last set), immediately after switch-on set the temperature
setpoint to zero, to prevent heating and drawing excessive current.
First select user level 2. Press and hold the page until ‘Access Goto’ is displayed.
Select Level 2 using the down or up . Access pass code should now be displayed.
Using the down or up enter pass code 9. The word 'Pass' should be shown briefly
and then the display will revert back to main display screen.
To Select Output high. From the main screen. Press page twice to display 'Control
output High'. Using the down or up keys select the correct power setting.
Correct values for the OP.Hi parameter, with new elements, are:
200 V 208 V 220 V
380 V
230 V
400 V
240 V
415 V
79% 74% 65% 60% 55%
See also the section 5.3
3.7 Exhaust Vent Connections
Note: Significant amounts of carbon monoxide may be exhausted from
the work tube during the use of this furnace. Carbon monoxide is toxic
and inflammable (see section 1.2) it is recommended that the vent tube
is routed out of the building.
The furnace must always be positioned as recommended in section 3.4.
The furnace has two exhaust vents, the main vent at the back of the heating chamber
and a safety pressure relief vent at the side of the furnace. The purpose of the safety
vent is to prevent dangerous pressure build up as the furnace warms up if the main
vent tube becomes blocked.
The main vent and the safety pressure relief vent must be connected to separate vent
runs and routed out of the building.
With the back panel removed access is gained to the main vent tube fitting situated on
the work tube back seal assembly below the thermocouples. The main vent tube fitting
is a 12 mm x 3/8" BSP adapter suitable for connecting 12 mm diameter copper tube.
See fig 6.
The safety pressure relief vent tube fitting is a 6 mm x 1/8" BSP adapter suitable for
connecting 6 mm copper tube. See fig 11a.
Note: It is important that the vents are not restricted in any way, do not use a tube of
less than 6 mm diameter for the safety pressure relief vent connection and 12 mm for
the main vent connection.
Check regularly that the main and safety pressure relief vents are clear from
obstructions.
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3.8 Gas Connections
3.8.1 Furnaces for CO/ CO2and Air Test Gases with N2Purge Gas
See below if a mixer box for separate CO & CO2inputs is supplied.
Note: The gas supply pressure required is 4 psi (0.276 bar) and must not exceed this.
There are three gas connections on the side of the furnace, CO/ CO2pre mixed
'reducing' atmosphere gas, Air 'oxidising' gas and N2'Purge' gas. See fig 11a. It is
recommended that the gases are supplied to the furnace via separate isolation valves
that can be quickly switched off in the event of an emergency or potential hazard
without danger to the operator. See section 1.2.
The 'Purge' gas line is pre-set to allow a flow of N2into the work tube equal to 6 litre/
minute, the 'oxidising' and 'reducing' atmosphere gases have adjustable flow via the
flow meters on the front of the furnace. See fig 11a. The gas supply fittings are 6 mm x
1/8" BSP adaptors suitable for connecting 6 mm copper tube.
Separate CO and CO2supplies.
If a mixer box is supplied, separate input connections of CO and CO2may be made to
the lower connections at the back of the box. A pipe from the upper connection is to
be taken to the CO/ CO2inlet on the furnace.
The box is fitted with two flow-meters which may be adjusted to ensure that equal
mixtures of CO and CO2are supplied. The box also contains two non-return valves to
ensure that neither gas can flow back out of either inlet connection.
3.8.2 Furnaces for H2and CO2Test Gases with CO2Purge Gas.
Note: The gas supply pressure required is 4 psi (0.276 bar) and must not exceed this.
There are three gas connections on the side of the furnace, CO2'oxidising' atmosphere
gas, H2(mixed with CO2in the work tube) 'reducing' atmosphere gas and CO2'Purge'
gas. See fig 11a. It is recommended that the gases are supplied to the furnace via
separate isolation valves that can be quickly switched off in the event of an emergency
or potential hazard without danger to the operator. See section 1.3.
The 'Purge' gas line is pre-set to allow a flow of CO2into the work tube equal to 6 litre/
minute, the 'oxidising' and 'reducing' atmosphere gases have adjustable flow via the
flow meters on the front of the furnace. See fig 11a. The gas supply fittings are 6 mm x
1/8" BSP adaptors suitable for connecting 6 mm copper tube.
3.9 Camera Mounting and Connections
Fit the camera mounting bracket onto the door arm as shown in fig 5c and 5d. Note that
the camera shown in fig 5c and 5d is not fitted for this operation.
Note: Depending on the age of your furnace, it will have one of two camera mount
fittings. Older models will have the type 1 fitting, while newer models will have the
type 2 fitting.
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Fitting Type 1 - Bayonet
lMount the lens and camera assembly (fig 5b) onto the camera mounting bracket as
shown in fig 5e and 5f.
lRotate the lens and camera assembly anti-clockwise to locate in position. The socket
head screws are fixed in position and do not require tightening.
lEnsure that the camera is in a horizontal position.
lTo rotate the camera independently of the lens, hold the camera firmly in position
and use a 1.25 mm Allen key to loosen the three grub screws positioned around the
adapter ring as shown in fig 5b, and position the camera horizontally.
lOnce the camera is in the correct position, tighten the three grub screws and release
the camera.
lConnect the Ethernet cable from the front of the door arm to the Ethernet socket on
the rear of the camera. See fig 11a.
Fitting Type 2 - Screw
lMount the lens and camera assembly onto the camera mounting bracket as shown
in fig 5e and 5f.
lSecure the camera assembly in place with the four nuts and socket head screws
provided.
lScrew the nuts onto the screw threads by hand, then hold them in place using an 8
mm spanner.
lTighten the screws using a 3 mm Allen key.
lTo adjust the positioning of the camera, loosen the outer screws to allow vertical
movement, or the inner screws to allow movement horizontally.
Horizontal and Vertical Adjustment Securing Camera Assembly
3.9.1 Camera and Lens Settings
1. The camera settings are pre adjusted in the software to give the best image qual-
ity and should not need any additional further adjustment.
2. The lens is manually adjusted to give the best quality picture in the following way:
lFocusing ring on the front of the lens, see fig 5b.
lAperture adjustment, see fig 5b. The ideal position for the aperture is at f16. At this
position exposure will be maintained between 450 °C (with rear lighting) and 1600
°C. If a specific test temperature range is be utilised i.e. maximum temperature set
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to 1200 °C, the aperture can be set to a suitable position to maximise the exposure
range e.g. f8.
3.9.2 Adjusting the Lens.
To adjust the lens for the ideal image quality the furnace and computer must be
connected, see section 3.10 and the software must be running in configure mode see
section 4.7.2. The image displayed in the image window is a real time image, so the
camera focus can easily be adjusted. The camera must be mounted as described
above.
Prepare a number of test samples and load into the work tube as described in section
4.5. Close the door and ensure it is securely closed using the swing bolts.
For there to be sufficient light in the work tube to allow image capture the furnace must
be either at a standby temperature of 450 °C with rear light activated (if available) or at
a standby temperature of 815 °C.
With the lens set at a suitable aperture, ideally f16 an image should now be displayed in
the software. Loosen the focus locking screw and with the focusing ring at the front of
the lens see fig 5b the image can be focused on the screen. It may be useful to take the
weight of the camera in one hand while focusing with the other. Once the image is
focused on the screen the focus locking screw can now be tightened (care must be taken
not to over-tighten these screws.)
Note: As the furnace warms up the work tube will increase slightly in length causing the
camera focus to alter, it may be necessary to re-focus the camera during the initial Ash
Fusion test run. Once the camera is focused the focus ring can be locked in position
using the locking screw, unless the camera is disturbed it should not require re-focusing
during subsequent tests.
3.10 Computer Connections
Unpack the computer from its transit boxes and assemble in accordance with the
manufacturers instructions provided.
Connect the Ethernet cable from the Ethernet socket on the back of the furnace case to
the Ethernet socket on the back of the computer.
Connect the comms lead from the 'Comms Port' on the back of the furnace to the
comms port on the back of the computer.
Connect the Monitor DVI in lead to the socket on the rear of the computer via the DVI to
display port adaptor.
Connect the keyboard and mouse to a USB socket on the rear of the computer.
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