Installation, Operation &
Section page
Maintenance Instructions
Coal Ash Fusion Furnace
CAF 16/38
This manual is for the guidance of operators of the above Carbolite product and
should be read before the furnace is connected to the electricity supply.
Manuals are supplied separately for the furnace controller
(and overtemperature controller when fitted).
MF45 – 1.05
DANGER of electrical shock– read any warning printed by this symbol.
DANGER – hot surface. Read any warning printed by this symbol.
WARNING: all surfaces of a furnace may be hot.
DANGER – read any warning printed by this symbol.
Instrument switch: when the instrument switch is operated the temperature
control circuit is energised.
Heat Light: the adjacent light glows or flashes to indicate that power is
being supplied to the elements
Heat Switch: the switch disconnects power to the heating elements; unless
this switch is off there is a danger of electric shock when inserting objects
into the furnace
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1.0 SYMBOLS & WARNINGS
1.1 Switches and Lights
1.2 Warning Symbols
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Parts per
million
Effect.
50
Recommended Exposure Limit (8 hours time weighted average concentration).
200
Headache after about 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.
1.3 Hydrogen and Carbon Dioxide Warning
H2 can form explosive gas mixtures, take precautions to avoid leakage of H2.
H2 and CO2 can react to form CO. See section 1.4: Carbon Monoxide
Warning.
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 CO2 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.
1.4 Carbon Monoxide Warning
Carbon monoxide is a product of reaction of H2 and 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:
For further information refer to:
- Guidance Note EH43 (1996) from the Health and Safety Executive. ISBN 0 11 883597 1
- EH40/97 Occupational Exposure Limits 1997. ISBN 0 7176 1315 1
MF45 1.05 3
supply type
Cable colour
Terminal
label
Live-Neutral
Reversible or Live-Live
Brown
L
to live
to either power conductor
Blue
N
to neutral
to the other power conductor
Green/Yellow
PE
to earth (ground)
to earth (ground)
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2.0 INSTALLATION
2.1 Unpacking & Handling
When unpacking or moving the furnace always lift it by its base, not by any protruding fittings.
Use two people to carry the furnace where possible. Remove all packing material.
NOTE: This product contains Refractory Ceramic Fibre (better described as Alumino Silicate
Wool) for precautions and advice in handling this material see the ‘Repairs and Replacements’
section.
2.2 Siting
Place the furnace in a well ventilated room: positive ventilation is recommended. See the warnings
in sections 1.3 and 1.4.
Site the furnace away from other sources of heat, on a surface which is resistant to accidental
spillage of hot materials. Do not mount the furnace on an inflammable surface.
Ensure that there is free space around the furnace. Do not obstruct any of the vents in the control
section: they are needed to keep the controls cool.
Ensure that the furnace is placed in such a way that it can be quickly switched off or disconnected
from the electrical supply - see below.
2.3 Fitting the Heating Elements
The Silicon Carbide elements are VERY FRAGILE and are packed separately. Fit them according to
the instructions in section 5.6.
2.4 Telescope
The telescope and its trunion arm are packed separately, and should be attached to the front of the
furnace.
2.5 Electrical Connections
Connection by a qualified electrician is recommended.
The furnace requires a single-phase A.C. supply with earth (ground). The supply may be Live to
Neutral non-reversible, Live to Neutral with reversible plug, or Live to Live.
Check the furnace rating label before connection. The supply voltage should agree with the voltage
on the label, and the supply capacity should be sufficient for the amperage on the label.
The supply should be fused at the next size equal to or higher than the amperage on the label. See
section 8.1 for fuse rating data. Internal supply fuses are only fitted if a supply cable is fitted;
customer fusing is essential.
Furnace with supply cable: either wire directly to an isolator or fit with a line plug.
Furnace without supply cable: a permanent connection to a fused and isolated supply should be
made to the internal terminals after temporary removal of the furnace back panel.
Connection by line plug: the plug should be within reach of the operator, and should be quickly
removable. Connection to isolating switch: this should operate on both conductors (single phase)
or on all live conductors (three phase), and should be within reach of the operator.
Single phase: connect the supply as follows:
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The supply MUST incorporate an earth (ground).
2.6 Gas Connections
The furnace is fitted with two flowmeters, one for Carbon Dioxide (CO2) on the left, and the other
for Hygrogen (H2) on the right. The output from the flowmeters is mixed and taken directly to the
work tube through a connection at the front.
There are no valves or non-return devices on this furnace. Regulated supplies of CO2 and H2 must
be connected in a safe manner to ensure that all gas flow is through the work tube. The gas supply
pressure required is 4 psi (0.276 bar) and must not exceed this.
At the back of the furnace is a copper exhaust vent pipe. The exhaust fumes are dangerous (see
Carbon Monoxide warning, section 1.4). The exhaust must be properly vented into a suitable duct
or fume cupboard, and must not be allowed to contaminate the atmosphere of the room in which
the furnace is sited.
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