GTA100-VSD-DES Oven

SMELTING FURNACE
Model: GTA100-VSD-DES
Installation, Operation, Maintenance & Spare Parts Manual
Revision 1
Furnace Technologies, Feb 2016
Furnace Technologies Pty Ltd

60 Cutler Road, Jandakot, WA 6164
P: +61 8 9417 4226 | F: +61 8 9417 9827
service@furnace-technologies.com.au | www.furnace-technologies.com.au
Contents
1. INTRODUCTION ......................................................................................... 5
1.1 Contact information ................................................................................. 6
1.2 General Information................................................................................. 7
1.3 Warranties .............................................................................................. 9
1.4 Using this Manual .................................................................................... 9
2 TRANSPORTATION, HANDLING AND INSTALLATION ......................................13
2.1 Safety Information .................................................................................14
2.2 Transportation and Handling ....................................................................14
2.3 Unpacking .............................................................................................14
2.4 Furnace Installation ................................................................................17
2.5 Burner Set-Up ........................................................................................21
3 OPERATION INSTRUCTIONS .......................................................................23
3.2 Thermocouple Information .......................................................................25
3.3 Loading the Furnace ...............................................................................25
3.4 Starting the Furnace ...............................................................................26
3.5 Tilting the Furnace ..................................................................................26
3.6 Control Panel Layout ...............................................................................27
3.7 Temperature Controller Instructions..........................................................29
4 MAINTENANCE AND LUBRICATION ..............................................................33
4.2 Maintenance Schedule.............................................................................35
4.3 Maintenance Instructions .........................................................................35
4.4 Refractory Rebuild ..................................................................................39
4.5 Crucible Care .........................................................................................49
5 PARTS .....................................................................................................54
5.1 Reline Kit...............................................................................................55
5.2 Electrical Spares .....................................................................................56
5.3 Consumables .........................................................................................57
5.4 Accessories ............................................................................................58
5.5 Safety Clothes........................................................................................60
6 APPENDICIES ...........................................................................................61
The information contained in this document is the proprietary and confidential property of Furnace Technologies and
may not be duplicated, disclosed or utilized without written consent from Furnace Technologies Managing Director.
Page 2 of 71
6.1 Appendix 1 – Fuel Supply Options. ...........................................................62

6.2 Appendix 2 – Burner Start up Cycle ..........................................................63
6.3 Appendix 3 – Parts List............................................................................64
6.4 Appendix 4 – Burner Spare Parts ..............................................................65
6.5 Appendix 5 – Combustion Adjustment .......................................................66
6.6 Appendix 6 – Combustion Head Setting .....................................................67
6.7 Appendix 7 – Electrodes Adjustment .........................................................68
6.8 Appendix 8 – Maintenance Position ...........................................................69
6.9 Appendix 9 – Maintenance .......................................................................69
6.10 Appendix 10 – Burner Troubleshooting ......................................................70
6.11 Appendix 11 – Wiring schematic ...............................................................71
Figure 1 - A100 Smelting Furnace ......................................................................... 7

Figure 2 - Danger Caution ..................................................................................10
Figure 3 - Warning Caution .................................................................................10
Figure 4 - Control Box Rotation ...........................................................................17
Figure 5 - Cascade Table Position ........................................................................19
Figure 6 - Cams.................................................................................................20
Figure 7 - External Fuel Filter ..............................................................................21
Figure 8 - Burner pointing away from furnace body ................................................22
Figure 9 - Tilting Control Hand Pendant ................................................................26
Figure 10 - Control Box (Front) ...........................................................................27
Figure 11 - Control Box (Components Layout) .......................................................28
Figure 12 - Temperature Controller (Front) ...........................................................29
Figure 13 - Autotuning (AT) Function ...................................................................30
Figure 14 - Bearing Housing ................................................................................35
Figure 15 - Gearbox ...........................................................................................36
Figure 16 - Spill Tube Location ............................................................................37
Figure 17 - Burner Fibre .....................................................................................38
Figure 18 - Refractory Parts Exploded View ...........................................................39
Figure 19 - Base Fibre/Tiles ................................................................................40
Figure 20 - Base Plate ........................................................................................40
Figure 21 - Front and Rear Panels ........................................................................41
Figure 22 - Burner Port Alignment .......................................................................41
Figure 23 - SC85 Balls ........................................................................................42
Figure 24 - Crucible Stand ..................................................................................42
Figure 25 - Front and Rear Panels ........................................................................43
Figure 26 - Crucible Position ...............................................................................43
Figure 27 - Supporting Bricks ..............................................................................44
Page 3 of 71
Figure 28 - Supporting Bricks Alignment ...............................................................44

Figure 29 - Ceramic Fibre Installation ...................................................................45
Figure 30 - Pouring Spout ...................................................................................46
Figure 31 - Cast Lid ...........................................................................................47
Figure 32 - Fibre................................................................................................47
Figure 33 - Lid Fibre...........................................................................................47
Figure 34 - Fitting the Lid ...................................................................................48
Figure 35 - Holes in Fibre ...................................................................................48
Figure 36 - Crucible Handling ..............................................................................49
Figure 37 - Oxidation Caused by Glaze Damage ....................................................49
Figure 38 - Stacked Crucibles .............................................................................49
Figure 39 - Crucible Storage ...............................................................................49
Figure 40 - Correct Crucible Loading ....................................................................50
Figure 41 - Crucible Loading Best Practice ............................................................50
Figure 42 - Cone Shaped Crack ...........................................................................51
Figure 43 - Y-shaped Crack .................................................................................51
Figure 44 - U-shaped Crack ................................................................................51
Figure 45 - Frozen Metal .....................................................................................51
Figure 46 - Dross/Slag Build-up ...........................................................................52
Figure 47 - Thermal Shock ..................................................................................52
Figure 48 - Cracking Due to Poor Furnace Conditions .............................................53
Figure 49 - Cracking Near top Edge from Poor Setting ............................................53
Table 1-General Description ................................................................................. 8

Table 2 - Minimum Recommended PPE .................................................................11
Table 3 - Cautionary Symbols .............................................................................12
Table 4 - Supplied Items/Parts ............................................................................16
Table 5 - Temperature Controller Settings ............................................................29
Table 6 - Controller Error Information ..................................................................30
Table 7 - Maintenance Schedule ..........................................................................35
Table 8 - Refractory Parts ...................................................................................39
Table 9 - Reline Kit Parts ....................................................................................55
Table 10 - Electrical Spare Parts ..........................................................................56
Page 4 of 71
1. INTRODUCTION
1.1 Contact information ................................................................................. 6

1.2 General Information................................................................................. 7
1.3 Warranties .............................................................................................. 9
1.3.1 Attendances at remote sites or outside of the Perth metropolitan area. ..... 9
1.4 Using this Manual .................................................................................... 9
1.4.1 Duty of Care...................................................................................... 9
1.4.2 Safety Information ............................................................................10
1.4.3 Personal Protective Equipment (PPE) Requirements ...............................11
1.4.4 Other Cautionary Signs ......................................................................12
Page 5 of 71
1.1 Contact information
FURNACE TECHNOLOGIES PTY LTD
60 Cutler Road
Jandakot WA 6164
Australia
PO Box 3838
Success WA 6964
Ph: +61 8 9417 4226
Fax: +61 8 9417 9827
Sales: sales@furnace-technologies.com.au
Service: service@furnace-technologies.com.au
General Enquiries: info@furnace-technologies.com.au
www.furnace-technologies.com.au
ABN: 47 063 407 581
ACN: 063 407 581
Page 6 of 71
1.2 General Information
Furnace Technologies Equipment Manual

Equipment Type: Smelting/Tilt Furnace
Variations: Variable Speed Drive/Diesel
Figure 1 - A100 Smelting Furnace
Note: The pictures in this manual are representations of parts and equipment, and
their colours may vary from the actual colours of the equipment and parts.
Page 7 of 71
General Description
•3mm Plate steel
•10mm Plate steel
•100 x 100 x 4 mm RHS
Metal Framework:
•80mm NB Pipe 6mm Wall
•75mm Solid Bar
•1.2mm Control housing
•Diesoline Low High Off operation.
Burner:
•Supply, ring main or gravity feed.
•A temperature control will monitor the
furnace temperature. This control does not
remove the need for an operator. It
Controls:
allows the operator to set the control to make
his job easier. The control will switch the
burner between high and low fire.
•5 amp single phase 380 – 415 Vac for
Electrical Connections: controls and burner. Other voltages available
on request.
Maximum Operating Temperature: •14000C
•A reduction gear box and motor with VSD. It
will pivot the furnace around the pouring
Tilting Mechanism:
spout. The burner tilts with the furnace and
switches to low fire.
•Carbon cascade moulds are 400oz. The
cascade table is made to accommodate 6
moulds. The table will be mounted on swivel
Cascade Moulds and Table: break castors. Adjustable feet that can be
used to level the table are also fitted.
•The carbon moulds give far better
performance compared to cast iron moulds.
•Pre-fired cast insulation.
Refractory Lining:
•150mm backup insulation minimum.
•AXO100 SiC Crucible working level holds
Crucible:
100 kg copper.
•2,400mm long x 2200mm wide x 1100mm
high approx.
•The cascade table will require 2400mm of
External Dimensions length in front of the furnace.
•Ample room should be provided around the
furnace for inspections - allow 1000mm of
free space.
Total Mass: •575Kgs unloaded and un-crated.
Table 1-General Description
Page 8 of 71
1.3 Warranties
Furnace Technologies warrants its furnaces against faulty parts and workmanship for a
period of 18 months from the date of purchase or 12 months from the date of
installation whichever occurs first. Should any fault occur during the warranty period,
other than those caused by neglect, physical damage or use of the furnace outside its
performance settings, Furnace Technologies will, at its discretion, repair or replace the
faulty parts or equipment upon their return to the Furnace Technologies factory, freight
paid. Furnace Technologies accepts no liability for consequential loss or damage caused
through operation or malfunction of the furnace.
If the furnace is being operated at a remote location or out of the Perth metropolitan
area, you should advise Furnace Technologies of the nature of the problem before
return and instructions will be given on the removal and replacement of faulty parts to
avoid return of the complete unit and to expedite the furnaces return to service. The
faulty part will need to be returned to us so we can determine the cause.
1.3.1 Attendances at remote sites or outside of the Perth metropolitan area.

If the furnace system has been commissioned by Furnace Technologies, we will send
suitable staff at no cost for the labour, however transportation, accommodation, food
and all other incurred expenses such as travel visas must be paid for by the customer.
We will only require short notice to affect such attendance. Should the error be
determined not to be our responsibility then our standard rates will apply.
1.4 Using this Manual
1.4.1 Duty of Care

As the purchaser/end user of potentially dangerous equipment you are responsible for:
 Providing all operators and maintenance personnel with the relevant required
Personal Protective Equipment (PPE)
 Ensuring that all staff (both operators and maintenance) are fully trained and
competent
 Maintaining the equipment to a high standard
 Providing access to employees for all relevant MSDS for products used in the
manufacturing process or operation of the equipment
Page 9 of 71
1.4.2 Safety Information

Australian Standards (AS 1319-1994) safety signs are used in this manual.
Throughout the manual you will see two safety cautions – Danger and Warning. They
will appear as shown in Fig 2 and Fig 3 – with the symbol, word and explanation.
Danger – Possible life-threatening danger or hazard.
Figure 2 - Danger Caution
Warning – Possible hazard or risk of machinery damage.
Figure 3 - Warning Caution
Page 10 of 71
1.4.3 Personal Protective Equipment (PPE) Requirements

Table 2 contains all necessary Personal Protective Equipment (PPE) which may be
required when installing, maintaining and operating this equipment. In addition, each
section will contain a table demonstrating minimum recommended PPE.
Minimum Recommended PPE
Eye Protection must be worn
Head Protection must be worn
Hearing Protection must be worn
Foot Protection must be worn
Hand Protection must be worn
Dust Mask must be worn
Full Face Shield must be worn
Table 2 - Minimum Recommended PPE
Page 11 of 71
1.4.4 Other Cautionary Signs

Cautionary Symbols
Table 3 - Cautionary Symbols
Page 12 of 71
2 TRANSPORTATION, HANDLING AND INSTALLATION

2.1.1 Minimum PPE ...................................................................................14
2.1.2 Cautionary Signs...............................................................................14
2.2 Transportation and Handling ....................................................................14
2.3 Unpacking .............................................................................................14
2.3.1 Unpacking the Equipment ..................................................................15
2.3.2 Checklist of Supplied Parts .................................................................15
2.4 Furnace Installation ................................................................................17
2.4.1 Setting up the Furnace ......................................................................18
2.4.2 Setting up the Cascade Table .............................................................19
2.4.3 Setting up for Rotation ......................................................................20
2.5 Burner Set-Up ........................................................................................21
Page 13 of 71
2.1 Safety Information

Only trained and licenced operators of forklifts or cranes should lift or move the crated
or un-created furnace.
2.1.1 Minimum PPE

We recommend that the minimum PPE to be used includes:
2.1.2 Cautionary Signs
2.2 Transportation and Handling

The crate includes a pallet base to allow for easy movement with a forklift. Please
ensure that you only use a forklift rated to lift the required weight. See section 1.2 for
weight.
Always use a forklift to lift and move the crated machine and place this close to the
installation point, prior to unpacking.
2.3 Unpacking
Prior to unpacking the crate, visually inspect it for damaged caused during transit.
Furnace Technologies will provide you with photographs of the packed crate for you to
compare any damage you notice. If any damage is noticeable, advise the transport
company at the time of delivery and take photos and notes of the damage, to forward
to Furnace Technologies if serious damage is detected once the equipment is
unpacked.
Page 14 of 71
2.3.1 Unpacking the Equipment

The crate should be taken apart one panel at a time as lifting the complete upper crate
from the base may cause damage to the machine.
Procedure for unpacking the furnace:
 Visually inspect the furnace for damage and to ensure that it has not moved
during the transportation process
 Remove screws that hold the front of the packing crate, set aside panel
 Remove roof, side and rear panels of the crate
 Remove all small boxes
 Remove and discard any protective wrapping
 Carefully cut and remove any strapping which has been used to secure the
furnace during transportation
 Move the furnace to installation location using a forklift or overhead gantry;
o Forklift – pick up furnace under the main body. To stop it from swinging,
secure to the frame with a light rope
o Overhead Gantry – pick up the furnace using the 4 lifting points
 The crucible is secured using expanding foam. It is vital that this is removed
prior to firing.
2.3.2 Checklist of Supplied Parts

The following is a list of separate items and quantities which are supplied with the
furnace.
Supplied Items/Parts
Qty. Description
1 A100 Smelting Furnace
1 Cascade Table
6 400oz graphite moulds
1 Canopy
1 Internal crucible lifting tool
3 AXO 100 Crucibles
1 Extraction fan with start/stop station
1 Slag scoop tool/ Spout cleaning tool
1 Duct work
1 Slag bucket
1 Spill tray
2 Aprons
3 Gloves
Page 15 of 71
2 Hard hats
20 Cotton liners
Table 4 - Supplied Items/Parts
Page 16 of 71
2.4 Furnace Installation

The furnace should be installed on a flat and even floor.
Warning – Combustible materials should not be in placed in close

proximity to the furnace and should never be placed directly
above it.
Warning – Do not install in a room with insufficient air for

combustion. There must be adequate air supply if the room is
enclosed, it may be necessary to create a window to increase air
flow.
Danger – Burner exhaust and melt fumes/gas must be correctly

vented. Ensure that there is sufficient ventilation for the level of
gas and fumes present.
Note: For transportation the control box is rotated 90o anticlockwise. It must be
returned to its correct position before use. See Fig 4. In the first picture the control box
is rotated for transport. The second picture depicts its correct positioning after rotating
it back once unpacked.
Figure 4 - Control Box Rotation
Page 17 of 71
2.4.1 Setting up the Furnace
1. The control box needs to be rotated 90 degrees on the side of the gear box. See
note on previous page and Fig 4.
2. Bolt the furnace to the ground through the 4 bolt down plates.
3. Fill the gearbox with SYN680 high performance industrial gear oil.
4. Connect the furnace to diesel supply. See Appendix 1 for instructions on fuel
supply options.
5. Connect the furnace to electrical supply. This must be performed by a
licenced and competent electrician.
6. Check that the crucible location and the pouring spout location have not become
dislodged during transportation. If this has occurred then see “Installing the
pouring spout and cast lid” in section 4 “Refractory Re-build”.
7. Plug the spill spout with fibre so that any internal spills do not overflow during
tilting.
Page 18 of 71
2.4.2 Setting up the Cascade Table
1. The table comes with a base, 4 castors, and a table top that slides onto the
base. The threaded rods are used to level the table for operation and can be
adjusted for initial set up.
2. Sprinkle casting sand over the table top of the cascade table to seat the bullion
moulds, as this will assist in aligning and levelling them. Slight angles will
change the mass of produced bars.
3. Roll the table into position under the spout and adjust the threaded rods for a
height and level that is correct for your requirements.
Figure 5 - Cascade Table Position
Page 19 of 71
2.4.3 Setting up for Rotation
Caution – the gearbox and motor produce considerable force. If

rotated in the wrong direction they will shear off the retaining
pins and these will need to be replaced! The installing electrician
should check the motor rotation and reverse phases if necessary.
The Cams:
 The cams are locked on a threaded rod which screws into the centre of the
gearbox shaft. See Fig 4.
 When tilting, the inside cam controls the downward limit and the outside cam
controls the maximum tilt.
Figure 6 - Cams
Gearbox Oil:
 The gearbox needs to be filled with heavy weight oil.

 The oil level should be set very high as the gearbox only ever rotates a quarter
turn.
Note: We recommend using SYN680 high performance industrial gear oil.
Page 20 of 71
2.5 Burner Set-Up
Caution – an external fuel filter is required for the burner. The

filter should be replaced at least once a year and the filter
container thoroughly cleaned prior to installation of new filter
cartridge. See Fig 7 below.
Figure 7 - External Fuel Filter
Although there is no need to set up the burner as it will fire immediately, it is advisable
that certain adjustments be made to ensure that it is running at optimal efficiency.
In order to adjust the burner you need to;
 Read the burner manual “Gulliver RGD Burner Manual” for all set up details.
Some excerpts are offered in the appendices.
 Ensure that the combustion gases on high fire have an O2 concentration that is
as close to 0 as possible (below 3%). See Appendix 5.
 On low fire the O2 concentration should be greater than 11%.
 In order to maintain the temperature as constant, you will need to adjust the
low fire setting. Once the furnace temperature exceeds 1000oc check that the
low fire setting is resulting in a slight drop of temperature. These settings can be
finely adjusted so that when the furnace switches to low fire there is only a slight
drop in temperature.
Page 21 of 71
Warning – when not in operation, DO NOT LEAVE THE BURNER

POINTING INTO HOT FURNACE. Instead swing the burner away
from furnace body. See Fig 8 below.
Figure 8 - Burner pointing away from furnace body
Warning – BEFORE OPERATING THE FURNACE ENSURE THAT THE

GEARBOX IS FILLED WITH OIL.
Information on Combustion Head Settings is available in Appendix 6.

Electrodes Adjustment information is in Appendix 7.
Page 22 of 71
3 OPERATION INSTRUCTIONS

3.1.1 Minimum PPE ...................................................................................24
3.2 Thermocouple Information .......................................................................25
3.3 Loading the Furnace ...............................................................................25
3.4 Starting the Furnace ...............................................................................26
3.5 Tilting the Furnace ..................................................................................26
3.6 Control Panel Layout ...............................................................................27
3.7 Temperature Controller Instructions..........................................................29
3.7.1 Changing a Setting............................................................................29
3.7.2 Functions .........................................................................................30
3.7.3 Error Information ..............................................................................30
3.7.4 Controller Operations ........................................................................31
3.7.5 Temperature Controller Settings .........................................................32
Page 23 of 71

Only a trained operator should operate the smelting furnace.
3.1.1 Minimum PPE

At an absolute minimum the operator should wear fire resistant gloves, boots and a
face shield. Please see the below note for further information.
Danger – Beyond the standard PPE it is highly recommended

that specialist fire resistant safety clothing is worn. The furnace
will operate at an extremely high temperature and it is essential
that operators are sufficiently protected. For a list of
recommended clothing please see the “Spare Parts” section of
this manual.
For the safety of operators the following rules should be adhered to;
 Lubrication and maintenance must not be carried out whilst the furnace is in
operation
 Prior to starting the furnace check all cables for any defects
 Check that the working area is clear of any obstructions or combustible materials
 Check the tilting of the furnace prior to operation. Rotate the furnace slowly,
checking to ensure that the crucible remains in place. Check that the limit
switches are operating correctly.
 
Page 24 of 71
3.2 Thermocouple Information

The thermocouple is located on the side of the furnace with the tip flush with the inside
surface of the refractory.
The thermocouple reads the temperature of the lining and from this the temperature of
the melt is estimated. On the first operation record the temperature reading and
adjust the temperature controller settings accordingly. These instructions are
found in section 3.6.
When the furnace reaches the set point value it will automatically switch from high fire
to low fire as described in the burner set up instructions.
Note: the melt temperature will continue to rise after the lining temperature has
stabilised.
3.3 Loading the Furnace

If the load is a soft powder it can be pre-loaded into the crucible, however we suggest
that solid bars are not loaded at this time as there is a risk that they will expand and
crack/damage the crucible.
Loading during operation can be achieved by;
 Turning the burner off briefly, loading the furnace and then re-starting the
burner
 Alternatively the ore can be packaged into plastic or hessian bags and dripped
into the furnace with the burner still running
The crucibles and refractories are suitable to be rapidly fired to operating

temperatures.
Note: During smelting it can be quite beneficial to stir the melt.
Note:
 Melt times can vary due to the material make up and fluxes used.
 Temperature will rise quickly to 1000oC and the rise will then slow up to
1300oC.
 The temperature will halt at 1300oC.
Your melt may not occur quickly due to the boiling of other materials such as
zinc. Excessive heating to speed up this process can reduce the life of the
crucible. See crucible care in section
Page 25 of 71
3.4 Starting the Furnace

1. Check the furnace for any signs of damage
2. Check the pouring spout seal (this should be done prior to each firing) and use
AFLAM to re-seal the surface if necessary
3. Check to make sure that the burner is in the correct position and the burner seal
is in place
4. Check to make sure that the cascade table is correctly aligned
5. Start the ventilation system
6. Start the furnace – the burner will fire up in 60 seconds
7. Set the desired temperature. See controller operation instructions.
Note: after a flame failure swing the burner away from the hot furnace, re-
light the burner (this will take about 60 seconds) and then turn it back into
the furnace. See Appendix 2 for more information on burner start up cycles.
3.5 Tilting the Furnace

The gearbox and motor produce considerable force, so care must be taken to ensure
correct rotation. Wrong rotation may result in damage to the shaft holding pins.
Note: the gearbox will need to be filled with oil prior to tilting.
Danger – The Variable Speed Drive (VSD) should only be

adjusted by a skilled and competent operator. It poses an
Electrical Shock Risk.
 The hand pendant (Fig 9) controls the up and down tilting action
 Do not tilt the furnace over 100 degrees of rotation
 Adjustment of the tilting speed is controlled via the variable speed drive (VSD)
inside the control box. See Fig 10.
 Adjust the dial on the front of the VSD to increase or decrease the speed of
tilting to best suit your melt and pour
Figure 9 - Tilting Control

Hand Pendant
Page 26 of 71
3.6 Control Panel Layout
A
A
Main – This controller is used to
set the required temperature
and alarm settings at which the
furnace will operate.
Off/On/Tilt – Main mode

selector.
B
C
Burner Run – Indicates that the

burner is in run mode.
C D
Burner Fail – Indicates the

burner has failed to complete
the start-up cycle. (See
Appendix 2 for more
information on start-up cycles.
D E
Tilt Motor On – Indicates that

the furnace is ready to tilt.
Figure 10 - Control Box (Front)
Page 27 of 71
A
C
E F
Figure 11 - Control Box (Components Layout)
A Temperature Controller
B Variable Speed Drive (VSD)
C Tilt Speed Adjustment Dial
D Control Circuit Breaker
E Tilt Motor Circuit Breaker
F Tilt Motor Contactor
Page 28 of 71
3.7 Temperature Controller Instructions
Figure 12 - Temperature Controller (Front)
Symbol # Name Function

Measured Value Displays PV or various parameter symbols
PV 1
(PV) Display (red)
Setting Value (SV) Displays SV or various parameter values
SV 2
Display (green)
Used for parameter calling up and set value
SET 3 Set Key
registration
A/M 4 Available in Programmable Models Only
< 5 Shift Key Shift digits when settings are changed
Decrease numbers (*only for programmable
V 6 Down Key
controller)
Up Key (* Program Increase numbers (*only for programmable
^ 7
Run) controller)
Table 5 - Temperature Controller Settings
3.7.1 Changing a Setting

1. Press the SHIFT KEY to change the parameters. When the SHIFT KEY is
pressed the first digit begins blinking
2. Press the UP KEY or DOWN KEY to increase or decrease the value of the digit
3. Press the SHIFT KEY again to go to the next digit
4. After all digits are written press the SET KEY to enter the value
The SET KEY also changes MODES. When the SET KEY is pressed the display shows
the next MODE. Press it again to show the next mode and so on. After 30 seconds the
display will revert to the home screen.
Page 29 of 71
3.7.2 Functions
Use the AT function to automatically calculate and set the optimal PID value for your
system. This will help hold the PV at the SV.
Figure 13 - Autotuning (AT) Function
3.7.3 Error Information
Display Description
IN1E Open circuit of main control sensor
*ADCF A/D converter failed
*CJCE Cold junction compensation failed
IN2E Open circuit of sub control sensor
UUU1 PV exceeds USPL
NNN1 PV under LSPL
UUU2 Input signal of sub control exceeds the upper limit
NNN2 Input signal of sub control under the lower limit
*RAMF RAM failed
INTF Interface failed
AUTF Auto tuning failed
Table 6 - Controller Error Information
Page 30 of 71
3.7.4 Controller Operations
Page 31 of 71
3.7.5 Temperature Controller Settings
SV = 1300oC (SET VALUE). This

indicates the maximum
operating temperature at which
the furnace will operate. This
can be adjusted by the user.
AL1 = 20oC. This is set to 20 as

an over temperature cut off. It
is a deviation high alarm, so if
you set 1180oC as the main SV
then at 1200oC the burner will
shut off. This can be adjusted
by the user.
Page 32 of 71
4 MAINTENANCE AND LUBRICATION

4.1.1 Minimum PPE ...................................................................................34
4.2 Maintenance Schedule.............................................................................35
4.3 Maintenance Instructions .........................................................................35
4.3.1 Bearings ..........................................................................................35
4.3.2 Gearbox...........................................................................................36
4.3.3 Spillage Pours...................................................................................37
4.3.4 Burner Maintenance ..........................................................................38
4.4 Refractory Rebuild ..................................................................................39
4.4.1 Refractory Parts ................................................................................39
4.4.2 Refractory Rebuild Instruction ............................................................40
4.5 Crucible Care .........................................................................................49
4.5.1 Handling ..........................................................................................49
4.5.2 Storage ...........................................................................................49
4.5.3 Loading ...........................................................................................50
4.5.4 Mechanical Damage ..........................................................................51
4.5.5 Dross/Slag Build-up ..........................................................................52
4.5.6 Thermal Shock .................................................................................52
4.5.7 Oxidation .........................................................................................53
Page 33 of 71

Do not carry out any maintenance or lubrication while the equipment is in
operation.
Before carrying out any work on the equipment ensure that the power supply is
disconnected and that any relevant isolator is locked out and labelled with a suitable
warning notice.
If ever necessary for maintenance to be performed while the machine is in operation it

must be fitted with appropriate notices and tools, equipment and personnel must be
kept away from any moving parts.
Should access to any moving parts become necessary, the motor must be isolated and
not reconnected to power until all equipment, tools and personnel are clear of the
moving parts.
4.1.1 Minimum PPE

Page 34 of 71
4.2 Maintenance Schedule
Location
Daily Weekly Monthly Yearly
or Part
Overall Visually inspect Check
Machine equipment and thermocouple
wiring for any signs for damage.
of damage.
Bearings Check if lubrication
is required.
Gearbox Check oil level. Requires oil Oil must be
change after changed at
the first week least every 12
of operation. months
Burner The burner must be Clean and Replace burner
cleaned daily by check electrode fibre seal at
removing any build- gaps. least every 12
up around the months or as
burner head. needed.
Crucible Check crucible Visually inspect Replace as
pouring spout seal for cracks and needed.
and re-seal if heat damage.
necessary.
Table 7 - Maintenance Schedule
4.3 Maintenance Instructions
4.3.1 Bearings
Bearings should be lubricated before first use with a high temperature grease. These
should be checked daily and greased as/when necessary. See figure 14.
Figure 14 - Bearing Housing
Page 35 of 71
4.3.2 Gearbox
Warning – There is NO OIL in this unit. Prior to operation you

must fill the gearbox with oil.
Oil level checks should be conducted whilst the unit is at rest and not when in
operation. See Figure 15. When the viscosity of the oil is high it may take some
time until the oil level settles uniformly.
 The gearbox requires an oil change after the first week of operation and must be
checked regularly.
 It is recommended that the oil be changed at least every 12 months.
Note: to ensure top performance we recommend using SYN680. See the spare
parts list for ordering details.
A A – Oil Fill
B – Oil Level
Figure 15 - Gearbox
Page 36 of 71
4.3.3 Spillage Pours

When a spillage into the furnace occurs, it can be removed while tilting.
 Remove the fibre plug from the spill tube on the front of the furnace
 Tilt the furnace to 90o – if any spills are present they will trickle out of the spill
tube.
 Always re-pack the spill tube with a fibre plug after a spill clean. See A
on figure 16.
Figure 16 - Spill Tube Location
Spills and losses around the pouring spout can damage the front of the unit. If this
occurs remove the front plate by undoing the nuts and striking the plate upward.
If this area needs to be repacked then:
1. Remove the damaged fibre

2. Shape up SC85 grout to hold the ceramic tube
3. Re-pack the area with fibre.
4. When repairs are completed replace the front face plate.
Note: the pouring spout can also be replaced at this time. See instructions in
section 4.4.2.
Page 37 of 71
4.3.4 Burner Maintenance

The fibre (A) in figure 17 below assists in keeping the radiant heat away from the
burner and stopping the flames from leaking back around the burner head. Note: do
not fully pack this area with fibre as burner tubes need to radiate away heat.
Use only one 25mm thick seal.
Your furnace will come with this fibre in place, but it will need to be replaced whenever
it becomes damaged. This will depend on use. It should be replaced whenever
damaged but every 12 months regardless. In order to replace this:
1. Use a piece of fibre roughly 200mm square.

2. Position it over the burner port and push the burner into the fibre to leave an
indent mark.
3. Cut a central hole out of the fibre where the indent is and then fit the fibre over
the burner tube.
4. The hole can be cut slightly smaller than the burner tube to ensure a more snug
fit.
5. When the burner is swung in to meet the burner port, the fibre can be patted
down to add additional seal.
6. It is advisable to have spare seals ready cut.
Figure 17 - Burner Fibre
For burner maintenance position and further instructions see Appendix 8 and
9.
Page 38 of 71
4.4 Refractory Rebuild
4.4.1 Refractory Parts
Figure 18 - Refractory Parts Exploded View
# Description Mass (KGs)

1 Base 64
2 Crucible Stand 12
3 Bottom Front Cast Panel 43.9
4 Bottom Rear Cast Panel 39.8
5 Top Front Cast Panel 27
6 Top Rear Cast Panel 30.6
7 Lid 59.9
8 Burner Port 38
9 Crucible 8.6
10 Pouring Spout 17.4
11 Spill Tube 0.1
12 Floor Tiles 4.2
13 Front Support Bricks 10
Table 8 - Refractory Parts
Page 39 of 71
4.4.2 Refractory Rebuild Instruction
Installing the Base:
1. Lay 25mm thick fibre on the base of the furnace.

2. On top of the fibre, set out some floor tiles to support the base casting.
3. Cut out around the tiles and remove any fibre from underneath.
4. Set tiles back into the cut outs. See Figure 19.
5. Install the base plate ensuring that it is centrally positioned – you will need to
measure this as it needs to be accurate. See Figure 20.
Figure 19 - Base Fibre/Tiles
Figure 20 - Base Plate
Page 40 of 71
Installing the Bottom Front and Rear Panels:
1. Set the front and rear panels in position, ensuring that they are correctly
aligned. See Figure 21.
2. At this stage you will need to test fit the burner port and check for proper
alignment of this, and the slag spout recess. Accuracy at this stage is very
important. See Figure 22.
3. Any disparity can be easily rectified at this stage by the use of SC85 grout for
spacing and levelling. Height differences of up to 10mm can be filled during the
build.
Figure 21 - Front and Rear Panels
Figure 22 - Burner Port Alignment
Page 41 of 71
Installing the Crucible Stand:
1. Mix SC85 grout with a small amount of water by hand, until it becomes a dough-
like consistency.
2. Make 3 or 4 balls. See Figure 23.
3. Press the crucible stand down onto the balls and twist. This will flatten the grout
and provide a good seat for the crucible stand. See Figure 24.
4. The stand must sit below the lip in the base and should not rock. If it does this
step will need to be repeated.
5. There will be a small gap around the crucible stand and the lip on the base – fill
this with SC85 grout.
Figure 23 - SC85 Balls
Figure 24 - Crucible Stand
Page 42 of 71
Installing the Top Front and Rear Panels and Crucible:
1. Install the top front and rear cast panels directly on top of the bottom panels.
You may use some SC85 grout to fill in any gaps and help keep the panels level.
See Figure 25.
2. Place a small ball of SC85 on the stand and place the crucible on top.
3. Twist the crucible down onto the grout to make a flat and level seat. Ensure
that the crucible is centred. See Figure 26.
4. Seal between any cast sections using SC85.
5. Test fit the pouring spout to ensure correct alignment with the crucible.
Figure 25 - Front and Rear Panels
Figure 26 - Crucible Position
Page 43 of 71
Installing the Front Support Bricks:
These are used to support the castings and crucible during the tilting process. Note:
They are cut to suit the shape of the outer edge of the castings and should be
as snug a fit as possible.
See Figure 27 & 28.
 Give consideration to how the load is supported

 Two of these brick columns run from the floor to the top of the casting
(approximately 400mm apart). This could differ slightly depending on the model.
 It is a good idea to take some measurements and even some photographs prior
to disassembling. This will assist with the rebuilding process.
Figure 27 - Supporting Bricks
Figure 28 - Supporting Bricks Alignment
Page 44 of 71
Installing New Ceramic Fibre:
1. The void between the castings and the drum must be packed with fibre.
2. Cut strips off the roll of fibre, the same width as the gap between the casting
and the metal drum.
3. Start to lay the fibre in the gap, off-setting the joins in each layer.
4. After laying approximately 300mm deep of fibre, gently compress this down to
ensure it is well packed.
5. Continue this until you reach the top of the casting.
See Figure 29.
Figure 29 - Ceramic Fibre Installation
Page 45 of 71
Installing the Pouring Spout and Cast Lid:
1. Mix about 10kgs of SC85 grout with water until it becomes a dough-like
consistency.
2. Work out the position of the spout and crucible, adjusting the height of the
pouring spout to suit. See Figure 30,30A and 31
3. The pouring spout front adjustment bar will help correctly position and secure
the pouring spout to maintain a constant pour location during tilting. It will also
provide support when installing and grouting a replacement pouring spout. The
ideal position of the mouth of the pouring spout is shown in the picture 30A. The
bottom of the pouring spout mouth should be inline with the centre line of the
main pivot point both laterally and vertically.
4. Pack around the edges of the pouring spout and the top cast panel to stop
movement and create a seal.
5. To assist, roll up a newspaper and put under the pouring spout to stop
the grout falling through. Pack grout against the paper, while holding it
in place.
6. Check the location of the thermocouple probe. It should be flush with the inside
of the casting and not protruding into the furnace.
7. Place a small amount of SC85 on the probe to seal it.
8. Place the cast lid in position, and bend the threaded rods back far enough so as
the metal lid just clears. This helps to support the lid when tilting. See
Figure 31.
9. Remove the metal lid and then pack with SC85 around the side of the spout and
cast lid. Small rods are used here to stop the SC85 from pushing out.
Figure 30 - Pouring Spout Figure 30A - Pouring Spout Adjustment bar
Page 46 of 71
Figure 31 - Cast Lid

Installing the Fibre:
1. Roll the fibre around the lid.

2. This is best done by cutting strips 120-150mm wide and rolling them around the
lid, cutting small slits to fit around the thread rods.
3. Pack out below the rods once finished. See Figure 32.
Figure 32 - Fibre
Installing the Lid Fibre:
1. Lay out two layers of 25mm thick fibre on top of the lid, offsetting the joins, as
the fibre is only 610mm wide. See Figure 33.
Figure 33 - Lid Fibre

Fitting the Metal Lid:
1. Fit the metal lid over the top of the fibre and compress it.
Page 47 of 71
2. Once in position tighten down with bolts. See Figure 34.
Figure 34 - Fitting the Lid
Note: Stainless steel rods do not need to protrude and can be bent back inside
the lid.
Cutting the Holes in the Fibre:
1. Cut out the hole in the fibre for the flue. This can be done with a long knife or
hacksaw blade.
2. You can also cut away the fibre over the spout to allow you to see the melt while
pouring
3. You can cut out the quarter moon shape hole over the pouring spout - this will
allow you to see the metal pouring into the spout during operation. See Figure
35.
4. Over time the fibre around these holes will wear, especially from metal slag. It
will need to be re-packed occasionally.
Figure 35 - Holes in Fibre
Page 48 of 71
4.5 Crucible Care
4.5.1 Handling
 Avoid abrasion of the glaze – this will lead to oxidation during service. See
Figure 37.
 Avoid impact damage
 Do not roll the crucible as glaze damage will occur. See Figure 36
Figure 36 - Crucible Handling
Figure 37 - Oxidation Caused by Glaze

Damage
4.5.2 Storage
 Store crucibles in a warm dry location (above 20oC)
 Stand crucibles on pallets – never directly on the floor. See Figure 39.
 Never rest crucibles inside one another. See Figure 38.
 When stacking crucibles separate with hardboard or similar material
Figure 39 - Crucible Storage
Figure 38 - Stacked
Crucibles
Page 49 of 71
4.5.3 Loading
 Load and melt as soon as the crucible has reached red heat all over
 Never introduce moist material
 Load light scrap first to form a cushion for heavier material
 Use tongs to load ingots or large pieces to avoid crucible damage
 Place ingots vertically to avoid bridging or wedging across the crucible
 Do not pack metal tightly as it will need room for expansion
Figure 40 - Correct Crucible Loading
Figure 41 - Crucible Loading Best Practice
Page 50 of 71
4.5.4 Mechanical Damage

 Tightly packed loading causes U-shaped cracking. Figure 44.
 Bridged ingots causes inverted Y-shaped cracking. Figure 43.
 Ingot impacts produce cone shaped holes. Figure 42.
 Re-heating frozen loads leads to bursting cracks due to metal expansion. Figure
45.
Figure 44 - U-shaped Crack Figure 43 - Y-shaped

Figure 42 - Cone Shaped
Crack
Crack
Figure 45 - Frozen Metal
Page 51 of 71
4.5.5 Dross/Slag Build-up

 The high expansion rate of dross causes internal pressure (approximately ten
times the rate of crucible material)
 Dross has low thermal conductivity which insulates the metal thus requiring
higher furnace temperature
 This leads to higher energy costs
 Dross absorbs flux, which in turn accelerates chemical attack on the crucible
Figure 46 - Dross/Slag Build-up
4.5.6 Thermal Shock

 Thermal stress cracking is caused by rapid or localised heating
 Excessive heating in an attempt to melt quickly reduces the life of the
crucible
 Can be caused by improperly positioning the crucible
 Caused by direct burner impingement or a poorly adjusted burner (short flame)
Figure 47 - Thermal Shock
Page 52 of 71
4.5.7 Oxidation
 Oxidation results in reduced strength and thermal conductivity and loss of
material integrity
 It is generally caused by;
o Glaze damage prior to use
o Excessive use of ceramic fibre around the top wall of the crucible
o Use of excess oxygen in fuel fired furnaces
o Flame impingement – glaze is stripped by the flame being in direct contact
with the crucible
Figure 49 - Cracking Near top Edge from Poor

Setting
Figure 48 - Cracking Due to Poor

Furnace Conditions
Page 53 of 71
5 PARTS
5.1 Reline Kit...............................................................................................55

5.2 Electrical Spares .....................................................................................56
5.3 Consumables .........................................................................................57
5.4 Accessories ............................................................................................58
5.5 Safety Clothes........................................................................................60
Page 54 of 71
5.1 Reline Kit
Part No. Category Description Qty UOM

SLG 40ID- Casting Spill Tube 1 Unit
150
A100TRCP Casting Top Rear Cast Panel 1 Unit
A100TFCP Casting Top Front Cast Panel 1 Unit
A100PS Casting Pouring Spout 1 Unit
A100LID Casting Lid 1 Unit
A100CS Casting Crucible Stand 1 Unit
A100BRCP Casting Bottom Rear Cast Panel 1 Unit
A100BFCP Casting Bottom Front Cast Panel 1 Unit
A100BP Casting Burner Port 1 Unit
A100B Casting Base 1 Unit
A100 FT-25-8 Casting Floor Spacer Tiles (8 set) 1 Set
FB610-128 Fibre Ceramic Fibre Blanket 1260c 2 Box
A100-SB Bricks Bricks 10 Unit
SC85 Refractory SC85 Grout 20kgs 1 Bucket
TC-K235-CS Electrical Thermocouple Sheathed Type K 1 Unit
Table 9 - Reline Kit Parts
Page 55 of 71
5.2 Electrical Spares
Part No. Description Qty

FY400-10200 Temperature controller 1
TP53 3 pos switch 1
ZB2-BE101 N/O aux contact block 1
ZB2-BE102 N/C aux contact block 1
AD16-22C Green Indicator LED green 1
AD16-22M/R Flasher buzzer 1
E1-430P7 VSD.75kw/1hp 1
LC1-D1210 Contactor LC101210 1
LA1-D05 LA1-DN22 contactor aux contacts 1
MCB6-106 Circuit breaker 6amp 1P 1
MCB6-306 Circuit breaker 6amp 3P 1
AZ7311 Limit switch 1
COB61 Hand pendant 1
TC-K235-CS Thermocouple Type K 1
R2132UA Fuel filter 1
LHYM05-38 Gearbox LHYM05-3B12DA-Y1-B 1
3008983 Electrical start delaying device 1
3001174 Control box 552SE 1
3007396 Fuse 1
3007458 Viewing port 1
3007839 PE cell 1
3007495 Electrode assembly 1
3007476 Fan 1
3008489 Burner Motor 1
3007479 Capacitor 4 uf 1
3008917 Coil 1 1
3007858 Coil 2 1
3006925 Needle valve 1
3007465 High voltage head 1
Table 10 - Electrical Spare Parts
Page 56 of 71
5.3 Consumables
Product Use QTY

MB50 This product is a super duty air set mortar, supplied ready for use. It is a 1
volume stable, refractory mortar. It shows no sign of flowing from pier
testing joints at 1600°C. 5 kg Bucket
Marfus Fine powder ranging in colour from grey to off-white. Use as a spill 1
soaking agent in smelting furnaces up to 1300°C. 25 Kg Bucket
SC85 Grout A trowel grade, low iron refractory castable based on premium grade raw 1
materials and binders. This product is developed for use as repair
material for furnaces and ladles operating at high temperature. 10 kg
Bucket
AFLAM-CCD A flexible high temperature sealing paste with good wet metal resistance. 1
This material is used on the floor insulating bricks under the floor tiles. It
should be re-coated whenever the floor tiles are removed. 10 kg
CoatZ A zircon rich refractory, supplied in powder form to which clean water is 1
added to form pastes and/or slurries. It has been developed to protect
refractory and insulation products from the various effects that occur in
high temperature furnace environments and associated vessels. 10kg
Bucket
Crucibles Wear will depend upon many factors. You should keep 4 in stock. Must 4
be kept dry.
Crucible These are generally replaced as crucibles are replaced, often they can be 2
stands re-used depending on their condition. It is recommended that 2 are kept
in stock.
Pouring Spouts These are generally replaced as crucibles are replaced, often they can be 2
re-used depending on their condition. It is recommended that 2 are kept
in stock.
Cast lids These can break over time as they have tension loads. We recommend 1
keeping one spare in addition to the re-line kit.
Spill tube These can block and break. We recommend keeping 4 in stock 2
Thermocouple Should be replaced after 6 months of continuous use. 2
Ceramic Fibre Supplied in boxes it is used to insulate the furnace, repack around spills 2
and to seal around the lid.
SYN680 Lubricant recommended for gearboxes. Comes in 4L bottles. 1
Page 57 of 71
5.4 Accessories
SLAG BUCKET SPILL TRAY
CRUCIBLE LIFTING TOOL

CRUCIBLES
CASCADE TABLE
BULLION MOULD
Page 58 of 71
LOADING PLATFORM
Page 59 of 71
5.5 Safety Clothes
Page 60 of 71
6 APPENDICIES
6.1 Appendix 1 – Fuel Supply Options. ...........................................................62

6.2 Appendix 2 – Burner Start up Cycle ..........................................................63
6.3 Appendix 3 – Parts List............................................................................64
6.4 Appendix 4 – Burner Spare Parts ..............................................................65
6.5 Appendix 5 – Combustion Adjustment .......................................................66
6.6 Appendix 6 – Combustion Head Setting .....................................................67
6.7 Appendix 7 – Electrodes Adjustment .........................................................68
6.8 Appendix 8 – Maintenance Position ...........................................................69
6.9 Appendix 9 – Maintenance .......................................................................69
6.10 Appendix 10 – Burner Troubleshooting ...................................................70
6.11 Appendix 11 – Wiring schematic ............................................................71
Page 61 of 71
6.1 Appendix 1 – Fuel Supply Options.
Page 62 of 71
6.2 Appendix 2 – Burner Start up Cycle
Page 63 of 71
6.3 Appendix 3 – Parts List

Part No. Description Qty Category
FY400-10200 Temperature controller 1 Electrical
XB3-BD3 3 pos switch 1 Electrical
ZB2-BE101 N/O aux contact block 1 Electrical
ZB2-BE102 N/C aux contact block 1 Electrical
AD16-22C Green Indicator LED green 2 Electrical
AD16-22M/R Flasher buzzer 1 Electrical
E1-430P7 VSD.75kw/1hp 1 Electrical
LC1-D1210 Contactor LC101210 1 Electrical
LA1-D05 LA1-DN22 contactor aux contacts 1 Electrical
MCB6-106 Circuit breaker 6amp 1P 1 Electrical
MCB6-306 Circuit breaker 6amp 3P 1 Electrical
AZ7311 Limit switch 2 Electrical
COB61 Hand pendant 1 Electrical
TC-K235-CS Thermocouple Type K 1 Electrical
R2132UA Fuel filter 1 Electrical
LHYM05-38 Gearbox LHYM05-3B12DA-Y1-B 1 Electrical
RIELLO RG2D RG2D burner 1 Electrical
F215NBR Bearing housing 4 bolt square flange 4 Fasteners
UC215DH Bearings 4 Fasteners
TC-FX/FB-054 Brake motor 1 Motor
CASTOR 3478 Castors 3478 rigid 2 Wheels
CASTOR 3477 Castors 3477 Total lock plate 2 Wheels
AXO100 A100 silicon carbide crucible 1 Crucible
A100-SB Bricks 10 Bricks
WDXS 400oz Cascade mould 7 Castings
SLG40ID-150 Spill tube 1 Castings
A100TRCP Top rear cast panel 1 Castings
A100TFCP Top front cast panel 1 Castings
A100PS Pouring spout – cast 1 Castings
A100LID Lid – cast 1 Castings
A100CS Crucible stand 1 Castings
A100BRCP Bottom rear cast panel 1 Castings
A100BFCP Bottom front cast panel 1 Castings
A100BP Burner port – cast 1 Castings
A100B Base - cast 1 Castings
A100ft-25-8 Floor spacer tile 25mm (8 set) 1 Castings
Page 64 of 71
6.4 Appendix 4 – Burner Spare Parts
Page 65 of 71
6.5 Appendix 5 – Combustion Adjustment
Page 66 of 71
6.6 Appendix 6 – Combustion Head Setting
Page 67 of 71
6.7 Appendix 7 – Electrodes Adjustment
Page 68 of 71
6.8 Appendix 8 – Maintenance Position
6.9 Appendix 9 – Maintenance
Page 69 of 71
6.10 Appendix 10 – Burner Troubleshooting
Page 70 of 71
6.11 Appendix 11 – Wiring schematic
Page 71 of 71

GTA100-VSD-DES Oven

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

GTA100-VSD-DES Oven

Uploaded by

Copyright:

Available Formats

SMELTING FURNACE

Installation, Operation, Maintenance & Spare Parts Manual

Furnace Technologies, Feb 2016

Furnace Technologies Pty Ltd

6.1 Appendix 1 – Fuel Supply Options. ...........................................................62

Figure 1 - A100 Smelting Furnace ......................................................................... 7

Figure 28 - Supporting Bricks Alignment ...............................................................44

Table 1-General Description ................................................................................. 8

1.1 Contact information ................................................................................. 6

1.1 Contact information

FURNACE TECHNOLOGIES PTY LTD

Ph: +61 8 9417 4226

Fax: +61 8 9417 9827

General Enquiries: info@furnace-technologies.com.au

ABN: 47 063 407 581

ACN: 063 407 581

1.2 General Information

Furnace Technologies Equipment Manual

Figure 1 - A100 Smelting Furnace

1.3.1 Attendances at remote sites or outside of the Perth metropolitan area.

1.4 Using this Manual

1.4.1 Duty of Care

1.4.2 Safety Information

Danger – Possible life-threatening danger or hazard.

Figure 2 - Danger Caution

Warning – Possible hazard or risk of machinery damage.

Figure 3 - Warning Caution

1.4.3 Personal Protective Equipment (PPE) Requirements

Minimum Recommended PPE

Eye Protection must be worn

Head Protection must be worn

Hearing Protection must be worn

Foot Protection must be worn

Hand Protection must be worn

Dust Mask must be worn

Full Face Shield must be worn

Table 2 - Minimum Recommended PPE

1.4.4 Other Cautionary Signs

Table 3 - Cautionary Symbols

2 TRANSPORTATION, HANDLING AND INSTALLATION

2.1 Safety Information .................................................................................14

2.1 Safety Information

2.1.1 Minimum PPE

2.1.2 Cautionary Signs

2.2 Transportation and Handling

2.3.1 Unpacking the Equipment

Procedure for unpacking the furnace:

2.3.2 Checklist of Supplied Parts

2.4 Furnace Installation

Warning – Combustible materials should not be in placed in close

Warning – Do not install in a room with insufficient air for

Danger – Burner exhaust and melt fumes/gas must be correctly

Figure 4 - Control Box Rotation

2.4.1 Setting up the Furnace

2.4.2 Setting up the Cascade Table

Figure 5 - Cascade Table Position

2.4.3 Setting up for Rotation

Caution – the gearbox and motor produce considerable force. If

 The gearbox needs to be filled with heavy weight oil.

Note: We recommend using SYN680 high performance industrial gear oil.

2.5 Burner Set-Up

Caution – an external fuel filter is required for the burner. The

Figure 7 - External Fuel Filter