FURNACE INDUSTRIES

Lot 13 Cutler Road, Jandakot W.A. Phone + 61 8 9417 9600 Fax + 61 8 9417 3991
Email furnace@dfcceramics.com.au

CONTACT : Peter Bellinger

CLIENT: Independent Lab Supplies

USER :

MODEL No. : EMF-D

SERIAL No. : BN1186-87

Warranty
I. Product Guarantee:

All equipment and parts manufactured by DFC Ceramics, (The Supplier) are warranted when sold by it, to be free from defects in material for workmanship for a
period of 90 days after such sale under normal use and care and in the absence of unauthorised alterations by the purchaser or the substitution or additions by them
of any parts of accessories not approved by the Supplier. Its obligation under this warranty being limited to replacing, at its factory in Canon City, Colorado, any
part or parts which within 90 days after delivery to the original purchaser thereof be returned, and under examination shall disclose to have been thus defective.
This warranty and obligation are in lieu of all other warranties expressed, implied, or statutory, and all other obligations or liabilities of DFC Ceramics, in
connection with sales of its products, and no representation to the contrary unless in writing and signed by an officer of the Supplier will be considered valid or will
be recognised. This warranty does not apply to and there is no warranty by DFC Ceramics, express, implied or statutory, respecting (a) parts or accessories which
are not of its manufacture sold by it either separately or as part of any equipment or machine, nor (b) machinery or equipment parts or accessories, whether
manufactured by it or not, which are sold by it as used or second-hand equipment (c) refractory parts manufactured or purchased by DFC Ceramics. The Supplier
shall not be liable for and the Purchaser assumes and will indemnify and save harmless the Supplier in respect of any loss damage that may arise through use by the
Purchaser or any others with said equipment, our liability being limited to the replacement of defective parts, as aforesaid. This guarantee does not include the
normal deterioration of material, or other damage resulting from exposure to heat or other wear and tear arising under operating conditions. In addition, the
Supplier is not responsible in any way when we build or fabricate equipment designed by the Purchaser.

Delivery, Claims and Shipping

I. Delivery:

All sales are F.O.B. the Suppliers plant in Jandakot, Western Australia, unless otherwise specified.

The Supplier shall not be liable for any delays or defaults hereunder by reason of fire, flood, acts of God, labour troubles, inability to secure raw materials, acts
of Government, or other causes beyond its reasonable control In event of any such delay, the date of delivery shall be extended for a period equal to the item
lost by reason of delay.

The Supplier shall not be liable for special or consequential damages by delay in delivery or failure to manufacture

II. Claims for Shortage:

Each shipment shall be examined by the Purchaser promptly upon their receipt thereof, and any claim for shortage or any other cause must be reported to the
Supplier within thirty (30) days after such a receipt, the Purchaser will be deemed to have accepted shipment and to have waived any claim it might have.

III. Return Product for Credit

No credit will be given for return of material or equipment except with the prior approval of the Supplier. All special materials or special equipment are shipped
without the privilege of return, and under no circumstances can burner nozzles or burner blocks be returned for credit after they have been used, even for short
operating periods. No returns are permitted on used refractories.

IV. Shipping

The Purchaser should state when ordering the exact method of shipment preferred. In absence of shipping directions, the Supplier will use its best judgement
in routing the shipment. All goods are shipped at the Purchasers risk. If the Purchaser gives the transportation a clean receipt for damaged goods or for
shipment upon which there are shortage, he does so at his own risk. The Supplier is not responsible for goods broken, damaged or lost in transit.
 FURNACE INDUSTRIES
Lot 13 Cutler Road, Jandakot W.A. Phone + 61 8 9417 9600 Fax + 61 8 9417 3991
Email furnace@dfcceramics.com.au

1 PARTS LIST

2 INSTALLATION INSTRUCTIONS

3 OPERATING INSTRUCTIONS

4 MAINTENANCE INSTRUCTIONS

5&6 ELEMENT INSTUCTIONS

7 ELECTRICAL SCHEMATIC

8 TEMPERATURE CONTROLLER
 FURNACE INDUSTRIES
Lot 13 Cutler Road, Jandakot W.A. Phone + 61 8 9417 9600 Fax + 61 8 9417 3991

SPARE PARTS : MODEL EMF-D CUPELLATION FURNACE ELECTRIC

PART No. DESCRIPTION

C101L Thermocouple Element 230mm +75mm Type K C102
Thermocouple Sheath Inner
C103 Thermocouple Sheath Outer
F354 Temperature Control RKC
CAL433 Contactor ABB D50 110v
C112201 Heating Element 20x500x1000
C114 Element Clip 16mm
C116 Element Strap
C-110-D Muffle # 5
C124 Muffle Vent
LFT56022 Floor Tile 560x480x22
F128 3 Ceramic Anchor Complete with Nut & Bolt
JB160025 Kaowool Blanket 160kg ( Ceramic Fibre )
C503 Omron H5SB Timer
 FURNACE INDUSTRIES
Lot 13 Cutler Road, Jandakot W.A. Phone + 61 8 9417 9600 Fax + 61 8 9417 3991

TECHNICAL SPECIFICATION

MODEL EMF-D CUPELLATION FURNACE ELECTRIC

POWER SUPPLY 380v VOLT 50/ 60 HZ 3 PHASE

POWER CONSUMPTION 15 KW ( NOMINAL )

DESIGN TEMPERATURE - 1150C

MAXIMUM OPERATING TEMPERATURE - 1150C

TEMERATURE SENSING K TYPE THERMOCOUPLE.

ELEMENTS 20mm SILICON CARBIDE 1000mm LONG, 500mm HOT ZONE

TEMERATURE CONTROL RKC SWITCHING 1 * D50 CONTACTOR . ALARM CONTACT SET

TO 10 ABOVE SET POINT, SWITCHES 1 * D50 CONTACTOR.
 FURNACE INDUSTRIES
Lot 13 Cutler Road, Jandakot W.A. Phone + 61 8 9417 9600 Fax + 61 8 9417 3991

INSTALLATION INSTRUCTIONS

MODEL EMF-D ELECTRIC

1 FURNACE IS TO BE INSTALLED ON A FLAT LEVEL FLOOR.

2 THE FURNACE IS NOT REGARDED AS WEATHER RESISTANT. THEREFORE IT MUST BE

INSTALLED IN A SUITABLE LOCATION .

3 LOCATION SHOULD ALLOW A MINIMUM CLEARANCE TO ENSURE SAFE

OPERATING AND MAINTENANCE.

4 ELECTRICAL WIRING TO BE INSTALLED BY A LICENSED ELECTRICIAN. IN A MANNER

SUITABLE FOR THE LOCATION , AND COMPLYING WITH LOCAL REGULATIONS. CHECK
ALL WIRING CONNECTIONS
NOTE:

5 INSTALL SILICON CARBIDE ELEMENTS. TAKE CARE TO ENSURE CONNECTIONS

REMAIN THE SAME. CAUTION ELEMENTS ARE FRAGILE.

6 REMOVE THERMOCOUPLE AND SLIDE MUFFLE CHAMBER INTO POSITION.

FIT VENT TUBE INTO POSITION, AND USE MORTAR TO SEAL THE JOINT FROM INSIDE THE CHAMBER.
SEAL GAP AT FRONT OF CHAMBER USING STRIPS OF CERAMIC FIBRE, AND COVER WITH A LAYER OF
MORTAR.

7 PLACE A 2-3mm LAYER OF MAGNESITE POWDER ON THE FLOOR OF THE MUFFLE

CHAMBER. PLACE FLOOR TILE INTO POSITION.

TIMER SETTING INSTRUCTIONS

1 To set correct Day and Time

Press SHIFT key to move to correct day, press SET key

Press H key to set correct hours.

Press M key to set correct minutes

Press WRITE key, Time and day is now set

2 To adjust Day and Time

Press and hold TIME ADJ key for 1 second or longer

Follow steps as per section 1

3 To set Timer operation

Shift MODE switch from RUN to P1

Select days to operate using SHIFT key, then SET key

Select time to turn on using H, then M key

Press WRITE key to set

Select time to turn off using H, then M key

Press WRITE key to set

Shift MODE switch from P1 to RUN

4 To Reset Timer operation

Shift MODE switch from RUN to P1

Open cover on Timer and press CLR-WRITE

Set as per section 3 above.

5 Shift CYCLE SELECTOR SWITCH to AUTOMATIC

The furnace will now operate on Automatic Cycle.

Install Elements by sliding through top holes. Make sure that they are
sitting firmly on insulating board at bottom. Connect straps top and
bottom. Careful that straps are not touching any part of frame .

MUFFLE INSTALLATION
Carefully place muffle into the chamber
NOTE: Remove thermocouple before starting and be careful not to hit
any elements.

Using a lever assist from rear to help install muffle.

Using a trough place some Super 3000 refractory cement

Around the vent inlet of the muffle

 Place vent into position and then seal all cracks

This is a very important part of muffle installation. If the vent is sealed correctly
then there will be no contamination of the chamber and rear bricks inside the
furnace. If cracking appears around vent then plan maintenance shut and reseal.
Insert Kao Wool into the gaps at the front of the muffle. Trim neatly

Carefully cover with a thin layer of Super 3000 over the Kao Wool to help seal off
the front area of the muffle.

NOTE: Vent holes must be kept clear at all times to allow hot air to be drawn
through the muffle chamber
Replace Thermocouple
BLOCKED FLU
If air adjustment is not working correctly you will end up with you furnace flu looking like this. There will always
be some build-up but that can be cleaned with a metal scraper on a regular basis

If you furnace gets to this condition then the lead fumes only have a couple of places to go 1/. Out the door and into
the lab. Not very ideal 2/. Through any cracks in muffle chamber and then into the element chamber causing
serious damage to brickwork and elements

Extraction unit to be installed after muffle vent has been installed

There are two mounting screws for installation
Air flow adjustment is made using slide. Forward is closed . Backward
is open. Can only set properly once cupelling.
 FURNACE INDUSTRIES
Lot 13 Cutler Road, Jandakot W.A. Phone + 61 8 9417 9600 Fax + 61 8 9417 3991

OPERATING INSTRUCTIONS

MODEL EMF-D ELECTRIC

1 TURN ON ELECTRICAL SUPPLY
2 TURN MAIN ISOLATION SWITCH
3 YOU NOW HAVE THE OPTION OF RUNNING MANUAL OR AUTO
TO RUN MANUAL SWITCH SELECTOR SWITCH TO MANUAL
TO RUN AUTO SET SWITCH TO AUTO AND SET TIMER PERIMETERS

4 CHECK CURRENT DRAW IS WITHIN LIMITS ( 5-10 Amps at initial start up. This will increase to
15-24 Amps as temperature increases. )

5 SET REQUIRED TEMPERATURE.

6 IF CURRENT DRAW IS BELOW 10amps ( at operating temperature),

TURN OFF CONTROL CIRCUIT ISOLATOR, OPEN FRONT PANEL,INCREASE SETTING
ON ALL THREE TRANSFORMER TAPPINGS. (ALL THREE TAPPINGS MUST BE ON THE SAME
SETTING )
IF TAPPINGS ARE SET TO MAXIMUM POSITION, REPLACE ELEMENTS AND RESET
TAPPINGS TO MINIMUM POSITION.

FURNACE SHUTDOWN
1 TURN CONTROL CIRCUIT ISOLATOR OFF.

3 ISOLATE ELECTRICAL SUPPLY.

 FURNACE INDUSTRIES
Lot 13 Cutler Road, Jandakot W.A. Phone + 61 8 9417 9600 Fax + 61 8 9417 3991

SILICON CARBIDE ELEMENTS.

Generally a heating element made of silicon carbide is gradually oxidised due to its application over long periods,
increasing its electrical resistance; that is, aging results. This is due to the partial oxidisation of SiC, which is formed
into SiO2, diminishing the electrical conductivity of SiC according to the reaction.

SiC + 202 - SiO2 + CO2

To prevent oxidisation and to preclude an increase in electrical resistance, the surface is covered with a film coating,
which, being stable without comparison, helps minimise aging and ensures a considerably longer life. When the
electrical resistance has increased to about five times the incipient value, the service life of a heating element may
be considered expired. In actual application its aging speed depends on the applicable temperature, watt density,
operating type (continuous or intermittent), atmosphere in the furnace, and so on.

EFFECT OF APPLICABLE TEMPERATURE:

The aging speed on SiC varies considerably according to its applicable temperature; the high the temperature, the
quicker the aging speed.
If, however, the density of its ' surface load is diminished despite high temperatures inside the furnace, silicon carbide
elements can be employed over a prolonged time.

EFFECT OF OPERATING TYPE: (CONTINUOUS OR INTERMITTENT)

Even when the furnace temperature and the watt density remain the same the effect on continuous operation of
silicon carbide differs from that of intermittent operation (for instance, operations only during the day); that is, the
latter type has harmful influence upon silicon carbide. This is considered due to the fact that SiO2 formed by the
oxidisation of SiC experiences abnormal expansion and,contraction at about 25O degrees C ( the transformation
point,of cristobalite), the repetition of which imparts mechanical shocks.to the inner structure of the heating element,
producing tiny cracks.

INSTRUCTIONS ON REPLACING PROCEDURES:

When replacing the heating elements, replace all of the elements installed in the same regulating circuit. This will not
only ensure their.long service life, but will also prove more economical for the following reasons:
Partial replacement of heating elements in a parallel connection will overload the new elements, and that in a series
connection will overload the old elements.. This will not only disturb temperature distribution but also will impair the
service life of the elements. Classify the removed elements according to their electrical resistance, and store them
as spares.
 FURNACE INDUSTRIES
Lot 13 Cutler Road, Jandakot W.A. Phone + 61 8 9417 9600 Fax + 61 8 9417 3991

BECAUSE SILICON CARBIDE ELEMENTS INCREASE IN RESISTANCE AS THEY AGE, THE POWER SUPPLY
TO THE ELEMENTS IS SUPPLIED PER A MULTI-TAPPED TRANSFORMER. THE TAPPINGS ON THE
TRANSFORMER FITTED TO THE FURNACE MAY START AS LOW AS 30 VOLTS AND GENERALLY ARE IN 5
TO 10 VOLT STEPS TO AS HIGH AS 150 VOLTS, WITH ONE TERMINAL MARKED COMMON OR TO" VOLTS.
TO INCREASE THE VOLTAGE SUPPLY TO THE ELEMENTS, MOVE ONLY THE'. CABLES ON THE VOLTAGE
TAPS.
DO NOT MOVE THE CABLE MARKED ZERO V (COMMON) UNLESS THE TRANS-
FORMER IS FITTED WITH OV + 5V TERMINALS, IN THIS CASE THE MAIN
TAPS ARE AT 10 V INTERVALS AND IT IS POSSIBLE TO SPLIT EACH
1OV TAP BY MOVING THE LEAD FROM THE 0V TAP TO THE + 5V TAP
THEN BACK TO THE OV TAP ON THE NEXT CHANGE UP ON THE MAIN TERMINALS AND SO ON.
INCREASE IN THE RESISTANCE OF THE ELEMENTS WILL BE EVIDENT BY A SLOWING DOWN OF THE
RECOVERY TIME ( HEAT UP) OF THE FURNACE. THIS IS ALSO INDICATED BY THE AMMETER/S.
THE MAXIMUM RECOMMENDED READING ON THE AMMETER/S FOR THIS FURNACE is AMPS.
IT IS POSSIBLE THAT THIS READING MAY BE EXCEEDED BY 10% UPON STEPPING UP THE
TRANSFORMER. THIS IS ACCEPTABLE BUT HIGHER READINGS WILL OVERLOAD THE ELEMENTS AND
TRANSFORMER.

REPLACING ELEMENTS
SHOULD ONE OR MORE ELEMENTS FAIL PREMATURELY IT IS RECOMMENDED THAT THE COMPLETE SET
BE REPLACED.
THE AGED ELEMENTS CAN BE STORED AS SPARES AND GRADED BY THEIR ELECTRICAL RESISTANCE.
PARTIAL REPLACEMENT OF A SET OF ELEMENTS IS NOT RECOMMENDED.

ELEMENT LIFE.
AS PREVIOUSLY STATED, THE LIFE EXPECTANCY OF SILICON CARBIDE ELEMENTS DEPENDS ON
SEVERAL FACTORS.
BECAUSE OF THE RELATIVELY LOW OPERATING TEMPERATURE OF CUPELLATION FURNACES, THE
INCREASE IN RESISTANCE OF THE ELEMENTS SHOULD REMAIN WITHIN 7 -10% PER 1000 HOURS OF
OPERATION.
AFTER FITTING A, NEW SET OF ELEMENTS, GO BACK TO THE LOWEST TAP ON THE TRANSFORMER TO
START.
 AC C
M
G C O N TA C T O R C O N TA C TO R
PO W ER TR A N SFO R M ER 15K VA

L1
X1
X2
L2
X3
X4
L3 X5

X6
CONTROL
TRANSFORM ER
600 VA
D O O R S W IT C H
2
5 AMP
CONTROL 120 V O LT C O N T R O L P O W E R IN D IC A T O R
FUSE 5 0 -6 0 H z
D E S C R IP T IO N PAR T NU M B ER
1

1 2 PO W ER TR A N SFO R M ER , 3 PH A SE, 380v

C O N T R O L T R A N S F O R M E R , 2 0 8 -4 8 0 V O LT, 5 0 -6 0 H Z
A U T O M A T IC 3
3 4 TEM PER ATUR E C O N TRO L, R KC
OFF T IM E R
O M R O N H 5S T IM E R , O M R O N H 5 S -B
MANUAL
C O N T A C T O R , A B B .D 5 0 1 1 0 v
S E L E C T O R S W IT C H , T E L E M E C A N IQ U E Z B E -1 0 1
4

A M P M E T E R S , R Q 7 2 E 0 -5 0 a m p

C O N T R O L F U S E - 5 A M P , 1 .2 5 " * 0 .2 5 " ( 6 m m * 3 2 m m )
5 A L A R M C O N TA C T O R
1 7 AC

6 M A IN C O N T A C T O R
4 5 MC

9 2

8 F U R N A C E IN D .
TEM PER ATU R E O V E R T E M P . IN D IC A T O R
CONTROL + D R A W N : P B e llin g e r M O D E L E M F -D
11
OMRON - RKC
THERM OCO UPLE D ATE : D EC 2002 F IR E A S S A Y F U R N A C E
12 TY P E "K "
- R E V IS IO N : 0 15 K VA
C F U R N A C E IN D U S T R IE S
FRONT PANEL

AMP METERS TEMP CONTROLLER TIMER

AUTO /MANUAL SWITCH FUSE

AMP METERS- Show the amps drawn at the primary connection for each phase
TEMPERATURE CONTROLLER- RKC
TIMER- Used on Auto selection for auto start up of furnace each day at a pre determined time
AUTO/MANUAL SWITCH- Auto selection used with timer. Manual used to run furnace any time.
FUSE- 5 amp fuse used for control equipment protection

MAIN ISOLATION SWITCH- Used to isolate furnace main power.