FC8824

FC Series Ceramic Fiber Lined Electric & Gas Fired Car Bottom Furnaces Up To 2200°F (1200°C)

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LOCKED BY SERIES
Type Default
Power Source Electric Or Gas
Loading Car (Bogie)
Uniformity AMS Class 5 (± 25ºF / 14ºC)
Atmosphere Air
Lining Ceramic Fiber

Applications

LOCKED BY SERIES

Description

The FC Series are ceramic fiber lined car bottom furnaces. They feature tight pneumatic car seals, electric car drives and a wide range of custom options including electric and pneumatic vertical doors, fans, zoning, program controls and custom hearths. The car bottom makes these furnaces extremely easy to load. They achieve high precision by featuring highly accurate controls, solid state contactors or SCR power controls, fans, multi-zoning, and very even spacing of elements for uniformity. Gas versions feature high velocity multi-zoned burners. Gas versions can reach 2400ºF (1300°C). Electric versions reach 2200°F (1200°C) with iron-aluminum-chrome elements, and up to 2000°F (1095°C) with the standard nickel-chrome elements. Insulation is all ceramic fiber except for hearth and hearth support. These furnaces can be designed for extremely heavy loads. Gas fired units are also available.


Processes


Markets

Specifications

Dimension
W
H
D
Inside
102
108
296
Working
96
96
288
External
138
156
323
Hearth
96
-
288
Work Cubic Feet 1541
Total Length 643
* All dimensions in inches unless otherwise specified.
Power
Standard Pwr 725
High Power 1075
Max Temp (°F) 2200
* All power values in KW unless otherwise specified.
Weight
Ship Weight 50000
Max Load 28800
* All weights in Lbs unless otherwise specified.


Additional Features

TIGHT, TROUBLE FREE PNEUMATIC CAR SEALS
The car seals feature a wide pad of ceramic fiber blanket. These are pushed by pneumatic cylinders against the castable edge of the car. They retract when the car is about to be moved. Limit switches prevent car movement unless the seals are fully retracted. This seal is extremely tight and features low wear because there is no rubbing.
DOOR AND SEAL
The door seal is also a wide pad of ceramic fiber, which seals against a rigid ceramic fiber board attached to the case front. The most common door is an electrically operated counterbalanced vertical door with a torque limiter to guard against jams. Seal is by adjustment of gravity using the counterbalance. Car mounted doors and double pivoted horizontal doors are available.
CAR BOTTOM FEATURES ELECTRIC DRIVE
The car bottom is made with heavy plate steel and structural members. The perimeter of the car is cast with a reinforced and anchored castable that is suitable for heat shock. Inside this perimeter, the car is insulated with insulating firebrick and surfaced with 2” cast slabs of castable for heavy duty wear resistance. Alternately, cast piers for easy forklift loading can be provided. Low mass cars are also available depending on the load configuration and weight. The car is driven in and out of the furnace with a car mounted AC brake motor drive. A cable reel feeds power to the car. Railroad type rails are provided with mounting plates. These can be mounted in or on the floor. Flanged wheels on car match rails.
SIDE MOUNTED CONTROL PANEL WITH HINGED DOOR HOLDS ALL COMPONENTS
All temperature controls, relays, contactors, power controls, switches, transformers and fuses are located in a side mounted NEMA 1 control panel with a gasketed hinged door. J.I.C. wire coding is used throughout. An oil tight NEMA 13 lighted on/off push -button switch turns the furnace on. Controls are mounted at eye level for easy visibility. A NEMA 12 panel with fused disconnect switch is optional. A cooling fan is included with SCR power controls.
DIGITAL PID CONTROL SYSTEM
The standard control is a Honeywell UDC 2500 digital PID 3 mode tuning control with two displays. All fuses, transformers, contactors, and controls are located in a NEMA 12 panel with a panel mounted fused disconnect switch. Quiet, long life solid state power contactors are standard; SCR power controls are optional. The thermocouples are Type K. Thermocouple break protection is included. A Honeywell UDC 1200 digital FM approved high limit back up control with manual reset is included with back up contactors and separate thermocouple element. Limit switch shuts off furnace power if the door is opened. Control voltage is 120 volts. The control circuit and each power branch circuit are fully fused. A NEMA 13 lighted On/Off switch is included. Meets National Electrical Code.
DIGITAL PID CONTROL SYSTEM
The standard control is a Honeywell UDC 2500 digital PID 3 mode tuning control with two displays. All fuses, transformers, contactors, and controls are located in a NEMA 1 panel. (NEMA 12 panels with fused disconnects are optional). Quiet, long life solid state power contactors are standard; SCR power controls are optional. The thermocouples are Type K. Thermocouple break protection is included. Limit switches shut off furnace power if the door is opened or the element cover plate is removed. Control voltage is 120 volts. The control circuit and each power branch circuit are fully fused. A NEMA 13 lighted On/Off switch is included. Customer must connect fused power supply to single point on panel.
EVEN ELEMENT PLACEMENT AND ZONE CONTROL FOR HIGH UNIFORMITY
The elements are normally divided into top and bottom zones. The control output is routed through two input switches, which allow adjustment of the total time on to each zone. If SCR power controls are used these can be zoned using digital biasing switches. Coiled alloy elements are evenly spaced along the sides, back, and door creating an even wall of radiation. The standard furnace is uniform to within +/-25F ( +/-15C) or better at 1500F (815C). Optional fan systems and multiple control zones are available for uniformity of up to +/-10F (+/-5C).
TESTING AND INSTRUCTIONS
The furnace is power tested to insure proper watt ratings. The controls are fully calibrated and the control system completely tested. A complete instruction manual includes easy start up instructions, theory of operation, maintenance instructions, parts list, general dimension drawing, general assembly and subassembly drawings where required, and a detailed trouble shooting guide. A ladder logic diagram and panel layout are prepared on CAD for easy readability.
WARRANTY
The furnace is warranted for one year except for elements and thermocouples which are warranted for six months. See warranty sheet Q12W.
LOW DENSITY CERAMIC FIBER INSULATION
The furnace, except for the car, is insulated with low density, high “K” factor ceramic fiber and mineral wool for fast heat up and cool down. The total insulation thickness is 8”. 2600F(1425C) fiber is used for 2200F (1200C) furnaces and 2300F (1260C) fiber is used for 2000F (1095C) or below. No asbestos is used.
PROPRIETARY CERAMIC ELEMENT HOLDERS
The elements are supported in proprietary high temperature ceramic element holders. These provide perfect support for the coiled elements as well as excellent radiating characteristics. The smooth surface prevents premature failure of the element as it expands and contracts. The holders are kept in place on the insulation walls with specially designed ceramic clamps and screws which fasten to a stainless steel mesh screen which is an integral component of the insulation system.
HEAVY DUTY CASE
The case is made of strongly reinforced 3/16” thick steel with an integrated base fabricated of heavy square tube and angle sections. Case is entirely primed with 800F silicone paint and finished in machine enamel.

Additional Options

CONTROL, RECORDER AND ELECTRICAL OPTIONS
CONTROL, RECORDER AND ELECTRICAL OPTIONS
COUNTERBALANCED VERTICAL DOORS
Manual hand crank, pneumatic or electric operation. For dual chamber furnaces available only for the top chamber.
FAN WATER COOLING SYSTEM
This is used typically when a water cooled fan or fans are employed. A manual ball valve shut off, flowmeter and regulating valve, and low flow switch are included plus hook ups for the inlet and outlet. The adjustable low flow switch alarm turns off element power and sounds an audible alarm.
HIGH TEMPERATURE FANS
Fans are the best way to increase the gradient uniformity inside the furnace. The maximum continuous temperature of the standard L&L fan system is 1875F. This system will normally provide a gradient uniformity within the furnace chamber of +/-15F or better with appropriate loading of the furnace. A machined aluminum heat dissipator removes heat from the shaft before the heat reaches the bearings. Two self centering pillow block bearings hold the shaft and a belt drives it from the motor. An OSHA shield is provided. The fan automatically turns off when the door is opened. Some fans have 6 pitched blades and blow down. The blade section is cast and then welded to a machined alloy shaft. Others have either 4 or 6 flat blades and pull the air up, discharging it to the sides. See quote for specifics.
HORIZONTAL DOOR
The door is a double pivoted horizontal door with thrust bearings for ease of operation. The double pivoting allows the hot face to be kept from the operator. There are four large manual turndown clamps for tight sealing. There are two overlapping gaskets for gas tightness. This door is typically used only because of overhead space limitations.
JIC CONTROL OPTION
This includes a NEMA 12 control cabinet, all oil tight switches and a panel mounted fused disconnect switch. Zone switches if included are percentage timers.
LOADER
A heavy duty loader will pick up the hearth tray by pivoting slightly in the back by means of a hydraulic cylinder actuated by a hand pump located on the loader. The loader can have two swivel wheels and two fixed wheels. Optionally, the wheel can be mounted on either inverted "V" tracks or railroad tracks embedded in the floor. All distances are engineered for precise and trouble free operation. The loader is typically designed to pick up the maximum rated load of the furnace. The loaders can be fitted with motorized drives.
MANUAL INLET WITH DAMPER
Various kinds of sliding manual dampers are offered, each sized and located according to specific requirements.
MANUAL OUTLET WITH DAMPER
A sliding stainless steel damper with a heat resistant handle allow a 4” vent hole to open and closed.
MOTOR DRIVEN VENTURI SYSTEM
A motor driven venturi vent system is available. This system exhausts air out of the furnace and pulls in fresh air. Air inlets are located per customer specifications. (NOTE: venturis work by blowing air past a tube that is inserted into the furnace. This creates a vacuum without blowing cold air into the furnace. It has the advantage of having a controlled exhaust and minimizing heat shock in the furnace.) A 1 H.P. motor, complete with motor starter, drives the system. Capacity is 300, 600 or 1250 CFM, depending on the size of unit ordered. A stack should be installed to exhaust the hot air. Normally, a hand operated stainless steel damper is provided with the venturi system to control the amount of air being exhausted from the furnace.
PROGRAMMABLE MOTORIZED VENTURI
The venturi motor is controlled with a magnetic motor starter and push-button, with a relay programmed by the programmable temperature controller for turning the motor on and off in order to follow a programmed cooling curve. A separate pneumatically controlled inlet damper is normally also added. The inlet and out dampers then open or close with the programmed switch.
RECIRCULATION MUFFLE
This system will insure a gradient uniformity within the furnace chamber of up to +/-5F. It is used in conjunction with a furnace fan. A reinforced, welded stainless steel recirculation muffle rests inside the furnace chamber. (This can be lifted out without damaging the refractory.) The muffle typically includes baffles along the sides. On recirculation muffles with top mounted fans the bottom is typically constructed of heavy reinforced perforated or expanded alloy which becomes the hearth of the furnace. These baffles direct the moving air around the elements and through the work space to the fan. They also shield the work from radiant hot spots. Where the fan is mounted horizontally in the back, the bottom is solid and the air is recirculated around through the open front. On top loading furnaces, the fan is normally mounted on the bottom and the air is pulled through the open top. A stainless steel 304 recirculation muffle can be used to 1400F while the 330 alloy muffles can be used to 1875F.
TWO TO EIGHT ZONE SCR POWER CONTROL WITH MANUAL BIASING
Digital biasing control is included to adjust relative output of SCRs to adjust temperature uniformity. There are up to 8 separate Zero Fired SCR power controls, one for each zone of heating. This allows you to fine tune the furnace for different temperature points. The SCRs are microprocessor based. The biasing switches have 99 increments.
TWO ZONE SCR POWER CONTROL WITH MANUAL BIASING
Digital biasing control is included to adjust relative output of SCRs to adjust temperature uniformity. There are 2 separate Zero Fired SCR power controls, one for each zone of heating. This allows you to fine tune the furnace for different temperature points. The SCRs are microprocessor based. The biasing switches have 99 increments.
WATER COOLED FAN FOR 2000F OR 2200F
Various water cooled fans made by Industrial Gas Engineering are available. These generally include a vertically mounted fan cartridge assembly for operation up to 2200F. The fan shaft and blade is statically and dynamically balanced. Typically these fans use about one gallon of water per minute for cooling.

Downloads

Brochure For FC