FS246

FS Series Shuttle / Envelope Kiln (Moving Kiln With Fixed Bases) 2200°F (1200°C)

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

Applications

LOCKED BY SERIES

Description

The FS Series Shuttle Envelope Kilns are primarily designed for the firing of ceramic ware. Each furnace system includes two fixed stationary bases and a moving kiln that "shuttles" between the two bases. The stationary bases provide a stable platform for loading delicate ceramics. The base is easy to load because it can be loaded from all four sides once the kiln is shuttled out of the way. Normally the kiln is removed from the fired ware at a fairly high temperature for a fast cool down in the slowest part of the cooling curve. This greatly adds to the efficiency of the whole system. The entire kiln is built for heavy duty daily production and easy in-house maintenance.


Processes


Markets

Specifications

Dimension
W
H
D
Inside
38
54
80
Working
30
48
72
External
88
92
104
Hearth
30
-
72
Work Cubic Feet 60
Total Length 244
* All dimensions in inches unless otherwise specified.
Power
Standard Pwr 113
Max Temp (°F) 2200
* All power values in KW unless otherwise specified.
Weight
Ship Weight 6500
Max Load 1125
* All weights in Lbs unless otherwise specified.


Additional Features

HORIZONTAL DOORS
There is a door at either end of the kiln. Both doors are opened while the kiln is being moved. The doors are on heavy duty single pivoted hinges. The door seal consists of folded ceramic fiber blanket which compresses against the hard castable refractory vestibule which surrounds the door. Two mechanical latches close the door.
DIGITAL PID CONTROL AND HIGH LIMIT SYSTEM
The standard control is a Honeywell UDC 2500 digital PID 3 mode tuning control. All fuses, transformers, contactors, and controls are located in a NEMA 12 panel with a panel mounted fused disconnect switch. Power control is normally solid state contactors. Thermocouple type is typically type R. Thermocouple break protection is included. Limit switches shut off kiln power if either kiln door is opened. Control voltage is transformed to 120 volts. A Honeywell UDC 1200 digital high limit back up control with manual reset, back up contactors and separate thermocouple is standard. The control circuit and each power branch circuit are fully fused. Single point power connection. Meets National Electrical Code.
ZONED POWER CONTROL
The element circuits are separated into four heating zones (end-top, end-bottom, sides-top, sides-bottom.) This promotes temperature uniformity in the kiln. Each of these zones is typically controlled with percentage timers that control time on and time off for the elements. Optional SCR power controls are digitally biased. Separate 4 loop PID control is also available.
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.
GEARED KILN MOVER
The kiln is moved by one man with a geared manual turn wheel located on the side of the kiln. This is geared for easy movement. The kiln moves on railroad type flanged wheels. In addition there are horizontally mounted roller bearings that maintain a horizontal pressure on the track system to maintain the squareness of the kiln and prevent potential tipping.
LAP TYPE BASE/KILN JOINTS
The seal between the kiln and the bases consists of a close tolerance lap joint. This effectively prevents radiation transfer of heat. The slight air gap (less than 1/2”) allows for an air inlet when using the optional venturi cooling system. The seal surfaces are both dimensionally stable castable refractory.
CASTABLE BOTTOM AND VESTIBULES
The bases have 8” of poured castable refractory. The material chosen is a special extremely light weight castable which still retains great mechanical strength while being reasonably energy efficient. The door vestibules and base seals are also made of t he same castable refractory. They are poured in replaceable sections which bolt onto the furnace frame.
CERAMIC FIBER INSULATION
The kiln sides and roof are typically lined with 10” of 10 pound density 2300F ceramic fiber Pyroblock insulation blocks. This provides a highly efficient insulation which has low heat storage of 2635 BTU per square foot, heat loss of 209 BTU/Square foot/hour and case temperature of 176F when operating at 2200F. This results in about a 30% energy savings over standard firebrick construction.
HEAVY DUTY POWER GRADED ELEMENTS
Elements are located on the sides and two doors. These are made of coiled heavy gauge iron-aluminum-chrome alloy wire (Kanthal A-1 or equivalent.) They are mounted on alumina rods (not subject to sag like cheaper mullite rods) which in turn are mounted on heavy ceramic blocks along the walls. The alumina rods allow the coiled elements to be completely exposed to the air. This helps maintain cool element temperature which is critical at these high temperatures. The wattage of the elements is graded top to bottom to promote good temperature uniformity.
SHUTTLE CASE DESIGN
The case is a heavy duty fabrication which is carefully built to prevent bowing in (which can be a problem with having no bottom structure in the case.) Two bases and a complete track system are included with the furnace. Stops are built into the track system to prevent overtravel. The entire case, bases and car are primed with 800F silicone paint and finished in machine enamel.
FURNACE CONSTRUCTION
The furnace is made of polygonal heater sections with a stainless steel wrap around casing. These are supported in heavy metal frame that completely supports and protects these heaters.

Additional Options

AUTOMATIC FURNACE MOVING
Includes electric vertical doors, electric car drive and logic control for automatically moving kiln.
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.
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.
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.
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.
ON SITE START UP AND TRAINING
An L&L factory technician will review and check out customer’s installation, start up and burn in furnace, and train the operators.
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 FS