This manual contains proprietary information that is protected by copyright. All rights are reserved and no part of this document may be photocopied or reproduced in any way without the prior consent of Inductotherm (India) Limited. Information contained in this document is subject to change without notice.
Inductotherm (India) Limited makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Inductotherm shall not be liable for errors contained herein or for incidental consequential damages in connection with the furnishing, performance, or use of the material.
The Precautions outlined below are for your safety – read them first. Molten metal and electricity can be hazardous. Be sure to follow your company’s safety procedures. Inductotherm equipment is buil with safety devices. Do not defeat or bypass any protective component or circuit.
FOR THE OPERATOR
All induction heating/melting equipment uses high-voltage power during operation. Inductotherm built equipment is designed for safe, efficient and reliable operation with ease of maintenance. Even so, the simple rules of operation must be observed.
Several safety features are built into Inductotherm equipment to provid the operator with protection. Do not defeat these safety features.
》Keep all cabinet doors locked and make keys available only to those who require access to the enclosure.
》 Keep shields, covers, insulating materials, and other protective devices in place at all times. They are provided for the express purpose of making the equipment safe to operate. An open enclosure is a peril to personnel. These devices must be in place whenoperating the equipment.
Should it be necessary to remove them, ensure that the equipment is off and circuit breakers and/or disconnects are locked open. Always replace these safety devices prior to energising the equipment.
》 Don’t depend on interlock devices for protection. Be sure power switches are in the “off position before opening doors or removing any access panels.
》Put warning tags and padlocks on main power disconnects whenever working on cubicles, vaults, bus trenches or furnace to prevent anyone from mistakenly applying power to the equipment.
》 Always switch power off when lifting, pouring, or transporting hand furnaces.
》The lead connections to the induction furnace must be insulated or isolated so that operating personnel cannot touch the parts and receive an electrical shock.
》Even after disconnects are opened, high voltage will remain for at least five minutes. Be sure to allow sufficient time for capacitors to bleed down through the discharge resistors and check voltage levels with a meter before touching internal components.
WHEN CHANGING A FURNACE
》 Use only dry charge material.
》 Be sure bundled or baled scrapes dry before adding to melt.
》 Do not allow closed or partially closed containers that may contain liquids (beverage cans, sheared tubing, etc.) to be mixed with the furnace charge. Liquids or pieces of combustible material can vaporise instantly upon contacting the melt and scatter molten metal.
》 The above precautions are especially important with aluminum because scattered molten particles can combine with oxygen which can result in a secondary explosion.
FOR MAINTENANCE PERSONNEL
》 Study this Maintenance Manual.
》 Become familiar with the unit and its dangerous areas before attempting maintenance of any kind.
》 Never enter a cubicle or transformervault without tagging and padlocking the main disconnect breaker in the open or off position.
》 Always use two independent methods to support a tilited furnace whenever working on or near it.
》 If a bus from two furnaces is located in a common area, lock out both units.
The precautions outlined here are well-knownto foundrymen They are common to all metal melting operations and are not peculiar to induction melting. The following are offered as general precautions, applicable to the foundry industry, and cannot be construed to cover all types of operations. We suggest that the users evaluate these precautions in light of their specific operations and expand or modify the necessary. The central & state statutory and regulatory requirements should be followed by the customer at the place of use.
》 Access to melting and pouring operations should be limited to authorised personnel only.
》 Personnel shouldwear safety glasses at all times and should use special light reducing glasses when viewing metals at high temperatures.
》 Heat-and flame-retardant safety clothing should be worn by personnel who work at or near furnaces.
》 The refractory that is used to line thefurnace must be suitable for the materialbeing melted. Referto the refractory manufacturer’s specifications. Be sure the furnace linings have been thoroughly dried and sintered in accordance with the manufacturer’s recommendations.
》 In induction melting, furnaces should be charged carefully to avoid bridging of the charge. Excessive temperatures in the bath below the bridge can cause rapid erosion of the furnace lining and a dangerous run-through whichwould cause an explosion. To melt out a bridge after it has formed, the power supply should be run at reduced power to prevent superheating. Normally about 25 percent above holding poweris sufficientto slowly melt out the bridge. Holding power is the power level required to maintain the molten metal in a fully molten furnace at constant temperature. While running at this power level, tilt the furnace to bring the molten metal in contact withthe bridge. After a hole has been melted through the bridge, return the furnace to the upright position. Then checkthe temperature to make sure the molten metal is not superheated. Begin adding charge through the hole in the bridge to bring the molten metal in contact with the bridge Becareful notto superheatthe molten metal during this procedure.
》 Regularly inspect furnace linings to minimise the possibility of a dangerous run-through”occurring. –
》 The furnace lid (where one is used) should be closed before the furnace is tilted.
》 Charge materials must be dry and free of combustible materials Combustible materials and liquids, if submerged under a molten bath, can vaporise and cause apossible boil-over orexplosion.
》 Care shouldbe exercisedwhen adding low melting point materials that have low vaporisation temperatures into high temperature baths. If such materials become submerged before they melt, they can vaporise and cause a possible boil-over or explosion.
》 Crucibles for lift coilorpush outfurnaces should be used onlyfor those metals for which they are suitable. Generally removable crucibles are not designed for the high temperatures encountered in melting nickel, monel, copper – nickel, or ferrous materials. Refer to the crucible manufacturer’s specifications regarding the materials that may be melted in crucibles.
》 When metal is to be transferred in a crucible, a cradle t provides adequate bottom support for the crucible must used.
ABOUT THIS POST
Be knowledgeable of the chemistry of your melt. Chemi reactions such as rapid carbon boil can damage equipme and be dangerous.
The Duraline furnace built by Inductotherm is designed a manufactured for reliable prolonged service. But, like any w engineered piece of equipment, it must be operated ar maintained in a proper manner. This manual is intendedt assist you in this process. As you can see from the Table Contents, this manualis organised to help you identify, instal operate, and maintain the equipment which makes up th we call the Duraline Furnace. Since the skill ofinductio stem melting is an on-going process, comments and suggestion
WARNINGS :- THROUGHOUT THIS MANUAL YOU WILL ENCOUNTE I WARNING NOTES. THESE WARNINGS ARE INTENDE TO ALERT YOU TO SITUATIONSTHAT ARE HAZARDOU AND WHICH COULD CAUSE DEATH OR INJURY T PERSONNEL OPERATING OR MAINTAINING TH I EQUIPMENT. BECAUSEOF THEIRHAZADOUS NATUR THEY SHOULD NOT BE IGNORED.
CAUTIONS :- CAUTIONS ARE NOTES ABOUT SITUATIONS THAT COULD CAUSE DAMAGE TO EQUIPMENT. WHILE THEY MAY NOT RESULT IN DEATHORINJURY, THE RESULTING DAMAGE COULD BE COSTLY AND TIME-CONSUMING. CAUTIONS SHOULD BE FOLLOWED.