1. PERIODIC MAINTENANCE CHECKS.
Duraline furnaces require very little routine maintenance. However,systematic scheduled attention to general inspection, cleaning, and adjustments can prevent equipment failure and loss of production time. The following maintenance schedule is suggested as a guide for this procedure.
WARNING :- Do not perform any maintenance on the system with power on. Place cabinet switch or circuit breaker off. Padlock or secure input power (circuit breaker switch) to off, to prevent accidental live power on to the system. Be sure capacitors are discharged and circuit breaker is off.
NOTE :- All cable connections on the circuit breaker should be re-tightened 90 days after installation.
1. Check for correct external water leakage.
2. Check for and correct internal water leakage.
3. Check for signs of condensation. (wipe clean with lint-free rag)
4. Check external power cable to cabinet integrity.
5. Checkgeneral cleanliness at hydraulic connections.
6. Cleanliness at furnace-do not allow slag or water to touch furnace leads.
7. Check fluid level in hydraulic power unit Topupif below level.
furnace maintenance tips
1. Open the front & back covers from the furnace.
2. Remove any slag or metal chips that have accumulated inside thefurnace. Care must be taken not to dislodge control wiring or damage components.
3. Check coils for signs of overheating or discoloration.
4. Inspect all water connections for signs of leaks.
5. Wipe all hydraulic rams and check for loose connections.
6. Inspect all hoses and leads for loose connections & tighten if found loose.
7. Replace the furnace panel covers.
8. Inspect the water and hydraulic filter. Clean or replace as needed.
9. Inspect the furnace lining for sign of deterioration, cracks, or metal penetration.
10. Inspect furnace leads for sign of external damage. Clean, repair, or replace furnace leads that show sign of excessive oxidation, distortion, cracks, or leaks.
11. Remove and replace connectors that are damaged .
12. Check all the pipe joints and tighten them up if found loose.
13. Remove and replace hoses which leaks or show sign of fatigue .
14. Before returning the unit to operation, make sure that all cleaning material and flammable solvents have been removed. Failure to do so could subject operating personnel to hazards.
15. Tighten tie rods & coil restrained per procedure outlined in Section 4
NOTE :- The following procedures describe removal and replacement of components. Do notremove any equipment prior to noting its exact location. Tag or label each unit priorto removal.Unless advised otherwise by official bulletins or instructions, replace all like items with similar units.
2. MECHANICAL MAINTENANCE
It is necessary to perform periodic inspection and weekly lubrication for trouble free operation of Lid mechanism.
There are two grease fittings located under a cover on top of the lidpost mechanism; they should be lubricated weekly with a high temperature grease. Atthe time oflubrication, the hydrauficlines should be checked for integrity
Ensure that the flow controls regulate the lid opening orclosing for ten seconds or longer.
3. FURNACE PIVOTS & CYLINDER ROD ENDS.
To ensure the proper operation of the various pivot points, it is necessary to perform periodic inspections and weekly lubrication.
There is one grease fitting located on every pivot bearings; they should be lubricated weekly with a hightemperature grease. Thoughthe pivot pins are housedin self-lubricating bearings, periodically greasing thempushes out any dirt that may havebeen trappedinthe bearings during operation.
4. HYDRAULIC SYSTEM MAINTENANCE
At the end of the two weeks’operation, drain and discard all the fluid in the system. Inspect the reservoirinterior for cleanliness and,if necessary, wipe with a lint-free rag. Remove and clean the suction strainer. Replace cover and refill with duplicate of fluid originally used. This process should be repeated per the following schedule.
furnace maintenance check
furnace maintenance schedule
Equipment Usage – Fluid Change Schedule
One Shift Operation – Every Six Months
Two Shift Operation – Every Four Months
Three Shift Operation – Every Three Months.
The fluid level and pump delivery pressure should be checked daily. If the level is low, replenish with the original brand and type of fluid, taking care to use clean implements. Find and repairleaks. Adecrease in pumppressure usually indicates a malfunctionint hydraulic system. Do not Mix Fluids exceptin anemergency situation and thenonlyifthe supplier guarantees complete compatibility with the original fluid. When a change in fluid becomes necessary, the entire systemshouldbe drained and flushed before the new fluid is installed.
Replace filter element immediately when indicator says to or when filter is bypassing. Strainers (if any) shouldbe cleaned and filter elements shouldbe replaced with eachfluid change.
5. FURNACE TIE ROD & COIL RESTRAINED TIE ROD TIGHTENING SCHEDULE
Periodic checks should be made to determine if the side plates with tops & bottom are sufficiently tight. The following procedure is recommended After the first 2 melts approx. check that all tie rods nuts are fully tightened. Check these again and retighten after max. 7 days then check weekly. The vertical tie rods are sealed at the top but are accessible from the bottom of the furnace. The horizontal tie rods canbe tighteneddown hardbutverticaltie rods mustonly be tightened enough to maintain the top/ bottom blocks firmly in place. Excessive over tightening of the vertical rods can lead to E cracking of the top/bottom blocks. Before tightening the vertical rods slacken off the coil bracketnuts and retighten after checking the tie rod nuts. The checking must be done with the furnace in a cold condition.
Tie rod dia – Torque
3/8″ – 30/45 lb.ft.
1/2″ – 70/90 lb.ft.
3/4″ – 150/160 lb.ft
1″ – 220/240 lb.ft
1 1/4″ – 260/280 lb.ft.