Operation of the furnace maintenance should be in accordance with the procedures described in individual system VIP instruction manuals, bulletins, or data provided with the power supply used.
Observe all precautions in the Foreword section of this manual.
The following checkout procedure should be carefully followed prior to operating the furnace:
a. Inspect the furnace cavity for voids, cracks, chipping, or protrusions after lining is dry. Minor scratches or voids (1/8″or 3 mm) are acceptable. Other faults must be repaired by patching the refractory. Be sure the lining patch is thoroughly dry before starting a melt.
b. Inspect the furnace for rigidity. Test inlet/out let piping and the coil for leaks. Repair that does not pass this test.
c. Be sure hydraulic system tank is filled with hydraulic fluid as specified in Hydraulic Manual.
2. FINAL INSTALLATION CONNECTIONS
Once the VIP, furnace, water system, and the hydraulic systems have been setin position, completion of the installation requires.
A. Interconnecting the VIP and the furnace by water cooled leads.
B. Interconnecting the feeds and drains to manifolds.
C. Interconnecting the manifolds to the water system.
D. Connecting the specified power sources to the VIP, the water system, and the hydraulic power supply.
E. Interconnecting all the hydraulics.
F. Interconnecting all wiring and miscellaneous systems.
– use only dry charge material.
– inspect bundled or baled scrap for trapped moisture before adding it to the melt.
-avoid charging partially closed containers (soft drink bottles or cans) that could contain trapped liquids. Liquids or pieces of combustible material can vaporise with explosive violence in the melt and cause an eruption of molten metal.
WARNING :- Failure to comply with these procedures may result in an explosion, with possible serious injury to personnel.
3. CONTROLS AND INDICATORS
Furnace operation or melting requires control of the power supply, possible adjustments and adherence to established procedures for individual indicator/control functions that is not within the scope of this manual. Refer to instructions provided with the power supply and drawings/data supplied with the furnace for this information. Consult with the Inductotherm Service engineer or Sales Representative if there is any doubt about the operation of the furnace maintenance.
CAUTION :- Be sure no one is on or near the furnace when controls are operating. The lift, tilt, and swing movements could injure bystanders.
Proceed as follows
1. Before starting the drive motor it must be made certain that oil reservoir, pumps, valves Hydraulic cylinders, Hydraulic motors and all other loose supply components, pipes and fittings are properly cleaned and inter connected correctly with suitable and correct size of pipe lines.
2. Filter and fill the Hydraulic oil in the reservoir up to the maximum level indicated.
3. Check the level of the unit in respective planes. Also check the alignment of pump and electric motor.
4. Check and tighten all the fittings and joints provided in the Hydraulic systems.
5. Loosen the Bleeding screws wherever provided.
6. Unscrew and adjust relief valve at lowest pressure setting. Also adjust various pressure control valves/flow control valves/pressure switch/directional control valves suitably for initial starting.
7. Ensure that water flow is available to the cooler in case a water cooled cooler is incorporated in the circuit.
8. Connect Electric supply to the motor and also to electrically operated solenoid valves through proper isolators, limit switches and relays as per electric cir cult diagram. (if any) .
9. In case a shutoff valve is provided between tank and pump suction line the same must be opened fully to prevent damage to the pump.
10. Inch the motor, check the direction of rotation, correct the direction of rotation if necessary.
11. Run the pump on no load and operate each direction control valve manually or by hand emergency button so that oil reaches to every part of the circuit.
12. Observe the bleeding screws already loosened. Tighten up the bleeding screws after clear oil free from foaming and air comes out.
13. Gradually increase the pressure setting of the relief valve to the required working pressure,if necessary in suitable steps.
14. Set all the valves in the system so as to obtain the required function from the actuators.
15. Check the level of oil continuously and go on adding more hydraulic oil through filter and maintain required minimum level in the oil reservoir. furnace maintenance service
16. Run systems for at-least 50 to 100 cycles on load.
17. Flush the oil completely from the system, replace filter cartridge and clean the inside of oil reservoir.
18. Refill the tank with the fresh and clean hydraulic oil, properly filtered and free from of oil reservoir contaminants. Fill up the hydraulic oil up to the maximum mark as indicated on the reservoir.
19. Restart the motor after adjusting the relief valve to its lowest pressure setting or d event the relief valve if venting arrangement is provided.
20. To set relief valve pressure, gradually increase relief valve setting till furnace just start titing. When furnace is fully tited and cylinder stroke is fully utilized, oil will start bypassing through relief valve showing relief valve set pressure in the pressure gauge. At this time, set required working pressure by relief valve and fully tighten its check nut to avoid set pressure disturbance due to vibration.
21. Top up the oil level to required maximum limit. furnace maintenance tips.
22. Run the unit for 50 to 100 cycles on load. Tighten up such of joints and tittings where leakages appear.
23. Record oil temperature at suitable intervals and ensure that its within the recommended range.
WARNING :- Observe safety precautions. Do not charge a furnace without knowing the chemical reactions of a melt.
4. INITIAL MELTING
A. After following the initial sintering procedure recommended by the refractory manufacturer, charge the furnace carefully to avoid damage to the still fragile lining. Observe melting to avoid excessive heating or stirring.
B. The initial melt should be made more slowly than usual, keeping the power down if necessary to extend the melting time over 2 to 3 hours.
C. Care should be taken so that the charge continues to feed into the molten pool properly If it hangs up due to interlocking or bridging, super heating below can erode the refractory causing molten metal to penetrate to the coil. This results in loss of the melt and loss of the lining, and represents a very dangerous condition. Should the molten metal burn through the coil, the water in the coil can cause a serious explosion. annual furnace maintenance
CAUTION :- Do not pour molten metal into moulds that may contain water or other fluids. Moulds should not be of a type that would react with the chemical composition of the melt. Do not overfill any old.