Inductotherm Power-Track/Power-Melt are efficient units, designed with interlocks and circuit protection modules. Operators, however, should be aware of all potential hazards involving high voltage and general foundry operations. The following safety precautions should be read and understood by all operating and maintenance personnel and man- agrment personnel responsible for safety.
The purpose of this booklet is to familiarize operating and maintenance personnel with safety precautions that pertain to foundry operations in general and to the core less induction melt system in part ocular. The safety precautions listed in this section should be observed and complied with at all times. Those precautions should be considered the minimum to be followed.
(3) GENERAL FOUNDRY PRECAUTIONS
It is not the purpose of this section to list every precaution which should be followed under every circumstance. Rather, these general safety precautions form a minimum set from which each installation manager can establish precautions and procedures tailored to the Individual circumstances. Nothing in these precautions can substitute for properly qualified and trained operators and maintenance person- nel exercising good judgment The precautions which follow here are well known to found by men. They are common to all metal melting operations, not only core less GENERA Induction melting. Offered as general precautions and should not be considered to cover all types of operations. They should be evaluated in light of your particular operation and expanded or modified as appropriate.
Access to melting and pouring operation should be limited to authorized personnel only.
Personnel should wear safety glasses at all times and should use special light reducing glasses when viewing molten metal at high temperature.
Heat and flame retardant clothing should be won by personnel who work at or near furnaces.
The refractory that is used to line the furnace must be suitable for the material being melted. Refer to the refractory manufacturer’s specifications. Before the furnace is charged for a melt, be sure that furnace lining has been thoroughly dried and sintered in accordance with manufacturers recommendations.
Furnace linings should be inspected frequently at regular intervals to protect against the danger of RUN THROUGH. The lining should be always be inspected after cool down.
Furnaces should be charged carefully to avoid BRIDGING of the charge. Excessively high temperatures of the metal in the bath below the bridge can cause rapid erosion of the furnace lining.
Low melting point material (such as aluminum or zinc) should be added carefully to high temperature baths (such as iron or steel) If low melting point additives submerge before they melt, they can vaporize violently and cause boil-overs or explosions.
Charge materials should be dry and free of combustibles, excessive rust, and/or liquids. Violent vaporization of liquids or combustible can cause boil-overs or explosions in the metal bath.
Removable crucibles or push out furnaces should be used only for metals and furnace sizes for which they are suitable. They are not designed for high temperatures required for melting ferrous metals. The crucible manufacturer’s specifications should be the guide for crucible use.
When metal is transferred in a crucible, a cradle that provides adequate side and bottom support for the crucible must be used Cradles must be provided with a means to prevent the crucible from slipping out during pouring
Be knowledgeable of the chemistry of your melt. Chemical reaction (such as rapid carbon boil-over) can damage equipment and can be dangerous to personnel.
Areas provided to receive run outs, or spills must be kept free of accumulations of liquids. Hot metal in contact with liquids can cause violent explosions resulting in personal injuries.
Personnel with implanted organs, joints, plates or similar objects should keep away from any induction equipment. A current may be Induced in metallic implants. Those using Cardiac Pacemaker- ors are particularly at risk.
(4) SAFETY PRECAUTIONS FOR OPERATIONAL PERSONAL
All induction heating and melting equipment’s are using potentially dangerous electrical power. Inductotherm built equipment is designed for safo, officiant, reliable operation and easy maintenance, if it is operator properly.
Operator safety is enhanced by several design features built into the equipment. Deliberately defeating these safeguards can expose the operator to hazards.
The following precautions should always be observed.
Keep all cabinet doors locked, Make keys available only to those qualified maintenance personnel who require access to the enclosures.
Keep shields, covers and other protective devices in place at all times during equipment operation. Exposed high voltage equip- meant is a potential hazard to personnel in the work area.
Always set main power disconnect to the OFF position before opening doors or removing access panels. Don’t depend upon interlock devices for protection.
Always switch power OFF when lifting, pausing or transporting hand furnaces.
(4. A) WHEN CHARGING THE FURNACE
Use only proven test equipment when trouble-shooting a unit or components. Follow manufacturer’s recommended procedure .
Prevent inadvertent application of power while work is in progress in crucible or on furnaces by placing waning tags and padlocks on main power disconnects.
Use only dry charge material.
Inspect bundled or baled scrap for trapped moisture before adding it to the melt.
Do not allow closed or partially closed containers (beverage cans sheared tubing etc.) that may contain liquids to be mixed with the furnace charge.
furnace safety tips
FAILURE TO COMPLY WITH THESE PROCEDURES MAY RESULT IN AN EXPLOSION WITH POSSIBLE SERIOUS INJURY TO PERSONNEL.
furnace safety check
Study the maintenance procedures.
Become familiar with the melt system and its dangerous areas before attempting maintenance of any kind.
Never enter a crucible or transformer vault without tagging and padlocking the main disconnect breaker in the OFF (De energized) position.
Always use two independent methods to support a tilted furnace whenever working on or near to it.
Use only first-class test equipment when trouble-shooting a unit and follow the manufacturer’s procedure for using the equipment.
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