300KG High Frequency Induction Melting Furnaceinstruction Book KGYSc-3250

上海朐燕实业有限公司
JAR HING PRODUCTS CORPORATION LIMITED

Add：Rm805,Huaxu building,No.95 Renmin South Road,Taicang City,Jiangsu Province,China 215400
KGYSc-3/250 High-frequency
Induction Furnace Insturction book
1.Profile
2.Working principle
3.Operational Process
4.Operational safety and announcement
5.Maintenance and servicing.
6.Troubleshooting and maintenance
7. Gas diffusion specification
8.Attached map
9.Packing list
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Tel: ++86 / 512 / 52873271 Fax: ++86 / 512 / 53556919
1.Profile
KGYSC-250/3High frenqucy induciton furnace，The development of
the third generation of coreless induction furnace.

1-1. Technical specification：
Note Unit KGYSC-250/3
Rated power KW 250KW
Supply voltage V 380
Phase number phase 3
Rated frequency of work HZ 3000
Power factor 0.95
Max. temperature of molten
℃ 1750
steel
Rated capacity of furnace body KG 300
Furnace output voltage V 1800
Power cabinet size（L*W*H） mm 2800×1000×1860
Outline dimension of furnace
mm 1840×910×1210
body（L*W*H）
Outline dimension of hydraulic
mm 680×460×1000
station（L*W*H）
Weght of power cabinet kg 1317
Weight of single furnace body kg 702
1-2.Uses and features：

1. Effective,using series resonant inverter of induction heating，
increaseing the furnace body output voltage,improve the
melting speed.the metling time will be 60minutes for 300kg
stainless steel.
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2. Energy conservation：1ton steel liquid spend 600 degree

electricity.Save 240 degress per ton,compare with normal
induction furance.
3. low fault
a. In control system ,use chain closed-loop control system to
monitoring the equipment to reduce the faut possibility.
b.Using series resonant inverter of induction heating,simplized the
circuit ,to reduce the fault.
c.Main circuit component such as air circuit breaker,SCR,diode using
imported brand,High quality components,increaseing the equipment
reliablity.
d.Control cabinet inside cooling water use pure water circulation.
e.Integrated circuit PC main control panel,aging test before
installment to enusre the control panel have long life time.
f.Reliable power control.Voltage limited,high pressure limited,high-
frenquency,low frequency limited,tempreture of water,pressure of
inside water,outside water tempreture,SCR control,Body shift etc
protection fection.to make the furnace stable.
2.Working principle
KGYSC-250/3High-frequency induction furnace，use AC circuit
---DC cricuit--Ac circuit freqence ,effection use SCR, DC

transformer,simplize the control system.
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KGYSc-3/225 High-frequency induction furnace of elementary

diagram ,main circuit.
2-1.3phase of 380～460VAC AC power supply，through air circuit
breaker QF1 import three bridge recifierV1 、V2 、V3 、；(SCR1 –
SCR2 –SCR3 ).
2-2.Frenquency transformer main components including SCR5-
1 ，SCR5-2， SCR6-1，SCR6-2.controled by stable pulse signal.
2-3.Frenquency transformer resonant circuit ,LE、C12 、C13 、
C14 、C15 output high frequency power to furnace body coil to heat
the metel by electromagnetic induction.
3.Equipments installment：
3-1 Installment：
Foundation engineering:
1. Please according to manufactures foundation drawing to work.
2. The quipment grounding area refer to the drawing.Prepare
before installment.
3. Mainboard need brass cable 185 ㎜ 2 available.
4.Position：According to the instructurer
5.Wiring project：Stainless steel or PVC plastic tube.If in winter
the weather is cold,it is better to use zinc plated,stell tube instead
of pvc tube.Furnace body and main circuit board wiring need
technical engineer to install.the supplier to provide assistance.
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6.Buid furnace： According to the instructurer and material

requirements.
7.Independent cooling tower needed.
8.Perforance test:
Main circuit board—water pump—tower fan,water tube line if
any leak,water pressure if within tolerance（inside water 2.5kg/
㎝ 2）.
Note：before working,the france need to be warmed,firstly
add steel material ,dry for at least 8hours with small power,the
steel material shapes will be no change and no changing the
colour to red.
3-2. Equipment introduce：
KGYSC-250/3 is the third generation coreless furance,all components
contain in the ciruit board without any dusty pollution.larger the
lifetime and make the operation more safety,convenience. The
furnace cotains three sections:
1)Main circuit board
2)Cooling water system
3)Furnace body
4)Main circuit board
Outside dimension：L2800×W1000×H1860
1)main circuit board introduce：
2)main power supplier light on：3phases power supply turn to AC
power supply.
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3)high frequency light on:high frequency wave output to furnace

body.
4)Setup light on： setup ok；
5)high frequency limited light on:the frequency wave in highest level.
6)Power control light on:power control normal.othewise it will be off.
7)Voltage limited light on: inside furnace body voltage to limited
8) Electric power limited light on:the eletric power to limited
state.circuit board automatic limited.；
9)TOT limited light on：SCR turn off time too short；
10)Outside water tempreturer light on: cooling water temperture
higher .
11)Inside water tempreturer light on：main circuit body water
temperture is high；
12)Inside water pressure light on: main circuit body import water
pressure not enough.
13)Outside water pressure light on:furance body coil cooling water
pressure not enough.
14)Furnace shift light no：furnace body shift not in position；
15)SCR light on：SCR demage or fault；
16)Checking switching ：checking red switching light on or not；
17)Power meter：High frequency wave output；
18)Furnace pressure meter：furnace 2ends pressure；
19)Frenquency meter：high frequency wave high or short；
20) “high frequency close，rectifier start”Bottom：start rectifier
output,turn off high frequency output signal；
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22)High frequency start bottom（green）：start high frequency

signal output
2.Cooling Water system:
（1） Furnace body cooling system:
Cooling tower output water-----water pump-------coolinb cable----
furnace coil---cooling tower input.
（2） Main circuit body cooling system:
Pure water tank--water pump(imput water)--heat exchanger(output
water)
3. Furnace body：
（1）furnace body contain furnace shell,induction coil,furnace
lining,fixed seating.
（2）Induction coil use rectangle hollow tube to make it,inside
cooling water.
（3）Furnace lining contain by silica sand and magnesia sand
sintering.
4.Operational process：
4-1.setup furnace：（daily process）
1. Check the furace body if any cracks or leaking；
2. Turn on the wating switch；
3. Check the water circle water level,repalce or add water;
4. Setup main circuit circle water and furnace water pump；
5. Check inside,outside water if any leaking；
6. Check inside,outside water pressure ,inside 2.5kg/cm2
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Ourside 2-3kg/cm2
7. Turn on the furnace bottom to working position,close the cabinet
door；
8.Close the air circuit breaker signal of power supply green and red
fault light on；
9.Turn off the red fault light；
10.Press“high frequency close，rectifier start”Bottom，Yellow
main power supply light on；
11.Ensure the power bottom in zero position,press red start bottom
10-15 seconds,start well(full the material first then start)
12.Full the steel material,notice the material no oil,water,to avoid any
empty place like bridge situation;
13.When the voltage limited and TOT limited lihgt on,turn low the
power,Notice:the first batch of melting,it is not allowed to increase
the tempreturer sharply,in case any furnace body or crucible damage.
4-2.Standard operation：
During melting the steel,seldom need opeartor adjusted,except
the power knob.
The best contdition is :from the beginning to end, to keep the
power limited in high power output to reach the pouring
tempreture.The operator need to monitor the process,familiar with
the meter,any light turn to red,it stand of not normal.
Operator need to record the
power ,voltage,frequency,pressure,any issue or operation not
well,Please feel free to contact us.
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4-3Stop working：
1.Coreless furnace feature could be work intermittent,when the
furnace stop working,it need to do following step to protect the
furnace.
2.Melting the steel liquid ,it can not pouring all material,try to make
the furnace in inclined angle position
3.Firstly,turn the power knob to zero position.
4.Press the hight frequency close bottom；
5.if dont open the furnace shortly,pull down the air circuit breaker
QF within 3minutes.
6.After stop working,outside water cooling system still nee to open,in
case the heat shaking ,and protect the furnace.induction coil cooling
water pressure maintain 1.5kg, after 60-90minites,turn off the
cooling water(outside water);
5.Casting Operation notice：

5-1casting notice：
The following items is comon notice,may not including every
situation,The user need to adjusted according to the real
performance.
1. Melting and pouring road limited for relative people；
2. Operator need to wearing uniform anti fire ,safety
shoes,helmet and ND glasses；
3. Furnace lining material need to be qualified.；
4. Crucible size suitable and operate well；
5. If you crucible delivery liquid,need fame to support crucible.
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5-2Opearator notice：
All induction heating and melting equipments are high pressure
power equipment.Every operator need to following the instruction
for protection:
1. Lock all power supply door,relative people have the key；
2. Keep the cover and device on original equipment,open any of
them may cuase dangerous；
3. Open any circuit board,ensure the power in OFF position,Place
warning mark to avoid anyone imput the power；
4. Full dry material without any firing or liquid,incase the
explosion；
5. Be careful to add low tempreture material into high tempreture
furnace.Avoid any gasify ,boilling or explosion；
6. Full understand the melting material chemial composition and
chemical reaction if may damage the equipment；
7. Full material should notice the precedenc order.；
8. Avoid any possible container may contain water or liquid mixed
into the material.The liquid and combustible material may cause
the gasify and metal liquid spray out；
9. Start or end the furnace need to check the furnace body if leak
or induction coil reach water,need to be repare on time；
10. To avoid bridge performance in melting the material,it will hurt
the furnace body,pouring the furnace body to bridge area and
keep the 3/4 power；
11. Operator follow the instruction and in good condition.
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5-3 Maintenance People notice：

1. Read the instruction book and talk with engineer；
2. Study equipment and its dagerous area；
3. No entrance the main circuit board without place power supply
breaker.
4. Approach the furnace body,use two method suppor the furnace
body.
6.Maintenance and servicing.

6-1 Furnace body maintenance and emergency handling：
1. Building furnace line material need to make according to the
scale；
2. Building furnace line no mixted other material；
3. Furnace body and inductional coil gap could be filled in mica
plate and asbestos fiber；
4. Building furnace line material need to make little by little.up to
30 ㎜ area then built by wet method；
5. Building furnace line should be careful without damage the
induciton coil；
6. Furance pouring system area,add lubricating oil,；
7. Outside water cooling cable need to protected by asbestos
fibers and bind up by plastic wire；
8. Furnace line if has cracks or corrasive,need to remove the old
line and rebuild；
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9. Please notice the builing line will be leak when the output water
tempreture higher or combine with slaggy；
10. When leacking the melting liquid,turn off the power supplier
and pouring all the liquid on time；
11. Before smelting,prepare dry sand pit to contain all quid,to avoid
and hurt；
12. If the coil damage and high tempreture steel liquid with cooling
water,turn off the water pump ,leave the scene for further
process.
6-2Main circuit maintenance
1. Open the circuit board （no power),spray the air dust by gun
blasting,brush the dust with brusher,no damage control circuit
board or components；
2. Remove all attachement on the conductive copper board；
3. Oiled the switch of shift furnace body,using electrical
properties of lubricating oil；
4. Chek all screws,cables,buscar,components if too hot or change
colour；
5. Check the water tube around,if leak or not；
6. Check control liner,electric relay is loose or not；
7. Check all screes and components locking well and Make sure all
tools took out.
6-3Routine maintenance sheet：
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N Item dail mo Quar Half- Non-

O y nthl terly yearly schedule
y d
1. Check the furnace liner ※
material leak or not
2. Check the signal light work or ※
not
3. Check all plastic tube ※
coonection area
4. Clean the power cabinet ※ ※
inside(using dry pressure air)
5. Check all coper plate,cable ※
connection area(locked)
6. Check all component ※
conection area
7. Check the switch of water ※
pressure work or not
8. Check the switch of ※
tempretuer work or not
9. Check and oil the furnace ※
body,switch
10. Check the capacitor out of ※
shape or not,leak or not
11. Check the furance body and ※
oil
12. Clean and wash the cooling ※ ※
tower
13. Check the contact of air ※ ※
breaker
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14. Clean the heat exchanger and ※

storage tank
15. Cooling system,oil the ※ ※
bearing of fan
16. Replace the pur water inside ※ ※
the closing cooling system.
7. Troubelshoting and maintenance
7- 1 FLOW CHART：
1) Setup the imput and output valves,start the furnace body and water circle
motor
2)Open the board,check the inside water cycle if any leak
performance,components change colour or out of shaping or smelty.
3)using the meter to check SCR ,diode,RC and MOV if troubleshooting-----If
yes,change the components
4)Check the DC capacitor and AC capacitor if troubleshooting-----If yes,change
the components
5)check the switch of furnace body,buscar ,connect copper plate if touch not
well or over tempreture---relock and clean
6)Check the transformor if put110VAC---YES-380V-110 transformor trouble.
7)Signal of board light on or red-- 1NO-10 V QC/24VKC power supplier trouble
8)Press check the switch red light if all down----NO.-- 5A blown fuse.
---main circuit board trouble
----LED light trouble
9)Check high frequency open adn close buttom light ---No --check the
signal ,signal board trouble
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10)Start the high frequecy light on or not---No. Main circuit board trouble.
11)Wait 15-20second,start the light on or not----start board trouble
12)Turn the power knob to the high frequency limit light ---No ,limited but the
light not on.adjusted the main ciruit board limit ligh,can not limited,replace or
adjusted the main circuit board.
13)Turn the power knob to zero wait the result.
According to the process open
14)Send the host no fuse switch---escape-- check whether the three-phase
power supply is in good condition.static checking of three-phase rectifier diode
SCR, MOV fault.
15)Press the "start" button to turn off ----No fuse switch immediately jump off --
--Static checking three phase rectifier ,static check discharge diode,static check
discharge diode,static check DC, VC capacitor.static check frequency conversion
SCR group.
16)The main power is not bright--check the start of the signal board and the end
of the wiring terminal is locked.check the "start" button contact. check the
indicator light.check the pulse rectifier transformer.
17)Press the "test switch" to extinguish all red fault indicator lights. --The red
fault indicator can not be cut off.---Check in accordance with indicator light.
18)Press the "high frequency start" button-No fuse switch immediately jump off-
-static checking frequency SCR, diode, MOV.static check DV/DT, RC protection
circuit.
19)High frequency running light does not light or frequency meter does not
read--check whether the main control board and its wiring terminal is
locked.check the indicator light and button connection is good.check the
monitor board relay.
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20) Start the normal light is not bright--Check whether the rectifier start signal
board and its wiring terminal is locked.
21)Frequency meter reading but no high frequency output ---check frequency
pulse transformer.check the main control panel.Check the frequency conversion
SCR and whether the line is off.check the furnace body connection cable is
broken
22)SCR BAD LIGHT ---start frequency is too high, adjust the low-frequency
limiter VR.power knob is not zero. Inverter group fault.
23)Wait 15-20seconds,start light bright,Rotary power knob, KW table, KV table,
HZ table on the slow.--High frequency output signal of the abnormal
sound.check whether the power supply part of the phase. check rectifier
transformer. check whether the polar line between the rectifier SCR. check
whether the DC capacitor is low quality or part of the circuit breaker.
24）High frequency output signal instability --check the furnace body coil,
furnace body switch, the flow of the main circuit copper contact is loose and
jump fire.check the main engine, furnace cooling water pipe leakage or poor
insulation.Check the circuit board signal feedback system.check the main control
panel.check the host, DC, AC, isolation capacitance grounding wire is locked.
25)Adjust power knob output cannot be changed,heck the power knob of the
variable power group and wiring. check the main control panel.
26)Output power can not reach full load,Limiting the number of lights appears
to limit the output power.After the disappearance of the reasons to be excluded,
the power can be upgraded..
27)Automatic shutdown red fault signal display.Refer to red fault indicator.
28)Normal operation, dynamic check end.
8.Gas diffusion specification

8-1 feature of gas diffusion：
1.floating the impurity and slag,improve the steel liquid quality；
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2.Improve the infection of annexing agent；

3.Reduce the rejection rate；
4.Extended the furnace liner lifetime；
5.Low investment；
6.Add Refine function.
8-2 Installment gas diffusion
1. Preparation
Machine a hole of ¢18 ㎜ at the bottom of induction furnace
body(some reserved )
Coating insulating paint of H class.cover with earth scrp,and gaps full
with mica plate,asbestos fiber.
Prepare steel tank,thickness 1-2mm,according to the furnace
diameter 200-350mm,heigth 250-300mm,surface smooth,clean with
holder.
Gas supply,nitrogen,argon,99.99% chemical composition.connect
Pressure meter （range 0～2Mpa)、flowmeter(range 0～250L/min)、
Needle valves（control airflow precise）；or install“gas intelligent
control system”（we can supply for this system) to control the gas
effective,intelligent and reliable controled.
2.Install gas diffuser
Gas diffuse is external thread M16X2mm,lock it at the bottom of the
furnace body with screw and washer,make sure the gas diffusser to
furnace liner 100mm.(as attachment），Meanwhile,the gas diffussor
height lower than the last inducion coil height.Connect the gas
supply with PAGODA TYPE connector or use flexible metal tubing
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connect gas defusserwithout leaking gas.Notice no dust and other

impurity added into the hose.
After that,cover the gas diffusser with prepared steel tank,check the
tank position and make it in the core of the tank.Fill the dry material
outside the steel tank,according to the standard to make the furnace
liner process.Remove the steel tank,and cover of the gas
diffusser,add the breathable material into the bottom of the round
pit slowly,each time add 100m,to make the breathable material tight
and same height with dry shaking material.Becareful with shaking
machine and no damage of gas diffusser.repeat
shaking,planishing,hard up and complete the gas diffusser
installment.
Lay the steel model core(thickness above 6mm,)→according to
induction furnace dry shaking material process to make the furnace
liner.dry material height to furnace door 50mm,→Wet material makd
the top side of the furnace liner→wet material build furnace gate and
furnace mouth.Keep the steel model core inside and smelting with
steel liquid.
2.furnace liner smelting and testing

Smelting the furnace liner including the breathtable materl,it will
cause the lifetime of furnace liner and using of gas diffusser.
Melting furnace increase the tempreture,with speed of 200～300℃

/per hour to 1100℃ keep 1hour ，and increas the tempreture 300℃
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/h ，steel liquid level a little over the dry/wet material liner.keep 1～

2hours.finish melting then testing gas diffussor.Open the needle
valves,inspect the airflow,and adjusted to ensure the steel liquid has
bubble spot in the surface,to avoid mass air,steel liquie boiling,and
exposed to air to oxygenization or slag inclusion.
3.Gas diffusser annoucements and maintenance
External screw thread need to be pretected without any
damage,incase connection untightly,leak gas,or airflow or target-hit
rate.
Notice Gas diffusser hose without any impurity or dust,to block.
Check regularly if any leak.
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8.Attachment.
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E-Mail:jennyhu@jh-products.com
Fax: ++86 / 512 / 53556919
电力表
电Power box
源
盒
电
Power box
源
盒
Frequ 频
ency 率
table
表
电力调整RT
Power Adjustment RT1
高频限制RT
High frequency limit RT2
低频限制RT
Low Frequency limit RT3
电力限制RT
Power Limit RT4
水泵
Water Voltage Limit RT5
pump 电压限制RT
Tot Limit RT6
炉体切换内水压力外水压力内水温度外水温度 TOT限制RT
SCR不良测漏贝相 ON/OFF
Website: www.jh-products.com
Tel: ++86 / 512 / 52873271
KA2 Furnace Body Switching 制图
KA3 Water Pressure
KA4 external pressure 审核 150KG高周波感应炉
KA5Water temperature
KA6 External temperature 图幅比例图号
KA7 SCR Bad
KA8 Side Leakage 材料部件名电器原理图
KS9 Bate
东营福浩精铸科技有限公司
-----------------------------------------------------------------------------------------------------------------------------------------------
E-Mail:jennyhu@jh-products.com
Fax: ++86 / 512 / 53556919
RED GREEN
红绿泵
PUMP
Main
主控柜 control
Cabinet
紧急用水进口（自来水或房顶备用水箱）
Emergency water inlet (tap water or roof standby
Description 说明
1.正常工作，Q1、Q2打开，Q3关闭。
1: Normal work, Q1, Q2 Open, Q3 closed
2.备用水箱上水，Q1关闭，Q2、Q3打开。
3.水泵停电或故障，使用备用水，Q2关闭，
Website: www.jh-products.com
2: Standby tank water, Q1 closed, Q2, Q3 Open
N
Q1、Q3打开。
Tel: ++86 / 512 / 52873271

3: Water pump power failure or fault, the use of
standby water, Q2 closed, Q1, Q32
注：（所有管线直径全为 Open,
制图
Drawing
审核 Pipeline 150KG高周波感应炉
diagram of
Note: (All pipe diameters are 2 ") Audit
图幅
Picture external
比例
SCALE
external
图号
材料
Materials
circulation
部件名外水循环管线图
东营福浩精铸科技有限公司
9.PACKING LIST
SPEC INDUCION FURNACE
Circuit board 1 unit
Instruction
1 unit
book
Circut diagram 1 unit
certificate
Packing list
components
date
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300KG High Frequency Induction Melting Furnaceinstruction Book KGYSc-3250

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上海朐燕实业有限公司

JAR HING PRODUCTS CORPORATION LIMITED

4.Operational safety and announcement

5.Maintenance and servicing.

6.Troubleshooting and maintenance

7. Gas diffusion specification

the third generation of coreless induction furnace.

1-2.Uses and features：

2. Energy conservation：1ton steel liquid spend 600 degree

---DC cricuit--Ac circuit freqence ,effection use SCR, DC

KGYSc-3/225 High-frequency induction furnace of elementary

6.Buid furnace： According to the instructurer and material

3)high frequency light on:high frequency wave output to furnace

22)High frequency start bottom（green）：start high frequency

5.Casting Operation notice：

5-3 Maintenance People notice：

6.Maintenance and servicing.

N Item dail mo Quar Half- Non-

14. Clean the heat exchanger and ※

7. Troubelshoting and maintenance

11)Wait 15-20second,start the light on or not----start board trouble

8.Gas diffusion specification

2.Improve the infection of annexing agent；

connect gas defusserwithout leaking gas.Notice no dust and other

2.furnace liner smelting and testing

Melting furnace increase the tempreture,with speed of 200～300℃

/h ，steel liquid level a little over the dry/wet material liner.keep 1～

Tel: ++86 / 512 / 52873271

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