Manual for safe induction furnace operation

Table of Contents

1. Foreword

2. System components

3. Functional description

4. Melting process

5. Safety instructions

6. Sanitary instructions

7. Conclusion
1. Foreword

With the aid of this Manual on the safe operation of induction furnaces, we would like to
provide all interested parties and operators of such systems with helpful information for their
employees.
A known or recognised danger can be prevented by taking suitable measures, before accidents
or damage are caused. Lack of awareness of dangers and their consequences is the greatest
omission in casting foundries. Avoiding accidents costs a lot less than rectifying the
consequences of accidents. Every works should therefore carry out relevant training for their
employees at least once per year. New employees can thereby learn from experienced
employees, and at the same time be familiarised with them about the latest state of the
technology.
2. System components

An induction furnace system consists of:

a) An energy supply with performance switch in front of the furnace transformer

b) An NF switching system with control devices for the performance unit and an
operating cabinet with switching and display devices for the operation of the furnace
system

c) An MF converter system with control devices for the performance unit and an
operating cabinet with switching and display devices and, if necessary to, a processor
for the operation of the furnace system

d) A cooling water supply system including return cooling system

e) A hydraulic system for the operation of the hydraulic components from a control panel

f) A ventilation system for the system areas

g) A charging system for charging the crucible furnaces

h) A scrap pre-heating system for drying out preheating charging materials

i) An induction crucible furnace for holding the melting crucible

j) Channel induction furnaces and casting equipment

3. Functional description of the system components

Energy supply

a) The energy supply with performance switch in front of the transformer serves
to connect the furnace transformer to the medium voltage power supply
network of the power supply company. The transformer converts the medium
voltage to the voltage required for the operation of the furnace, e.g. from 20 kV
three-phase current to 770 V for MF systems or 2000 V for NF systems. In the
case of MF systems, a secondary fixed voltage is used, and no multiple contact
switch is required. 10 or 12-stage multiple contact switches are used for NF
systems. The transformers are equipped with the following built-in monitoring
devices: Thermometers, oil filling level monitoring, Buchholz relays and air
de-humidifiers.

Power supply frequency switching system

b) A power supply frequency switching system consists of a main contactor

combination for operating the main power circuit, a switchable resistor for
reducing the surge current when switching on, which can be up to six times the
nominal current, the balancing system with the balancing reactor, capacitors
and switching devices to control the system in line with operating
requirements, compensating capacitors with switching devices for controlled
compensation to cos phi = 1 and the connecting leads to the furnace
connection. The system is controlled using the devices in the operating cabinet.

Medium frequency converter system

c) For an MF induction furnace, a converter is required to produce the necessary

to medium frequency from the 50 Hz power supply. In order to do this, a direct
voltage is produced in a rectifier, and fed to the inverter via a smoothing
choke, and a medium frequency voltage is produced in the inverter with the aid
of compensating capacitors and the inductivity of the furnace coil. The
regulation of the converter is carried out by the built-in control electronics. The
control of the furnace is carried out using the devices in the operating cabinet
and if necessary with the aid of the processor.

Cooling water supply system

d) The operation of an induction furnace system requires a cooling water system,

including return cooling of the heated water. In the converter, including the
capacitors and the smoothing choke, the water circulating in the circuit is
heated up from approx. 34 °C to 38 °C, and must be cooled down again to 34
°C by a cooling system activator to. Approximately 215 l/h must be pumped
through the electrical equipment per kW of performance loss. In the furnace
coil, the water is heated up from approx. 35 °C to 62 °C, and must be cooled
back down to 35 °C by a separate cooling system. Approximately 32 l/h have
to be pumped through the system per kW of performance loss. In the event of a
power failure or other interruption, an emergency water supply must be
installed for the furnace circuit. For operation in winter, when the furnace is
switched off, heating must be provided.