Electrotherm Induction Furnace Manual

The Electrotherm Induction Furnace is a high-efficiency melting system designed for ferrous and non-ferrous metal processing. Featuring advanced power control, water cooling system, tilting mechanism, and digital temperature monitoring. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Operating Procedures 7. Maintenance Schedule 8. Safety Features 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Induction coil, Power supply unit, Cooling system, Tilting mechanism, Control panel, Temperature sensors.

Feature	Description
Power supply unit	Medium frequency power supply with thyristor technology
Induction coil	Water-cooled copper coil for efficient heating
Cooling system	Closed-loop water cooling with temperature control
Tilting mechanism	Hydraulic or electric tilting for metal pouring
Control panel	Digital display with programmable settings
Temperature monitoring	Infrared and thermocouple temperature sensors
Safety interlocks	Multiple safety switches and emergency stops
Power control	Adjustable power output from 20-100%
Melting capacity	Various capacities from 100kg to 5000kg
Frequency range	50Hz to 1000Hz depending on model

Installation

Unpack and inspect all components. Ensure proper foundation and electrical connections.

Foundation preparation: Prepare reinforced concrete foundation as per specifications.
Electrical connection: Connect to appropriate power supply (380V/415V, 3-phase).
Water cooling system: Connect to water supply and drainage system.
Grounding: Ensure proper grounding of furnace body and electrical components.
Ventilation: Install adequate ventilation system for heat dissipation.

WARNING! Furnace is heavy; use proper lifting equipment. Ensure all electrical connections are made by qualified personnel.

First-Time Setup

Power on furnace; follow initialization procedure.

Cooling system check: Verify water flow and pressure in cooling system.
Power calibration: Calibrate power supply unit as per manual.
Temperature calibration: Calibrate temperature sensors.
Safety system test: Test all safety interlocks and emergency stops.
Tilting mechanism: Test tilting operation and set limits.

CAUTION! Always wear proper PPE during setup and operation.

Specifications

Melting Capacity: 100kg to 5000kg (model dependent)
Power Rating: 100kW to 3000kW
Frequency: 50Hz to 1000Hz
Power Supply: 380V/415V, 3-phase, 50Hz
Cooling Water: 10-30°C, 2-4 bar pressure
Melting Temperature: Up to 1600°C
Efficiency: 85-92% electrical efficiency
Control System: PLC with touch screen interface
Tilting Angle: 95 degrees maximum
Refractory Life: 200-500 heats depending on operation

Controls and Settings

Access control panel for all furnace operations. Main controls: POWER ON/OFF, MELTING START/STOP, TILTING CONTROL, TEMPERATURE SETTING.

Control Panel: Digital temperature display, Power meter, Water flow indicators, Emergency stop, Mode selection buttons.

Operating Modes: Manual mode, Semi-automatic mode, Automatic mode. Temperature Settings: Set point temperature, Ramp rate, Soak time. Power Settings: Power level (20-100%), Frequency adjustment. Safety Settings: Over-temperature protection, Water flow protection, Power limit settings.

Operating Procedures

Standard operating procedure for melting metals.

Pre-operation check: Verify cooling water, power supply, and safety systems.
Charging: Load metal charge into furnace crucible.
Start melting: Select melting program and start process.
Monitoring: Monitor temperature and power consumption.
Superheating: Maintain superheat temperature as required.
Tapping: Tilt furnace to pour molten metal.
Slag removal: Remove slag after tapping.
Shutdown: Follow proper shutdown procedure.

Tip: Always maintain proper refractory lining thickness.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Daily: Check water cooling system, inspect refractory lining, clean control panel.
Weekly: Check electrical connections, inspect induction coil, test safety systems.
Monthly: Calibrate temperature sensors, check hydraulic system, inspect power cables.
Quarterly: Replace cooling water, comprehensive electrical testing, refractory inspection.
Annually: Major overhaul, coil replacement if needed, complete system calibration.

WARNING! Always disconnect power before performing maintenance.

Safety Features

Multiple safety systems protect operators and equipment. Emergency stop buttons, Over-temperature protection, Water flow monitoring, Ground fault protection, Door safety switches, Power interlock systems.

Care & Cleaning

Regular cleaning prevents buildup and ensures efficiency. Use dry compressed air for electrical components. Clean water filters regularly. Remove metal spillage and slag buildup. Keep control panel clean and dry.

CAUTION! Never use water for cleaning electrical components. Always lock out power during cleaning.

Regulatory Information

CE certified for European markets. Complies with IEC standards for electrical safety. Meets OSHA requirements for industrial equipment. Copyright © 2024 Electrotherm; all rights reserved. For technical support, visit www.electrotherm.com or contact +91-79-26890000.

Troubleshooting

Symptom	Possible Cause	Corrective Action
No power	Main breaker, fuses	Check main breaker; replace fuses; verify power supply.
Overheating	Cooling system, refractory	Check water flow; inspect refractory lining; clean cooling system.
Poor melting rate	Power settings, charge material	Adjust power settings; check charge size and composition.
Water leakage	Hoses, connections	Inspect hoses and connections; replace damaged components.
Control panel error	Software, sensors	Restart system; check sensor connections; update software.
Vibration/noise	Loose components, coil	Tighten all fasteners; inspect induction coil; check foundation.
Irregular melting	Charge distribution, power	Evenly distribute charge; check power supply stability.

Reset: Control panel > System > Reset to factory settings if required.

Service: +91-79-26890000; www.electrotherm.com