(Indcution) FMUL0021-0022 - System Manual-R1 PDF

TABLE OF CONTENTS
SAFETY PRECAUTIONS
1 GENERAL ................................................................................................................................................................... 2
2. SAFETY PRECAUTIONS .......................................................................................................................................... 2
3. GENERAL FOUNDRY PRECAUTIONS .................................................................................................................... 2
4. SAFETY PRECAUTIONS FOR OPERATIONAL PERSONNEL .............................................................................. 4
4.1 WHEN CHARGING THE FURNACE ............................................................................................................. 5
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE PERSONNEL .................................................................. 5
4.3 SAFETY PRECAUTIONS DURING TROUBLE SHOOTING ....................................................................... 7
4.4 ELECTRICAL EQUIPMENT HAZARDS ......................................................................................................... 7
4.5 VOLTAGE MEASUREMENT ............................................................................................................................ 8
4.6 GROUNDING OF ELECTRICAL TOOLS AND TEST APPLIANCES .......................................................... 9
4.7 MECHANICAL EQUIPMENT HAZARDS ....................................................................................................... 9
PREFACE .......................................................................................................................................................................... 12
SECTION - 1 INTRODUCTION
1.1 GENERAL ................................................................................................................................................................. 13
1.2 THEORY OF OPERATION ...................................................................................................................................... 14
EDDY CURRENTS ........................................................................................................................................ 14
HYSTERISIS ................................................................................................................................................. 14
HYSTERISIS AND EDDY CURRENT LOSSES ......................................................................................... 14
POWER CONSUMPTION ............................................................................................................................ 14
1.3 THE CORELESS INDUCTION FURNACE ............................................................................................................ 15
1.4 THE ELECTRICAL EQUIVALENT OF THE CORELESS FURNACE .................................................................. 15
1.5 TANK TUNING DURING THE PROGRESS OF A HEAT .................................................................................... 17
1.6 INVERTER BLOCK DIAGRAM ANALYSIS ............................................................................................................ 18
1.7 Z-CONTROL ............................................................................................................................................................. 20
1.8 OVP ......................................................................................................................................................................... 20
SECTION - 2 DESCRIPTION
2.1 GENERAL ................................................................................................................................................................. 21
2.2 WATER SYSTEMS .................................................................................................................................................. 22
2.3 COOLING WATER ................................................................................................................................................... 23
2.3 [1] WATER-COOLED LEADS ............................................................................................................................ 23
2.4 WATER STANDARDS .............................................................................................................................................. 24
2.5 INTERNAL WATER SYSTEM ................................................................................................................................. 26
2.6 CIRCUIT BREAKER PROTECTION ....................................................................................................................... 26
2.7 CONTROLS AND INDICATORS ............................................................................................................................. 27
2.8 GROUND/LEAK DETECTOR .................................................................................................................................. 31
SECTION - 3 THEORY OF OPERATION
3.1 GENERAL ................................................................................................................................................................. 34
3.2 CIRCUIT BREAKER RESPONSE ........................................................................................................................... 35
3.3 AC-DC CONVERSION ............................................................................................................................................. 35
3.4 CURRENT LIMITING REACTOR (CLR ................................................................................................................. 36
3.5 INVERTER ................................................................................................................................................................ 37
3.6 INVERTER SCR FUNCTIONS ................................................................................................................................ 37
3.7 THE ISOLATION TRANSFORMER ........................................................................................................................ 39
3.8 THE TANK CIRCUIT ............................................................................................................................................... 40
3.9 CAPACITORS ........................................................................................................................................................... 40
SECTION - 4 TEST PROCEDURE - START-UP
4.1 GENERAL ................................................................................................................................................................. 41
4.2 CONTROL POWER AND INTERLOCK CHECK ................................................................................................... 41
4.3 AC INTERRUPTER CHECKS ................................................................................................................................. 42
4.4 CONTROL BOARD AND FREQUENCY SETTING CHECK ................................................................................. 43
4.4 [1] TEST PROCEDURE FOR POWER-TRAK .................................................................................................. 45
4.4 [2] TEST PROCEDURE FOR POWER-TRAK-R .............................................................................................. 47
4.4 [3] GROUND-LEAK DETECTOR START-UP ................................................................................................... 48
Doc. No: FMUL0021 & FMUL0022 | Issue No. 1 | Revision No: 0 | Rev. Dt. 01-10-2005
Table of Contents
SECTION - 5 NORMAL OPERATING PROCEDURES
5.1 GENERAL ................................................................................................................................................................. 50
5.2 DAILY START-UP ..................................................................................................................................................... 50
5.3 TURN OFF ............................................................................................................................................................... 52
5.4 ABNORMAL OPERATIONS ..................................................................................................................................... 52
SECTION - 6 MAINTENANCE
6.1 GENERAL ................................................................................................................................................................. 53
6.2 DAILY (VISUAL INSPECTIONS AND CHECKS) ................................................................................................... 53
6.3 MONTHLY (EXTENSIVE CHECKS, CLEANING, AND MAINTENANCE) ............................................................ 54
6.4 ROUTINE MAINTENANCE ...................................................................................................................................... 55
6.5 REMOVAL AND REPLACEMENT OF COMPONENTS ........................................................................................ 58
6.5 [1] STUD-MOUNTED DIODE REPLACEMENT ...................................................................................... 58
6.5 [2] REPLACEMENT OF DISK TYPE DIODES AND SCRS .................................................................. 59
6.5 [3] REMOVAL OF THE DEFECTIVE DEVICE ........................................................................................ 60
6.5 [4] HEAT SINK SURFACE PREPARATION PRIOR TO ASSEMBLY ................................................... 61
6.5 [5] DEVICE SURFACE PREPARATION PRIOR TO ASSEMBLY ......................................................... 61
6.5 [6] REPLACEMENT OF THE DEVICE ................................................................................................... 61
6.5 [7] WATER - COOLED COMPONENTS ................................................................................................... 64
6.5 [8] CAPACITOR MAINTENANCE ............................................................................................................. 64
6.5 [9] CAPACITOR PRESSURE SWITCH REPLACEMENT ....................................................................... 65
6.5 [10] FURNACE ............................................................................................................................................. 65
6.5 [11] FURNACE LEADS .............................................................................................................................. 66
6.5 [12] BUS BARS ............................................................................................................................................ 66
6.5 [13] HOSES .................................................................................................................................................. 66
SECTION - 7 TROUBLESHOOTING
7.1 GENERAL ................................................................................................................................................................. 68
7.2 PROCEDURE ........................................................................................................................................................... 68
7.3 INDICATORS ............................................................................................................................................................ 69
7.4 POWER FAILURE ................................................................................................................................................... 69
7.4 [1] POWER UNIT FAILURE ................................................................................................................... ...69
7.4 [2] FURNACE PROTECTION ................................................................................................................... 69
7.4 [2.1] REMELTING A FROZEN FURNACE .............................................................................................. ....71
7.5 POWER UNIT TROUBLE SHOOTING .................................................................................................................. 73
7.6 OCCASIONAL TRIPPING ........................................................................................................................................ 79
7.7 WATER COOLING PROBLEMS ............................................................................................................................. 80
7.8 UNIT RUNS BUT NOT DRAWING RATED POWER ........................................................................................... 81
7.9 POWER AND FURNACE VOLTAGE FALL TO ZERO, BREAKER HAS NOT TRIPPED ................................. 82
7.10 CHECKING SOLID STATE DEVICES .................................................................................................................... 82
APPENDIX 7.A SCR VOLTAGE CHECK .......................................................................................................... ...87
APPENDIX 7.B SCR SNUBBER COMPONENT CHECKS .............................................................................. 88
APPENDIX 7.C SCR GATE RESISTANCE CHECK ........................................................................................... 90
APPENDIX 7.D SCR FIRING BOARD ISOLATION TEST ................................................................................ 91
7.11 UNIT TRIPS WITH INTERNAL HIGH TEMPERATURE (UNIT HIGH TEMP.) ................................................... 91
7.12 UNIT TRIPS WITH EXTERNAL HIGH TEMPERATURE (FCE HIGH TEMP.) ................................................... 93
7.13 FURNACE SELECTOR SWITCH INTERLOCK ..................................................................................................... 93
7.14 CAPACITOR/DOOR FAULT INDICATION .............................................................................................................. 95
SECTION - 8 HIGH FREQUENCY CAPACITORS
8.1
SAFETY NOTICE ..................................................................................................................................................... 97
A) PROTECTION AGAINST SHOCK ................................................................................................................. 97
B) EXPLOSION HAZARD .................................................................................................................................. 97
C) HANDLING OF FAILED CAPACITORS ........................................................................................................ 97
D) COMBUSTIBLE IMPREGNANT FIRE HAZARD ........................................................................................... 98
F) DISPOSAL OF CAPACITORS OR IMPREGNANT ....................................................................................... 98
8.2 RECEIVING .............................................................................................................................................................. 98
8.2.1 HANDLING .................................................................................................................................................... 98
8.2.2 STORING ........................................................................................................................................................ 99
8.3 INSTALLATION ......................................................................................................................................................... 99
8.4 COOLING SYSTEM ................................................................................................................................................. 99
8.5 MAINTENANCE ...................................................................................................................................................... 100
CONTACT ADDRESS .......................................................................................................................................................... 101
Copyright C IIL 1998. All rights reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic,
mechanical, photo copying, recording, or otherwise, without the prior written permission of Inductotherm (India) Pvt. Ltd.
Table of Contents
SAFETY PRECAUTIONS
W A R N I N G
Electrical s h o ck s can be
hazardous. Explosion due to
i m p roper ch a rge may c a u s e
s e r i o u s i n j u r y t o p e rs o n n e l .
I m p roper operating procedure
is also dange ro u s. Fo r s a fe
operation, we sugge s t you to go
t h rough this booklet of s a fe t y
p re c a u t i o n s. B u t b e s u re t o
f ollow your company’s s a fe t y
r u l e s.
SF/1
SAFETY PRECAUTIONS
Inductotherm Power-Trak/Power-Melt are efficient units, designed with 1

interlocks and circuit protection modules. Operators, however, should GENERAL
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-
agement personnel responsible for safety.
The purpose of this booklet is to familiarise operating and mainte- 2

nance personnel with safety precautions that pertain to foundry op- SAFETY
erations in general and to the coreless induction melt system in par- PRECAUTIONS
ticular. The safety precautions listed in this section should be ob-
served and complied with at all times. Those precautions should be
considered the minimum to be followed.
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 judgement.
The precautions which follow here are well known to foundrymen. 3

They are common to all metal melting operations, not only coreless GENERAL
induction melting. They are offered as general precautions and should FOUNDRY
not be considered to cover all types of operations. They should be PRECAUTIONS
evaluated in light of your particular operation and expanded or modi-
fied as appropriate.
υ Access to melting and pouring operation should be limited to

authorised personnel only.
υ Personnel should wear safety glasses at all times and should use
special light reducing glasses when viewing molten metal at high
temperature.
SF/2
SAFETY PRECAUTIONS
υ Heat and flame retardant clothing should be worn by personnel
who work at or near furnaces.
υ 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 manufacturer’s recommendations.
υ Furnace linings should be inspected frequently at regular inter-

vals to protect against the danger of RUN THROUGH. The lining
should be always be inspected after cool down.
υ 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.
υ Low melting point material (such as aluminium 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
vaporise violently and cause boil-overs or explosions.
υ Charge materials should be dry and free of combustibles, exces-

sive rust, and/or liquids. Violent vaporisation of liquids or com-
bustible can cause boil-overs or explosions in the metal bath.
υ 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 fer-
rous metals. The crucible manufacturer’s specifications should
be the guide for crucible use.
υ 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.
υ Be knowledgeable of the chemistry of your melt. Chemical reac-

tions (such as rapid carbon boil-over) can damage equipment
and can be dangerous to personnel.
SF/3
SAFETY PRECAUTIONS
υ Areas provided to receive runouts, or spills must be kept free of
accumulations of liquids. Hot metal in contact with liquids can
cause violent explosions resulting in personal injuries.
υ 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 Pacemak-
ers are particularly at risk.
All induction heating and melting equipments are using potentially 4

dangerous electrical power. Inductotherm built equipment is designed SAFETY
for safe, efficient, reliable operation and easy maintenance, if it is PRECAUTIONS
operated properly. FOR
OPERATIONAL
PERSONNEL
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.
υ Keep all cabinet doors locked. Make keys available only to those
qualified maintenance personnel who require access to the enclo-
sures.
υ Keep shields, covers and other protective devices in place at all

times during equipment operation. Exposed high voltage equip-
ment is a potential hazard to personnel in the work area.
υ Always set main power disconnect to the OFF position before

opening doors or removing access panels. Don’t depend upon
interlock devices for protection.
υ Always switch power OFF when lifting, pausing or transporting

hand furnaces.
υ Use only proven test equipment when trouble-shooting a unit or

components. Follow manufacturer’s recommended procedure.
SF/4
SAFETY PRECAUTIONS
υ Prevent inadvertent application of power while work is in progress
in crucible or on furnaces by placing warning tags and padlocks
on main power disconnects.
υ Use only dry charge material. 4.1

WHEN
υ Inspect bundled or baled scrap for trapped moisture before add- CHARGING
ing it to the melt. THE FURNACE
υ Do not allow closed or partially closed containers (beverage cans,

sheared tubing etc.) that may contain liquids to be mixed with the
furnace charge.
WARNING
FAILURE TO COMPLY WITH THESE PROCEDURES

MAY RESULT IN AN EXPLOSION WITH POSSIBLE
SERIOUS INJURY TO PERSONNEL.
υ Study the maintenance procedures. 4.2

SAFETY
υ Become familiar with the melt system and its dangerous areas PRECAUTIONS
before attempting maintenance of any kind. FOR
MAINTENANCE
υ Never enter a crubicle or transformer vault without tagging and PERSONNEL
padlocking the main disconnect breaker in the OFF (de-energised)
position.
υ Always use two independent methods to support a tilted furnace

whenever working on or near to it.
υ Use only first-class test equipment when trouble-shooting a unit

and follow the manufacturer’s procedure for using the equipment.
SF/5
SAFETY PRECAUTIONS
WARNING
DO NOT TOUCH
HOT LEAD ENDS ON
A HAND FURNACE
υ Ensure exposed furnace leads are properly insulated at all times.
υ Use proper safeguards when performing work or repairs under

conditions which include high steady voltages and normal cur-
rents or high transient voltages and currents which may result
from a fault condition.
υ When breakdown or fault occurs, guard against exposure to elec-

trically live surfaces, wires, cables and other related hazards such
as hot surfaces, rough or sharp surfaces, etc..
υ Be careful around high pressure lines, fittings and equipment.

Never tighten or loosen couplings, packings, gauges etc.,
when system is pressurised.
υ Do not operate the melt system with any broken wires, loose or
cracked components, hydraulic or water leakage or electrical con-
trol malfunction.
υ Supply valves (water or air) and charging valves shall be opened

very slowly to avoid sudden application of pressure to lines, charge
tanks or accumulators.
υ Inductotherm’s melt system equipment contains safety devices

and interlocks. DO NOT defeat or by-pass their purpose (except
as specifically noted for trouble-shooting).
υ Be sure that the power unit is disconnected and locked out when
doing furnace maintenance. If the power unit is used to run
several furnaces, disconnect the leads to the furnace being main-
tained on both ends and ground the coil.
SF/6
SAFETY PRECAUTIONS
Induction furnaces and their power supplies are high powered electri- 4.3
cal units. Their operations routinely involves control of low voltage SAFETY
and high voltage power with currents in various components ranging
PRECAUTIONS
DURING
from a fraction of an amperes to thousands of amperes. This equip-
TROUBLE-
ment should always be treated as a high voltage system in which SHOOTING
shock hazards are deemed to exist. Therefore, the following safe
guards shall be adhered to at all times.
υ Maintenance or repair of electrical equipment, instrumentation,

and controls should only be performed by personnel qualified to
recognise SHOCK HAZARDS and TRAINED in the safety pre-
cautions required to avoid possible injury or death.
υ DO NOT work alone when making measurement of circuit where

a shock hazard might exist. Notify a nearby person that you are
making, or intend to make such measurements.
υ DO NOT touch any object which could provide a current path to

the common side of the circuit under test or power line ground.
Always stand on a dry insulating surface capable of withstanding
the voltage being measured or that could be encountered.
υ Hands, shoes, floor and area where test and repair is being per-
formed must be dry. Avoid making measurement under humid,
damp or other environmental conditions that could affect the di-
electric withstanding voltage of the test leads or test instruments.
υ For maximum safety, do not touch test leads or test instrument

while power is applied to the circuit under test.
υ DO NOT make measurement using test leads other than those

originally furnished with the instrument or those recommended by
the manufacturer of the test instruments.
υ Electrical equipment hazards must be recognised at all times, 4.4

therefore: ELECTRICAL
EQUIPMENT
υ Use extreme caution when making measurements where danger- HAZARDS
ous combinations of voltages (i.e., AC & DC) could be present,
such as in the reactors, DC supplies or leak detector system.
SF/7
SAFETY PRECAUTIONS
υ Remember voltages may appear expectedly in defective equip-
ment. An open bleeder resistor may results in a capacitor retain-
ing a dangerous charge. Therefore, TURN OFF power and dis-
charge all capacitors before removing a defective capacitor or
before connecting or disconnecting test equipment to and from a
power circuit being measured.
υ Locate all voltage sources and accessible current paths before

making measurement connections. Be sure that the equipment
is properly grounded and fuses of right rating and type are in-
stalled. Set the test instrument to the proper range before apply-
ing power.
υ Open and lock out main circuit disconnect and be sure that all
capacitors are discharged before making any checks with an ohm
meter.
υ Be extremely careful when working in high voltage power circuits. 4.5

DO NOT touch the instrument or test leads while the power is on VOLTAGE
in the circuit being measured. MEASUREMENT
υ When measuring line voltage, such as from 120 volt, 240 volt,
415 volt, 460 volt, 550 volts or 575 volt source, be sure that the
range switch is set to the proper voltage position.
υ Turn off power to the circuit and wait until the meter indicates
zero before disconnecting the test leads and testing instrument.
υ DO NOT change the range setting or function switches of the test

instrument while the circuit under measurement is energised.
υ Never disconnect the test leads from the circuit under measure-
ment while the circuit is energised.
υ Always turn the power off and discharge all capacitors that may
be in the circuit before the setting of the switches are changed or
the leads disconnected.
υ Never exceed the circuit-to-ground voltage of the test instrument.
SF/8
SAFETY PRECAUTIONS
υ All electrical test devices, including tools and test appliances must 4.6
be approved by a certifying authority and only approved ground- GROUNDING OF
ing devices should be used.
ELECTRICAL
TOOLS AND
TEST
υ All tools and appliances used in the melt system shall be equipped
APPLIANCES
with the three wire grounded power cords. These are to be used
in conjunction with the grounded service outlets. Under no cir-
cumstances shall any ground adapter or other means of JUMPER
be used. Proper grounding practice must be maintained. If it
becomes necessary to connect any temporary or special equip-
ment to the power supply by means other than a standard con-
nection, electricians are to make certain that the equipment is
properly grounded prior to use.
υ Inspect the power cord and test leads for cracks or breaks in the
insulation, probes and connectors before each use. Defective
pieces should be replaced immediately.
υ Test instruments are designed to prevent accidental shock to the

operator when properly used. Therefore, failure to follow direc-
tions for using the instrument can result in fatal accidents.
υ When in doubt about the voltage level present, always use the
highest voltage range as a protection to the instrument. If the
voltage is within a lower range, the switch may be set for the
lower range to obtain a more accurate reading.
υ Hot surfaces - Personnel working in the furnace area should 4.7

wear appropriate protective clothing to prevent burns and direct MECHANICAL
contact with hot metallic surfaces. EQUIPMENT
HAZARDS
υ High pressure blow-out - Personnel must never try to tighten
high pressure fittings with the system pressurised. Hydraulic and
other fluid systems shall be placed into a zero mechanical state
(ZMS) prior to doing any work on the system. After turning the
system OFF at its primary input source, verify that ON-OFF con-
trols (down stream or interconnected at another point) are OFF
to verify a ZMS condition.
SF/9
SAFETY PRECAUTIONS
υ If a joint leaks after being properly sealed, ascertain the cause
and eliminate it. DO NOT attempt to stop leaking by tightening
fasteners beyond their torque limits.
υ Uniform tightening of all nuts or bolts in a pressurised joints is of

paramount importance to assure that all bolts and studs are equally
loaded during operation.
υ Failure of safety devices can result in dangerous over pressure if

a pump continues to operate. Therefore, always check the safety
valves with pump operating.
υ Combustible and volatile fluids or materials must be kept away

from the furnace area and modules to reduce the hazards of fire
or explosion.
υ Equipment Guards - Guards must not be removed from the

equipment for any reason unless the machinery is tagged OUT
OF SERVICE and is physically and electrically disconnected.
Equipment must not be operated without these guards. The
guards must not be cut, bent or altered in any way except by
authorised personnel performing authorised repair/replacement.
WARNING
BEFORE CHARGING SCRAP OR OTHER

MATERIAL INTO A FURNACE CONTAINING
MOLTEN METAL, THE FOLLOWING PRE-CAUTIONS
MUST BE ADHERED TO
1 The charge material MUST be dry.
2 Bundled or baled material MUST NOT have water trapped within.
3 The charge MUST NOT contain closed or partially closed con-

tainers of liquids such as water, soft drinks or other liquids
combustibles or explosives.
SF/10
SAFETY PRECAUTIONS
F A I LU R E T O COMPLY W I T H
T H E S E W ARNINGS MAY
R E S U LT I N A N E X P LOSION
WITH POSSIBLE SERIOUS
I N J U RY T O P E R S O N N E L .
: NOT E :
B E S U R E T O F O L LOW
YOUR COMPA N Y ’ S
SAFETY RU L E S.
SF/11
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
P R E FAC E
Inductotherm introduced the first automated high frequency induction furnace melting system in 1968
called VIP or Variable Induction Power. It was designed to provide a source of automatically controlled
power for coreless induction melting furnaces.
One or more furnaces can be linked to each power unit. Since its introduction, the VIP power supply has
proven to be one of the best solid state induction power systems. Inductotherm has continuously improved
the VIP system and markets the VIP POWER-TRAK/POWER MELT in India.
Inductotherm's new VIP power systems have proven to be so automatic that an operator is needed only
to push the ON button and to set the desired power level. After that, automatic circuitry takes over to
maintain maximum possible power through the changing conditions of the melt cycle from start-of-melt
to pour. Capacitor switching is not required during the melt. With a POWER-TRAK/POWER MELT full
power is available from cold charge to fully molten. The power melt system's designed to operate most
efficiently as a back charge melter. Full power is available with 50% or greater heel in the furnace.
Capacitor adjustments may be needed when charging to another furnace size or to different alloys, or
during lining sinter.
Induction melting is more than simply another method of heating metal to the point where it can be poured
and cast successfully. An insight into the mechanics of induction melting and the characteristics of the
VIP system will enable the operator to take full advantage of the desirable features of the system. This
manual will provide much of that insight.
One important way in which induction melting differs from systems that derive their heat from the combustion
of gas, oil or solid fuels is that the heat developed by induction is developed within the charge, or melt
itself. Heat loss from the system is minimized in the case of induction heating. With gas, oil, or solid fuel
used for heating, large quantities of heat are lost up the stack without ever being used to heat the metal.
The electrical stability inherent in the new circuitry so simplifies control requirements that all electronic
control logic is contained on a single integrated circuit board. The power supply and its components have
been engineered for levels of dependability that have never before been achieved in foundry environments.
The need for delicate, high-speed fuses has been eliminated. Instead, another circuit innovation limits the
rate of fault current rise, so a high-speed circuit breaker will protect the components from both internal
and external faults.
Inductotherm VIP converters operate at nominal frequency of 50, 100, 200, 500, 1000, 3000, 10000 Hz
and are available with output from 15 KW to over 7500 KW and in single and multiple furnace installations.
VIP Power melts operate at 50, 100 and 200 Hz nominal frequency.
PF/12
SECTION - 1 INTRODUCTION
INTRODUCTION
1.1 GENERAL
This manual is divided into various sections that will provide information on safety operation,
maintenance and functional descriptions of the systems. It is essential that the drawings and
data packages included with each system be examined and understood prior to installation or
operation of the unit. Where a difference exists between data presented in this manual and an
installed unit, the drawings data package have priority over other documentation.
The VIP melting systems described in this manual provide information on systems in the 100
Hz to 10000 Hz frequency range with power rating from 15 KW to over 7500 KW.
Each melting system is composed of four main sections:
- the main power transformer and switch gear,

- a power unit,
- a water cooling system and
- a furnace.
These sections are described separately.
One significant advantage of induction heating or melting over other methods is that the heat
is produced directly in the work piece. Most of the induced energy goes toward raising the
temperature of the work piece or charge. When gaseous, liquid or solid fuels are used to heat
metal, the heat is applied to the surface of the charge (or the crucible surrounding the charge).
Much of the heat produced escapes as stack or fuel losses without even coming in contact with
the work piece or melt and makes no useful contribution to the process.
The following theory of operation and subsequent paragraphs in this section should clarify the
principles of induction heating and melting.
IN/13
1.2 THEORY OF OPERATION

INTRODUCTION
Induction heating is the heating of an electrically conducting object immersed in a varying

magnetic field. The object being heated need not be a magnetic material to heat efficiently. All
that is required is that it have reasonably good electrical conductivity. Most ferrous and nonferrous
metals can be heated and melted inductively. Direct induction heating and melting is possible
only with conducting materials. The eddy currents induced in the work piece or charge are
primarily responsible for the heating.
EDDY CURRENTS
Eddy currents are electrical currents induced by transformer action in the material. The term
eddy is derived from the action or flow of current in swirls or eddies within a solid mass of
material. Eddy current losses occur in any conducting material in a varying magnetic field. This
causes heating even if the materials do not have the magnetic properties associated with iron
and steel.
HYSTERISIS
Hysterisis is a discontinuity in the values of magnetization in a magnetic material due to

changing magnetic field. A reversal of a magnetic field requires energy. The energy converts
to heat. The heat generated by hysterisis helps to increase the temperature of the magnetic
material (iron, steel, nickel). The rate of expenditure of energy (power) increases with an
increased rate of reversal (frequency). Hysterisis losses disappear after the metal temperature
exceeds its "Curie temperature".
HYSTERISIS AND EDDY CURRENT LOSSES
Eddy current losses are more important than hysterisis losses in induction furnace. The induced
flow of current due to the changing magnetic field of the coil causes heating of the load.
POWER CONSUMPTION
Power is consumed in a resistance when current flows through the conductor. This power is the
rate at which electrical energy is transformed into heat energy. This power is proportional to the
square of the current, and does not depend upon the direction of flow. P=I2R, where P is the
power in watts, I the current in amperes, and R the resistance in ohms. Power draw is caused
by induced currents circulating in the work piece, melt or charge as described in the following
parts of this section.
IN/14
1.3 THE CORELESS INDUCTION FURNACE
INTRODUCTION
The coreless induction furnace is composed of a refractory container, capable of holding the
molten bath, which is surrounded by a water-cooled helical coil connected to a source of
alternating current. Figure 1-1 is a simplified cross section of a coreless induction furnace.
Crucible
or lining
Coil
Melt or
Charge
Fig. 1-1 Cross Section of Coreless Induction Furnace
The alternating current applied to the coil produces a varying magnetic field which is concentrated
with in the helical coil. This magnetic field passing through the charge induces an alternating
current in the charge. The current circulating in the charge produces I2R losses which heats the
charge.
1.4 THE ELECTRICAL EQUIVALENT OF THE CORELESS FURNACE
Electrically, the charged furnace can be thought of as a transformer with single shorted turn for
a secondary. Figure 1-2 shows the electrical equivalent of a charge. Table 1-1 defines symbols
used in this section.
IN/15
INTRODUCTION
Rc
LL
WORK
FURNACE Lc PIECE
OF
CHARGE
RL
Fig. 1-2 Electrical Equivalent of a charged Furnace
TABLE 1-1 SYMBOL DESIGNATIONS
Rc Resistance of Coil Lc- LL (Lc minus LL)
RL Resistance of the Load Xc Capacitive Reactance
Lc Inductance of Empty Coil XL Inductive Reactance
LL Inductance of Charge (Load)
Applying a fixed alternating current to the load results in a poor ratio of active power (power
which does work in the load) to apparent power. Expressed another way, the power factor of
the loaded coil is very poor.
Power factor can be improved by tuning the circuit with capacitors to improve the ratio of active
to apparent power. The VIP POWER-TRAK-R-SERIES contain tuning or "tank" capacitors for
coil power factor correction. The circuit combination of load coil and tuning capacitors (illustrated
in Figure 1-3 A and described in the following paragraphs) is known as the tank circuit.
IN/16
1.5 TANK TUNING DURING THE PROGRESS OF A HEAT
INTRODUCTION
The furnace tank circuit can be likened to a radio receiver, which can be tuned to a given
frequency. At any frequency, for a given set of furnace conditions, there is an optimum value
of capacitance that will tune the tank circuit to resonance. At resonance, the capacitive reactance
balances the inductive reactance of the coil. This means that the power factor of the circuit is
unity and the real power delivered to the load is at maximum. Figure 1-3A shows a simplified
tank circuit equivalent. Rc represents the resistance of the furnace coil. Lc - LL represents that
the inductance of the loaded coil, which is almost
C RC always less than the inductance of the empty
coil (Lc) RL represents the resistance of the
current paths in the load reflected into the coil
circuit.
LC - LL
Figure 1-3B is an impedance diagram of the

resonant circuit of Figure 1-3A. Note that the
RL value of the capacitance has been selected such
that the capacitive reactance (Xc) is exactly
equal to the inductive reactance (XL). Their
vector sum becomes zero. To the power supply,
xL the furnace circuit appears to be purely resistive
RC RL as shown in figure 1-3C. Figure 1-3C, also
xC
illustrates that real power is consumed not only
in the load (RL) but also in the resistance of the
coil (RC). This coil loss, as well as the loss of
heat conducted from the charge through the
RC RL I refractory to the coil, makes water cooling of
the coil necessary.
Fig. 1-3 Tank Circuit Equivalent
VIP "tank circuit" does not operate at unity power factor under any conditions.
The inductance of the load changes during the melt cycle as the charge melts. With older power
sources that operate at a fixed frequency, it was necessary to change the value of the power
factor correction capacitors to compensate for changes in inductance. These changes in
capacitance, even if accomplished automatically without operator attention, were made in discreet
steps. Each step only approximated the value which would yield optimum operating efficiency.
Another approach to this problem suggests itself. If we could adjust the frequency of the
IN/17
POWER
1200 100%
transmitter (the power
INTRODUCTION
source) to follow changes

in the tuning of the
75
FREQUENCY receiver (the furnace tank
circuit), we could maintain
POWER
FREQUENCY
(Hz) 50
the desired power factor
1100 without changing
capacitors. When we
25 investigate the magnitude
RELATIVE
INDUCTANCE of the frequency change
required during a melt to
1000
maintain optimum tuning,
0 10 20 30 40 50
we find that generally it is
TIME
(Minutes) less than 10% of the
Fig. 1- 4 Furnace Conditions During Melt of 304 Stainless Steel operating frequency. The
VIP Power Supply does
this automatically.
Figure 1-4 shows the relative changes in furnace conditions during the course of a melt. Note
that output power remains constant at rated output while frequency increases steadily to
compensate for the decrease in inductance that occurs as the bath goes from fresh change to
fully molten at pouring temperature. In a VIP power unit, this precise tracking of furnace tuning
is accomplished smoothly without operator's attention. With fixed frequency systems, the required
changes are made in discreet steps. Even if these adjustments are made automatically in small
increments, each change yields only an approximation of the point of optimum efficiency which
the VIP power supply follows precisely.
1.6 INVERTER BLOCK DIAGRAM ANALYSIS

Figure 1-5 shows a simple block diagram of a VIP power supply. 50 Hz AC power is fed to a
fast-acting three phase circuit breaker, which also serves as the primary means of energizing
the equipment and shutting it down. This three phase circuit breaker is also connected to the
cabinet door interlocks. Opening a cabinet door with the circuit breaker ON will cause the
breaker to trip to the OFF position. The circuit breaker cannot be moved to the ON position
unless the cabinet doors are closed.
A three phase bridge-rectifier uses power semiconductors to convert the 50 Hz AC input to a

DC voltage. This DC is smoothed by the action of the LC filter composed of the current limiting
reactor and the filter capacitors. The current limiting reactor also serves to delay and limit any
IN/18
in rush of current caused by a
INTRODUCTION
tank circuit short or an inverter
malfunction. This allows the fuses
or circuit breaker to open before
the current reaches a value that
would damage diodes or silicon
controlled rectifiers (SCRs).
The heart of the inverter section

is the power SCRs. They are
high-speed electronic switches
capable of controlling currents of
many hundreds of amperes with
relatively small input signals or
gating pulses. The frequency at
the output of the inverter is
determined by the rate at which
these SCRs are fired. The firing
signals are generated by the
Fig. 1-5 Block Diagram of VIP Power Trak-R control board.
The control board responds to inputs representing coil voltage, coil current, and coil power to
produce gating pulses for the SCRs. This results in either a power level selected by the operator
or the maximum possible power input to the furnace tank circuit under a particular set of melting
conditions. The control board also places limits on inverter operation to prevent damage to the
SCR due to high current, or to prevent damage to the furnace power factor correction capacitors
due to excess voltage. The control board also shuts down the unit if a SCR overvoltage module
(OVP) detects an instantaneous condition which could damage the semiconductors.
In Secondary Isolated units, the secondary capacitors are adjustable in steps to allow rough
tuning of the furnace tank circuit to a frequency within the VIP's operating range. This rough
tuning provides the versatility needed to match various coils, melt various alloys, and compensate
for changes in lining characteristics, particularly when sintering a new lining.
Transformer isolation of the melting furnace from the power mains is a feature of VIP power
supplies. It isolates the power circuit and operator from ground faults and shocks. With provision
of Ground Leak Detector (GLD) and also GFL (Ground fault Limiter) which limits the fault
current during any grounding/earthing and protects. This unit also isolates the power circuit and
operator from ground faults and shocks with the provision of GLD. In primary lsolated units
(Line lsolated units) the supply to VIP unit is isolated from Main Transformer with a electrostatic
IN/19
shield between HT & LT winding and the supply voltage to VIP is higher (550 volt OR 460 volt)
INTRODUCTION
to reduce the I2 R losses of unit and also rating of semi conductors.
1.7 Z-CONTROL
Z-Control is the latest innovation in VIP control technology. The system takes its name from the
manner in which the primary control parameter is determined. The timing, which sets the
repetition rate of the SCR firing pulses, is derived from the signal analysis of inverter current
and voltage. This analysis is completed each half-cycle of current.
The advantage of this system is that it can respond almost instantly to rapid changes in furnace
or line conditions which can produce dramatic changes in the electrical load seen by the
inverter. The ability of Z-control to control this basic inverter parameter on each cycle eliminates
the problems that rapid changes in load or line could cause. The Z system also provides for
convenient interface with microprocessor and computer-based control systems.
1.8 OVP
The new POWER-TRAK-R-SERIES VIPs include the over voltage protection (OVP) circuit
which eliminates trips caused by low-level transient noise while retaining the protection of the
SCRs from potentially harmful high energy transients.
IN/20
SECTION - 2 DESCRIPTION
2.1 GENERAL
The VIP system is a versatile design that allows high production melting in a batch and features
DESCRIPTION
the following :
λ Current Limiting Fault Protection
λ Integrated Circuit Solid State Control Board
λ Economical Operation
λ Simplified Operation Controls
λ Minimum of Pollution
λ Lighted and Visual Indicators
λ Easy Access to Components
λ Fast Melting Times
λ Multiple Source Cooling Water Capability
λ Operating Positions for Multiple Furnaces
λ Full power, Automatic Control, Continuously during Melting
λ Compatible with Most Melting Requirements
λ Heavy Gauge Attractive, Steel Cabinets
λ Close Loop Internal & External Water System
λ Reliable Operation
λ Numerous specialized, Other Furnace Options
λ Minimum Operator Training Required
λ Safety
Electrical interlock design prevents power from being applied to the unit when the cabinet door
is open. In addition, high water temperature and low water pressure interlocks shut down the
inverter when inlet temperature exceeds (set point) or water pressure is less than set point.
DS/21
2.2 WATER SYSTEMS

Most of the equipment contained within the cabinet or module is water-cooled. There are two
separate water systems in most VIP Power supplies, a closed-loop internal system, a closed
loop DM/soft water system and an external water system. The closed-loop internal system
circulates deionized, distilled water, and included a water-to-water heat exchanger, in most
DESCRIPTION
cases plate type heat exchanger (PHE). The SCR modules, three phase rectifier assembly,
reactors, commutating and coupling capacitor, transformer and tank capacitors, where applicable,
are connected in this system.
A closed loop DM/soft water system provides water to cool induction coil through a plate type
heat exchanger. Both the water system (internal & DM/soft water closed loop system) are
cooled by external raw water. A proper size cooling tower (induced draft type) is used to cool
this raw water. The maximum water temperature of cooling tower outlet should be 320 C. Refer
to the power unit individual internal and external water system drawing for specific details.
Both the external and internal water systems have water pressure gauges for monitoring pressure
and pressure switches will turn the inverter off if pressure drops below a preset level. Indicator
lamps on the circuit monitor will show which water system causes an inverter trip.
The inlet and drains on both systems are also monitored with thermal sensing switches (temperature
switch at inlet & temperature sensors at outlet). Should any water inlet or drain reaches an improper
(higher) temperature level, the inverter will shut down. Again, indicating lamps will show which
system caused the trip.
NOTE
SYSTEMS DESIGNED FOR DEIONIZED WATER MAY USE ONLY COPPER OR

PLASTIC PIPING. STEEL, IRON OR LEAD PIPE MAY NOT BE USED.
The maximum inlet water temperature for VIP POWER TRAK varies both with power unit size
and with type of external cooling system used. Be sure to consult your power unit water
drawing.
DS/22
2.3 COOLING WATER

NOTE
INDIVIDUAL INSTALLATIONS MAY VARY INSOFAR AS WATER

CONNECTIONS TO THE CABINET AND FURNACE(S) ARE CONCERNED.
DESCRIPTION
REFER TO THE WATER DIAGRAM FURNISHED WITH EACH UNIT FOR
SPECIFIED DETAILS.
The system water diagram furnished for the VIP shows details of the various circuits and
recommended sizes for the supply piping. These sizes are selected based upon a pressure of 40
to 50 PSI (2.8 to 3.4 BAR) available at the cabinet and a run to the drain not exceeding 100 feet
(30m). If pressure is low, or long pipe runs are required, pipe sizes larger than those recommended
must be used.
All water connections to electrical components are made with low conductivity rubber hose. The
minimum length of any hose connecting a point of AC potential to a grounded manifold must
be 18 inches (50 cm). The same minimum length applies to hoses that connect points on
opposite sides of the AC lines.
NOTE
THE ROUTING AND LENGTH OF ANY HOSE REPLACED SHOULD

DUPLICATE THE ORIGINAL.
The inlet manifold of the unit is equipped with both a pressure and a temperature switch. These
switches interrupt solenoid current to the inverter OFF control circuit if the water supply pressure
drops below 40 PSI (set value). Or the water temperature shoots up more than the set value.
An indication is given on the circuit monitor.
NOTE
FOR PROPER PRESSURE AND TEMPERATURE SETTING REFER THE

DRAWINGS SPECIFIC TO YOUR POWER UNIT.
2.3 [1] water-cooled leads
Water-cooled leads should be used wherever a flexible conductor is required. Figure 2-1 illustrates
a typical installation.
DS/23
Average Voltage Drop (in Volts)

per 1000 amps. per foot of lead run
Lead Configuration 1 KC 3 KC 10KC
1 + - 0.9 2.7 9
DESCRIPTION
+ -
2 + - 0.57 1.71 5.7
* 3
+ -
0.33 0.99 3.3
- +
4 + -  0.45 1.35 4.5
4"
+ - 
* MOST COMMONLY USED
Fig. 2-1 Water Cooled Lead
Regular checks should be made of water-cooled lead temperature and where it is feasible, rate
of flow should be measured. The readings should be recorded and compared to previous
readings to determine if any changes in operating conditions have occurred. Any changes
should be evaluated for possible sources of trouble.
2.4 WATER STANDARDS

The following standards apply to make-up water or initial fill for water recirculating external
cooling systems unless otherwise indicated in the water drawings.
1. Conductivity less than 400 micromhos per centimeter. (This will result in a conductivity of
800 micromhos per centimeter of the recirculating water with regular regeneration through
DM/soft water plant.
2. Total undissolved solids less than 10 parts per million. (PPM)
3. Pressure-40 PSI (2.8 to 3.4 BAR) differential pressure between supply manifold and drain
manifold .
4. Flow-See water diagram.
5. P.H. Value should be 7.2 to 7.8.
6. Temperature - The maximum temperature allowed varies between power units depending
on the size and type of cooling system. Refer the drawing specific to your power unit.
Under most conditions, local dew point is the lowest water temperature that is safe to use.
DS/24
This illustration shows a typical configuration

for hydraulic and water systems. Refer to
drawings provided for individual installations.
DESCRIPTION
Cooling Tower
Power in
VIP Cabinet
Main
Water
Furnace
in
Heat
Exchanger
Hydraulic
Controls
Water Water Cooled Leads

Pumping
Unit
Hydraulic
Pumping Unit
Fig. 2-2 Typical Water System
DS/25
2.5 INTERNAL WATER SYSTEM

Water- cooled components operated at DC potentials suffer from plumbing deterioration due to
electrolysis where points of different potential are bridged by a water path. There is no way to
completely stop this, but it can be minimized. Keeping the conductivity of the water low and
extending the length of the water path (and hence the current path), limits this slow self-destruction
DESCRIPTION
of the plumbing to levels which will provide years of trouble free use. If the conductivity of the
water can be controlled and if the path is long enough to limit potential gradient to about 20 volts
per foot (0.3m) (30 foot (10 m) hose length per 600 VDC potential difference) plumbing
deterioration will be very slow. Figure 2-2 illustrates a typical water system installation.
CAUTION
THE LENGTH AND ROUTING OF HOSE IN THE INTERNAL SYSTEM IS

CRITICAL. ANY HOSE REMOVED MUST BE REPLACED WITH LOW
CONDUCTIVITY HOSE THAT DUPLICATES THE ORIGINAL IN LENGTH
AND ROUTING. SERIOUS FLOW IMBALANCE AND ELECTROLYSIS
PROBLEMS CAN ARISE FROM FAILURE TO OBSERVE THIS PRECAUTION.
THE WATER DIAGRAM SUPPLIED WITH YOUR UNIT SHOWS THE
ROUTING OF ALL CIRCUITS AND INDICATES CRITICAL HOSE LENGTHS.
2.6 CIRCUIT BREAKER PROTECTION

VIP units employ either an automatic or non-automatic circuit breaker to act as a circuit
disconnecting means for maintenance and sustained power-OFF periods. The automatic circuit
breaker is co-ordinated with other circuit components to quickly open the line connections while
limiting current to values that do not degrade the inverter diodes and SCRs. In units of 450 KW
output and above, an input isolation switch (manually operated) is used with a solid state
automatic circuit interrupter (ACI) to quickly open the circuit under fault conditions to prevent
damage to diodes and SCRs.
The proper procedure to enter the cabinet is to first reduce operating power to idle and depress
the power OFF push button on the control panel. Second, manually trip the circuit breaker /
isolator switch to OFF. Disconnect control power to the unit to prevent reapplication of main or
control power.
The ACI in the 50/60 Hz AC line, control DC voltage available to the inverter. In the event of
a fault, the AC interrupter interrupts main power rectification, reducing the DC voltage to zero.
The interrupter is very fast in its operation, thus avoids the fault loading current on the isolator
switch. This in turn serves to improve the reliability and life of the isolator switch.
DS/26
WARNING
THE ACI IS NOT A DISCONNECT; DO NOT ATTEMPT TO PERFORM

MAINTENANCE WITH THE ACI OFF. ALWAYS ENSURE THAT THE CIRCUIT
BREAKER/ISOLATOR SWITCH IS OFF, THE CONTROL VOLTAGE IS OFF,
AND THAT ALL CAPACITORS ARE DISCHARGED BEFORE WORKING IN
THE CUBICLE. (VIP PANEL)
DESCRIPTION
NOTE
THE FOLLOWING DESCRIPTION IS INCLUDED TO PROVIDE A GENERAL

INFORMATION OUTLINE OF CONTROL AND INDICATOR FUNCTIONS
APPLICABLE TO SOME UNITS BUT NOT TO OTHERS. WHERE A
DIFFERENCE EXISTS, REFER TO THE DRAWING AND DOCUMENTATION
PROVIDED FOR THE INSTALLED SYSTEM. DRAWING AND DATA SUPPLIED
WITH THE UNIT HAVE PRIORITY OVER OTHER INFORMATION.
2.7 CONTROLS AND INDICATORS

Controls and indicators usually mounted on the front cabinet/module door, provide visual Indications
of system conditions and allow easy access to start, stop, and other operations. The following
paragraphs describe the function of controls and indicators.
NOTE
THE FOLLOWING CONTROLS AND INDICATORS ARE APPLICABLE TO

MOST VIP SYSTEMS. NOTE THAT INDIVIDUAL INSTALLATIONS MAY HAVE
CONTROLS THAT ARE DIFFERENT BECAUSE OF FURNACE OR WATER
COOLING REQUIREMENTS.
MAIN POWER ON - RED light comes ON when the cabinet mounted circuit breaker is
ON and power is available to the unit.
INVERTER ON - Light is ON when the INVERTER is ON, and Power is delivered to the
Furnace.
FULL POWER - GREEN lamp is ON when the POWER CONTROL is turned clockwise
to or beyond a setting that commands full output power and the unit is producing rated
power. The kilowatt meter should be at the red line mark. If the FULL POWER lamp is
not lit, the VOLTAGE, FREQUENCY, and CURRENT LIMIT lamp may be lit (depending
on system conditions). Under these conditions, the meter should indicate less than full
power.
DS/27
VOLTAGE - Light is ON when power factor correction capacitors are operating at maximum
1allowed voltage. The relationship between the furnace voltage and the secondary capacitors
determines the voltage. Voltage limits are factory adjusted to prevent an overvoltage condition
that will damage the equipment or capacitor.
FREQUENCY - Light is ON when the system operates at maximum rated frequency. A high
DESCRIPTION
frequency limit adjustment is made for a pulse repetition time which will produce this frequency.
Do not attempt to change settings; they have been factory adjusted for optimum performance.
Increasing capacitor steps will lower the operating frequency of the inverter operating at a given
power level and can be used to determine an out-of- frequency limit in relation to lining dimension.
EXCESS CHARGE (TOT) - The turn-off time light indicates that the inverter is not able to produce
the required power without operating at a repetition rate that would result in an SCR TOT less than
the design minimum of the device. This condition usually occurs with a dense charge of cold
magnetic material in the furnace. The TOT limit can be avoided by limiting the rate at which cold
charge is added to the furnace. Some improvement in the power output under a TOT limit can
be gained by adding secondary capacitor when provided.
CURRENT - Light is ON when inverter current output reaches the maximum rated current of
the system. The furnace coil, the high frequency transformer, and the SCRs are limited to the
current they can carry. Under certain conditions of load, the inverter current can reach maximum
allowable current before rated power is reached. The control board prevents damage to the
inverter by preventing an increase in inverter frequency. The control board current limit
potentiometer has been factory adjusted for maximum safe operating conditions.
FURNACE VOLT - Light is ON when the maximum allowed voltage appears across the coil.
It also serves the purpose of additional protection for capacitor voltage.
KILOWATT-METER - Measures the power, being delivered to the system at the inverter output.
Kilowatt-meter readings should not exceed red lined markings. The meter provides KW readings
from the KWMT transducer mounted on the back of the cabinet door. This transducer is built-
in in the control card in case of POWER-TRAK-R-SERIES.
NOTE
IN CASE OF ANY FAULT AND IF THE CONTROL BOARD NEEDS

REPLACEMENT, ALL THE LIMIT ADJUSTMENTS MUST BE DONE BY
INDUCTOTHERM AUTHORISED ENGINEER PRIOR TO PUT BACK THE UNIT
IN REGULAR PRODUCTION.
DS/28
ON - GREEN push button is pressed to turn the unit ON when MAIN POWER ON light is lit.
(Assuring that all interlocks are satisfied). This control and the OFF push button are HIGH
FREQUENCY CONTROLS. (i.e. Supply to Induction coil inside furnace).
OFF - RED push button is pressed to turn the inverter OFF, when a melt or heat cycle is
complete, or an INVERTER OFF condition is desired. Generally, the POWER CONTROL
DESCRIPTION
should be turned fully counter clockwise (at zero level) before the HIGH FREQUENCY CONTROL
- OFF push button is pressed.
RESET - Yellow push-button is pressed to turn the DC voltage ON during any fault if the DC
voltage drops to zero. The RESET (Red) indication on monitor will appear. In some of the units,
the OFF & RESET push-button is common (Red).
FURNACE SELECTION (If required) - VIP units can be equipped with FURNACE SELECTOR
SWITCHES. This allows the power units to be connected alternately to either of two or more
furnaces. Water cooled internal bus provides electrical power to power exits from the cabinet.
To use either furnace, place the switch in the desired position and operate the system in the
normal mode.
WARNING
DO NOT ATTEMPT FURNACE MAINTENANCE WITHOUT FIRST ALLOWING

FURNACE TO COOL AND LOCKING OUT MAIN DISCONNECT. IF
OPERATION OF ANOTHER FURNACE IS DESIRED, ALL POWER
CONDUCTORS TO THE FURNACE BEING MAINTAINED MUST BE REMOVED
ON BOTH ENDS AND NOW ISOLATED COIL MUST BE GROUNDED.
POWER CONTROL - The POWER CONTROL knob is a potentiometer wired to the control
board to provide control from idle to full red-line power shown on the kilowatt-meter. Rotation
in clockwise direction increases power. The opposite direction decreases power. The Power
Control is also used when adjusting limit or system functions.
CIRCUIT MONITOR LAMPS (FAULT LIGHTS) - The VIP circuit monitor has eight (8) small red
lamps which indicate the occurrence of a fault or interlock condition, and help to isolate the
fault. However a detailed check list for each interlock is given in trouble shooting section.
DS/29
DOOR OPEN - This indicates either an open cabinet door or a failing capacitor. The circuit
breaker opens when one of these faults occurs.
SCR OVER VOLTAGE OR SCR PROTECTION - The circuit breaker or the AC interrupter (ACI)
or both will trip when this type of fault occurs. This lamp is interpreted as :
DESCRIPTION
a. SCR lamp by itself or with Voltage lamp together. This indicates an OVP (over voltage)
condition on Inverter SCR. A detailed check List is given in trouble shooting Section.
b. SCR lamp or with TOT lamp. This indicates a TOT trip. Melting may be resumed immediately
as the condition clears itself. TOT trip may be minimized by taking cold metal out of the
furnace or by raising line voltage.
INTERNAL WATER SYSTEM HIGH TEMPERATURE - This indicates a trip on an internal

system temperature switch or sensor. This can be caused by high external water temperature,
poor cooling flow to the heat exchanger or operation above rated power.
INTERNAL WATER SYSTEM LOW PRESSURE - This indicates one or more of the following
reasons:
1. Pump is not operating
2. Pump rating direction not proper
3. Setting of pressure switch not proper.
EXTERNAL WATER SYSTEM HIGH TEMPERATURE - This indicates one or more of the
following conditions :
a. High external water inlet temperature.
b. Overheating of a furnace drain line (Coil Outlet Water).
EXTERNAL WATER SYSTEM LOW PRESSURE - This indicates inadequate cooling water
supply. External pressure is less than required.
FURNACE SELECTOR SWITCH INTERLOCKS OR FURNACE INTERLOCK - This lamp indi-

cates that a selector switch is not properly closed or has been moved, or that there is no water
flow to a furnace with a closed selector switch. Special furnace interlock will also be connected
to this indicator.
AUXILIARY TRIP DEVICE OR RESET - System with ACI's use this lamp to indicate that ACI
is OFF or no DC voltage in rectifier. During any electrical fault inside unit the DC voltage gets
short through inverter SCR. By pressing RESET button the DC voltage can be restored.
DS/30
CIRCUIT MONITOR TEST/RESET - This button tests the operation of the circuit monitor
lamps and also resets the monitor. Burned out lamps are easily identified by pressing the button
as it normally causes all lamps to light. In POWER-TRAK-R-SERIES unit LEDs are used in
place of lamps.
Lamps in the circuit monitor normally remain lit to help to identify a fault. Any fault will cause
DESCRIPTION
the circuit monitor to shut down the VIP power supply. To re-enable the VIP power supply, the
circuit monitor is reset, clearing the lamps. If the lamps do not turn off when the reset button
pressed and released, it means that the fault has not been cleared.
FURNACE WATER VALVES - These valves turn on supply water to the furnace. There is one
valve for each furnace selector switch or switch position. Generally, the valve is closed (off)
when the handle axis is vertical and open (on) when the axis is horizontal. Associated with each
valve is a positive action flow switch, interlocked through the circuit monitor, to shut down
the power supply if there is no flow in an active furnace.
FURNACE DRAIN MONITOR - Each water cooling returned from the furnace coil, and the
cabinet drain (if used), are monitored for temperature, both visually and with temperature
switch. The thermometers are located on a manifold, visible through a plexiglass panel. Each
return also has a shutoff valve to isolate the furnace for maintenance.
COIL MATCHING - In some lower KW units Electrically-operated contactors are provided

to add or subtract secondary capacitances so as to match various furnace coils. The controls
for these contactors are mounted in a small compartment in the control panel. The coil matching
door is interlocked to shut down the power to the furnace coil when it is open.
CABINET PRESSURE AND TEMPERATURE GAUGES - Several temperature and

pressure gauges are visible from outside the power unit. Generally their function is clearly
indicated.
2.8 GROUND/LEAK DETECTOR

Inductotherm VIP power units many times include a ground detector used to detect low ground
resistance in the electrical system. It is also used to give an indication of a molten metal leak
from the furnace to an electrical conductor (i.e., the coil).
The ground detector is located in the VIP power supply and is continuously in operation. It is
usually mounted in the door next to the controls. During operation, a meter indicates leakage
current from the electrical conductors to ground. A properly functioning system will always show
DS/31
some leakage. A zero reading on this meter indicates a fault in the ground detector sensing
circuit.
Test the Ground Detector prior to every heat. Press, and hold in, the "TEST" pushbutton. The
leakage meter reading should increase momentarily, the inverter will shut off, the red "CUR-
RENT TRIP" light will turn on, and the green "GLD ON" light will turn off. If the Ground
DESCRIPTION
Detector does not function properly, do not operate the power supply.
WARNING
THE GROUND DETECTOR IS A PRIMARY SAFETY DEVICE. NEVER OPERATE

THE UNIT WITH A FAULTY GROUND DETECTION SYSTEM.
Other controls on the ground detector are:
TEST BUTTON - This button puts an artificial ground on the ground detector to ensure that it
is functioning properly and will trip the unit.
SENSITIVITY ADJUST KNOB - This allows the ground detector to be de-sensitized (if needed)
to cure a new refractory linings.
WARNING
THE GROUND DETECTOR MUST ALWAYS OPERATE AT THE HIGHEST

POSSIBLE SENSITIVITY. CONTINUED OPERATION AT LESS THAN 100%
SENSITIVITY INDICATES EXCESSIVE GROUND LEAKAGE CURRENT IN THE
SYSTEM WHICH MUST BE CORRECTED.
RESET BUTTON - This resets the ground detector after a trip.
FURNACE (PROBE) DISCONNECT OR LEAK DETECTOR BY PASS - On systems with

furnace leak detectors, this control gives a verification of a molten metal leak condition. If a
ground fault is observed and this control clears the fault, it is a positive indication of a molten
metal leak to the coil. If this button does not clear the fault, however, there may still be a molten
metal leak.
Most of the furnaces for VIP power units are designed with leak detection capability. A furnace
leak detector consists of a probe connected through the refractory so that it contacts either the
molten metal or a pre-fired crucible. This probe is then connected back through the furnace by-
pass button to ground. Thus, any metal penetrating the lining or crucible and contacting the
furnace coil appears as a ground to the ground detector shutting off the power unit.
DS/32
WARNING
MANY FACTORS (LINING CONDITION, ETC.) INFLUENCE THE OPERATION

AND SPEED OF OPERATION OF THE LEAK DETECTOR. IT IS NOT A
FOOLPROOF INDICATION OF LEAKS OR LINING CONDITION, IF A LEAK IS
SUSPECTED AT ANY TIME, CEASE OPERATION AND EMPTY THE FURNACE.
DESCRIPTION
NOTE
WHEN INSTALLING LEAK DETECTOR PROBES IN FURNACE LINING, THE

PROBES MUST COME ALL THE WAY UP THROUGH THE LINING OR BACK-
UP MATERIAL SO THAT THEY CONTACT THE MOLTEN BATH, OR THE
EXTERIOR OF A PRE-FIRED CRUCIBLE.
The use of the leak detector probes with pre-fired crucibles does not provide a foolproof leak
detection system. With non-conducting crucibles, the system may not work at all. Even with
conducting crucibles, it may not always be possible to establish and maintain good electrical
contact between the crucible and the leak detector wire assembly.
DS/33
SECTION - 3 THEORY OF OPERATION

3.1 GENERAL
This section will describe the operation of the VIP system in general. Individual units may differ
in configuration, water supply, and installation requirements.
The inverter used in these system is tuned to provide the controlled medium frequency in these
units. With the input current fixed at 50 Hz, a variable frequency is required to achieve the better
power factor (resonance) described in introduction. This is accomplished by employing an AC-
OPERATION
THEORY OF
to-DC-to-AC conversion design that is described in paragraph 3.3.
Operation of the system is similar to other INDUCTOTHERM VIP system in that sensitive
components are protected by internal circuitry and a circuit breaker with quick response time.
Figure 3-1 is a simplified block diagram of the system.
Fig. 3-1 - Block Diagram
TH/34
3.2 CIRCUIT BREAKER RESPONSE

The 3 phase, 50 cycle input power is delivered to the fast-acting breaker that will trip within 20
milliseconds (msec.), and in higher KW unit an AC interrupter (ACI) will trip the unit within 6
millisecond (msec.) keeping fault current below failure levels.
However, even this unusually fast operation would not protect the diodes and SCRs of the
power unit from damage. A current limiting reactor is used to delay the onset of current peak
during short circuits or inverter misfires. This delay in the current peaks allow the circuit breaker/
ACI time to act before diode or SCR currents reach their tolerance limit. The valuable feature
of the power supply avoids the nuisance delays and cost of replacing expensive fast-acting
OPERATION
THEORY OF
fuses. Fuses are provided as a backup in the event of a circuit breaker malfunction, or shorting
of the three phase rectifier.
3.3 AC-DC CONVERSION

The first link in this AC-DC-AC design scheme is the AC-DC conversion accomplished by a
three-phase bridge rectifier. The semi-conductors (Diodes or SCRs) acting essentially as elec-
trical check valves, allow current flow only in the direction of the arrow upon which the symbol
is built. The output of the three phase bridge is a DC voltage with the 300 Hz ripple charac-
teristic of a three phase full-wave rectifier. The wiring diagram shows additional details of this
circuit. The RC snubber circuit across each semi-conductor suppresses high frequency noise
which occurs as the diodes break into and out of conduction.
Filtering of the three phase bridge output is contained in the DC link between the bridge and
the inverter input. The filter capacitor serve this function. Bleeder Resistors discharge the filter
capacitor when the equipment is turned off so that the capacitor charge does not remain as a
shock hazard to someone working on the equipment. The bleeder resistor reduces the residual
voltage to under 50 volts in less than five minutes after shutdown. The bleeder resistors are
located on the rectifier panel.
Units equipped with the AC interrupter (ACI) use high voltage hockey-puck SCRs to rectify AC
into DC. These SCRs are enabled by the ACI firing module, a part of the AC interrupter panel.
When enabled, the SCRs act like simple diode rectifiers as described above.
TH/35
Sensing circuit across the DC Bus and across the current limiting reactor sense faults in the
system and shuts down the ACI firing module. When not enabled, the SCRs turn off naturally
and block forward voltage. This, in effect, shuts down DC power to the inverter.
When the circuit breaker of the unit is originally energized, the ACI remains in the OFF state
with no DC voltage supplied to the inverter. The DC bus is energized by enabling the ACI firing
module (assuming all other interrupt conditions have been satisfied). Pressing the inverter OFF-
RESET button restarts firing pulses to the ACI after an inverter trip or shutdown. On start-up,
the ACI SCRs are pulsed at a low rate. This SOFT-START mode charges the filter capacitors
and bring the DC voltage to operating level with an inrush that is less than the normal operating
current and with minimum overshoot in the DC level. The ACI changes to its normal high pulse
OPERATION
THEORY OF
repetition rate as the normal DC level is approached. If, for any reason, the DC voltage rise is
not detected, the ACI will shutdown rather than switch to the high repetition rate at the end of
the soft-start cycle.
During trip conditions, the ACI shuts down, depriving the inverter of DC voltage. Before the unit
can be started up again, the OFF/RESET button must be depressed, enabling the AC inter-
rupter.
In some case, the main circuit breaker of the power unit will also trip during AC interrupter
operation. This is because of the very sensitive fast-acting circuit breaker which actually senses
the beginning of a fault condition and begins mechanical operation. However, the AC interrupter
will have extinguished virtually all DC voltage before these mechanical contacts of the circuit
breaker actually open and draw an arc.
3.4 CURRENT LIMITING REACTOR (CLR)

The current limiting reactor delays the current buildup that occurs under fault conditions allowing
the circuit breaker to open or to interrupt the DC volt by ACI and clear the circuit long before
current can reach the level that would damage SCRs and diodes.
The discharge diode(s) connected in parallel across the filter capacitors carries no current
during normal operation because it is reverse biased with its anode connected to the negative
bus and its cathode connected to the positive bus; thus providing a low impedance discharge
path in case a reverse charge appears across the capacitors.
TH/36
+Ve
3.5 INVERTER
DI/DT
REACTOR
The inverter described in this section consists of 1/2C TANK
SCR1 Lfce Rfce CAP
all of the components on the converter panel as- CR1
DC
sembly. This is the system circuitry required to CAP
CR2 SCR2
convert DC to medium frequency AC, and to con- 1/2C
trol the medium frequency AC current used in this

induction melting system.
Fig. 3-2 Inverter Schematic

OPERATION
THEORY OF
Inverter
Current 3.6 INVERTER SCR FUNCTIONS
Firing Pulse Figure 3-2 is a simplified schematic of the in-
SCR 1
verter with the input from the AC-DC conver-
sion replaced by a DC source and the output
SCR 1
Voltage circuit replaced by lumped elements of resis-
tance, capacitance, and inductance.
SCR 1
Current
As a first approximation, consider that the
Diode 1 SCRs are perfect switches, that is, that they
Current can be made to go from infinite resistance to
zero resistance (that is, open to short) instantly.
Firing Pulse
SCR 2 By triggering SCR No.1 into conduction at fixed
intervals and doing the same with SCR No.2
SCR 2 at other intervals, with the same repetition rate,
Voltage we could produce a rectangular wave of alter-
SCR 2 nating voltage related to the SCR triggers as
Current shown in Figure 3-3.
Diode 2
Figure 3-4 is a simplified circuit, extracted from
Current
figure 3-2, representing the current path
Fig. 3-3 through the inverter and furnace coil.
TH/37
CURRENT AND VOLTAGE RESPONSE OF AN RCL CIRCUIT
When SCR1 is gated into conduction state, half of the capacitors discharge through SCR1,
Ldi/dt, CP, Lfce, Rfce and CS1 generating 50% of the furnace current. The second 50% of the current
is produced by recharging capacitor CS2 via network + Ve, SCR1, CP, Ldi/dt, Lfce, Rfce, CS2, CF.
Due to the reactive nature of L, C, R circuit constituting both networks, the capacitors are
overcharged so that the current I in both loops changes direction. Since the SCR conducts
current of one polarity only, the inverse current flows through diode D1 by passing SCR1. In
the absence of Current, the SCR restores its isolation properties and after some time can
withstand full-rated voltage.
OPERATION
THEORY OF
+Ve
1/2 l 1/2 l
At this moment, SCR2 can be triggered over-
taking the D1 diode current and starting the
second half of the oscillation cycle. It is im-
TANK C1
CR1 SCR1 1/2 l
CAP perative not to fire the second SCR2 prior to
Cfce restoration of the isolation properties of SCR1.
Lfce Rfce
The control board assures this.
C2
1/2 l
When SCR1 and SCR2 are gated with inter-
vals close to 1/2 of the natural commutation of
1/2 l
-Ve the network, LFce, CP, CS1 and CS2, the inverter
Fig. 3-4 generates maximum output power.
When a SCR drops out of conduction, it must be protected against reapplication of forward
voltage for a minimum length of time, termed the turn-off time (TOT) while it resets or latches
itself in the off or forward blocking state. Each of the SCRs in the inverter are paralleled by a
diode which allows a flow of current around the SCR for an interval equal to or greater than
the required TOT.
During the TOT interval, the SCR is protected from the forward voltage by the anti-parallel
diode. This turn-off time or minimum relatch time becomes one of the most important param-
eters within which the inverter must operate. Any attempt to operate with too short a TOT will
result in inverter misfire and circuit breaker or ACI tripping.
With provisions made for reverse bias to provide adequate TOT, our inverter will now operate
at a given frequency if we supply alternate pairs of SCRs with gating pulses, that have the
proper frequency and time phase fig. 3-3 shows the gating pulses, their relationship to the SCR
current wave forms and the composite wave forms.
TH/38
Most of the other circuitry beyond the simple SCR and diode arrangement is associated with
the characteristics of the SCRs which determine the operating parameters of the inverter.
These are:
1. Forward blocking voltage.
2. Maximum current.
3. DI/DT, the rate of change of current with respect to time.
4. DV/DT, the rate of change of reapplied voltage with respect to time.

OPERATION
THEORY OF
If the SCR is subjected to too high a forward voltage, it will conduct without a gate signal
applied and may fail.
The inverter is designed to operate well below the maximum current that the SCR can safely
handle. Protection is provided to limit the inverter current demand of the load approaches the
maximum current capability of the SCRs.
The rate of current rise when the device is triggered must be controlled, if the rise in current
is too (rapid), the devices could be damaged. A DI/DT reactor is incorporated to control change
in current with respect to time to a safe level.
If the rate of rise of the reapplied forward voltage is too high, an SCR will break into conduction
without a gating pulse. The RC network in parallel with each SCR is a combination snubber
circuit and voltage equalizing circuit. This circuit controls the rise of reapplied forward voltage.
3.7 THE ISOLATION TRANSFORMER

In all secondary isolated (SI) units, the inverter is coupled to the tank circuit by an isolation
transformer. The inverter output is matched by the turns ratio of this transformer to produce the
levels required to drive the furnace coil. Transformer isolation is necessary to protect both the
furnace and other equipment from potentially destructive ground fault loops.
Some large units use an isolation transformer in the 50 Hz incoming line. It is required that this
transformer be dedicated to the one power supply only. Which has a electrostatic shield be-
tween primary and secondary winding.
TH/39
3.8 THE TANK CIRCUIT

The tank circuit consists of the furnace coil and its capacitors. The capacitors tune the circuit
to resonate at design frequency. They also correct power factor to reduce inverter current.
3.9 CAPACITORS
High frequency water-cooled capacitors are rated at maximum operating frequency, maximum
continuous working voltage and maximum KVAR. The operating conditions may be varied over
a wide range as long as these limits are not exceeded. Capacitors operated continuously for
Max. voltage during a melt cycle is harmful to capacitor & circuitry. DC capacitors are also rated
OPERATION
THEORY OF
for maximum working current (amps.).
TH/40
SECTION - 4 TEST PROCEDURE - START-UP

4.1 GENERAL
This section covers test procedure and start-up requirements for the VIP system. The actual
procedure is usually performed by INDUCTOTHERM service engineer. It is recommended that
customer maintenance and operating personnel assist in this operation in order to complete the
tests quickly and gain experience in operating the unit during a melt cycle. The training should
qualify individuals as system operators and familiarize qualified maintenance personnel with
routine maintenance and service procedures.
WARNING
ALL CHECKOUT AND TEST PROCEDURES, SPECIFIED IN THIS SECTION

SHOULD BE ATTENDED BY MAINTENANCE PERSONNEL TRAINED BY
INDUCTOTHERM OR PREFERABLY IN THE PRESENCE OF INDUCTOTHERM
PROCEDURE
SERVICE ENGINEER ONLY.
TEST
4.2 CONTROL POWER AND INTERLOCK CHECK
Before applying main power to the unit, the control circuit should be checked. The units have
internal control transformers to provide control power. Some systems have independent sources
of main power and auxiliary or control power. To engage only the controls on a system with all
power coming from a single main circuit breaker, it is necessary to remove the power fuses as
described below. Control checks are:
1. Inspect unit for signs of loose or damaged components. Re-torque all bus and wiring
joints. Do not proceed until all transit damage has been repaired and all connections are
tightened.
2. Remove power fuses from the three phase bridge panel(s).
3. Open water shut-off valve (customer furnished).
4. Check water pressure gauge. Pressure should be between 40 and 60 PSI (2.8 and 4.2
BAR) with all furnaces operating at full flow.
5. Check water temperature gauge. The temperature should be below what mentioned in the
name plate.
ST/41
6. Check the rotation of the internal pump by "Jogging" the starter. Be sure that the internal
system reservoir is properly filled before starting the pump.
7. Check all indication of Monitor Board and interlocking system operation.
8. Place circuit breaker switch in "ON" position. The circuit breaker can only be enabled
when the doors are closed. When a cabinet is open, the door interlock disables the circuit
breaker.
NOTE
INDIVIDUAL INSTALLATIONS MAY REQUIRE SPECIFIC TEST PROCEDURES

NOT COVERED IN THIS SECTION. REFER TO DRAWINGS AND DATA
FURNISHED WITH THE UNIT. REQUEST ADVICE FROM INDUCTOTHERM
ENGINEER IF THERE IS ANY DOUBT CONCERNING THIS INSTALLATION.
SCR OVP AND ACI RESET INTERLOCK SYSTEM (WHEREVER INSTALLED)

PROCEDURE
CHECKS SHOULD BE PERFORMED BY INDUCTOTHERM SERVICE

TEST
ENGINEER OR BY AN AUTHORISED ENGINEER ONLY.
4.3 AC INTERRUPTER CHECKS

The procedures and precautions outlined in Section 4.4, Control Board Check(s), should be
read and followed when checking out the ACI. The following checks should be made after ACI
maintenance or on initial start-up. The following check is made with the control power key lock
ON but with the unit circuit breaker(s) OFF.
1. Before depressing "off-reset" button, check for 24VDC available between pins 3 and 4,
and 5 and 4 on TB-103 of the ACI module. Pins 3 and 5 should be positive with respect
to pin 4 (common).
2. Check for-15VDC between pins 2 and 4 and + 15 VDC between pins 10 and 4 on TB 103
of the ACI module.
3. Depress the OFF-RESET button to start the ACI. All the green LED's on the ACI SCR
firing module should begin to blink at a rate of about 2.5Hz. Verify that the blinking stops
after about one minute.
4. Turn OFF the control power key switch for one minute.
5. Repeat steps 1 through 4 for additional ACIs as required.
ST/42
6. Turn control power key lock switch OFF for one minute.
7. Turn control power key lock switch ON.
8. Set circuit breaker to the ON position.
CAUTION
HIGH VOLTAGE WILL BE PRESENT IN THE POWER SUPPLY WHILE THE

FOLLOWING CHECKS ARE MADE. ALL DOORS SHOULD BE CLOSED
EXCEPT THOSE REQUIRED TO GIVE ACCESS TO THE ACI.
9. Depress the OFF-RESET button. The LEDs on the ACI SCR firing modules should blink
at 2.5 Hz for a short time before coming on bright. This indicates that the ACI has
transitioned from soft start to hard firing in response to the rising voltage on the DC bus.
10. Place circuit breaker in the OFF position and switch control power key switch to off.
PROCEDURE
CAUTION
TEST
ALLOW 5 MINUTES FOR FILTER CAPACITORS TO BLEED OFF BEFORE
PROCEEDING WITH ADDITIONAL CHECKS. VERIFY BLEED-OFF WITH
METER OR SHORTING STICK.
4.4 CONTROL BOARD AND FREQUENCY SETTING CHECK

These checks should be performed by a trained and qualified factory service engineer.
NOTE
WATER FOR COOLING IS NOT REQUIRED DURING THIS CONTROL

CHECKS. HOWEVER, IF COOLING WATER IS NOT SUPPLIED, WPS1 MUST
BE JUMPERED TO MAINTAIN CONTROL CONTINUITY.
CAUTION
BE SURE THAT THREE PHASE POWER FUSES ARE REMOVED PRIOR TO

PROCEEDING WITH THE FOLLOWING ADJUSTMENTS. FAILURE TO
OBSERVE THIS CAUTION COULD RESULT IN INVERTER COMPONENT
FAILURE.
This procedure should be followed whenever a new control board is installed or for initial start-
up of a new unit. The following control board checks may be made without applying primary
ST/43
power to the unit.
The following procedure requires a multimeter (Simpson Rs-260 or similar) and an oscilloscope.
Measure control board voltages as follows:
CAUTION
MOST OSCILLOSCOPES USED A CHASSIS GROUND. THESE SCOPES CAN

GET DAMAGED UNLESS THEY ARE ISOLATED FROM GROUND PRIOR TO
BEING USED FOR MEASUREMENTS ON THE UNGROUNDED HIGH
VOLTAGE CIRCUITS OF THE POWER-TRAK-R. THE SCOPE CHASSIS
MUST BE ISOLATED FROM GROUND.
WARNING
WHEN USED TO MEASURE VOLTAGES IN THE POWER-TRAK-R- SERIES

SYSTEM, THE SCOPE CASE AND CHASSIS WILL BE AT AN ELEVATED
PROCEDURE
VOLTAGE WITH RESPECT TO GROUND. EVEN THE SET SCREWS ON THE

CONTROL KNOBS PRESENT A SHOCK HAZARD.
TEST
ALL SCOPE CONNECTIONS AND ADJUSTMENTS SHOULD BE MADE WITH

MAIN SYSTEM POWER OFF. IF A MINOR SCOPE ADJUSTMENT MUST BE
MADE WITH POWER ON THE UNIT, THE TECHNICIAN SHOULD STAND ON
A RUBBER MAT OR A DRY BOARD TO ISOLATE HIMSELF FROM GROUND.
THE USE OF CERTIFIED INSULATING GLOVES IS ESSENTIAL. EACH TIME
POWER IS INTERRUPTED TO CHANGE SCOPE CONNECTION OR
ADJUSTMENTS, UP TO 5 MINUTES IS REQUIRED FOR THE CHARGE ON
CAPACITORS TO DRAIN OFF COMPLETELY.
THE USE OF A SHORTING BAR WITH AN INSULATED HANDLE IS

RECOMMENDED TO ENSURE THAT THE CHARGE HAS BEEN BLED OFF.
MULTIPLE FAILURES WITHIN THE EQUIPMENT WOULD HAVE TO OCCUR
FOR THE HAZARD TO EXIST, HOWEVER THE USE OF A GROUNDING STICK
ELIMINATES EVEN THIS REMOTE POSSIBILITY. USE OF A MULTI CHANNEL
SCOPE IN THE DIFFERENTIAL MODE ELIMINATES THE LIVE CHASSIS
HAZARD. MAKE TEST CONNECTIONS TO THE UNIT WITH TWO SEPARATE
PROBES FROM WHICH THE GROUND LEADS HAVE BEEN REMOVED.
ON THE DUAL CHANNEL AMPLIFIER, PLACE THE DISPLAY MODE SELECT

SWITCH TO "ADD" AND INVERT CHANNEL TWO. THIS IS THE ONLY SAFE
METHOD OF MAKING SUCH MEASUREMENTS. REFER YOUR
OSCILLOSCOPE MANUAL FOR DETAILS ON DIFFERENTIAL MODE OF
OPERATION.
ST/44
NOTE
WHEN MAKING MEASUREMENTS IN THE STEPS THAT FOLLOW, THE

PROCEDURE BELOW SHOULD BE USED :
A. DE-ENERGIZE THE UNIT.
B. CONNECT TEST EQUIPMENTS AS DESCRIBED.
C. RE-ENERGIZE THE UNIT AND PERFORM THE TEST.
D. DE-ENERGIZE THE UNIT AND DISCONNECT THE TEST EQUIPMENT.
4.4 [1] TEST PROCEDURE FOR POWER-TRAK
1. Remove the main fuses.
PROCEDURE
2. Measure +24 VDC ± 1.2 volts from TB-103 pin 10 to TB-103 pin 9 (Pin 10 is the positive
TEST
terminal; pin 9 is negative).
3. Measure -24 VDC ± 1.2 volts from TB-103 pin 11 to TB-103 pin 12. (Pin 11 is the positive
terminal; pin 12 is the negative terminal.)
4. If voltages are not as specified, check for loose or broken wires. Replace or repair as
required. An additional check may be made at the DC power supply (See VIP control
wiring diagram).
5. Reset the circuit monitor, GLD and ACI (If provided), then depress the inverter ON button.
The control relay should energize. The "reduced power" lamp should be lit. Depress the
inverter OFF button.
6. a) Connect a scope to observe the output at terminals 1 and 2 of TB-102, with pin 2,
the scope common.
b) Press the inverter ON button. Check for an output as indicated in Figure 4-1. This
output starts approximately one second after the button is de-pressed. The output
should be positive going to at least 16 volts amplitude with a pulse width of approx-
imately 15 microseconds. These are the firing pulses which cause SCR firing.
ST/45
c) With the "Power Control Knob" fully counterclockwise, for a pulse repetition time
(between pulse) that corresponds to minimum frequency. Appropriate times and
waveforms are shown in Figures 4-1.
7. a) Check terminals 3 and 4 on TB-102 for an output similar to that observed at pins
1 and 2. If a Dualtrak scope is used, the two signals can be displayed simultaneous-
ly, as illustrated in Figure 4-1. They will be 1800 out of phase. That is the output from
pins 3 and 4 will appear at the midpoint of the time interval between the pulses from
pins 1 and 2.
b) Turn the control knob fully clockwise.
c) Check for a pulse repetition time corresponding to the desired high frequency.
8. With the frequency at limit, frequency meter should show redline frequency. Adjustment
is proper when the frequency meter indicates frequency limit as per name plate.
PROCEDURE
TEST
9. Rotate the control knob through its full range rechecking idle frequency, limit frequency
calibration and frequency limit light operation.
10. Reinstall the main fuses.
(BOTTOM SCR)
Fig. 4-1 Control Board Firing Pulse Output
ST/46
4.4 [2] TEST PROCEDURE FOR POWER-TRAK-R
1. Control power key switch ON.
NOTE: SEE CONTROL WIRING DIAGRAM FOR TERMINAL DETAILS.
2. Measure +24 VDC ± (1.2) volts from DC power supply, to the control board & all
modules.
3. Measure -24 VDC ± (1.2) volts from DC power supply, to the control board & all modules.
4. If voltages are not as specified, check wiring for loose or broken wires. Replace or repair
as required. An additional check may be made at the DC power supply ( See VIP control
wiring diagram).
5. Observe LEDs glowing on the control board & modules provided for healthy supply.
PROCEDURE
6. Reset the circuit monitor, GLD and ACI (if provided).
TEST
7. a) Connect a scope to observe the output at Terminals 1 and 2 of TB-102 with pin 2,
the scope common.
WARNING
HIGH VOLTAGE WILL BE PRESENT IN THE CABINET FROM THIS POINT

ON. ALL DOORS EXCEPT THE CONTROL DOOR (THE DOOR WITH THE
METERS ON IT) SHOULD BE CLOSED BEFORE PROCEEDING.
b) Remove the fanning strip from TB 102 of the control board and support it so that
it does not touch the terminal strip or the cabinet skin or frame.
c) Close the unit circuit breaker. Press OFF-RESET to reset the ACI.
d) Press the inverter ON button. Check for an output as indicated in Figure 4-1. This
output starts approximately one second after the button is depressed. The output
should be positive going to atleast 16 volts amplitude with a pulse width of approxi-
mately 15 microseconds. These are the firing pulses which cause SCR firing.
e) With the "Power Control Knob" fully counterclockwise, for a pulse repetition time
(between pulses) that corresponds to an idle frequency. Appropriate times and
waveforms are shown in figures 4-1.
ST/47
8. Check Terminals 3 and 4 on TB-102 for an output similar to that observed at pins 1 and
2. If a Dualtrak scope is used, the two signals can be displayed simultaneously, as
illustrated in Figure 4.3. They will be 1800 out of phase. That is, the output from pins 3
and 4 will appear at the midpoint of the time interval between the pulses from pins 1 and
2.
4.4 [3] GROUND-LEAK DETECTOR START-UP
1. Ensure that the ground detector is installed and wired correctly.
2. Ensure that the ground wire connections (G) are properly connected to a solid cabinet
ground. DO NOT connect this wire to a hinged door ground.
3. Turn ON control power. Unit should come on in tripped mode.
The RED "current trip" light will be ON.

PROCEDURE
The RED "voltage trip" light may or may not be ON.

TEST
The GREEN "GLD ON" light will be OFF.
5. Leakage current as read on the meter should be low if no high leakage paths are present;
about 3-5 mA is typical.
6. Observe that the polarity reversing circuit is operating. The leakage current will drop to
zero momentarily as the polarity is reversed. This occurs every 20 seconds.
7. Depress the test button. Unit should trip.
GREEN "GLD ON" light turns OFF.
RED "current trip" light turn on.
Milliamps momentarily go to about 90 and then drop to zero. The increase to 90 may not
be noticeable on the meter. (with sensitivity pot on 0%)
8. Depress reset button for one second.
RED "current trip" light turns OFF.
GREEN "GLD ON" light turns ON.
ST/48
9. Jumper the furnace bus to a suitable ground point. Unit should trip.
10. Depress and hold in reset button. Milliammeter should read approximately 90 mA.
Release reset button.
11. Remove ground on furnace bus.
12. Reset ground detector.
13. During normal operation keep sensitivity knob on 100%. So as to trip at 60 mA. leakage
current.
PROCEDURE
TEST
ST/49
SECTION - 5 NORMAL OPERATING PROCEDURES

5.1 GENERAL
This section outlines the normal procedure for starting up a VIP system, for making heats and
for shut down. Because systems vary greatly in type of installation, type of furnaces and type
of cooling system This section is very general.
Some operator procedures for abnormal condition are suggested at the end of this section.
However, each customer must review their own needs and develop specific emergency proce-
dures based on their own unique installation and requirements.
5.2 DAILY START-UP

1. Turn water on.
2. Inspect lining and patch as necessary. When the lining is proper, then charge the furnace.
CAUTION
- USE ONLY DRY CHARGE MATERIAL.
PROCEDURE
OPERATING
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 VAPORIZE
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. Set the furnace selector switches (where installed) for operation on the desired furnace
and open the corresponding water valve fully to the furnace.
4. Turn the control power key on (if provided) and Close the main circuit breaker.
5. Reset the circuit monitor, earth/leak detector. Reset ACI, then push the start button.
OP/50
6. Turn the control knob potentiometer to the full clock-wise position for full power operation.
The system will automatically maintain the highest allowable power without further adjust-
ment of the controls.
7. If lesser power for melting is needed, set the desired KW output by observing the KW
meter as the control knob is turned.
8. During melting, following limits may be observed. This is not a fault condition. The inverter
will not trip. But the limit will not allow and further increase in power. When full power is
drawn 'Full Power' limit should glow. If any constraint like frequency, voltage, current, TOT
occurs, then proceed as follows :-
a. INVERTER ON (REDUCED POWER) - This indication says that the unit is deliver-
ing power but not fully. This will be ON when no other limit will be present. In
POWER TRAK-R "INV ON" light will be on when inverter will on.
b. FULL POWER - The green light - is on when the inverter is at full power.
c. FREQUENCY LIMIT - This light indicates that maximum frequency has been reached.
d. VOLTAGE LIMIT - This light indicates that the charge is not sufficient in the
furnace. To eliminate this limit "add metal".
PROCEDURE
OPERATING
e. CURRENT LIMIT - This light says you have reached maximum current. Also verify
the MELT dia and height.
f. TOT LIMIT (EXCESS CHARGE) - This light indicates you have reached minimum
TOT. To eliminate this limit reduce the power till the limit goes OFF and try to
increase it after a little time. It is not advisable to add any more scrap (metal) during
TOT limit.
g. NORMAL OPERATION - With the system operating in a normal melt cycle, all
(other than INV ON & Full power) lights are extinguished.
9. Proceed with daily melting.
10. Test the Ground Leak Detector prior to every heat.
If the Ground Leak Detector does not function properly, do not operate the power supply.
Call Inductotherm's Service Engineer.
OP/51
5.3 TURN OFF

When melting operations are complete:
1. Turn control knob to zero.
2. High frequency control push button OFF.
3. Turn circuit breaker OFF and Turn the control power key switch OFF.
4. Allow water to circulate through the furnace coils to prevent thermal shock and coil
damage until refractory is cool.
NOTE
OBSERVE ALL SAFETY PRECAUTIONS. WHEN MELTING OPERATIONS ARE

COMPLETED, BE SURE THAT THE MAIN POWER RED LIGHT IS
EXTINGUISHED. REFER TO THE TROUBLE SHOOTING SECTION OF THIS
MANUAL IF FAULTS ARE EXPERIENCED. CABINET DOORS SHOULD BE
KEPT LOCKED DURING NORMAL OPERATION.
5.4 ABNORMAL OPERATIONS
PROCEDURE
OPERATING
1. POWER FAILURE - The U.V. trip on the circuit breaker will automatically shutdown the
VIP power supply. See section 7.4 on Trouble Shooting for detailed procedures.
2. WATER PRESSURE FAILURE - The VIP will automatically shutdown. If the furnace coil
is hot, minimum water flow must be re-established within minutes to prevent damage to
equipment and possible personnel hazard from steam.
3. HIGH COOLING WATER TEMPERATURE - Try to reduce power before the unit trips and
continue operations at reduced power while trouble shooting.
After a "trip" it may be necessary to allow a considerable period for water to cool-down.
Troubleshooting and corrective procedures for other abnormal conditions are covered in the
"Safety Precautions," "Troubleshooting," and "Maintenance": sections. Generally, these proce-
dures are to be undertaken only with the direction of qualified maintenance and supervisory
personnel.
OP/52
SECTION - 6 MAINTENANCE
6.1 GENERAL
VIP system requires very little routine maintenance. However, systematic scheduled attention
to general inspection, cleaning and adjustments can prevent equipment failure and loss of
production time. The following maintenance schedule should be used as a guide for this pro-
cedure. This schedule is summarized in figure 6.1
Except for visual checks of the meters and lights on the outside of the VIP cabinet, all trouble-
shooting, maintenance, and repair must be performed by a qualified maintenance person. This
qualified maintenance person must be able to recognize "shock hazards" and be trained in the
safety precautions required to avoid possible injury or death.
WARNING
DO NOT PERFORM ANY MAINTENANCE ON THE SYSTEM WITH POWER

ON. PLACE CABINET PANEL INVERTER (RED) SWITCH OFF. BE SURE
CAPACITORS ARE DISCHARGED AND CIRCUIT BREAKER IS LOCKED
OFF AND TAGGED. CONTROL POWER KEY SWITCH "OFF". REMOVE AND
RETAIN KEY.
6.2 DAILY (VISUAL INSPECTIONS AND CHECKS)

1. Check for and correct external water leakage.
MAINTENANCE
2. Check for and correct internal water leakage.
3. Bus bar to furnace - look for signs of severe discoloration.
4. Cleanliness at furnace-do not allow slag to touch furnace leads.
5. Check general cleanliness at cabinet exits.
6. Check integrity of power cables feeding the VIP power supply.
7. Check lining condition and patch it, if required.
8. Check water level in all water tanks.
9. Remove scrap under the furnace and keep the working area clean.
MN/53
6.3 MONTHLY (EXTENSIVE CHECKS, CLEANING, AND MAINTENANCE)

1. Blow or vacuum out any dust that has accumulated in the cabinet. Using an industrial
vacuum cleaner with a small point brush (or a dry cotton) to loosen the dust from corners
is the preferred method. Care must be taken not to dislodge control wiring or damage
components.
NOTE
DO NOT USE COMPRESSOR AIR TO CLEAN ELECTRONIC CARD/MODULE

AS IT MAY CONTAIN OIL/WATER PARTICLE WHICH IS HAZARDOUS TO
ELECTRONIC CIRCUIT.
2. Wipe all contactor, selector switch blades and check for burrs or pitting that may be the
result of arcing.
3. Clean the furnace selector switches with CTC or thinner and re-lubricate the same with
a very thin film of a good grade electrical grease.
4. Inspect all cables and bus for loose connections, signs of overheating, or discoloration,
particularly the connection of the circuit breaker, External Busbar, Furnace Selector
Switch etc.
5. Inspect all water connections for signs of leaks. Retighten connections, fitting, or hose
clamps as may needed. For persistent drips, it may be necessary to add an additional
hose clamp. Use only all stainless (including worm gear) hose clamps.
MAINTENANCE
6. Check conductivity of water in internal (Distilled) & external (DM/Soft) water system. Test
procedures are described in Section 6.4.
7. Check all control wiring for loose connections. Pay particular attention to connections at
the control relay.
8. Inspect furnace for general condition. Inspect furnace leads. See that they move freely
without excess rubbing or abrasion.
9. Check for oil leakage in Hydraulic Circuit. Retighten all connections. Pay particular atten-
tion to connections at cylinder and bi-directional valve.
MN/54
NOTE
MAINTENANCE PERSONNEL SHOULD GO THROUGH THE DAILY CHECK

WITH THE OPERATOR ATLEAST ONCE A MONTH.
10. Before returning the unit to operation, check to make sure that the door interlocks are
working properly. The breaker should not turn ON with the cabinet door open.
11. Before returning the unit to operation, make sure that any jumpers and temporary trouble-
shooting connections have been removed. Failure to do so could subject operating per-
sonnel to hazards. Be sure that all cabinet doors are properly locked.
NOTE
THE FOLLOWING PROCEDURES DESCRIBES REMOVAL AND

REPLACEMENT OF COMPONENTS. DO NOT REMOVE ANY EQUIPMENT
PRIOR TO NOTING ITS EXACT LOCATION. TAG OR LABEL EACH UNIT
PRIOR TO REMOVAL. UNLESS ADVISED OTHERWISE BY OFFICIAL
BULLETINS OR INSTRUCTIONS, REPLACE ALL LIKE ITEMS WITH SIMILAR
UNITS.
6.4 ROUTINE MAINTENANCE

GO/NO-GO METHOD OF MEASURING THE RESISTANCE OF WATER
When a conductivity tester is not available, a rough method of determining if the water in the
closed system is acceptable can be made using a Simpson 260 Multimeter or equivalent. Any
clean, insulated container (a drinking glass, for example) can be used. Add the water to be MAINTENANCE
tested to the level shown below and insert the meter leads as shown in figure 6-2.
When using alligator clip leads, press them firmly together with the jaws adjacent. The biting
edge of the jaws should be in line, like they would be if connected to a piece of sheet metal.
The distance between them should be 1/4" (0.64 cm). Immerse them in the water 0.4"(1 cm)
and read the ohmmeter on the R X 10,000 scale.
MN/55
ROUTINE MAINTENANCE
FOR DETAILS REFER TO VIP SYSTEM MANUAL
Daily as Req Monthly Qtrly Semi-annually Annually DATE NAME
1. CHECK RE-FRACTORY LINING BEFORE MELTING X
2. VACCUUM CONTROL & POWER CABINET(WHERE APPLICABLE) X
3. RETIGHTEN & CHECK ALL ELECTRICAL CONNECTIONS * X X
4. RETIGHTEN & CHECK ALL BUS BAR CONNECTIONS * X X
5. RETIGHTEN & CHECK ALL WATER HOSE CONNECTIONS * X X
6. CHECK & LUBRICATE FURNACE SELECTOR SWITCHES * X X
7. CHECK OPERATION OF WATER PRESSURE AND WATER X

TEMPERATURE SWITCHES.
8. CHECK OPERATION OF FURNACE WATER FLOW SWITCHES X
9. CHANGE DEIONIZER CARTRIDGE X X
10. CHANGE CLOSED SYSTEM H20 & WINTERIZED W/ETHYLENE

GYCOL (WHERE APPLICABLE) X
11. INSPECT CAPACITOR CONTACTORS(WHERE APPLICABLE) X
12. INSURE OPERATION OF DOOR INTERLOCKS X
13. CHECK CIRCUIT BREAKER CONNECTIONS (DISCONNECT

MAIN POWER) & MECHANISM * X X
14. CHECK OPERATION OF INDICATING LIGHTS X
15. CLEAN, TIGHTEN BELT, OIL FAN BEARINGS ON COOLING
TOWER X
16. BACKWASH, SAND FILTER X
17. CLEAN WATER TANK, GREASE PUMP BEARINGS ON WATER

SYSTEM X
18. CHECK HYDRAULIC OIL LEVEL X
19. REPLACE HYDRAULIC OIL FILTER X
20. CHECK INTERNAL & EXTERNAL WATER LEVELS & LOOK

FOR WATER LEAKS X
21. KEEP WATER AREA CLEAN & ACCESS TO POWER UNIT X
22. INSPECT FURNACE - WATER POWER & MECHANICAL

CONNECTIONS X
23. CHECK OPERATION OF GROUND DETECTOR X
* Indicates for first 3 months of operation, quarterly thereafter.

ALLIGATOR CLIP PIN PROBE
Fig. 6-2
When using the pin-type probes, hold or tape them together. The distance between the pins
should be 0.4" (1 cm). Again, immerse them in the water 0.4 (1 cm) and read the ohmmeter
on the R X 10,000 scale. The chart on the following page can be used to convert ohms to
micromhos. The water conductivity should not exceed 20 micromhos. If it exceeds 20 micromhos,
water should be changed. If conductivity reaches 100 micromhos, water should be changed
along with the deionizer cartridge.
ALLIGATOR CLIP PIN PROBE

OHMS MICROMHOS OHMS MICROMHOS
350K 1.5 550K 1.5
180K 3.0 260K 3.0
105K 5.0 190K 5.0
70K 9.9 120K 9.0
50K 10.0 110K 10.0 MAINTENANCE
24K 25.0 60K 20.0
14K 55.0 38K 55.0
9K 85.0 24K 85.0
8K 100.0 23K 100.0
7.7K 125.0 21K 125.0
7K 150.0 20K 150.0
6K 200.0 19K 200.0
5.5K 250.0 18K 250.0
5K 300.0 17.5K 300.0
4K 500.0 16K 400.0
MN/57
6.5 REMOVAL AND REPLACEMENT OF COMPONENTS

6.5 [1] STUD-MOUNTED DIODE REPLACEMENT
1. Remove the old diode by removing the cap screw from the pig tail and the nut from the
stud.
2. Clean the surface of the heat sink that will contact the diode base and polish out any
nicks or burrs.
3. Use a Simpson meter on the R X 1 scale to check the new device prior to installation.
The meter should read 5 to 10 ohms with the diode forward biased (anode positive with
respect to base) with the anode of the device biased negative with respect to the base,
the ohmmeter should read essentially open on the R X 1 scale. The polarity of the new
device may be indicated by a diode symbol on the device as shown.
Anode Cathode
Devices with the diode anode connected to the stud may also be marked with a black
boot where the pig tail enters the device holder. Devices with the pig tail connected to
the anode may have red boots at the device end of the pig tail.
MAINTENANCE
4. Apply thermal grease (Wakefield Thermal Compound Type 120, Dow Corning Silicone
Heat Sink Compound, or Thermally Thermocote) to the base of the diode. Be careful not
to smear the grease on the threads of the stud. This coating should be thin. Excess
compound will cause high contact resistance between the diode and its heat sink.
5. Reinstall the diode by bolting the pig tail to its bus and replacing the star lock washer
and nut on the stud. Tighten the nut on the diode stud to the correct inch-pounds of
torque. Do not allow the base diode to turn. Tighten the nut while holding the base.
6. Rectifier and discharge diodes should be tightened to 300 inch-pounds; SCR heat sink
diodes to 150 inch-pounds.
MN/58
CAUTION
OVER-TIGHTENING THIS NUT CAN DAMAGE THE DIODE ASSEMBLY. TOO

LITTLE TORQUE WILL GIVE POOR THERMAL AND ELECTRICAL
CONDUCTIVITY FROM STUD TO HEAT SINK AND CAUSE PREMATURE
FAILURE OF THE DEVICE.
6.5 [2] REPLACEMENT OF DISK TYPE DIODES AND SCRs
The clamp assemblies used for VIP disk type SCR's and diodes are designed to permit the
changing of individual devices without removing the clamp assembly from the inverter. Figure
6-3 illustrates a clamp with various parts identified.
MAINTENANCE
Fig. 6-3 SCR and Diode Assemblies
N O T E S :
[1] ILLUSTRATION SHOWS SCRs & DIODES MUST BE INSTALLED WITH CATHODE RING ON
OPPOSITE SIDE. THE DIODE CATHODE WILL BE NEARER THE STUD BAR 4 REFER TO THE
MAINTENANCE MANUAL.
[2] Ns IS THE NUMBER OF SPRING BARS IN THE SPRING ASSEMBLY, FOR THE TWO BAR
ASSEMBLY SHOWN, Ns=2 AND THE INDICATIONS REPRESENT ZERO,4000,6000,8000 POUNDS.
MN/59
Proper size fixed wrenches are required to replace a disk type device. However, great care
must be taken to produce an assembly with high electrical and thermal conductivity between
devices and the chill blocks. All mating faces between chill blocks and devices must be free of
foreign matter, oxides, and films. It will be necessary to clean the area of the assembly with
compressed air or a vacuum cleaner before starting to disassemble the clamp. Dirt dislodged
from adjacent surfaces can contaminate the pole faces of the chill blocks and the new devices.
To ensure satisfactory results, the following procedure is recommended :
6.5 [3] REMOVAL OF THE DEFECTIVE DEVICE
1. Note the orientation of the device in the clamp. The replacement device must duplicate
the orientation of the original. In general, the cathode of an SCR will face the spring
assembly of the clamp and the antiparallel diode cathode will face the stud bar.
Several methods are used to identify the cathode of a device. In the case of the SCR,
the red lead is usually fastened to the cathode with the white wire of the pair going to the
gate. In any case, the cathode will have a lead connection, whereas the anode will not.
A metal fin, noticeably large in diameter than the body of the device, indicates the cathode
end. This is identified as the cathode ring in figure 6-3. Many devices also display the
diode symbol on the devices with point of the arrow indicating the cathode end.
CAUTION
INSTALLATION OF A DEVICE WITH REVERSED ORIENTATION WILL

REVERSE THE POLARITY OF ITS BIAS VOLTAGES. DESTRUCTION OF THE
MAINTENANCE
DEVICE AND DAMAGE TO OTHER CIRCUIT COMPONENTS CAN RESULT.
2. Remove the clamp stud nuts from the clamp studs.
3. If the device to be replaced is the upper one in an assembly, loosen the upper heat sink
mounting flange bolt. This will allow the stud bar to be lifted upward to allow the upper
chill block to be moved up and away from the power tab chill block for removal of the
device. If the defective device is the lower one in a clamp, loosen the lower heat sink
mounting flange bolt. This will allow the lower chill block to be moved down and away from
the power tab chill block to allow removal of the device.
4. (For SCR replacement only). Disconnect the red and white gate leads at the firing module
noting carefully their respective positions on the terminal block.
MN/60
CAUTION
INTERCHANGING THE RED (CATHODE) AND WHITE (GATE) LEADS

RESPECTIVELY WILL CAUSE SCR MISFIRING, WHICH CAN RESULT IN
DAMAGE TO SCR AND OTHER COMPONENTS.
5. Carefully spread the chill blocks on either side of the device to allow the device to be lifted
clear of the centering pins (IIP # FHAD0804).
6. Remove the device from between chill blocks being careful not to scratch the pole faces
on the centering pins that project from the face of each chill block.
6.5 [4] HEAT SINK SURFACE PREPARATION PRIOR TO ASSEMBLY
1. Using a clean Scotchbrite pad, polish the pole-face contact area of both chill blocks with
a combination of back and forth, side to side, and circular motions.
2. Wipe both surface for cleanliness and smoothness. Heat sinks with deep scratches that
cannot be polished out must be replaced.
6.5 [5] DEVICE SURFACE PREPARATION PRIOR TO ASSEMBLY
1. Clean anode and cathode faces with a clean Scotchbrite pad using a figure eight motion
pattern. Use light pressure. If the copper surface beneath the plating is exposed, the
device must be rejected.
MAINTENANCE
2. Dust the pole faces with lint-free paper.
3. Apply a thin film of silicone oil (GE SF 1154) or the equivalent to both pole faces.
Wakefield Thermal Compound, type 120 Dow (IIP # FCOM0506) corning silicone Heat
Sink Compound, type 340, or Thermalloy Thermacote may also be used. If any of the
compounds are used instead of the oil, care must be taken to keep the layer very thin
with no dry spots. One surface of the device removed can be cleaned and placed in
contact with the wetted surface of the replacement device. Rotating the devices with
respect to one another will spread the oil or grease evenly over the entire surface.
6.5 [6] REPLACEMENT OF THE DEVICE
1. Spread the chill blocks enough to allow the device to be inserted between them without
danger of the pole faces dragging across the centering pins.
MN/61
2. Make sure that the orientation of the device is identical to that of the device removed.
3. Tighten the clamping nuts finger tight. Rotate the disc slightly to ensure that it is indeed
lined up and centered on the pole face pins.
4. Before applying any tool to the device, check to see that the lever gauge reads zero.
Figure-6.3 shows the clamping force gauge indication. If the gauge does not read zero
with the clamp nuts hand tight, the level should be bent until it does read zero.
5. The auxiliary cathode and gate connections should be rotated so as point toward firing
boards as shown in View A-A of Figure 6-3.
6. The clamping nuts should be tightened alternately with an equal number of turn on each
nut so as to keep the spring bars reasonably square with the axis of the clamp.
7. The gauge indication times the number of bars in the spring assembly gives the clamping
pressure in thousands of pounds.
8. Clamping pressure for the various devices used are listed in Table 6.1.
TABLE 6.1
CLAMPING PRESSURE FOR VARIOUS DISK TYPE SCRs AND DIODES
DEVICE TYPE DIAMETER (m.m.) CLAMPING #. OF LEVER

PRESSURE (LBS.) SPRINGS INDICATION
MAINTENANCE
Diode 40 to 42 mm. 700-900 1 0.7 to 0.9

Diode 48 mm 2000-2400 1 2.0 to 2.4
SCR 48 to 50 mm 5000-6000 1 5.0 to 5.5
SCR 48 to 50 mm 5000-6000 2 2.5 to 3.0
SCR 77mm 9000-9500 1 9.0 to 9.5
SCR 77mm 9000-9500 NONE (See figure 6.4 for
guage Disk)
Note: Do not turn the factory set center gauge disk nut.
MN/62
MAINTENANCE
Fig. 6-4 77mm SCR Assembly
ITEM QTY DESCRIPTION IIP NO.
1 1 SCR CLAMP ASSEMBLY 10,000 LB FDEV0180

2 2 INSULATING BUSH
3 2 FRP TUBE
4 2 HEATSINK MOUNTING CLAMP B37006A FZS00009
5 2 3" CHILL BLOCK AS PER B37004 FZSE0005
6 1 3" CHILL BLOCK WITH TAB AS PER B37005 FZSE0007
7 2 SCR GE 4000A (INV) FIMP5020
8 2 FORCE DISTRIBUTION DISK-1/4" THK. FSEF1054
AS PER A31139A
9 CALIBRATED DISC GAUGE (WASHER)
CAUTION
THE PIN AND WASHER SETS USED WITH THESE CLAMPS ARE
CALIBRATED AT A PARTICULAR CLAMPING PRESSURE. THEY MUST
NEVER BE INTERCHANGED AMONG ASSEMBLIES.
MN/63
6.5 [7] WATER - COOLED COMPONENTS
Removal and replacement of water-cooled (internal water circulation) components require water
to be turned off at the source and the system drained off all water to prevent damage to solid
state devices, switches, lights, relay wiring, capacitors, transformers and other parts if a water
spill occurs. Therefore, drain all water from the system, connect a high pressure 40 to 60 psi
(2.8 to 4.1 BAR) air source at the water inlet, and blow out all residual water in the system prior
to removing and replacing parts as noted. Drain cocks are provided on manifolds and on the
pump casing.
6.5 [8] CAPACITOR MAINTENANCE
Remove capacitors that show signs of excessive swelling. Insulation failure is usually indicated
by a swollen case, or by an open capacitor pressure switch. Slight warping of the box sides
does not usually indicate failure. Remove busbars and capacitor connections carefully to avoid
damaging connecting threaded parts. Observe the following precautions :
1. RECEIVING : When unpacked, CAREFULLY INSPECT THE UNIT FOR DAMAGE AND
CHECK THE NAME PLATE TO BE SURE THAT DESIRED RATING HAS BEEN RE-
CEIVED. File a claim immediately with the carrier for any damages sustained in transit
and notify the nearest Inductotherm Sales Office.
2. HANDLING : Do not lift the capacitor by the bushings, Dragging the capacitor across the
floor or striking the case may cause leaks.
MAINTENANCE
3. STORING : When the capacitors are exposed to freezing temperatures and are not in
operation, the residual water in the cooling coils must be blown out with air.
NOTE
THE CAPACITORS CONTAIN DIELECTRIC FLUIDS OF THE NON-PCB TYPE

AND ARE FLAMMABLE. DO NOT STORE NEAR EXCESSIVE HEAT OR OPEN
FLAME.
NEVER CAPACITORS ARE EQUIPPED WITH CAPACITOR PRESSURE

SWITCHES WHICH OPEN IN THE EVENT OF FAILURE. THESE ARE
GENERALLY WIRED AS PART OF THE CIRCUIT BREAKER UNDER
VOLTAGE SYSTEM, CAUSING THE CIRCUIT BREAKER TO OPEN IN THE
EVENT OF CAPACITOR FAILURE. ALWAYS REPLACE ANY CAPACITORS
WITH OPEN PRESSURE SWITCH.
MN/64
WARNING
NEVER OPERATE A UNIT WITH A LEAKING OR BULGED CAPACITOR. A LEAKING

CAPACITOR CAN ARC INTERNALLY CAUSING A VIOLENT EXPLOSION.
NEVER OPERATE A UNIT WITH A CAPACITOR WITH AN OPEN PRESSURE

SWITCH. THE PRESSURE SWITCH BEING OPEN IS AN INDICATION OF A FAULTY
AND POTENTIALLY DANGEROUS CAPACITOR.
ALWAYS REPLACE ANY CAPACITOR WHICH IS LEAKING.
6.5 [9] CAPACITOR PRESSURE SWITCH REPLACEMENT
Capacitor pressure switches may occasionally be physically damaged in shipment or during

normal maintenance. They can be field replaced using the procedure below :
1. Clean face of capacitor and stand it on end with pressure switch up.
2. Remove old pressure switch.
3. Compress the sides of the capacitor gently until a drop of oil comes out (A large "C" clamp
with two pressure spreader boards can be used to compress the capacitor case).
4. Install new pressure switch while maintaining pressure on the capacitor.
CAUTION
MAINTENANCE
THE PROCEDURE MUST BE CAREFULLY FOLLOWED TO AVOID INTRODUCTION
OF AIR INTO THE CAPACITOR. ANY AIR INTRODUCED CAN CAUSE RAPID
DETERIORATION OF THE DIELECTRIC FLUID AND EARLY FAILURE OF THE
CAPACITOR.
6.5 [10] FURNACE
Inspect the furnace for sign of deterioration, cracks or lining failure. Refer to section-7.4 Trouble-
shooting, for furnace problems and replacement.
Follow the refractory manufacturer's instructions for patching or replacing linings or crucibles.
MN/65
6.5 [11] FURNACE LEADS
Inspect furnace leads for signs of external water jacket cracks or deterioration. Clean, repair or
replace furnace leads that show signs of excessive oxidation, distortion, cracks or leaks. Refer
Chart of Lead Configuration for power loss.
6.5 [12] BUS BARS
Remove and replace bus bars that are damaged. All fasteners should be retightened after an
initial 24 hour setting period and at longer intervals thereafter to compensate for the cold flow
of the material from beneath the fastener. This problem exists with copper bus. It is less
pronounced than with aluminum.
6.5 [13] HOSES
Clean the hoses with water from out side for dust & dirt collection to avoid hygroscopic effect
and conduction problem. Remove & replace hoses that leaks or show signs of fatigue (crack,
bulging due to metal penetration and scrap scratching).
MAINTENANCE
MN/66
MAINTENANCE
SCR Assembly for SCP Units
MN/67
SECTION - 7 TROUBLESHOOTING
7.1 GENERAL
The troubleshooting procedures contained in this section list the more common faults which
may occur during use of the equipment. Probable causes and solutions are provided to expedite
corrective action.
Except for visual checks of the meters and lights on the outside of the VIP cabinet, all trouble
shooting, maintenance, and repair must be performed by a qualified maintenance person. This
qualified maintenance person must be able to recognize "shock hazards" and be trained in the
safety precautions required to avoid possible injury or death.
WARNING
DISCONNECT ALL ELECTRICAL POWER (CIRCUIT BREAKER AND

CONTROL POWER OFF) BEFORE WORKING ON THE EQUIPMENT UNLESS
SPECIFICALLY CALLED FOR, DO NOT TROUBLESHOOT THE EQUIPMENT
WITH ELECTRICAL POWER APPLIED.
7.2 PROCEDURE
Effective trouble shooting consists of :
- Identification of a fault or problem.
- Isolation of the problem to a particular area within the system.
- Solution of the problem by repair, replacement, or adjustment.
The procedures described in this section will generally state the nature of a problem and then
SHOOTING
TROUBLE
refer the technician to table(s) where detailed trouble shooting procedures are outlined to assist
in effective repair or solutions to problems.
TR/68
CAUTION
DO NOT DISASSEMBLE PARTS UNTIL EACH COMPONENT IS TAGGED AND

PROPERLY IDENTIFIED. ASSEMBLE ALL PARTS IN REVERSE ORDER OF
DISASSEMBLY. OBSERVE PROPER TORQUE VALUES. DO NOT CHANGE
CONTROL BOARD ADJUSTMENTS WITH OUT PROPER AUTHORIZATION.
7.3 INDICATORS
The cabinet is provided with visual indicators showing system conditions. When a malfunction
occurs, check the lighted indicators, and meters to isolate a fault. Normal furnace or melting
operations should be in accordance with the procedures described in Normal operating proce-
dure. When an abnormal condition occurs such as low KW output, appropriate lights will show
the possible fault to isolate the problem. Refer to the appropriate troubleshooting paragraph and
reference table to isolate a fault and affect a solution to the problem. General familiarity with
checkout, test and start-up procedures (and drawings) will help in isolating problems and assist
in trouble-shooting procedures.
7.4 POWER FAILURE

A power failure or loss of electrical power from a utility or from the power supply requires imme-
diate attention to prevent damage. If the power failure is a failure on the utility lines themselves,
proceed immediately to the section on furnaces. See section 7.4.2. Also see Figure 7-1.
7.4 [1] POWER UNIT FAILURE
VIP units are protected from damaging by internal and external electrical transients and control
malfunctions by the quick-trip circuit breaker and other protection circuits. An occasional trip of
the unit may be tolerated. However, a brief maintenance check of the unit should be made after
any circuit breaker trip. Only if a check of the unit reveals some repairs are required or if the
circuit breaker cannot be reset, then situation requires further actions, section 7.5 covers power
unit troubleshooting.
SHOOTING
TROUBLE
7.4 [2] FURNACE PROTECTION
If the repairs appear extensive or if the nature of the malfunction is not readily apparent, then
measures must be taken to protect the furnace from damage. If the furnace is empty with a
relatively cool lining, all that may be required to protect the lining is to place a cover on the
furnace. If the furnace is empty, with a hot lining, it may be necessary to provide a torch or other
source of heat to protect the lining from thermal shock. The nature of the lining will determine
the appropriate action. In most cases, a normal shutdown procedure can be followed.
TR/69
WAS LINE POWER LOST ?
NO YES
CAN POWER SUPPLY BE CAN POWER BE

REPAIRED IN 15 MINUTES ? RESTORED IN 15
MINUTES ?
NO YES NO YES
IS PRIMARY COOLING WATER RESTORE

RESTORE POWER
SOURCE AVAILABLE ? POWER
YES NO
IS ANY OF THE SWITCH TO

CHARGE MOLTEN? BACKUP
NO YES
COVER THE FURNACE AND IS POWER AVAILABLE

MAKE PREPARATIONS FOR AN TO TILT THE
EXTENDED SHUTDOWN FURNACE?
NO YES
POSITION STANDBY EQUIPMENT DUMP THE FURNACE

OR ALLOW FURNACE TO FREEZE OR ALLOW TO FREEZE
SHOOTING
TROUBLE
Fig. 7-1 Power to the furnace has been lost
NOTE : THE INDUCTOTHERM SERVICE DEPARTMENT IS AVAILABLE BY TELEPHONE

FOR CONSULTATION ON THE ABOVE AND OTHER PROBLEMS IN CASE OF
EMERGENCY.
TR/70
If furnace power is lost with a molten load, the following must be considered :
- It will take up to half an hour for the metal to become too cold to pour, depending on
temperature.
- If the furnace is to be dumped, the runout area or ladles must be able to handle the full
volume or metal. The runout pit MUST be clean and DRY.
WARNING
METAL POURED INTO A PIT OR RUNOUT AREA WHERE EXCESS MOISTURE

OR STANDING WATER IS PRESENT CAN CAUSE A VIOLENT EXPLOSION
WHICH COULD CAUSE SERIOUS INJURY TO PERSONNEL.
- Dumping a load of metal may release a tremendous quantity of heat into the foundry,
perhaps causing other damage.
- It will take one to four hours for metal in the furnace to solidify enough to potentially
damage a lining, depending on temperature and furnace size.
- Water cooling must be maintained. This is even more important than handling the molten
metal. Figure 7-6 handles water cooling loss.
Considering these factors, a decision can be made on dumping or partially dumping of the
furnace. If the furnace is dumped, normal shutdown procedures should be followed.
To partially dump of furnace, enough metal should be removed to expose 50% of the furnace
floor. The furnace must then be left in the titled position, and remelted in the titled position. This
will minimize expansion cracking of the lining. It is always more desirable to fully dump a
furnace. Partial dumping should be attempted only when runout pit and/or ladle capacity is
insufficient.
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In many cases, it may be both more desirable and safer to simply allow the furnace to freeze
and accept probable loss of the lining. If furnace power is restored quickly, there is nothing lost.
If the slug freeze solid, it may be possible to remelt it and then dump the furnace.
7.4 [2.1] REMELTING A FROZEN FURNACE
The following general procedure applies in remelting either a fully frozen furnace or a partially
dumped furnace.
TR/71
- The furnace should be tilted.
- Furnace power must be applied very slowly. It should take atleast as long to melt out a
slug as it took to freeze it.
WARNING
MELTING A FROZEN SLUG TOO RAPIDLY WILL CAUSE THE LINING TO

CRACK, LEADING TO RUN OUTS WHICH MAY POSE A HAZARD TO
EQUIPMENT AND PERSONNEL.
- Monitor the ground leakage conditions. At any sign of metal leakage, shut down and pull
the slug and lining.
- Empty the furnace immediately after remelt, allow it to cool and thoroughly inspect and
repair the lining. If there is any doubt as to its condition, it should be replaced.
WARNING
THERE IS DANGER HERE THAT THE METAL IN THE BOTTOM OF THE

FURNACE WILL SUPERHEAT WHILE THE SURFACE IN CONTACT WITH
THE AIR REMAINS FROZEN. FOR THIS REASON, THE FURNACE SHOULD
BE TILTED UP SO THAT ANY METAL THAT MELTS BELOW THE SURFACE
IS IN INTIMATE CONTACT WITH THE UNDERSIDE OF THE FROZEN
SURFACE. POURING THE FURNACE DRY AS FAST AS THE METAL MELTS
WILL EASE THE STRESS ON THE LINING. IN ANY CASE, THE LINING
SHOULD BE INSPECTED AND PATCHED AS NECESSARY BEFORE A FULL
HEAT IS ATTEMPTED.
If the solid slug covers the complete furnace bottom, it is advisable to pull out and replace the
lining to remove the slug. The danger of a lining failure and the consequences of a run-out must
be weighed against the material, labour, and lost production required to pull out and replace
the lining. With small furnaces and furnaces with crucibles installed, the possibility of salvaging
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the lining, even by a careful melt-out of a solidified slug that covers the furnace bottom, is
remote.
TR/72
7.5 POWER UNIT TROUBLE SHOOTING

If power to the furnace is lost due to power unit failure, the procedures in Section 7.4.2 should
first be followed to protect the furnace and lining. Power unit troubleshooting by a qualified
technician can then proceed.
Power unit failure is evidenced by trip of the AC interrupter (if installed) and/or circuit breaker,
or by zero KW output from the unit. If the power unit will runs at partial power, proceed to
section 7.8.
Figure 7-2 covers a general trouble shooting procedure for VIP power units when tripping or
complete power output loss occurs. Appendices at the end of this section cover specific SCR
checks to be made. They are :
Appendix 7.A SCR Voltage Checks
7.B SCR Snubber Component Checks
7.C SCR Gate Resistance Checks
7.D SCR Firing Module Isolation Check

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TR/73
Circuit Breaker Tripped ?

No, but ACI tripped
Yes
Are Main Fuses OK ?
No Yes
Trouble shoot 3-phase Can circuit breaker be

Rectifier re-closed without pushing
the reset button ?
No Yes
Supply Voltage lost to Does unit trip immediately upon closing the
circuit breaker UV circuit breaker or turning on the AC
(UnderVoltage) coil
Check :
Yes
Proceed to Figure 7-3
1. That Voltage is present
on power supply No
terminals.
If not, check Does unit trip immediately
transformer fuses, etc. when inverter is turned on
2. That the door interlock
and capacitor pressure Yes
switches are closed. Proceed Figure 7-4
Correct, if necessary. No
3. If Voltage is present
Can unit run without tripping ?
and all interlocks are
satisfied, UV coil is not.
No
Proceed to Figure 7-5
Yes
Continue operation
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Fig. 7-2 Overall troubleshooting procedure
TR/74
FIGURE 7-3 BREAKER OR ACI TRIPS WHEN ENERGIZED

If the unit trips when energized, the main rectifier fuses must be checked first. If any main
fuses are blown, check for a defective SCR/diode in the rectifier, a short in the AC lines
or a blown discharge diode before CLR. Correct these conditions before proceeding.
In order for the unit to trip when it is energized without blowing the fuses. One of the
following conditions must exist :
- A short circuit must be present across the DC bus bar after the current limiting
reactor. (A short circuit in the rectifier of the AC lines will cause the main fuses to
blow.)
- The SCRs may be firing when the circuit breaker is energized. To isolate these,
make the following checks :
CAUTION
ENSURE THAT THE CIRCUIT BREAKER IS TURNED OFF AND THAT ALL
CAPACITORS ARE DISCHARGED BEFORE PERFORMING THE FOLLOWING
TEST : (USING SIMPSON METER IN R X 1 SCALE)
[A] Measure resistance between the +ve DC & -ve DC buses with the ohmmeter. Refer
to figure No. 7.7 (also see section 7.10).
TEST MEASURE RESULTS
Red lead on the positive DC Bus - Charge gradually, then
Black lead on the negative DC Bus Discharge,
(Ohmmeter needle first shows zero resistance and then infinite or very high Resistance).
Red lead on the negative DC Bus - Low resistance
Black lead on the positive DC Bus (5 to 10 ohms)
[B] Isolate the discharge diode and measure the following.
TEST MEASURE RESULTS
Red lead on the anode and the - Low resistance
Black lead on the cathode of (5 to 10 ohms)
Discharge diode
Black Lead on the Anode and - Reads high resistance
the Red Lead on the Cathod of
discharge diode
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[C] Isolate & check bleeder resistor

[D] Isolate and check snubber resistor of converter (bridge) diode/SCR. It should show
the value mentioned in drawing. [Refer Annexure I for more details]
[E] Isolate & check snubber capacitor, It should show charge and then discharge.
[F] Disconnect the DI/DT reactor. Perform the SCR resistance checks. (See Appendix
7.C.)
If above does not isolate your problem call the service department at Inductotherm
with the above information.
TR/75
Annexure I
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TR/76
FIGURE 7-4 BREAKER OR ACI TRIPS WHEN THE INVERTER IS TURNED

ON OR UNIT TRIPS WITH SCR/OVP AND/OR RESET INDICATION WHEN
INVERTER IS TURNED 'ON'.
[A] Switch to another furnace. Does the unit still trip?
[B] Perform the SCR resistance check (Appendix 7.C).
[C] Perform the SCR voltage check (Appendix 7.A).
[D] Perform the SCR snubber component check (Appendix 7.B).
[E] Check the primary and secondary or tank capacitors for shorts.
[F] Replace the control board with a spare if available.
[G] Replace the firing board with a spare if available.
[H] Check for open water-cooled leads if you do not have a spare furnace.
[I] Check for arcing in the unit, furnace or bus trench.
[J] Isolate all P.T.s, in the unit. (Potential sensors in POWER TRAK-R)
This can be done by removing the fuses from the P.T.s (Removing Two high voltage
connection in VIP-R). Make sure the power control pot is set to zero and see if the unit will
come on at an idle. Do not try to turn the unit up in power if the unit does come on without
tripping. Put the fuses back into one P.T./P.S. at a time, which ever P.T. /P.S. causes the
unit to trip must be replaced. (In VIP-R units the P.T.s are removed by P.S. i.e Potential
Sensors. There is no fuse in P.S.)
CAUTION
THE LEADS DISCONNECTED FROM THE POTENTIAL SENSORS WILL

CARRY HIGH VOLTAGE WHEN THE INVERTER IS ON. THEY MUST BE
CAREFULLY TAPED OR TIED AWAY FROM CONTACT WITH ANY
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GROUNDED COMPONENT OR BUS BAR.

TROUBLE
If the above does not isolate your problem, gather as much information as possible; i.e.
does unit trip with the indication of SCR over voltage; does the breaker dropout with a
bang, etc. Consult the Service Department at Inductotherm with the above information.
[Refer Annexure II]
TR/77
Annexure II
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TR/78
FIGURE 7-5 INVERTER CAN BE TURNED ON, BUT UNIT TRIPS WHEN RUN.
[A] Record voltage and power level at which unit trips. Does unit trip at a consistent
power or voltage level ?
[B] Perform the following checks :
1. SCR Resistance check (Appendix 7.C).
2. SCR Snubber component Check (Appendix 7.B).
3. SCR Voltage check (Appendix 7.A).
4. SCR firing module check (Appendix 7.D).
[C] Does unit trip on a different furnace?
It not, then check for arcing, sparking at Induction coil, bus bar or furnace selector
switch.
[D] Check water leakage inside panel and on external busbar or coil.
[E] Isolate P.T.s/P.S. (See figure 7-4 J.)
[F] Replace control board if a spare is available.
[G] Replace firing module if a spare is available.
If the above does not isolate your problem, gather as much information as possible and
call Inductotherm Service for assistance.
Figure 7-2 through 7-5 will guide you through specific check to isolate and identify the
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cause of problem. This is always good trouble shooting procedure and the data will be
very useful in working with Inductotherm service engineers by telephone.
7.6 OCCASIONAL TRIPPING

An occasional circuit breaker or ACI trip may occur due to line transients. Under such
circumstances, no harm would be done in resetting the circuit breaker and restarting the
TR/79
inverter immediately. However, it is a wise precaution to inspect the unit and make atleast the
power section continuity checks before restarting the unit. Repeated attempts to reset the unit
and restart the inverter with certain serious malfunctions existing can result in damage to the
very components that the circuit breaker and ACI are designed to protect. Repeated tripping
can also lead to premature circuit breaker failure.
7.7 WATER COOLING PROBLEMS

The circuit monitor will indicate water cooling problems. Refer to figure 7-6 for trouble shooting
water pressure problems in the system. Be sure that water circulation is maintained throughout
the unit to preclude components failure.
WATER PRESSURE LOST
RED EXTERNAL WATER PRESSURE LIGHT IS ON INVERTER IS OFF
Does pressure gauge read

more than 40 PSI at all times ?
NO YES
Can backup system provide Trouble shoot pressure

full flow ? switch in cabinet.
NO YES
Can cooling be Switch to backup

restored in 15 system and continue
minutes or less ? operation.
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YES NO
Switch to backup cooling Switch to backup cooling

system but prepare for system, then treat as a power
extended shutdown. system failure.(See Figure 7-1)
Fig. 7-6 Procedure for loss of water pressure
TR/80
7.8 UNIT RUNS BUT NOT DRAWING RATED POWER

VIP Units should run at rated power into a properly tuned load from cold charge to fully molten.
- Verify lining dimension. Lining buildup, erosion or a "thick" furnace bottom are the most
common cause of reduced draw. Check your furnace cross section drawing.
- TOT LIMIT (EXCESS CHARGE) This is caused by low line voltage or too much magnetic
charge in the furnace. Be sure that line voltage at the circuit breaker WHILE UNIT IS
OPERATING is atleast 95% of specified input. Removing metal from the furnace may
help.
- VOLTAGE LIMIT Adding metal to the furnace helps to overcome this limit. It usually
indicates improper lining conditions/dimensions.
- CURRENT LIMIT Again, an improper lining condition is indicated. Subtracting capacitor

steps (if installed) helps to increase power.
- FREQUENCY LIMIT Capacitors must be added to correct this condition. Lining erosion
is the most common cause for Frequency Limit.
However, also see trouble-shooting notes below.
If the furnace runs at less than full power, and not on a limit, the following check should be made:
1. Check line voltage, A minimum of 95% of rated input voltage on all three phases is
required to reach full power.
2. Check to see if a change in alloy has been made. A shift from ferrous to nonferrous
melting or from brass to pure copper could result in less than full power. Attempts to melt
less than full batch goes molten.
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3. Check to see that all capacitor contactors are working in the proper sequence and that
they are making solid contact with good tension. Check that all studs are in fast con-
nected.
4. Check primary and secondary or tank capacitors for open studs. Capacitors can checked
with a Simpson meter on the (R X 10,000) scale.
TR/81
a. Isolate the capacitor from the bus by removing the connecting straps.
b. Short each stud to the common stud momentarily to remove any residual charge.
c. With the Simpson meter set on the (R X 10,000) scale, measure from the common
stud to each of the other stud in order. A good stud will show an upscale deflection
(towards zero resistance) with a gradual swing back left (towards increased resis-
tance). A stud which shows no upscale deflection is open. A stud that gives an
upscale deflection with no drift back to the left is shorted or leaking.
5. Verify the lining dimensions and depth. Be sure that they confirm to your furnace cross-
section drawing.
6. Check for a cold ferrous charge of thin strips stacked vertically. Such a charge acts as
a shunt and will not melt properly. Rearrange the charge to lie horizontally.
7.9 POWER AND FURNACE VOLTAGE FALL TO ZERO, BREAKER

HAS NOT TRIPPED
This condition indicates that one or more fuses have opened, probably due to a semi-conductor
failure. Also check for a failure in the circuit monitor and control relay. If an interlock has
operated, the appropriate control lamp will be lit.
Frequency meter will swing upscale when power control knob is rotated clock wise, power and
furnace voltage will remain at zero. Check three phase bridge fuses, diodes and SCRs. Also
check water cooled cable (lead) for proper polarity. Wrong connection may cause by-passing
of coil.
7.10 CHECKING SOLID STATE DEVICES

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Most solid state devices can be checked with a simple ohm-meter. A good quality analog
TROUBLE
instrument should be used as digital meters require special handling when checking semi-
conductors.
Individual diodes and SCRs can be checked only by isolating them from any parallel paths and
checking them for conductivity in both directions. Solid state devices usually fail by shorting. An
ohmmeter will show a low resistance regardless of test lead polarity.
TR/82
By contrast, a good diode will show low resistance with the anode positive with respect to the
cathode and a high resistance with anode negative with respect to the cathode. A good SCR
will show a high resistance with either polarity of the test leads with no gate input. An additional
check for continuity of the gate circuit can be made with a SCR. The resistance between the
gate leads should be 25 to 75 ohms. The actual values are not critical but open or shorted
readings would indicate a defective device.
NOTE
WHEN CHECKING HOCKEY-PUCK DEVICES, THE DEVICE MUST BE

INSTALLED IN ITS HEAT SINK AND PROPERLY TORQUED TO GET A TRULY
RELIABLE RESULT.
Unfortunately, a device checks out with an ohmmeter may still not function properly in the
circuit. The device could break down only with high voltage applied or short intermittently only
when it becomes hot. This can lead to symptoms such as "unit trips only at high power settings"
or "unit trips only after operating for some length of time".
Hockey-puck diodes and SCRs should be checked only while mounted in their clamp assem-
blies with proper pressure applied. Devices that show short when mounted in the clamp may
go open when the clamping pressure is released.
CAUTION
THE CIRCUIT BREAKER USED IN THE UNIT SHOULD BE LOCKED "OFF"

AND ALL CAPACITORS DISCHARGED. WHILE THE FOLLOWING CHECKS
ARE IN PROGRESS TO PREVENT INADVERTENT APPLICATION OF POWER
TO THE UNIT WITH PERSONNEL WORKING IN THE CABINET.
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TR/83
Refer to figures 7-8 to make the following power-off checks with a Simpson meter to the Rx1
scale. Checks are made with the first-named point positive with respect to the second-named
point.
Do points 1 to 1A,
2 to 2A, and 3 to 3A
read zero ohms?
λ
λ
Replace defective fuse(s) and *Does 1A to 4 read 5 to 10 ohms
NO λ YES
proceed with remaining checks and 4 to 1A read high?
λ
λ
Isolate and check diode D1 and *Does 2A to 4 read 5 to 10 ohms

its snubber. Complete checks. NO λ YES
and 4 to 2A read high?
λ
λ
Isolate and check diode D2 and *Does 3A to 4 read 5 to 10 ohms

its snubber. Complete checks. NO λ YES and 4 to 3A read high?
λ
λ
Isolate and check diode D3 and NO λ *Does 5 to 1A read 5 to 10 ohms

YES
its snubber. Complete checks. and 1A to 5 read high?
λ
λ
Isolate and check diode D4 and *Does 5 to 2A read 5 to 10 ohms

its snubber. Complete checks. NO λ YES
and 2A to 5 read high?
λ
λ
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Isolate and check diode D5 and *Does 5 to 3A read 5 to 10 ohms

NO λ YES
its snubber. Complete checks. and 3A to 5 read high?
λ
λ
Fig. 7-7 Power system continuity checks
Continued on next page
TR/84
Isolate and check diode D6 and *Does 5 to 4 read 5 to 10 ohms and

its snubber. Complete check NO λ YES 4 to 5 read above 2K ohms?
λ
λ
Isolate and check discharge diode *Does 6 to 4 read 5 to 10 ohms and
and bleeder resistor. Continue NO λ YES 4 to 6 read above 2K ohms?
with remaining checks. λ
λ
Isolate and check diode SCR1, its *Does 5 to 6 read 5 to 10 ohms and
diode and snubber. Continue NO λ YES 6 to 5 read above 2K ohms?
with remaining checks.
λ
λ
Isolate and check diode SCR3, its *Does 7 to 4 read 5 to 10 ohms and
diode and snubber. Continue NO λ YES 4 to 7 read above 2K ohms?
with remaining checks.
λ
λ
Isolate and check SCR2, its diode **Does 5 to 7 read 5 to 10 ohms
and snubber. Continue with NO λ YES and 7 to 5 read above 2K ohms?
remaining checks.
λ
λ
Isolate and check SCR4, its diode This completes power OFF checks.
and snubber. Continue with NO λ YES Continue with control and power ON
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remaining checks. checks in Table 7-4 if problem persists.
* These readings will be high on units with an AC interrupter which uses SCRs in the three-
phase bridge.
** These readings do not apply to half-bridge units (Ref. Fig. 7-8)
TR/85
Power from
Dedicated Line
Transformer
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Fig. 7.8 Basic Circuit with Test Points
TR/86
APPENDIX 7.A SCR VOLTAGE CHECK

Figure 7-9 shows typical views of the SCR assemblies used in the VIP units. Diode assemblies
look the same although the diodes have no gate wires (red and white wires). In making the
following voltage checks, the measurements need only be made on the SCRs as the diodes
are electrically paralleled and will have the same voltages. Some of the parts designations are:
[A] Mounting Flanges
[B] Chill Blocks
[C] SCR Pucks
[D] Clamping Pressure Indicators
[E] Hose Connections on the Chill Blocks
[F] Bus Connector
[G] Diode Pucks.
Fig. 7 - 9 Details of Diode and SCR Assembly
CAUTION
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IN-MAKING THE FOLLOWING CHECKS, HIGH D.C. VOLTAGE POTENTIALS

EXISTS. THE FOLLOWING PROCEDURES MUST BE ADHERED TO IN ORDER
TO AVOID DANGEROUS ELECTRICAL SHOCKS.
Each SCR assembly has two (2) SCRs (C) installed in it. The SCRs are cooled on both sides
with chill blocks (B). Each assembly has three chill blocks, the middle chill block having a power
tab for bus connection. When making the following readings, record each reading on the
attached chart.
TR/87
Using a voltmeter capable of reading a D.C. voltage of more than 900 volts, make the following
readings, in the following manner :
SCR VOLTAGE READINGS
[A] Turn circuit breaker OFF. Wait five minutes for the capacitors in the unit to discharge.
Short all capacitors to ensure that they are discharged. Do not rely on discharge or
bleeder resistors to discharge the capacitors as they may be defective.
[B] Connect your voltmeter to the top mounting flage (A1) and to the power tab (J).
NOTE: The flange is positive and the bus connector is negative.
[C] With the meter connected, turn the circuit breaker ON.
CAUTION
DO NOT TOUCH ANYTHING INSIDE THE UNIT AS DANGEROUSLY HIGH

VOLTAGE IS PRESENT. DO NOT TOUCH THE VOLTMETER.
[D] Record the voltage (SCR "C1" of figure 7-9).
[E] Turn the circuit breaker off. Follow step 'A' above.
[F] Connect your voltmeter to the power tab (J) and the bottom flange (A2). Note : The power
tab is positive and the bottom flange is negative.
[G] Repeat step C and D. This reading is on SCR "C2" of figure 7.9.
[H] The voltage across top SCR and bottom SCR must be equal, and should be around 300V
to 400V D.C depending input voltage.
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[I] Repeat the above on all SCR assemblies (where required).
APPENDIX 7.B SCR SNUBBER COMPONENT CHECKS
Refer figure 7-10 A or B for following checks.
Using an ohmmeter on R X 1 scale, make the following check. (make sure your meter
is zero')
TR/88
B
A
Fig. 7-10A SCR Snubber Heat sink details for 77 mm SCRs

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Fig. 7.10 B SCR Snubber Heat Sink Details for 50 mm SCRs
TR/89
NOTE
THE CIRCUIT BREAKER SHOULD BE LOCKED "OFF". CHECK THE

INDIVIDUAL COMPONENTS BY ISOLATING THEM FROM THE CIRCUIT FOR
PROPER VALUE OF EACH COMPONENTS (WHICH IS MENTIONED IN YOUR
POWER CIRCUIT DRAWING).
1. Check the value of snubber resistor 'A' and compare.
2. Check the value of snubber resistor 'B' and compare.
3. Check the value of voltage sharing resistor 'C'. It should be 20 kohm. (Use R x 100 range)
4. Check the snubber capacitor for change & discharge.
5. Check snubber diode for low resistance value in forward bias and high resistance value
in reverse bias as per symbol given on diode.
6. Check the MOV (Metal Oxide Varistor) (wherever connected). It should show very high
resistance (use R x 10,000 range) between two terminals. (In all VIP-R units MOVs are
not provided in inverter section.)
7. Check for proper connection (soldering/wire joints).
8. Check for proper mounting of snubber components with copper heat sink (i.e. for proper
cooling of each components).
APPENDIX 7.C SCR GATE RESISTANCE CHECK
Each SCR puck has two wires coming from it. These wires are red and white and connected
to a firing module. These wires are the SCR gate wires. To check these, the following checks
must be made on each SCR gate :
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- Ohmmeter on the Rx1 scale and disconnect the white wire from the firing module.
- Red lead on the red SCR gate wire. Black lead on the white, 25 to 75 ohms.
- Black lead on the SCR gate wire. Red lead on the white, 25 to 75 ohms.
Repeat in on all SCRs.
TR/90
APPENDIX 7.D SCR FIRING BOARD ISOLATION TEST
Occasionally, a problem may arise where a unit can be turned on but the circuit breaker will
trip as power is raised. Although there are other things which can cause this to happen, the
firing modules can cause this type of trip. To find out if this is the case, a simple test can be
made. A voltage check across the SCRs as in the "SCR voltage check" but with one difference
should be made. The difference is to measure the DC voltage with the inverter running at idle
(power control dial at zero). List these readings under SCR voltages.
WARNING
MAKE ALL TEST CONNECTIONS ONLY AFTER THE UNIT HAS BEEN OFF
LONG ENOUGH FOR THE DC VOLTAGE TO DRAIN AWAY.
7.11 UNIT TRIPS WITH INTERNAL HIGH TEMPERATURE (Unit high temp.)
[Refer Annexure III]
1. Check raw water inlet temperature to heat exchanger (distilled water side). It should not
be more than 320 C. always.
2. Check inlet water temperature of distilled water.
3. Check for proper wiring contacts/connections.
4. Check distilled water level in tank.
5. Open and check water heat exchanger for chock up/scaling. (normally, it is required to
clean the heat exchanger once in every 3 or 4 months.)
6. Check outlet water temperature of different water paths at outlet manifold of distilled water
system. Is any one of the path getting heated up ? If yes, then measure the water flow
of that particular path, and compare the flow with data given in drawing.
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7. If the flow is less than specified then blow compressed air in that path in forward and
reverse direction and again measure the flow and compare it.
8. After carrying out the above steps if the problem persists, consult Inductotherm Service
Department.
TR/91
INT. HIGH
Annexure III
TEMPERATURE
CHK
ABOVE
THE
SPECIFIED
INPUT TEMP.
OF INTERNAL
WATER TEMP GAUGE/
TEMP GAUGE/
THERMOMETER
THERMOMETER
BELOW
SPECIFIED
CHK
THE
RAW WATER ABOVE
INPUT TEMP OF SPECIFIED
PANEL HEAT
EXCHANGER
CHK
FOR ANY
YES
OUTLET TEMP SPECIFIED
SENSOR
TRIPPING
CHECK YES
FOR
NO SCALING IN
PHE
VISUALLY
CHECK MEASURE
FOR LOOSE FLOW OF
YES NOT OK
CONNECTION IN THAT PARTICULAR
WIRING WATER PATH NO
VISUALLY
NO
OK
CHECK
FOR THE NOT OK
FUNCTIONING
OF COOLING
TOWER
OK
MEASURE
DELTA-T
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FLOW FOUND LESS FAULT MAY BE IMPROPER

LOOSE
THAN SPECIFIED SOMEWHERE ELSE FUNCTION OF
CONNECTION SCALING IN PHE
COULD NOT FIND COOLING TOWER
IN WIRING
TIGHTENING CLEANING EXPERT'S

REPLACING/
LOOSE ALL HELP IS DESCALE
REPAIRING OF
CONNECTION PATHS REQUIRED THE PHE
COOLING
TOWER
TR/92
WARNING
DO NOT EVER TRY TO BY-PASS WATER TEMPERATURE SWITCH/SENSOR.

THIS MAY CAUSE DAMAGE TO FURNACE/UNIT AND MAY AFFECT THE
PERFORMANCE OF OTHER COMPONENTS IN THE UNIT.
7.12 UNIT TRIPS WITH EXTERNAL HIGH TEMPERATURE (FCE High Temp.)
[Refer Annexure IV]
1. Check the inlet water temperature to heat exchanger (furnace side). It should not be more
than 320 C always.
2. Check outlet temperature of Induction coil, It should not be more than 800 C or 1750 F.
3. Check the inlet water temperature to the induction coil. (Refer proper water diagram for
current setting of temperature switch/sensor.)
4. Check the direction of cooling tower fan.
5. Check water level of DM/soft water and raw water tanks.
6. Check for proper wiring contacts/connections.
7. Open and check water heat exchanger for chock-up/scaling. (Normally it is required to
clean the heat exchanger once in every 3 or 4 months.)
After carrying out the above steps if the problem persists, consult Inductotherm Service
Department.
7.13 FURNACE SELECTOR SWITCH INTERLOCK

FSS INDICATION
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1. The main purpose of this interlock is such that at a time two induction coils (i.e. two
furnaces) can not be connected with one inverter (i.e. VIP panel) because of limitation of
power as well as matching of coil (load) and inverter (power supply). The interlock wiring
of all (two or three) selector switches are arranged in such a way that the inverter can
be turned 'ON' with only one selector switch "ON".
TR/93
Annexure IV
EXT. HIGH
TEMPERATURE
ABOVE
CHECK SPECIFIED
THE TEMP. OF
INLET W ATER
TEM P. GAUGE
TO COIL THERMAMETER
ABOVE
SPECIFIED
SPECIFED
CHECK
INPUT TEMP
AT COIL
ABOVE PHE
SPECIFED
CHECK
OUTLET TEMP
OF COIL/W CL BELOW
SPECIFED
CHECK
YES
BELOW
FOR
SPECIFED SCALING IN
PHE
VISUALLY
NO
BELOW
SPECIFED
CHECK CHECK
FOR LOOSE YES
OUTLET FLOW BELOW
OF COIL/W CL CONNECTION CHECK SPECIFED
IN W ATER
W IRING FLOW
AT INPUT
VISUALLY
& OUTPUT
NO OFCOIL
PHE M ANUALLY
SPECIFIED ABOVE
SPECIFED
CHECK
FOR THE NOT OK
FUNCTION
OF
COOLING
TOW ER
SHOOTING
OK
TROUBLE
W ATER FAULT MAY BE IMPROPER

LOOSE FLOW FOUND
FLOW SOMEW HERE FUNCTION OF SCALING IN
CONNECTION LESS THAN
FOUND ELSE-COULD NOT COOLING PHE
IN W IRING SPECIFIED
LESS THAN FIND TOW ER
SPECIFIED
REPLACING/
CLEANING/ TIGHTENING EXPERT'S HELP REPARING OF CLEANING DESCALING
DESCALING LOOSE IS REQUIRED ALL PATHS PHE
COOLING
OF CONNECTION TOW ER
W CL/COIL
TR/94
2. Two or three different Micro Limit Switches are connected with lever/handle of a selector
switch to sense the position (close/open) and movement of switch.
3. It is advisable to use proper drawings as there are three/four different type of circuits are
used for different configuration.
4. A flow switch is also connected in series with Micro Limit Switches (of selector switch) to
make sure that the water circulation in induction coil is continuous-which is connected with
selector switch.
If unit tripping or could not switching on because of FSS interlock following checks should
be made :
a. If both the switches (or both pairs) are closed or open at a time, the FSS interlock
indication will appear on monitor board.
b. Improper position (even slight close/open) of switch will result in tripping of the unit
with FSS interlock indication.
c. Check for proper contacts/connections at micro limit switches, wiring joints at termi-
nal strips and also at flow switches.
d. Improper wiring of micro switch/flow switch will also result in tripping.
After carrying out the above steps if problem persists, consult Inductotherm Service
Department.
7.14 CAPACITOR/DOOR FAULT INDICATION [Refer Annexure V]

SHOOTING
TROUBLE
TR/95
Annexure V
CAP/DOOR
INT.LOCK
CH EC K YES
W H ETH ER ANY
PAN EL D OOR IS
VIS UALL Y
OPEN
NO
CH EC K YES
FOR BU LGING
OF ANY
VIS UALL Y
CAPAC ITOR
NO
NOT OK
CH EC K
CONTACTS
OF MIC RO LIMIT
SW ITCH ES
M ULT IM ETE R
OK
CH EC K
THE COIL OF
DIC
CONTACTOR
M ULT IM ETE R
OK
OPEN/BURNT
CH EC K
UV COIL OF
BR EAKER
M ULT IM ETE R
SHOOTING
TROUBLE
OK
CONTACTOR FAU LT MAY BE IN

ELEC TRICAL/ELEC. CAPAC ITOR PAN EL D OOR
FAU LTY COIL/UV COIL FOUN D BULGED FOUN D OPEN
FOUN D OPEN/ TRON IC
LIMIT SW ITCH
SH OR T COMPONTS.
RETIGH TEN ED / REPLAC ING EXPERT'S CAPAC ITOR CLOSED

REPLAC ED LIMIT CONTACTOR COIL/ HELP FOUN D BULGED OPEN DOOR
SW ITCH UV COIL REQU IRED
TR/96
High Frequency Capacitors

SECTION 8 - INSTRUCTION MANUAL
8.1 SAFETY NOTICE
The objective of these instructions is to help make capacitor users aware of application and
handling practices which will aid them in the use of power capacitors. The guides cover good
practices in receiving, handling, installing, field-testing and disposal of power capacitor unit. The
guides do not address themselves to the requirements of insurance underwriters, which may be
applicable to any given capacitor application. Compliance with codes and insurance underwrit-
ers’ requirements demand individual consideration on the part of capacitor users for each
particular situation and should not be assumed to have been achieved simply by complying with
the suggestions contained in these instructions.
A PROTECTION AGAINST SHOCK
CAUTION
POWER MUST BE SWITCHED OFF BEFORE DOING ANY WORK ON

CAPACITORS OR EQUIPMENTS TO BE CERTAIN THAT THE CAPACITORS
HAVE BEEN DISCONNECTED FROM THE POWER SOURCE. IT IS NECESSARY
TO MAKE A VISUAL CHECK FOR AN OPEN CONTACT DISCONNECT.BEFORE
USE & AFTER TAKING OUT, SHORT THE CAPACITOR WITH INSULATED
SHORTING STICKS TO DISCHARGE ANY RESIDUAL CHARGE.
B EXPLOSION HAZARD
The correct application of capacitor disconnecting system will greatly minimize the possibility of
case rupture; but since considerable stored energy may be available upon the occurrence of a
fault inside a capacitor, it is possible to get explosive case rupture in any application even with
proper disconnecting system.
C HANDLING OF FAILED CAPACITORS
Some failed capacitors may be found considerably bulged due to internal pressure from gassing
CAPACITORS
prior to circuit clearing. Such units should be handled very carefully. A failed capacitor should be
H.F.
shorted with suitable insulated shorting sticks, to discharge any residual charge. It is further
recommended that a bulged capacitor be permitted to cool before handling. This will lower the
CP/97
internal pressure, reducing the possibility of case rupture with leakage of gasses during subse-
quent handling.
WARNING
AVOID LIQUID CONTACT WITH SKIN AND EYES AND EXPOSURE TO FUMES
IN AN UNVENTILATED AREA.
D COMBUSTIBLE IMPREGNANT FIRE HAZARD
These capacitors contain a class III B combustible liquid which could possibly ignite if there is a
case puncture or rupture in the presence of an electric arc. Capacitors should be suitably
protected from mechanical damage and located where possible fire would not result in damage
or hazard to the surrounding area.
E DISPOSAL OF CAPACITORS OR IMPREGNANT
The preferred method of liquid disposal is by incineration. If feasible, the solid portion of the
capacitor, the elements, should also be incinerated and the capacitor case should be disposed
of in a waste disposal site approved for hazardous industrial waste.
An alternate method of disposal to be considered is the incineration of the liquid and disposal of
the solid reminder, consisting of elements, and capacitor case, in a waste disposal site ap-
proved for hazardous industrial waste.
Disposal of whole capacitor, including the liquid, in a site approved for hazardous industrial
waste is a third method, which may be considered for the disposal of the capacitors.
Do not let impregnating liquid enter into drain.
8.2 RECEIVING
When unpacked CAREFULLY INSPECT THE UNIT FOR DAMAGE AND CHECK THE NAME-
PLATE TO BE SURE THE DESIRED RATING HAS BEEN RECEIVED. File a claim immedi-
ately with the carrier for any damages sustained in transit, and notify nearest office of
INDUCTOTHERM (India) Pvt. Ltd.
CAPACITORS
8.2.1 Handling
H.F.
Do not lift the capacitor by bushing. Dragging the capacitor across the floor or striking the case
may cause leaks.
CP/98
8.2.2 Storing
Where the capacitors are exposed to freezing temperature and are not in operation, cooling
coils must be protected from damage due to water freezing solid. While storing the capacitor,
the water from the cooling coil is to be removed by blowing the air. Capacitor should be suitably
protected from mechanical damage and located possible fire would not result in damage or
hazard to the surrounding area.
8.3 INSTALLATION
Since this product contains a combustible liquid (OSHA class III- B), the location of the capaci-
tors should be chosen with consideration given to the possibility of fire in the event of capacitor
damage and subsequent case rupture.
If a capacitor fails in service, it is important to remove the energy source as quickly as possible.
As long as the capacitor remains energized, gases are generated as a result of arcing and
burning of the dielectric material in the faulted area. These gases can expand the capacitor
case until it ruptures. Once the case in vented, the gases and free dielectric fluid will be
released into the equipment enclosure.
CAUTION
TIGHTENING THE TERMINAL NUTS TO MORE THAN 15 FOOT-POUNDS IS NOT

REQUIRED OR RECOMMENDED: EXCESIVE TORQUE CAN BREAK GASKET SEALS
OR STRIP THREADS ON GROUND BAR OR BUSHING TERMINALS.
8.4 COOLING SYSTEM

The cooling coil is a continuous copper tube terminated. It is generally rediused to reduce the
hazard of clogging. A minimum flow rate of 0.5 gal/ min. must be maintained and the outlet
water temperature must not exceed 450 C (1130 F) to prevent erosion of the tubing the flow rate
must not exceed 16 lit. min. and be free of abrasive grit.
“Only a few minutes of operation without water will damage the capacitor. If water
is discontinued until one unit fails, the other units on the same water line must be
assumed to have been severely abused even though no obvious damage is seen.”
CAPACITORS
H.F.
A screen is sometimes used in the water supply lines to prevent clogging due to deposits, and
should be checked and cleaned periodically. These deposits are not only harmful in that they
reduce the flow of water but also because they reduce the flow of heat from the capacitor into
CP/99
the water and gives wrong outlet water readings. The interconnecting insulating hoses should
be of sufficient quality and length such that the case to ground voltage and leakage current will
not damage them.
8.5 MAINTENANCE
FOR THE SAFETY OF PERSONNEL, THIS APPARATUS SHOULD BE ISOLATED
FROM HIGH VOLTAGE CIRCUITS BEFORE PERFORMING MAINTENANCE,
INSPECTIONS AND SERVICING. ALL COMPONENTS SHOULD BE ELECTRICALLY
DISCONNECTED BY MEANS OF A VISIBLE BREAK, AND SHOULD BE SECURELY
GROUNDED.
During initial startup the capacitors should be monitored to find any problems. Some things to
look for are water leaks, wet and/or dirty conditions around insulation systems, proper capacitor
cooling water quality, and temperature to all capacitors, sparking of case to mounting frames as
well as hot capacitor terminals due to loose terminal nuts and hot spots in materials caused by
inductive heating. Frequently scheduled maintenance check should follow until routine mainte-
nance scheduled timing is determined.
CAPACITORS
H.F.
CP/100
CONTACT ADDRESS
Head office
Ambli-Bopal Road
Bopal, Ahmedabad 380 058
Gujarat, India
Phone : +91 2717 231961 (8 Lines)
Fax : +91 2717 231266/231268
Mr. Dholakia : Dy Manager - Service Mr. Sanjiv Joshi : Asst. Manager - Service
Phone : 079-27417147-R / 93761 96153 Phone : 02717 230452-R / 93279 80576
Mumbai Branch Bangalore Branch

“Shraddha” 2nd Floor, 81 old Nagardas Rd Door # 1053, 5th Cross, 12th Main Road,
Andheri (E), Mumbai 400 069, Maharashtra Nr. Maruthi Hospital, Indira Nagar, HAL second Stage,
Phone : 022 26844000/26835000 Bangalore 560 008, India.
Fax : 022 26840546 Phone : 080 25276378/25276379
E-Mail : mumbai@inductothermindia.com Fax : 080 25276319
Mr. P D Chaubal - Manager - Branches E-Mail : inductoblr@satyamlanmail.com
Phone : 022 26182476 Mr. S Rajasekhar - Marketing Manager
Mobile : 93247 79182 Mobile : 93421 27272
Kolkata Branch New Delhi Branch

2A, Camac Court, 25/B Camac Street, 2nd Floor, Ashoka Apartment, E-1/10 East Patel Ngr.
Calcutta 700016. Phone : 033 22477611 Opp. Vivek Cinema, New Delhi 110 008, India
22472445/2280 8945/22809820 Phone : 011 25881459/25885139 Fax : 01125881210
Fax : 033 2247 2445 E-Mail : inductodel@satyamlanmail.com
E-Mail : inductocal@satyamlanmail.com Mr Tarun Sangal - Regional Sales Head
Mr. Aloke Mukherjee - Dy. Branch Manager Phone : 011 28742494 - R
Phone : 033 25774963 Mobile : 93318 28277 Mobile : 93505 04593
Mr. Pinaki Roy Mobile : 98302 69113 Mr. Manoj Mathur Mobile : 93589 16049
Coimbatore Branch Pune Service Center

Renaissance Terrace, Flat # “L”, 2nd Floor, 126 “Saket”, Block # A-3, Plot # C/2, TELCO Employees’
Tirugnasambantham Street, Race course, Co-operative Housing Society, PCNTDA, Nigdi,
Coimbatore 641 018. Phone: 0422 2210302 Pune 411 044.
Fax : 0422 2210295 Tele Fax : 020 27654322
E-mail : inductocoi@satyamlanmail.com E-mail : inductopun@satyamlanmail.com
Mr. S R Subramanian - Regional Sales Head Mr S V Shahane - Regional Service Head
Phone : 0422-2457923 (R) ,Mobile : 93441 30922 Mobile : 93260 75874
Mr. P V Vijayan - 0422-2322179 (R)
Mobile : 93441 30923
Service Centers
Chennai Mr S Ethirajan Tele fax 044 26521418/93806 33004
Dhanbad Mr T K Singh Phone 0326 2222363
Hyderabad Mr B Umashankar Phone 080 23376575 Fax: 23392475
Kanpur Mr S K Sharma Tele fax 0512 2502802
Kolhapur Mr Nikhil Shukla Tele fax 0231 2537849
Ludhiana Mr Surinder Arora Phone 0161 5050851
Muzaffarnagar Mr Manoj Mathur Phone 0131 2621981
Pondicherry Mr Ravikumar Phone 0413 2257284
Raipur Mr G Diyawar Tele fax 0771 2443537s
AD/101

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TABLE OF CONTENTS

Inductotherm Power-Trak/Power-Melt are efficient units, designed with 1

The purpose of this booklet is to familiarise operating and mainte- 2

It is not the purpose of this section to list every precaution which

The precautions which follow here are well known to foundrymen. 3

υ Access to melting and pouring operation should be limited to

υ Furnace linings should be inspected frequently at regular inter-

υ Furnaces should be charged carefully to avoid BRIDGING of the

υ Low melting point material (such as aluminium or zinc) should be

υ Charge materials should be dry and free of combustibles, exces-

υ Removable crucibles or push out furnaces should be used only

υ When metal is transferred in a crucible, a cradle that provides

υ Be knowledgeable of the chemistry of your melt. Chemical reac-

υ Personnel with implanted organs, joints, plates or similar objects

All induction heating and melting equipments are using potentially 4

The following precautions should always be observed.

υ Keep shields, covers and other protective devices in place at all

υ Always set main power disconnect to the OFF position before

υ Always switch power OFF when lifting, pausing or transporting

υ Use only proven test equipment when trouble-shooting a unit or

υ Use only dry charge material. 4.1

υ Do not allow closed or partially closed containers (beverage cans,

FAILURE TO COMPLY WITH THESE PROCEDURES

υ Study the maintenance procedures. 4.2

υ Always use two independent methods to support a tilted furnace

υ Use only first-class test equipment when trouble-shooting a unit

υ Ensure exposed furnace leads are properly insulated at all times.

υ Use proper safeguards when performing work or repairs under

υ When breakdown or fault occurs, guard against exposure to elec-

υ Be careful around high pressure lines, fittings and equipment.

υ Supply valves (water or air) and charging valves shall be opened

υ Inductotherm’s melt system equipment contains safety devices

υ Maintenance or repair of electrical equipment, instrumentation,

υ DO NOT work alone when making measurement of circuit where

υ DO NOT touch any object which could provide a current path to

υ For maximum safety, do not touch test leads or test instrument

υ DO NOT make measurement using test leads other than those

υ Electrical equipment hazards must be recognised at all times, 4.4

υ Locate all voltage sources and accessible current paths before

υ Be extremely careful when working in high voltage power circuits. 4.5

υ DO NOT change the range setting or function switches of the test

υ Never exceed the circuit-to-ground voltage of the test instrument.

υ Test instruments are designed to prevent accidental shock to the

υ Hot surfaces - Personnel working in the furnace area should 4.7

υ Uniform tightening of all nuts or bolts in a pressurised joints is of

υ Failure of safety devices can result in dangerous over pressure if

υ Combustible and volatile fluids or materials must be kept away

υ Equipment Guards - Guards must not be removed from the

BEFORE CHARGING SCRAP OR OTHER

1 The charge material MUST be dry.

2 Bundled or baled material MUST NOT have water trapped within.

3 The charge MUST NOT contain closed or partially closed con-

Each melting system is composed of four main sections:

- the main power transformer and switch gear,

These sections are described separately.

1.2 THEORY OF OPERATION

Induction heating is the heating of an electrically conducting object immersed in a varying

Hysterisis is a discontinuity in the values of magnetization in a magnetic material due to

HYSTERISIS AND EDDY CURRENT LOSSES

1.3 THE CORELESS INDUCTION FURNACE

Fig. 1-1 Cross Section of Coreless Induction Furnace

1.4 THE ELECTRICAL EQUIVALENT OF THE CORELESS FURNACE

Fig. 1-2 Electrical Equivalent of a charged Furnace