Escolar Documentos
Profissional Documentos
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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
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 Keep all cabinet doors locked. Make keys available only to those
qualified maintenance personnel who require access to the enclo-
sures.
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.
WARNING
SF/5
SAFETY PRECAUTIONS
WARNING
DO NOT TOUCH
HOT LEAD ENDS ON
A HAND FURNACE
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 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 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.
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 Open and lock out main circuit disconnect and be sure that all
capacitors are discharged before making any checks with an ohm
meter.
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 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.
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 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.
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.
WARNING
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
INTRODUCTION
Rc
LL
WORK
FURNACE Lc PIECE
OF
CHARGE
RL
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
POWER
1200 100%
transmitter (the power
INTRODUCTION
IN/18
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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 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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
shield between HT & LT winding and the supply voltage to VIP is higher (550 volt OR 460 volt)
INTRODUCTION
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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 Economical Operation
λ Minimum of Pollution
λ Reliable Operation
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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 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
Water-cooled leads should be used wherever a flexible conductor is required. Figure 2-1 illustrates
a typical installation.
DS/23
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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"
+ -
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
DESCRIPTION
Cooling Tower
Power in
VIP Cabinet
Main
Water
Furnace
in
Heat
Exchanger
Hydraulic
Controls
Hydraulic
Pumping Unit
DS/25
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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 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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
WARNING
DESCRIPTION
NOTE
NOTE
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
DS/28
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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 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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
WARNING
DESCRIPTION
NOTE
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
TH/34
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
+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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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:
2. Maximum current.
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
WARNING
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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
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.
ST/42
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
6. Turn control power key lock switch OFF for one minute.
CAUTION
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.
NOTE
CAUTION
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
The following procedure requires a multimeter (Simpson Rs-260 or similar) and an oscilloscope.
Measure control board voltages as follows:
CAUTION
WARNING
ST/44
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
NOTE
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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.
(BOTTOM SCR)
ST/46
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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.
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.
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%)
ST/48
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
13. During normal operation keep sensitivity knob on 100%. So as to trip at 60 mA. leakage
current.
PROCEDURE
TEST
ST/49
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
2. Inspect lining and patch as necessary. When the lining is proper, then charge the furnace.
CAUTION
PROCEDURE
OPERATING
INSPECT BUNDLED OR BALED SCRAP FOR TRAPPED MOISTURE
BEFORE ADDING IT TO THE MELT.
WARNING
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
If the Ground Leak Detector does not function properly, do not operate the power supply.
Call Inductotherm's Service Engineer.
OP/51
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
MAINTENANCE
2. Check for and correct internal water leakage.
9. Remove scrap under the furnace and keep the working area clean.
MN/53
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
NOTE
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
NOTE
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
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
TOWER X
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.
MN/57
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
CAUTION
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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
CAUTION
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.
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.
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
guage Disk)
Note: Do not turn the factory set center gauge disk nut.
MN/62
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
MAINTENANCE
Fig. 6-4 77mm SCR Assembly
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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
MN/64
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
WARNING
1. Clean face of capacitor and stand it on end with pressure switch up.
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).
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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.
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
MAINTENANCE
MN/67
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
7.2 PROCEDURE
Effective trouble shooting consists of :
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
CAUTION
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.
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
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
NO YES
NO YES NO YES
YES NO
NO YES
NO YES
TR/70
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
- 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.
SHOOTING
TROUBLE
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.
The following general procedure applies in remelting either a fully frozen furnace or a partially
dumped furnace.
TR/71
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
- 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
- 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
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
SHOOTING
TROUBLE
the lining, even by a careful melt-out of a solidified slug that covers the furnace bottom, is
remote.
TR/72
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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 :
TR/73
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
SHOOTING
TROUBLE
TR/74
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
TR/75
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
Annexure I
SHOOTING
TROUBLE
TR/76
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
[E] Check the primary and secondary or tank capacitors for shorts.
[H] Check for open water-cooled leads if you do not have a spare furnace.
[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
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.
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
Annexure II
SHOOTING
TROUBLE
TR/78
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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 ?
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.
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
SHOOTING
TROUBLE
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.
TR/79
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
NO YES
NO YES
YES NO
TR/80
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
- 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.
- FREQUENCY LIMIT Capacitors must be added to correct this condition. Lining erosion
is the most common cause for Frequency Limit.
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.
SHOOTING
TROUBLE
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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.
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.
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
SHOOTING
TROUBLE
* 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)
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
Power from
Dedicated Line
Transformer
SHOOTING
TROUBLE
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
CAUTION
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
Using a voltmeter capable of reading a D.C. voltage of more than 900 volts, make the following
readings, in the following manner :
[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).
[C] With the meter connected, turn the circuit breaker ON.
CAUTION
[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.
SHOOTING
TROUBLE
Using an ohmmeter on R X 1 scale, make the following check. (make sure your meter
is zero')
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
B
A
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
NOTE
3. Check the value of voltage sharing resistor 'C'. It should be 20 kohm. (Use R x 100 range)
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.)
8. Check for proper mounting of snubber components with copper heat sink (i.e. for proper
cooling of each components).
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 :
SHOOTING
TROUBLE
- 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.
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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.
SHOOTING
TROUBLE
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.
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
WARNING
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.)
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.
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".
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
After carrying out the above steps if problem persists, consult Inductotherm Service
Department.
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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OK
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
CAUTION
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.
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
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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.
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.
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.
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.
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
“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
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VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
VIP POWER-TRAK/POWER MELT SERIES SYSTEM MANUAL
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
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