Striko Dynarad Electric Melting and Holding Furnace Manual EC-1500

StrikoDynarad
ELECTRIC RESISTANCE
MELTING AND HOLDING FURNACE
INSTRUCTION MANUAL
STRIKODYNARAD ELECTRIC RESISTANCE FURNACE
Stri koDynarad
ELECTRIC RESISTANCE
MELTING AND HOLDING FURNACE
JNSTRllC'TION MANUAL
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Model Number EC- 500
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Serial Number 12
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Electrical Schematic D�
Date To Ship February 000
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L StrikoDynarad
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�Leandro · mi.a 94577
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INSTRUCTION MANUAL
INSTRUCTION MANUAL
StrikoDynarad MS SERIES
Version 1.5
TABLE OF CONTENTS
Section Page No.

Installation _)
II Routine Melting and

Holding Operations 10
III Furnace Maintenance 16
IV Troubleshooting 20
V Replacement Parts List 26
VI Index 28
VII Appendix Back
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INSTALLATION
A. Inspecting Shipment
I . Check for damage - Check all parts of the shipment for damage which may
have occurred in transit. Carefully check the carton containing the crucible for
obvious signs of damage such as fork lift holes. etc.
2. Report any Damage - Immediately report any damage to the freight carrier.
Visible signs of damage to cartons or crates should be noted on the bill of lading
and acknowledged by the freight canier's driver or other representative.
8. Removal of Packing Materials
I. Move all containers and crates to a clear area near the installation site.
2. Open all crates and cartons and again inspect for any hidden freight damage
which may have been previously missed. Immediately report any damage found to
the freight carrier.
3. Unpacking furnace
a) Remove protective plastic sheeting and any crating materials from furnace.
b) Carefolly lift furnace cover up at least 6 inches so that internal cover legs
won't interfere with furnace refractory or wiring terminals. Set cover on clear
space on floor. allowing the legs or cover rim to support the cover and protect
the refractory materials underneath.
c) Remove internal packing - Carefully remove all internal bracing which
protects the heating elements during shipment. Using a clean brush or
compressed air. brush or blow away any residual styrofoarn or packing
materials which may have adhered to the elements.
Carefully inspect the heating elements for any damage which may have
occurred in transit and report any damage to freight carrier.
Store all packing materials for later use if furnace is moved to a different
location.
d) Open all other crates and cartons carefully and prepare for installation.
C. Locating and Mounting Furnace and Controls

1. Place furnace - Set furnace in desired position on flat floor or platform using
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fork truck lifting from fork channels welded into the furnace base. Note that the
furnace is supported by four plate steel pads welded to each end of the fork
channels.
' Furnace may also be set into pit using chains or other lifting means. Be sure to
L allow at least 2" clearance around perimeter of furnace to permit the furnace to nm
cool. Also allow room for adequately sized runout pan within pit area. Floor plate
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or heavy expanded metal may be used for pit cover after installation.
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INSTRUCTION MANUAL
,, Leveling - Use a spirit level placed on a straight edge on top of the furnace
body (with the cover removed) to be sure furnace is level. Add shim stock under
pads to level as required.
Tilting furnace frames must be solidly anchored to floor or platform. It is not

necessary to bolt a stationary furnace to the floor.
3. Control Panel - Mount control panel on wall or other support structure nearby
furnace for operator's convenience. However, do not locate too close to furnace
crucible opening to avoid possibl�-damage from heat radiation when furnace cover
is off.
4. Runout pan - The furnace should be provided with a runout pan of adequate
capacity to contain the entire contents of a full crucible. The pan should be
approximately 5" high and positioned so that the edge of the pan is behind the
outlet of the furnace runout port. This will permit the collection of small amounts
of metal "dribble" which might otherwise build up between the runout port and the
runout pan.
D. Wiring and Checking - Refer to the electrical schematic and interconnection wiring
diagram in the Appendix at the back of this manual.
I . Main Switch - Install a circuit breaker or disconnect switch in the vicinitv
(usually within 25 feet) and within sight of the furnace in conformance with focal
electrical codes. Refer to the serial number plate on the lower left side of the
Control Panel to determine the correct operating voltage and maximum current.
Please check with the factory if there are any questions regarding the furnace power
requirements.
Run a conduit with properly sized wires from this breaker or switch directly to the
Control Panel and connect incoming electric leads behind the protective barrier at
the top of the panel as shown on the schematic diagram. Be sure to replace this
safety barrier before turning power on!
2. [nterconnect Control Panel and Furnace - Again referring to the electrical

schematic diagram, run conduit and leads from the Control Panel to the furnace pull
box at the rear of the furnace. Interconnect all identically numbered terminals in
Control Panel and furnace pull box. Be sure leads are properly sized to handle
currents shown on the electrical schematic.
3. Ground the furnace - Be sure to run a heavy gage ground wire from any
s�1itable point on the furnace frame to a solid plant ground, such as a cold water
pipe.
4. Connect thermocouple leads - Run a separate conduit for the low level
thermocouple lead wires (provided by StrikoDynarad) from the Control Panel to the
small thermocouple junction box next to the pull box on the furnace.
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l Allow sufficient lead length to directly reach both temperature instruments
inside the Control Panel from their respective thermocouples at the furnace without
connection to any intermediate terminal strips or spliced connections.
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Be sure the angle type crucible bath thermocouple is connected to the bath
pyrometer instrument mounted in the Control Panel door. Then connect the furnace
side wall mounted element temperature thermocouple to the Element Temperature
Limiter. also mounted in the Control Panel door. Be sure thermocouple lead wires
follo\V correct polarity as shown on schematic diagram (red is negative and
magnetic).
5. Special lead wires provided - StrikoDynarad has provided the thermocouple
lead wire for both thermocouple pyrometers. The user will provide all conduits and
all other interconnection wiring.
6. Check wiring - Again referring to the schematic diagram. use a low voltage
"buzz tester" or ohmmeter to be sure all interconnections have been completed
correctly . Also he sure that all connections are tightened securely.
7. Ddav Power Test - Do not turn on power until furnace is safe to operate. If
,1StrikoDynarad installation supervisor will he assisting with the furnace startup.
do not turn power on until he arrives and performs a second wiring check prior to
the initial power test. If a StrikoDynarad supervisor will not be assisting. wait until
the furnace is closed up and all exposed wiring is covered and protected and
otherwise completely safe for the initial power test which follows in Section I.
E. Accessories (Optional)
I . Pneumatically Operated Cover - Connect a 3/8" compressed air line to the
small regulator prepiped to the inlet side of the manual operating valve mounted on
the side of the furnace. Apply a minimum of 40 PSIG air pressure and open and
close the cover using the manual valve. Adjust the speed as required using the
exhaust port flow controls on the manual valve and the pressure regulator.
F. Installing Crucible
I. Check double glazing - Be sure crucible has been double glazed with oxidation
retarding low temperature glaze by checking distinguishing crucible markings
and/or supplier shipping documents to verify. Single glazed crucibles will have a
shorter operating life so this is an important check.
' Check crucible dimensions before installing the crucible in the furnace to
c Ii 111 inate the risk of having to remove it if the dimensions are not correct.
[ a) Inside diameter - Crucible ID should correspond with the ID of the furnace

cover opemng.
L b) Crufible height
I) "EC" Series furnaces - With furnace cover removed, lay a
l straightedge across top of furnace frame and measure height from

underside of straightedge (top of furnace frame) to top of permanent
crucible pedestal in furnace refractory base. This dimension should be 2"
greater than height of crucible.
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.:1. Check cover refractory for any missing pieces and replace where necessary.
Be sure the furnace cover has an uninterrupted 2" thick layer of high temperattire
refractory blanket (StrikoDynarad Part No. 520-0035) to tightly seal it against top
of crucible.
-l-. Set cover in position taking care to keep refractory blanket undisturbed. If any
n t· the refractory blanketing or gasketing is accidentally nudged out of position.
reposition as required and reset the cover. Replace hold-down lugs on cover and
tighten down gradually in rotation to compress refractory blanket uniformly.
5. Trim excess blanket from around inside top of crucible and inspect for gaps.
Reset the cover again. if necessary. to insure a tight fit around the top of crucible to
prevent internal metal leakage.
11. Installing Bath Thermocouple

I . VERY IMPORTANT: Only isostatically pressed silicon carbide
thermocouple protection tubes with internal steel support tube (StrikoDynarad Part
No. 530-0100 for 18" length or Part No. 530-0105 for 24" length) should be used
\Vith aluminum. brass. or zinc to properly ground the metal bath and provide the
longest operating life.
2. Position the thermocouple protection tube approx. l " away from the side of the
crucible and place the horizontal pipe section of the thermocouple assembly into
the support clamp cradle. Place the U-bolt clamp over the thermocouple pipe and
into the holes on either side of the cradle and thread the nuts onto the U-bolt.
VERY IMPORTANT: Use a suitable wrench to tighten the nuts so that the
thermocouple support clamp is very tight to insure that the metal bath is
electrically well grounded. Also tighten the 90 degree elbow union on the
thermocouple assembly to obtain the same result.
3. Polarity - Observe correct polarity when connecting TIC lead wires to junction
block. Red is negative(-) and magnetic; yellow is positive(+) and non-magnetic.
I. Initial Electrical Check

I. With the furnace cover in position. close and screw shut the furnace pull box
lid and check to be sure all high voltage connections are closed and protected in
preparation for electrical checking.
2. Set the bath pyrometer at the desired operating setpoint temperature. Then set
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the heating element limit setpoint temperature not to exceed 2000 ° F. If provided.
turn the optional " Seven Day Timer" switch "Off' and the optional "Power Level"
switch to the lowest position.
l 3. Close the main disconnect or circuit breaker. The alarm horn should give a
short chirp and the green "Main Switch On" lamp should light. The bath pyrometer
and element temperature limiter should be on. The three ammeters should show
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current flow. though not necessarily all exactly equaL depending on furnace model.
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INSTRUCTION MANUAL
Refer to the electrical schematic diagram to determine if the furnace is wired in

a '\vye" or "delta" configuration. In most cases. 480 volt fornaces are wye
connected and 240 and 208 volt furnaces are delta connected.
a) " Wye" connection - The highest ammeter reading (with the optional Power
Level Selector in the highest position) should approximately equal the current
shown on the serial number plate (on the lower left side of the Control Panel).
vvith allowance given for utility supply voltage variations.
h) "Delta" connection - The highest ammeter reading should approximately

equal the current shown on the serial number plate (on the lower left side o f the
Control Panel) divided by 1 .73 (the square root of three). with allowance given
ror utility supply voltage variations.
4. Power Level Switch (optional) - Slowly turn the " Power Level" switch to the
full right. maximum power position. As the switch is rotated through each position.
the current shown on the ammeters should increase in all three phases.
5 . Ground fault interrupter (GFI) check - Loosen the keeper nut on the sensitivity
adjustment on the front of the GFI relay inside the control panel. Using a small
blade screwdriver. turn the sensitivity adjustment counterclockwise until it reaches
the detented "Test Position."
The GFI should immediately trip causing the alarm horn to sound and the
"Ground Fault" lamp on the front panel to light. The sensitivity adjustment should
then he rotated clockwise. just out of the detented "Test Position". but otherwise at
the maximum counterclockwise position which won't cause a test trip.
Tighten the lock nut to permanently retain this highest sensitivity adjustment.
Reset the white circuit breaker on the GFI relay to silence the horn and reset the
alarm circuit.
1r the G FI does not operate per the above. shut off all power to the furnace and
check that the two shielded leads are connected to the correct corresponding
terminals on both the GFI relay and sensor with the proper polarity (refer to the
schematic diagram).
6. Concluding tests - After completing all tests. turn off the main power switch.
l Furnace is now ready for regular melting operations.
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II ROUTINE MELTING AND HOLDING OPERATIONS

1\. Setting Instruments
I . Element temperature limit - As stated in the previous section. the element

temperature limit should be set no higher than 2000° F. This represents a
comfortable. conservative limit for the element wire (which has a melting point o f
2750 ° F) consistent with long operating life. Higher operating temperatures will
result in shorter element life which may not be cost effective even though higher
melting rates will be attained.
' Setting bath pyrometer - Through experience gained from many furnace
installations. StrikoDynarad can recommend the following starting settings for the
J -mode metal bath pyrometer which differ depending on whether the furnace is to
he used for continuous or batch melting. Settings for holding use only follow in
Section G below.
Rder to the temperature controller instruction manual in the Appendix at the
rear of this manual for instructions on how to make these adjustments.
a) Continuous wet bath melting - In this melting mode solid charge material
is continuously fed back into the furnace at the same rate that it is drawn out.
Recommended starting settings are: Reset: 0.5 repeats per minute: Rate: 2.0
minutes: Proportional Band: 4: Cycle Rate: 60. Do not disturb any other
tuning parameters.
h) Batch melting - In this mode. a larger quantity of charge material is placed
in the furnace and brought up to tapping temperature. poured. and another
hatch is then charged. Recommended starting settings are : Reset: 0 repeats
per minute: Rate: 0 minutes: Proportional Band : 10: Cycle Rate: 60. Again. do
not disturb any other tuning parameters.
J. Setting Seven Day Timer (Optional)- The timer is provided with on and off
trippers so that it can be set to turn on and off daily or over weekends. as desired.
Refer to the instructions on the inside of the timer door for setting on and off times.
The timer motor will operate continuously (regardless of whether the "Seven
Day Timer" switch on the front panel is off or on) as long as the main switch is
closed and will require resetting if the main power is turned off The "Seven Day
Timer" coin switch on the front of the control panel must be turned on to enable the
timer to operate. When this switch is turned on the yellow "Seven Day Timer On"
lamp will be lighted.
B. WARNING ! ! Please take note of the warning sign on the furnace which reads.
l "EXPLOSION HAZARD - DO NOT PUT WET O R MOISTURE BEARING
CHARGE MATERIALS O R TOOLS INTO THIS FURNACE AS EXPLOSION
CAUSING DEATH. SERIOUS INJURY AND/OR PROPERTY DAMAGE MAY
l RESULT. DO NOT REMOVE THIS SIGN."

This is a very serious warning which applies to all furnaces containing molten
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metals. Be sure that all charge material is completely dry and free of ice crystals. snow,
absorbed moisture. etc. before charging into fornace. All charge material should be
stored in a protected. dry area before use.
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INSTRUCTION MANUAL
Preheat ingots. scrap. and other charge material on top of the furnace before melting and
inspect each individual piece of charge material for signs of moisture before placing in
crucible.
Lower ingots in slowly. If "sputtering" from moisture should start pull the ingot
back out of the bath and let it dry out or set it aside until dry. Ingots should be lowered
in slowly and carefully to insure against crucible damage as well. If "bubbling" should
start following the submersion of any charge material in the crucible. all personnel
should quickly move away from the furnace until it is clear that there is no danger of
"popping." "sputtering." or explosions from moisture on the material.
C. First melt
I . Remove the manual crucible cover or open the optional pneumatic crucible
cover and place sufficient charge material to develop a heel into the crucible.
Always be careful not to wedge in any material which could expand faster than the
crucible causing cracks to develop.
2. Close the main power switch or breaker to turn the furnace on and confirm that
pm,vcr is flowing to the heating elements by observing the ammeters.
.1 . Observe element temperature shown on the temperature limit pyrometer and
look for a rise in element temperature.
4. Watch for steam - With the crucible cover still open. watch for any steam
which may come out of the top of the furnace or through the refractory blanket
material around the top of the crucible. If steam is seen, shut off the power and
wait for it to disappear (20 to 30 minutes) and turn the power back on again.
Repeat this as necessary until the furnace reaches the melting point and a
molten heel starts to develop in the crucible. Then add more charge material to fill
up the crucible and set the crucible cover in place (or close the optional
pneumatically operated cover).
The amount of steam generated. if any. will depend on how much moisture
,vas absorbed by the lining prior to furnace startup. If the furnace has been out of
service for any length of time. the operator should watch for steam when it is again
restarted.
D. Continuous Melting
I. Maximizing the melt rate - To maximize melting rate and temperature control
accuracy. charge material should be charged back into the furnace at the same rate
it is taken out. in increments as small as possible. preferably no more than one or
two ingots at a time. The 3-mode fully time proportioning temperature controller
will "anticipate" the addition of solid charge material and heat will be conducted
l through the crucible in time to melt each charge.
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' I k)\,\,; to keep temperature constant - If the charge is not added. the heat \'Vhich
mrnld have melted the charge will raise the temperature of the bath. But if charge
material is added at the same rate molten metal is taken out. the furnace will come
to equilibrium at that melting rate and the metal temperature will remain constant
indefinitely. making it possible to continuously operate the furnace at a heavy
melting output level.
.1. Element temperature limit - If the temperature of the heating elements reaches
the preset temperature limit. power to the elements will automatically be switched
off and the white "Element Temp Limit" lamp on the control panel will be lighted.
This is a normal limiting function and power will be switched back on as soon as
the element temperature drops below the setpoint.
E. Batch Melting
I . Description of batch melting: Metal is added in bulk quantities. melted. and
brought to the �esired tapping temperature. It may then be treated and ladled out
and the process repeated.
2. For maximum throughput the batch should be kept as small as possible and the
crucible heel maintained as large as possible. This minimizes temperature drop and
can prevent the heel from freezing which will promote faster melting.
, Furnace utilization - Increase furnace "utilization" to increase the average
melting rate. Furnace utilization is defined as the time a furnace is actually 711elting
metal during a given production period divided by the total time in that production
period and is usually expressed as a percentage. The more time the furnace is doing
something other than melting. the lower the utilization. If it is desirable to melt as
much metal as possible. the time used to hold. recharge. and treat the metal must be
minimized so that the furnace can melt more metal during the available time period.
4. Element temperature limit - If the temperature of the heating elements reaches
the preset temperature limit. power to the elements will automatically be switched
oil and the white "Element Temp Limit" lamp on the control panel will be lighted.
This is a normal limiting function and power will be switched back on as soon as
the clement temperature drops below the setpoint.
.'i . Close the cover ! - The crucible cover should be replaced as soon as a charge is
placed in the crucible to stop convective and radiation heat losses and improve
efficiency. Several types of optional StrikoDynarad pneumatically operated
crucible covers have been designed to make it convenient for the operator to close
the cover. particularly when frequent access to the furnace is required.
[ 6. Controlling temperature overshoot
a) Why does temperature overshoot? - The large heat of fusion of aluminum

l has always made it a problem to batch melt. Forty percent of the heat energy
required to melt aluminum is absorbed during the heat of fusion phase at the
end of the melting cycle. During this phase. while 40% of the total energy is
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absorbed. the metal temperature does not rise one degree!
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INSTRUCTION MANUAL
Temperature control instruments are designed to react to temperature

changes and in the case of aluminum. when the Bath Temperature Controller
calls for more power. it doesn't "see" much increase because it is "masked" by
the heat of fusion. The controller thus continues calling f or power. increasing
the heating element temperature. Finally. when the metal is melted. the
furnace has become hotter than necessary because the controller has been
" fooled" and the excess heat raises the temperature of the bath above the
desired setpoint.
h) How· to control overshoot during batch melting
l ) Keep the batch as small as possible and the heel as large as possible.
Then the impact of the heat of fusion will be smaller as a percentage of the
total energy contained in the entire bath.
2) Increase the proportional band setting on the Bath Temperature
Controller. This will cause the controller to begin cutting back on the heat
input sooner as the metal bath temperature rises. How- ever. this means
that the fi.1rnace's average melting rate will be reduced because when
power is reduced. melt rate is reduced. If this is not a problem. increasing
the proportional band is a good solution.
., ) Add a predetermined amount of ingot to the furnace after the Bath

Temperature Controller's indicated temperature has passed the setpoint.
When this happens. the controller will stop all power input to the furnace
and the extra ingot added at the end of the melt cycle will absorb the extra
energy. keeping the temperature at the setpoint.
The exact amount of ingot to absorb this energy will depend on the
batch size. the molten metal heel and the desired temperature but it can be
easily determined experimentally during several melting cycles. When the
right number of ingot is determined. sufficient space must be left in the
crucible for them so the crucible isn't over-filled.
This method has the added advantage of maximizing average melting

output because the furnace stays at full power longer and is brought to a
" quick stop" by the ingot addition.
However. it is essential that the ingot be added after the setpoint is
passed. Otherwise, the controller will just call for more power and the
advantage of the ingot addition will be lost.
F. Power Level Control (Optional)
l I . Reduce demand charges - This control can be effectively used to limit the input
power and resulting utility demand charges whenever the furnace can be operated
below its maximum power input level.
l When full power is required. the Power Level Control is turned to the highest
setting. But if the melt rate for a given job is less than the maximum melt rate of
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the furnace. the Power Level Control may be used to reduce the input power to a
level just above what is needed. In this way. power demand charges can be
minimized.
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' Multiple furnace installations - This control is particularly helpful for multiple
1·urnace installations where some furnaces are needed to melt at lower rates than
nthers. The correct power setting is chosen for each furnace and excess power
demand is readily and positively curtailed.
3. Lov,: level for holding - The lowest power level should be chosen when the
l'urnace is to be used for holding purposes only. The power available will be more
than enough to maintain holding temperature but the power demand will be just a
fraction of the full power available so that utility demand charges will be
minimized.
C i . 1-Iolding Use Only
I . Production holding - When the furnace is to be used for holding purposes only.
no special preparations are required. The Bath Temperature Controller on the front
of the control panel is simply set for the desired holding temperature and the
l'urnace will maintain that temperature indefinitely.
1 B ath Temperature Controller Tuning Constants - If the furnace will not be used
!'or melting. StrikoDynarad recommends a different set of tuning constants for
holding use only as follows: Reset: 0.05 repeats per minute: Rate: 0 minutes:
Proportional Band: 2: Cycle Rate: 6 0.
� Id I ing at night or other off shift periods
a) Reduce holding temperature - The bath temperature pyrometer should be

set at the lowest practical holding temperature for the metal alloy used but not
below 1200 ° F. For example. the usual overnight hold-ing temperature for
most aluminum alloys is 1 200° F.
Keep the metal molten. The metal should not be allowed to solidify whenever
refractory crucibles such as silicon carbide are employed to avoid risk of
cracking when the metal is remelted.
The temperature must not be allowed to drop below 1200° r in silicon carbide
crucibles to prevent low temperature oxidation which can drastically shorten
crucible life.
b) Fill the crucible - Keep the crucible full during off shift periods. This will
extend crucible life by reducing oxidation and resulting cracking around the
top. It will also insure the furnace will be ready for production with a full pot
of metal.
c ) Close the cover ! - The crucible cover should be placed in position over the
crucible so that heat losses are minimized during off shift periods.
l H. Don't Overfill Crucible - Do not permit the metal level in the crucible to exceed the
top of the pot. Molten metal can soak through and eventually penetrate the refractory
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fiber gasket at the top of the crucible and run down into the heating chamber. If the
metal penetration is heavy enough. heating elements might be damaged.
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INSTRUCTION MANUAL
I. l Jsing Fluxes in Electric Resistance Furnaces
I . Introduction - Because of the nature and purpose of reactive chemical fluxes.

their use in electric resistance furnaces can potentially cause severe problems ,:vith
furnace internal electrical components.
13y understanding how adverse reactions can take place. the electric resistance
li.m1ace user can weil!h the benefits of using reactive fluxes af2:ainst risk o f damaQe
:rnd can minimize th; risk if their use is ess'ential. He can also consider using
nonreactive fluxes which pose no danger to electric furnace components.
2. Definition - Reactive fluxes are defined as solid. liquid or gaseous chemical

agents which. when brought into contact with molten metal. cause chemical
reactions to take place either spontaneously by themselves or in conjunction ,:vith
metallic components of the metal bath.
Non-reactive f luxes function strictly in a physical or mechanical manner and do not
take part in chemical reactions.
]. l .lsc of' Fluxes - Reactive and non-reactive fluxes are used for many purposes:
for example. to cleanse molten metal of suspended oxides or dissolved gas. to
separate liquid metal from dross on the metal surface. or to carry out silicon
modification or grain refinement.
4. Examples of reactive fluxes include exothermic surface dross treatment

" cover" fluxes which typicall y contain halide salt mixtures such as potassium and
sodium chlorides. crvolite or sodium fluoride; submersible volatile halides in the
form o f tablets or "d�)ughnuts" which generate halide gases; chlorine. fluorine. and
f-reon gases used for hydrogen degassing; compounds of titanium. boron. and
zirconium used for grain refining; metallic sodium or sodium containing salts used
for silicon modification or grain refinement.
5 . l:xamples of non-reactive fluxes include nitrogen. argon, and helium gases
used principally for hydrogen degassing and the removal of entrained aluminum
oxide or dross.
(). Chemical Reactions - The risk of problems with reactive fluxes is simply
understood. lf tluxes or any flux derivative (such as chlorine or fluorine) are an
effective chemical agent in fluxing the molten metal in the furnace, they can be
equally effective in chemically f1uxing ( corrosively attacking) furnace components
( and other nearby objects) which they contact.
l All electrically conductive components including heating elements. lead wires.

cables. bus bars and metal framework together with sheet metal roofs. steel
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building girders. etc. are especially susc;ptible to chemical attack from reactive
fluxes. In electric fornaces. these include commonly used resistance materials such
as nickel-chromium alloys. iron-chrome-aluminum alloys. and silicon carbide.
Anything which will conduct electricity contains metallic components and is
l subject to attack from reactive chemical fluxes.
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7. I low these reactions take place - In electric resistance crucible furnaces. the
crucible acts as an effective barrier between the metal and the heating elements. A
refractory seal is employed betvveen the top of the crucible and the underside of the
rurnace cover to prevent metal splashing from causing internal damage to the
l't1rnaee.
However. this seal must accommodate crucible expansion without stressing the
crucible and is generally made of a material such as ceramic fiber refractory which
is resilient at higher temperatures. These materials effectively prevent damage
from metal splashing but cannot be made gas tight. Thus. if a cover is placed over
the crucible while reactive fluxes are present. any gases generated cannot rise freely
hut can pass through the crucible seal and enter the interior of the fornace and do
serious damage.
8. I -low to minimize risk of damage
a) Eliminate the use of reactive fluxes - This is the simplest solution. Much
of today's foundry practice has evolved from the use of foel fired furnaces and
the metallurgical problems they generate. By eliminating water vapor which is
a product of combustion in fuel fired furnaces, electric resistance furnaces
eliminate the largest source of dross and dissolved gas. Thus. it may be
possible that reactive fluxes are not even necessary but may be just a carryover
fhHn previous fuel fired furnace practice.
h ) l lse onlv non-reactive fluxes - Drv. inert non-reactive !.WSes such as
nitrogen. argon. and helium can act as"effective degassers a�d suspended dross
removers in electric resistance furnaces where the presence of water vapor has
been dramatically reduced. The driest non-reactive gases are the most effective
and come from a liquified gas source.
c) Use reactive fluxes with great care - If reactive fluxes are absolutely
necessary. the gaseous types are the best to use in an electric resistance
furnace. The furnace cover must always be kept off so the gases can rise
freely. Nitrogen/chlorine, nitrogen/Freon or nitrogen/SF 6 mixtures can be
used with good results if they are not allowed to be trapped inside the fu rn ace
where they can do damage.
StrikoDynaracl's ChemClean aluminum degassing system automatically
blends nitrogen or argon with SF 6 or Freon 12 for safer. more effective
al uminum degassing. ChemClean's single-knob flow control design simplifies
operation by eliminating troublesome dual flow controls. ChemC!ean
maintains a constant mixing ratio for improved consistency. It is safer than
risky chlorine or chemical tablets and is smokeless with low toxic gas
emissions and won't harm furnace equipment. ChemC!ean is used by many
Il aluminum foundries and die casting plants around the world. StrikoDynarnd
will gladly furnish complete information about its ChemClean system upon
request.
l The next best choice are the submersible tablet or "doughnut" ring
degassers which can be used effectively. particularly the type which leaves no
reactive residual. As with the gaseous types. the furnace cover must be kept
off during the treatment.
L
l -16-
l
INSTRUCTION MANUAL
Solid powdered or granular "cover" fluxes should be used only with

extreme care. They present the highest risk because flux material left behind
on the molten metaL the crucible or thermocouple protection tube can continue
to react when the crucible cover is closed causing extensive damage.
If they must be used. the furnace operator should apply them only when
the crucible seal is intact and the furnace cover is off. The minimum
"dosage" should be used and. following treatment. all traces of granular or
Iiquid (melted) flux must be carefully removed, with the operator paying
particular attention to less accessible areas such as behind the thermocouple
protection tube.
Also. the operator should wait until all gas generating reactions are
complete before removing the residue and replacing the cover to insure that no
further adverse reactions can take place.
<). J\.sk First - Always contact StrikoDynarad before attempting to use reactive
chemical fluxes in a StrikoDynarad furnace. Obtain the commercial name and
number of the flux in question and. if possible. find out from the supplier if
corrosive gases are generated and what compounds are included. A few moments
taken to check could prevent possible 1m1jor damage from an adverse reaction.
J . Furnace Shutdown - The shutdown procedure is very simple. Metal is ladled or

poured out of the crucible until very little is left at the bottom and then the furnace is
shut off. It can later he restarted following the instructions above.
The optional Seven Day Timer may then be employed to restart the furnace (see
instructions in paragraph A (3). page 1 0).
I<.. Pmver Failures - If furnace power should be interrupted. the furnace will
automatically restart itself upon restoration of power without requiring a manual reset.
Since the furnace is highly insulated. it can sustain a power failure of several hours
duration with the crucible cover in place.
l f a power failure of long duration is anticipated. the furnace should be emptied and
shut down in an orderly manner.
The user may wish to consider equipping the furnace with a central station alarm if
power failures can be expected and the furnace is idled during off shift periods. This
wiII help prevent crucible and thermocouple damage which can occur if metal is
allowed to solidify in a non-metallic crucible.
l
l
L -17-
[
III Fl iRNACE MAINTENANCE
J\. Crucibles
I. Scraping
a) Why crucibles should be scraped - The crucible should be scraped on a

regular basis to prevent the buildup of oxides on the side walls. Oxide
buildups will reduce heat flow through the crucible and reduced heat flow v,:i !I
cause a reduction in melting rate and an excessive increase in the temperature
or the outside surface of the crucible. Abnormal temperature differences
between the inside and outside surfaces will result in higher internal stresses
which will contribute to shorter operating life.
b ) How to scrape a crucible - Make up a "half moon" shaped piece o f metal
such that its outside curvature matches the inside curvature of the crucible.
Weld it to a piece of solid rod with a handle at the opposite end.
With the crucible full of molten metaL carefully scrape the inside surfr1 ce
o f the crucible up and down. all around the full perimeter to loosen and free
any oxides attached to the side wall. Then skim the oxides off the top surface.
Bubbling dry nitrogen through the bath with a suitable lance will aid in
bringing loose oxides to the surface.
c ) Repeat as needed - Crucibles should be scraped on a regular basis. usually

once a week. More frequent scrapings may be required if oxide buildup is
more rapid due to increased oxides in the charge material.
2. Crucible inspection - Non-metallic (e.g. silicon carbide) crucibles should be

inspected on a regular basis. usually daily. to watch for the development of cracks
or other signs of wear. Crucible cracks quite commonly develop around the top and
may increase in length and begin to approach the metal line. The furnace runout
pan should also be checked for evidence of metal dripping which might indicate
that the crucible will need to be changed.
Once suspicious cracks or dripping are detected. the crucible should be
changed as soon as possible to prevent the occurrence of larger spills.
.,
.l . Crucible Replacement
a) Remove old crucible - The crucible should be ladled out and the furnace
power shut off and the main switch locked off as a safety measure. The hold
down lugs on the furnace cover can then be loosened and released and the
l cover lifted off.
If the crucible is to be permanently retired. heavy duty C-c!amps can be

firmly attached in three or four places around the top of the crucible. Chains
l ooped through the clamps can be used to remove the crucible. taking care not
to attach clamps too close to cracks which could result in pieces of the crucible
splitting away.
-18-
INS TRUCTION MANUAL
b) Install new crucible - A new refractory paper crucible separation disk ( see
Parts List) should be set in place on the crucible pedestal and the new crucible
installed following the instructions in Section I (Installation). Paragraph F.
page 6.
c) Replace runout membrane - If the foil runout membrane in the fu rnace
runout port was damaged. it should be replaced with a single thickness of
ordinary aluminum foil.
1 3 . Thermocouples
I. Type K. Elements - Both furnace thermocouple assemblies use heavy gage

Type K.. Chromel/Alumel thermocouple elements. Both thermocouple pyrometers
me calibrated to accept millivolt outputs from Type K thermocouples so other types
,-vill not provide correct readings and should not be substituted.
7
Metal Bath Thermocouple Replacement - Disconnect the thermocouple lead
wires at the junction block inside the thermocouple head at the end of the horizontal
pipe. Then remove the U-bolt clamp from the horizontal thermocouple pipe and
n.:rnovc the thermocouple assembly. Replace it with a spare thermocouple bath
assembly (StrikoDynarad Part No. 140-000 I for 18" assembly. Part No. 140-00 I 0
for 24" assembly) taking care to follow the instructions in Section I (Installation).
paragraph H. page 8.
CAUTION: Be sure to use only isostatically pressed silicon carbide
protection tubes for melting and holding aluminum. brass, or zinc. Tighten the U
holt clamp and the 90 degree elbow union to be sure the thermocouple provides an
adequate ground for the metal bath.
:,. StrikoDynarad recommends that the element temperature limit thermocouple
( StrikoDynarad Part No. 380-00 I 5) be replaced annually to reduce the possibility
or a failure which could affect production operations. The Inconel protection tube
wi 11 rarely need replacement.
4. Polarity - Observe correct polarity when connecting T/C lead wires to junction
block. Red is negative (-) and magnetic: yellow is positive (+) and non-magnetic.
C. Heating Elements
l . Description - StrikoDynarad electric heating elements are constructed from
high temperature iron-chrome-aluminum alloys which have a very high melting
point ( 2750° f). StrikoDynarad recommends they be operated at a conservative
l
maximum temperature of 2000° F (which is well below the maximum operating
temperature of 2500 ° F recommended by the alloy suppliers) to insure long life and
trouble free operation.
StrikoDynarad elements are supported from individual free standing ceramic
L panels and the elements are separately wired and fused so they will operate
independently.
l
l -19-
l
' Replacement of heating elements - Problems with cracked or broken crucibles

can occur in metal casting plants and usually spell disaster in conventional electric
!'urnaces. Fortunatelv. the damage thev can cause in a StrikoDvnarad furnace is
usuallv quite minor. ·This is because StrikoDynarad uses mam; individual heati rn2.
clemei1ts and such damage is usually limited to one or two elei11ents while the
others continue in operation.
Using methods described in Section IV (Troubleshooting). Paragraph D ( 4 ).
page 3 1. the user should determine which heating element(s) require replacement
and proceed as follows.
a ) Cold replacement - The furnace power should first be switched off and
locked out for protection of maintenance personnel. Then the cover hold-down
Iugs can be loosened and the cover lifted off and set aside. The element(s ) to
he replaced should he located and the lead wires detached from the copper
terminals using a pair of 7/ 16" end wrenches. The top ceramic stud and
support washer can then be lifted aside and the heating element lifted vertically
out without removing the crucible.
The replacement heating element can then be vertically lowered into place
with its base resting on the element support pad in the furnace floor. Using a
pair of heavy duty pointed nose pliers. grip the heating element lead wire close
to the point where it comes out of the ceramic panel at the top of the element
and bend the lead wire back at a 90 degree angle just above the point gripped
hy the pliers.
Thread the lead wire through the hole in the protective refractory blanket
and. with the heating element firmly in place and supported at the top by the
ceramic stud and washer. bend the lead wire 90 degrees toward the terminal
screvv. just in front of the face of the copper terminal.
Then. while pressing the lead wire into the ceramic fiber blanket in a
fashion similar to the other lead wires, bend a hook completely around the
stainless steel bolt in the fi:ont of the copper terminal and cut off the excess
lead wire.
l Jse only the special stainless steel bolts. washers. and nuts provided by
Strik.oDvnarad (Part Nos. 270-0 120. bolt: 270-0230, washer: and 270-0040.
nut) and-assemble just like the other connections. (Please note that the use of
substitute hardware or any other deviation from factory design could lead to
junction failures. ) Tighten the hardware firmly with the end wrenches and the
installation is complete.
b) Hot replacement - Heating elements may be replaced from a

StrikoDynarad furnace containing molten metal by following all of the above
l directions with these additional instructions.
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l -20-
(
INS TRUCTION MANUAL
Equip personnel with high temperature gloves and protective insulating

clothing. When the furnace cover is removed. place the crucible cover or a
suitable piece of ceramic fiber board or blanket over the crucible and lay a two
foot wide. five foot long strip of high temperature cerami c fiber blanket
( StrikoDynarad Part No. 520-00 10) over the gap between the heating elements
and the crucible to eliminate glare and heat radiation from this area.
Additional strips may be used to cover this gap all around the furnace to
m inimize the overall temperature loss during the element change. Using high
temperature gloves and the tools described above. the element(s) can be
quickly replaced. One element should be replaced in about one-half hour.
D. Tightening Electrical Connections
All conductors of electric current such as cables. connectors. terminals. etc. generate a
small amount of heat which. in turn. causes these conductors to expand and conttact. This
expansion and contraction can cause electrical junctions and connections to loosen. In
addition. vibration during shipment can also loosen electrical connections. Loose electrical
connections are highly undesirable because they increase the resistance to current flow.
generating hot spots at loose _joints which can damage or destroy the connectors and any
components to which they are connected such as contactors. fuse blocks. terminal blocks.
etc.
To avoid electrical hot spots. StrikoDynarad recommends the user regularly turn off and
lock out all electrical power and tighten all electrical connections at the power source. inside
the control panel. and in the fornace junction box. This should be done immediately after
the furnace is put in service (to catch any loose junctions caused by shipping vibration) and
thereafter on a quarterly basis. A "tug test" consisting of pulling firmly on the attached wire
or cable to check for looseness should be performed after tightening each junction.
Regularly tightening electrical connections is a sound maintenance practice for all electrical
equipment including electric furnaces which will pay dividends in time and money saved.
IV TROUBLESHOOTING
A Control Panel Electrical Safety
1 . DANGER - HIGH VOLTAGE! - Turn power off before opening the Control
Panel door. The fused disconnect switch or circuit breaker which supplies power to
the Control Panel should always be opened and locked out before opening the
( \mtrol Panel door and particularly before performing any maintenance work inside
the panel.
l
' Do not rely on the door switch - While the Control Panel is equipped vvith a
safety door switch which opens all high voltage contactors and shuts off all low
rnltage ( 120 VAC) control power. it is still possible to sustain dangerous and
potentially lethal electrical shock if personnel should touch any terminals behind
l the protective barrier. or if the barrier should be removed and not replaced. or if any
components such as contactors should become defective and remain closed when
they are turned off and expected to be open.
Don't rely on the door switch ! Shut off and lock out incoming power before
L.
opening the Control Panel door.
L - 2 1-
l
I�. Thermocouples
1. Metal Bath Thermocouple
a) Thermocouple failure - If the bath thermocouple protection tube is worn

out or damaged. molten metal can enter the tube and damage the thermocouple
element. This usually results in an open circuit condition which drives the bath
pyrometer temperature indicator to the maximum or full upscale position
causing the pyrometer to turn off power to the furnace.
However_ if any metal leakage through the protection tube is slow and
gradual. the thermocouple element may not immediately go into an open
circuit condition but instead. may degrade slowly and provide an incorrect
millivolt output (usually a low output). The bath pyrometer will then give an
incorrect reading which can be checked with a separate (perhaps a portable)
temperature sensing instrument.
,\ bath thermocouple short circuit condition. usually caused by a loose
connection somewhere in the thermocouple or lead wire circuit will result in
the pyrometer driving to the low end of the scale which will call for power to
the furnace. This can result in overheating of the bath with the highest
temperature ultimately determined by the setting of the Element Temperature
Limiter. Thus. care must be taken to avoid short circuits in thermocouples or
lead wires.
b) Replacement - A defective thermocouple should be replaced. Refer to
Section III ( Furnace Maintenance). Paragraph B (2). page 22. for thermocouple
replacement instructions.
Element temperature limit thermocouple

a) Thermocouple failure - The element temperature limit thermocouple is not
subject to constant submersion in molten metal so this is not a normal cause of
failure. However. the element will slowly deteriorate as a result of time and
temperature and will eventually fail. usually by an open circuit.
b) Result of failure - An open circuit thermocouple failure will result in the

clement temperature limit pyrometer indicator being driven fully upscale
vvhich will turn off power to the furnace. This could result in a freezeup of the
metal bath if the furnace is not supervised.
c) Replacement - A defective thermocouple should be replaced. Refer to
l
Section III (Furnace Maintenance). Paragraph B (3 & 4), page 23. for thermo
couple replacement instructions.
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L -22-
INSTRUCTION MANUAL
C •. 1\larms
I. Ground Fault Alarm
a) Description of operation - The Ground F ault Interrupter (GFI) senses

current flow into and out of the furnace. If inflowing current above the C i FI's
set sensitivity adjustment finds a path to ground instead of returning through
the normal supply cables. the GFI will detect the fault to ground and instantly
shut off power to the furnace. sound the alarm and light the "Ground Fault"
lamp. However. the GFI is designed to ignore very low level leakage currents.
which are normal. to avoid nuisance tripping.
b ) Possible causes - Any ground fault above the GFI's low level minimum
sensitivity (which is adjustable. but factory set at the most sensitive setting l
which occurs anywhere in the furnace power circuits beyond the GFI sensor
(located inside the furnace pull box) can trip the GFI.
For example. metal leakage from the crucible of sufficient quantity to
complete a path from the metal bath to a heating element should cause the (; FI
lo trip. Thus the isostatically pressed silicon carbide bath thermocouple
protection tube must always be tightly clamped in its U-bolt clamp with its l)()
degree union similarly tight to adequately ground the metal bath so that the
C ; Fl can operate properly.
Similarly. any other such path to ground caused by any metallic object
contacting any current carrying cable or component in the furnace should trip
the GFI.
c) Reset - Open the Control Panel door and locate the ground fault relay
inside the panel. Switch the white circuit breaker lever upward to the reset
position. If the fault is clear. this will silence the alarm.
d ) Find the cause - lf the GFI successfully resets. the furnace should be
closely inspected for the cause of the original trip. For example. the rune.mt
port should be inspected for evidence of dripping metal which might have
resulted in a GFI trip.
If the GFI will not reset. the fault has not been cleared and the furnace
must be shut off and checked for the cause of the ground fault. Use the
following procedure :
I ) Be sure the ground fault relay sensitivity adjustment has not been left in
the "test" position which would cause continuous tripping. Refer to page
I 0. paragraph 5 for directions on how to check this.
2) Open the main disconnect and check inside the control panel and the
li.mmce terminal box to be sure that the neutral terminal has not been
connected to ground. If it has, remove this ground connection.
l -23 -
l
3 ) With all povver off remove all of the heating element fuses and
disconnect the neutral lead going to the furnace at the _junction terminal
inside the control panel. Then close the door and restore power and see if
the ground fault relay trips. If it does. the ground fault relay or sensor is
causing the problem.
4 ) If the ground fault doesn't trip. the fault is somewhere "downstream" of
the heating element fuses. To find it. connect one lead of an ohmmeter to
LJ:round and touch the other lead to each of the lower fuse terminals vvhere
the wires going to the heating elements in the furnace are connected. Also
touch this ohmmeter lead wire to the neutral lead going to the furnace
which you _just removed.
1r you find resistance ranging from a dead short to several thousand

ohms between any of these wires and ground you have found the ground
fault. Trace it out and locate the exact point of the fault which could be in
the wiring going to the furnace or somewhere inside the furnace. perhaps
caused by a recent metal spill. When the fault is cleared. you're back in
business.
NOTE: A new furnace which has been operated less than two or
three weeks or an older furnace which has been placed back into service
after several months of inoperation may contain moisture which can
register resistance readings. usually in excess of ten thousand ohms. which
is normally insufficient to trip the ground fault. Resistance readings
caused by moisture also tend to give "erratic" readings which seem to
constantly change. These readings will increase up to the megohm and
higher range. effectively disappearing. after the furnace dries out fully.
Should GFI tripping continue without obvious cause. the user should
contact StrikoDynarad's Service Department for assistance.
2. lligh temperature limit - The element temperature limit pyrometer is equipped
,vith a second high temperature alarm setpoint which actuates approximately I 25 ° f
;1bove the normal adjustable high limit setpoint (which should not be set above
:2000 ° F). If actuated. this high temperature alarm will open the power contactor.
sound the alarm. and light the red "Element Over Temp" lamp.
Should this alarm be tripped. the user should shut off power to the furnace and
permit it to cool down below the normal high limit setpoint and then investigate the
l cause of the alarm and correct the problem.
t
D. Heating elements
1. Using ammeters to monitor the heating elements
l a) Introduction - This StrikoDynarad furnace is equipped with ammeters

,v-hich continuously indicate current flow to the heating elements. These
ammeters provide helpful information about the condition and performance of
l
the heating elements.
-24-
(
INSTRUCTION MANUAL
b) Independent readings - Each ammeter independently reads the current in

.i ust one phase regardless of furnace voltage or whether the furnace is wired in
a "delta" or "wye" configuration.
c) Element grouping - A group of elements is wired across each phase. the
exact number depending on the size of the furnace. I n some furnace models
the number of elements in each group may vary. but never by more than one
dcment. Thus. all meters will read close to each other but may not read
exactly the same.
d) Separately fused - Each heating element is separately wired and

individually fused. Heating element fuse blocks are located inside the Control
Panel. The Control Panel should never be opened without shutting off all
power to the furnace.
e) Determine elements per group - The user should refer to the electrical
schematic diagram for his particular StrikoDynarad furnace model and
determine the number of heating elements connected in each phase group.
Then he can divide the number of elements in each group into the ammeter
reading for that group to determine the current flowing through each individual
hcatin!! element. This information will be useful for check.in�� elements
following instructions in Paragraph 3 below.
' Normal current variations
a) Voltage fluctuations - Most electric utilities are obligated to maintain their
customers' voltage to no better than plus or minus five percent of the nominal
supply voltage. Since the current flow to the heating elements is proportional
lo the supply voltage, ammeter readings can vary by this amount as well.
The supply voltage normally follows grid wide as well as local demand
patterns. It will drop during periods of heavy use and rise during off-peak
periods.
h) New elements - When StrikoDynarad heating elements are brought to fu ll
operating temperature for the first time. aluminum in the resistance alloy
oxidizes at the surface. forming a protective coating of aluminum oxide. This
effectively stops further oxidation and gives StrikoDynarad heating elements a
decided advantage over other types, such as nickel/chrome elements. which
form no protective coating and continuously oxidize until they are no longer
useful.
When StrikoDynarad elements form this protective oxide coating. the
dectric resistance rises slightly causing the current to drop slightly. Then the
l
resistance remains relatively constant throughout the operating life of the
element.
c) Temperature changes - As with most resistance heating alloys. the
l clements will draw slightly more current when the furnace is cold than when it
has reached operating temperature. This is normal.
l
L -25-
(
3. 1\bnorn1al an1111eter readings
a) Element out of circuit - If the current reading of any ammeter should drop
hy an amount equal to the current required for a single heating element. then
one element is out of the circuit for that group. A current change of this type
can be distinguished from a normal voltage fluctuation by noting that the
change is larger than most normal fluctuations and appears in just one meter
while voltage fluctuations usually affect all three phases at once.
b) Causes - An individual heating element can drop out of the circuit because
of an open fuse. an open wire or junction. or an open heating element.
..J.. Checking individual element circuits.
The follO\ving procedure may he used to troubleshoot heating element circuits.
a) Shut off all power to the furnace. Lock out the breaker or disconnect to be
safe. However. it will not be necessary to empty the furnace since the
checking procedure can be completed quickly.
b) Open the Control Panel and remove all fuses from the element fuse blocks.
(It will not be necessary to remove the two fuses which protect the step-down
transformer which provides low voltage instrument power.)
c) Use a continuitv checker or ohmmeter to check the fuses. Ir any are open.
obtain replacement; of the same size and rating.
d) Re fer to the electrical schematic and determine whether the furnace is

'\.vye" or "delta" connected.
Most 480 volt furnaces are wye connected and the return leads of all
heating elements are connected to "neutral".
Most 240 and 208 volt furnaces are delta connected and the return leads of
the heating elements are connected to the incoming three phase power legs
designated "A". "13". and "C".
Referring to the connection lugs on the main contactor and the heatirn2:
dernent retm;1 terminals to the lefl:�of the element fuse blocks. the left lu!.! �ff
terminal is leg ":\". the center lug or terminal is leg "B". and the right lug or
terminal is leg "C".
e) Checking "wye" connected furnaces - Connect one probe of an ohmmeter
to the furnace neutral terminal. This will be the red colored stand-off insulator
terminal to the left of heating element fuse blocks. Then. with the fuses still
out of the fuse blocks. measure the electrical resistance of each heatin!.! element
by contacting the other ohmmeter probe in turn to each of the lower fi3se block
terminals.
l - 2, 6 -
(
INSTRUCTION MANUAL
All elements should read approximately the same resistance (this

resistance will depend on the furnace operating voltage). If any circuits are
open (the ohmmeter reads infinity) or read much lower than the others
( including a direct short). note the element number for later checking.
Ir all elements read approximately the same resistance. and a fuse was
previously found to be open. the problem is the fuse. Replace it and place the
1·urnace back in operation.
I') Checking "delta" connected furnaces - Note that each fuse is labeled with
a number followed by two phase leg designation letters separated with a slash
mark. For example. a fuse might be labeled. " 3 CIA."
To check each element first connect one probe of an ohmmeter to the

appropriate furnace return terminal lug (to the left of the heating clement ti.1sc
blocks) corresponding with the second letter on the fuse label. (Remember.
the left lug is "A". center lug is "B". and right lug is "C".) Then connect the
other ohmmeter probe to the lower terminal of that fose holder and read the
clement resistance.
Similarly. determine the resistance of each of the other heating elements.
carcfolly following the above procedure. Just like the "wye" connected
rurnace. all elements should read approximately the same resistance (this
resistance will depend on the furnace voltage). If any circuits are open (the
ohmmeter reads infinity) or read much lower than the others (including a direct
short). note the element number.
If all elements read approximately the same resistance. and a fuse was
previously found to be open. the problem is the fuse. Replace it and place the
fi.1rnace back in operation.
:'i. Ir any of the heating element resistance readings show an open circuit (the
ohmmeter reads infinity). or if they are much lower or even a direct short the
i"u rnace must be opened and the element(s) checked.
However. it is not necessary to do so immediately. If the user would prefer to
check the element(s) later, all fuses may be replaced except those which protect the
clement circuits in question and the furnace may be placed back in operation. The
clement(s) can then be checked at the convenience of the user.
6. Element numbering system - Looking down at the furnace in plan view·. the
he,1tirn1: elements arc numbered in consecutive clockwise order starting with the
clement closest to the element protection thermocouple. These numbers correspond
{
\\·ith the numbers shown on the individual element fose holders.
7. Replacement of heating elements - rollow the instructions in Section III

( Furnace Maintenance). Paragraph C (2).
l
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l -27-
E. Temperature Control Instruments
I . Fine Tuning - The bath thermocouple pyrometer may require "fine tuning"
acl_justment(s) of the Reset Rate. Proportional Band. or Load Line settings to
improve temperature control performance in a particular installation. The element
temperature limit pyrometer requires no internal adjustment.
' Refer to manuals - Please refer to the individual operating and servicing
manuals for "fine tuning" or other information concerning the pyrometer
instruments which are found in the Appendix at the back of this manual.
l
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L - 2 8-
L
V REPLACEMENT PARTS LIST - MODEL EC- 1500
Following is a partial list of replacement parts for your StrikoDynarad furnace. Please contact
the factory for any parts which are not found on this list.
DESCRIPTION PART NO.

THERMOCOUPLES & ACCESSORIES �
Bath thermocouple assembly. complete 24"
B ath thermocouple protection tube 24" . .e
Bath thermocouple element 24" hot side
High Limit TIC Element Assy. 12" 140-0012
REFRACTORIES & CERAMIC COMPONENTS
Blanket 1/2" thick ceramic fiber 520-0030
Blanket I" thick ceramic fiber 520-001 0
Blanket 2" thick ceramic fiber 520-0035
Patching cement for floor. castable. 75-lb bag 50 1-0010
Ceramic studs 2 1/2" 530-0020
Ceramic pink washer 530-00 1 0
�O \ ,....,. �� 1 � '
HEATING ELEMENTS \ i-.t
Type E. 28". 277 volt ) � \� -
MISC. F U RNACE COMPONENTS
I-lat Ring
Element Terminal Assy. EC-Series 103-0025
1-l igh Temp Stand-off Assy. 103-0 1 00RP
Pedestal Size
Seperation disk-one size. customer cut to pedestal size 530-0138RP
Wire Harness
Heating Element Restraint Replacement Assy. ( Heater Hanger) 320-2110
INSTRUMENTS. REL\YS & MISC.

Bath Controller. Honeywell UDC 3000 350- 1 1 1 5
High-Limit controller. Honeywell UDC 2000 350- 1 150
Relay. Contactor Control 320- 1 120
F uses ATM 30 3 60-5230
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VI INDEX
Fluctuations. voltage 30
current 30
Alarms 2 1 -22 Fluxes 17-20
Ammeters. reading 29.3 1 definition 17
Argon degassing 16- 1 8 non-reactive 17. 19
Batch melting. pyrometer reactive 17-20
settinQs 11 tablet 17. 1 9
Batch 1;1clting. maximizing Fork channels. furnace 4
utilization 13- 14 Freon degassing 17. 19
Bath pyrometer. setting I I Furnace cover. proper
Charge material. drying 12 sealing 7-8
Chlorine. use of 18 Fuse. open 3 1. 33
Connections. tightening 25 fuses 29-33
Continuous melting. Granular fluxes I9
maximizing melt rate l 0 Ground fault interrupter
pyrometer settings I I 1 0. 27-28
C�ontrol PaneL n1ounting 3 Ground. furnace 5
wmncr 4-5 Heating elements 23-24
safctvc 26 checking 31
Cover: furnace. proper designation 32-33
seal in!! 6-7 groupmg 30
( ·over. 1-1neumatic 7 new. current readinQs 30
Crucible cover 13 numbering 33
Crucible cracks I7 over temperature alarm 25
dimensions 5 oxide coating 24
double glazing 5 proper lifting 4
filling at night 13 replacement. cold 22
gasket 8. 15 replacement. hot 21
17 rubber padding ,.,
inspection _)
installing 6 temperature change.

overfilling 17 effect 30
replacement 6. 7 temperature limit.
scraping 16 settinQ 8. 1 0- 1 3. 25-26
sling 6 Holding: off shift l6
l
Crucible separation production 16- 1 7
disk 7. 22 Main switch. installing 5
Current fluctuations 30 Melt rate. maximizing l 0
l
Delta connection Metal leakage. thermo-
current readings 8 couple 22
Demand control 15 Moisture danger I0
Drying charge material 12 Nitrogen degassing 16-18
Electric resistance. Overshoot, temperature 15
heatin!! elements 29-33 Oxidation. heating
Electric'al connections. elements 24
l
tid1tcnin!2. 25 Packing. styrofoam 3
l�l�ctrical ::Viring check 6 Padding. elements. rubber 3
Explosion hazard 12 Phase designation 25-26
First melt I 0- 1 I
l
l -30-
VI INDEX (continued)
Pit installation 4
Pneumatic cover ()
Power failure 20
Po\\er level switch 9. 1 5
Protection tube. bath
thermocouple 8. 22-23
Protective coating.
heatinf2: clements 30-3 1
Pyrometer settings
9. 1 1 . 33
element temperature
limit setting
()_ 1 3. 1 4. 28
Runout membrane 22
Runout pan 4
Salt fluxes 1 7-20
Seven day timer 1 1 . 20
Shutdown 20
Steam. startup 12
Tablet degassers 1 7. 1 9
Temperature control
1 3- 1 6. 33
Temperature overshoot 1 5
Testing.
electrical 5. ')- 1 0. 3 1 -33
Thermocouple
installing. bath 8
conduit 5
connections 5 -6
failure 26-27
lead wires 5-6
metal leak.acre 26
open circuit�ondition 27
polarity 5 . 9. 23
short circuit condition
l
26-27
replacement 8. 22-23
specif'ying: 8. 22-23
Thermocouple. bath.
l { I-bolt clamp
Tie:htenini! connections 25
8. 22
Ti�1er. se;en day 1 1 - 1 2. 20
l
Utilization. furnace I 4
VoltaLl.e fluctuations 30
Wve ;onnection. current
r�ading:s 9
l
-31-
r-·
FU RNACE COVER
INSULATION
FURNACE
COVER
PLATE
\
-- 2" GASKET
INSULATION
HIGH -TEMP
CERAMIC
STAND-OFF
WIRE __J CRUCIBLE

HARNESS
H EATING
ELEMENT
RUN -OUT PORT
NOTICE
CMWWl CORP. - - � - - be
bu--
ln• doc.- is tr-eel ,oieiy fo, the pu,poN
"' aang the tr-lion cl l>at
r.tumed on �- ,.. drowir>9a, inlormotion ond

GRADED
FURNACE
doto inck"""i ol � - � cont......S
t>er-aon c:n the .,.--ty of O'l'KAIVD CORP. -
INSULATION
ffiOy � be � ,,, coi>ied in - « in �
nor oppr-opriGted to uM{s) in Otty --, � to
the -• ct D..-..0 CIJflf'. including d;.do-
it be - f« the .......,oc:t..-. "' .,,,,

...-. t.o out...i. po,tin, directly o, indirktly, nor con
,cribe(I �t the �ic ,.;tt-, con...t ct

�
......-,t
IMWW> CORP.
(1:10)
DYNARAD TEl...£PHONE: (510) 638-2000

FAX: (510) 639--4�
INSULAT ION DETAILS A 0132
EC FURNACES FILE: A0132A-l.D\JG
VI I NDEX (continued)
Pit installation 4
Pneumatic cover 6
Power failure 20
Pmvcr level switch 9. 1 5
Protection tube. bath
thermocouple 8. 22-23
Protective coating.
heating elements 30-3 1
Pyrometer settings
9. 1 1 . 33
element temperature
l imit. setting
<)_ 1 3. 1 4. 28
Runout membrane ''
Runout pan 4
Salt !luxes 1 7-20
Seven dav timer 1 I . 20
Shutc.f ow�1 20
Steam. startup 12
Tablet degassers 1 7. 1 9
Temperature control
1 3- 1 6. 33
Temperature overshoot 1 5
Testing.
electrical 5 . 9- 1 0. 3 1 -33
Thermocouple
installing. bath 8
conduit 5
connections 5-6
failure 26-27
lead wires 5-6
metal leakage 26
[
open circuit condition 27
polarity 5. 9. 23
short circuit condition
26-27
replacement 8. 22-23
specifying 8. 22-23
Thermocouple. bath.
[ lJ-bolt clamp
Ti!!htcnin!! connections 25
8. 22
Ti�1er. se;en day 1 1 - 1 2. 20
l
Utilization. furnace 1 4
Voltage fluctuations 30
Wve connection. current
r�adings 9
l
l -31-
,--- ,--- -
r�:==::i
i:
:!
i: t,,,,,J n t �
L� SUPf'ORT MO.( <RE,.,
·-��
�¼ \_ 1£AT(lt L(AD <1t£F.l
·\/IRE LUG ON '--{1 1

\IJRING HARl<SS
<R(F.)
EDIT EDIT EDITIEDIT

REV I ZONE DESCRIPTlON BY I Do>,T
(
TOLERANCES:
UNLESS OTHE:R'MSE SPEClflED TEl...E?tiONE
�·fmY l:a
Olhl(t(S)()NS � 1K INO£S
--.a
"' ..'lfA STRIKO
-:::. .• DYNARAD
(510) 638-2000
FAX
(5 I 0) 639-�5&4-
...................
�:.��---=--
NOTlC£
...., ...... ..,,...
ELECTRICAL S T AND-OFF
... .......
.. ....................
=_..........
� r::.= cn:..
· :.:: .::=--
.,_... _ .....-L · ---- ---- -
.... � ->- � UR'. ... ------ -- - - ---- -- - --
AO1 68
..-.-.
- - .. - ., -.. "' - ., " - --DHT """' 1 -20-98 OR»l'ING NO.
........._ _ �
REV.
.. _ _ _ _ _
......._.. _ .., ... - """' A
:.0"":_- - - - • =.,: """-' 4 / 7 A0168A-l.D\JG
SHcrr l or l
ELECTRIC STANDOl"F ASSEMDL Y & IIARDWARE
FOR CONNECTING TI I E STANDOFF TO TIIE HEAT I NG ELEM ENT
r
---- --(
l
�
---·tl·-·-·-·-·-
SIPPOII I N«il.C (R[r.>
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\_ 1-l[l\l[lt L[AD (R(r.>
VfRt LUG Cl'f

VIRl'fti HMNCU
(RE.r.J
The sla11Joffassemb.ly is used as a connection between the wire harness and the healing
cl�ment.
The Part Number is 103-0J00RI' and may be purchased as an assembly 011ly. II consists o[
Q) Stainless steel screw, ¼ x 2¼", 1 8-8 stainless steel.

(Z) Female cup bushing, ceramic standoff
0) Shoulder bushing, ceramic standoff
®
(J)
<ID
Duss bar, copper clip assembly
Hex. nut, 1 0-32, 1 8-8 stainless steel
Flat washer, # I O 1 8-8 stainless steel
��)J
® Lock washer # I O stainless steel 0
\..........
11,e l,ard"'are assembly used to connect the heating element to the stan<lon: is made up of
the remaining drawing numbers on the diagram below.
The Part Number 1.70-0J27. lt is supplied as part oflhe replacement heating element, but
may be purchased separately as an assembly. It consists of:
� Hex bolt, ¼-20 x I " 4 1 0 or 430 stainless steel.
(G) Hex nut, ¼-20 304 stainless steel.
(9) Flat washer ¼ x. 1 1 / l 6 304 stainless steel
1 1 . Flat washer ¼ x 7/8 304 stainless steel
__
1
r-
_
, r-
B A TH THERMOCOUPLE POWER CON TROLS
!OYNARAO!
r.::::::ir::=.::,r:;:;:-:::,
��
DIMENSION TABLE
� 83 � 3 6"
MODEL D,7T D2 P, P2
01
EC- 600 1 8 46" 1 2" 1 2"
"
El EC-700 21 ' 5 1 1 2" 1 2"
EC-950 2 7" 56' 1 8" 1 2"
ELECTRICAL P U LL B O X EC - 1 1 00 3 1 " 63" 1 8.. 1 2"
EC-1 500 34" 53- 1 8' 1 2"
"
EC-2400 37 ½ " 72 1 8" 1 2"
F--- 3 0" �
1 2"
IQ.._ II
..1. NOTE: RUN-OUT PORT MAY BE LOCATED
IN ANY OF THREE POSITIONS RELATIVE TO
ELECTRICAL PULL BOX.. CONFIGURATION
------- 02 -------; "A" SHOWN. PLEASE SPECIFY.
IO'YNARA0I
4 2"
[□� P2 �
TYPE "A"
ELEMENT PROTECTION
THERMOCOUPLE
EMERGENCY R U N - OU T PORT
FORK LI FT ACCESS
-•STRIKO
C R U C I B L E MAKE g. MODEL: _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ -.: DYNARAD
,� ..,,,..,_, StrTn,, S... L...--0. CA ,.,77
T- c:11� r... C,llll�---
S U P P L Y VCLT A G E : _ _ _ _ _ _ _ _ _ VOL TS, _ _ _ _ _ _ _ _ HERT Z ,
,,..,_,Ian to,..,_
Thte docMfflenl ia trOl'l""'ltled _.., fo, the � ol E C SERIES
v: TH O O
oldl,,g lhe of bel- STRIKOO'l1'NIAD
ELECTRIC RESISTANCE
OR 'w'I ) HDUT NEUTRAL ond lh• rcip..-it en- mu■l be ral\1.med Ql"t requel. AM
drowlgs. wtlormollan ...d clato Mtud� .. dal<!n• ...d WELTING FURNACES
O 0
can-I• ..,,.loi,,ed ,__ are Ille -ty ol STRIKO OYIIAlll,Q
.,..ol•
If·
S T A R T - U P SERVICE REQUIRED'? YES NO Oftd moy not N f"tlllll'OdUcad r,t CIIO.ed irl or lfl pearl
.,,_ta
nor �ted lo uN(1) i,, .,., _, detnm..toi lo lh•
ol STRIKO OYMAAAO lndudlflg died.,.,,_ lo outalclll
pcwll-. dlNc.Uy r, 1"d�U-,. "°' COi' ll tM uNd far -c oos1
S H I P V I A '? lhe rnant.tfact.ure al any -,.,ipm-,t ._,.ibed withaul lh• Flt.£: cooa,r-1.owc
IDeeiflc •ill., c:an_,t of ST'RIKO OYNAAAO• . SHEET 1 OF 1
Stri koDynarad
ALUMINUM AND WATER VAPOR
The origin of aluminum oxide and hydrogen gas is often misunderstood. Too often burner or
fuel fired furnace manufacturers would have us believe that their "advanced technology" has
solved the problems of dross and hydrogen gas contamination.
Although we agree that properly designed and operated fuel fired equipment can keep
contamination to a minimum, it also must be noted that certain laws of physics cannot be
altered or designed around. The following technical data is to inform you of the problems
inherent in fuel fired furnaces due to the by-products of combustion. More complete data is
available upon request.
With this information in mind, it is easy to understand the distinct advantages of electric
melting and the way in which it helps to insure reduced melting costs and a cleaner, purer melt.
Please refer to enclosed exerts from the Aluminum Casting Alloys Handbook and Casting
Kaiser Aluminum.
l
L F:\sales\sales aids\al and water vapor
L·
L
l
CAS'flNG l(Al�Elt ALUMINU1'1
l'ii; anJ Iugot l'roJuct Dal•
C1111i11g l'rnctlce■ and

C.l1aroclcri■tle1 of nloltcn Aluminum
nnsr EDITION
KAIStn ALVlllHVll A CIIOIICAL IALU, IHC.

IHl1 North Mlchl1•n Annul
Chlciigo 11, llllnolJ
Tho mere µnrncuce o{ tllseolvctl a11.s i n l h e mollcn mclnl t.loes 11ol
11ecess11rily menn lhnl hnrm{ul poro11lly w l l l appcnr 111 llio cn1li 1111,
Unt.l cr cu11di liu1111 or rupltl 1111litllllcnllon, ,wch 1111 IH fou11LI 111 111i r1111111011l
111111d 1·11:tl i111:, I lw i li:1:11,h·,·d �:11111•11 11111.v 111• t l i:qwnwd i 1 1 11111:h II li1rnl.v
d l v ldt:d 11l.11I.P 1.1111I. 1.111•.v c111111ol 1111 11i1Hu1 ° vu1l v il(1t11lly 1111tl i11 w l t it:lt llwy
1 1 0 11ol nlfccl 111lv1!rHuly lhu 11rc1111 u ro-lluhl11c1111 of the cnsling. Their
presence, ltow11nw. rnny hnvc l'omo oITccl on lowering lhc 111echu11ic11I
prnperli1!11 of l.111• 1·:1111i111r. parlic11l11rly d11l'.l i l l l.y 111ul lrnp:1cl 11lrc11iclh.
The :rnfc/\l prncl.ir.n i" to hnvo, a11 nearly n:1 po11Riulc, n gos-free mclnl
Lefore cnsllng.
T�1e -�e�ontl_J_��lalne the mechanism by�<:.!!__g_nscs -�-t_�
a_�sorl.,1:_d . .9_� rctJ uclng gase1 are dlssolvecl In mollen nluml11 u m._'l'ltc
f
oxygen In oxidizing gases forms oxide compounds which J >_!Cc�pi lnlo

out a11t.l ellher flont In the melt · or rise lo the 11urfncc, t..lcpent.llng 011
lhelr-aiJ'edficgriwlty relative to the melt. 'l'o repent, unless n reuucl11g
gas ls"ln-conlRct with the molten metal, none of tho irns wllr1o<l ls-
110lvct1:·wntor vnpor mu11l ho con11hiorctl In the cntcgory orrc<luclng
·g ases· sl nee 71ls-decomposed lnlo hydrogen Rn<l oxygen wlien l l comcR
1,iCoconliicfwilh mollen l\tumlnum,
AllhouK' h a n umuer ol reducing gases may uc present i n t h e
furnace almosphere, dcpentllnr on lhe na ture o! l h c f u e l n n t l co11 1 uus
lion contlillons, hydrogen is the gas mosl rcatJily nbsorl.,ctJ. Il Curlher
nµpcnrs that the grenlesl amount ol gos absorption occurs when l 1 1 e
hyt..lrogc11 Is In the Cree or nascent ala� ( hydrogen protlucet.1 uy some
l'eacllon in the vicinity ol the molten nluml n u m ) .
E F FECT O F M O I ST I.__J R E
When waler vapor 111 decomposed lite hydroge11 that fo pro<lucctl
Is In iiie nnscent or active stale. Itfollows lhal\vatcr, wnler vopor or
nny form o{ moisture nre very likely causes o{ gns nusorpl1011 n n u
j)oros"fty Ill cns tin!l','I , I t I s lherel�re Impera tive lokeep lo n iiilniniurli
the amount ol moisture comlnr Info coilTicCwiU,-i11·01 l'en-n l u 111iiiuil1.
,fiioThe·rs·o-urce on 1 1drogen Is luel llsc1f.7Cr1111_y_co1i lain-J i yd i·oiielll\· s
one o{ i ts components or may be composctJ o{ hyt.lrocnrLons w h i c h i n
l h c process o ! cornl.,usllon are converted Into wn ler vnpor.
ll is commonly M1:1umed lhat In crucll.,le or open pot 111 e l li 11 g 1 1 0
�!.!_g er exlRtR from g1111 nl.,sorptlon becnuRo lhr. tlnmo does not come
l ��conl�ct with tho molten ·metal. This nssump_�!�!.!_!�_fRl.�:�ses_
con difTuso very rendily lhrouirh a refrnclory crucible, nncJ It hns Riso
£,'cc1i11i:11v·ciltl111t. 11:t:-ICt!lll hydro run CIIII pcnulrnlc li10\Villliicir11 c1111l
•�neTflng pol. It shou ti e note thnt most Cu els cmifnTil7iy(li·oge1i
�.IJ!xdr_<?_c nrbons, 11nd lh11t 11everal gallons of water in the form olvnpor
nrc produced therefrom durlna- tho melting ol n h e n t of nlumlnum.
J\ 1111lhcr 11011rcc of wnler vapor Is the nlr. I n open-pol m e l t i n g this
i!! on i111µorln11l fnclor, s i nce the molten inclnl is n lwnys in cu11l11cl w i lh
lhe 1:urrounrllnu 11 l.rno.� rhr.ro. f:nri,l lllon!I n( hlid1 h u m lt.lily, llrcrcfurc,
mny vcr.v wull cu11 l.rili11lt! l11 1111 h 1 cru1111l! In poro:tily. ThlR 11111y 11ccou11t
fur lhc fncl lhnl ll1tli11fncl11ry cnl\tlllgK nre produced one day nntl on the
folluwi11g dny l'cJecls are high, although there is no u ppare11l change
in fuuntlry prucllcu.
1.
CASTI N G A LLOYS
HAN DBOOK
FEDERATED METALS DIVISION
AMER ICAN SM ELTING A N D R l!: F I N I N O COMPANY
1ao ■AOAOWAY, Nll!:W YOnK "· N lt W YOAK
COl"V,.IOHf " " ,101nA T I O MITAi.i OIVIIION, ,.,,u:,.,aAH eMII.TINCJ ANP nU'ININO coMrANV
our tltt•f II WAtt t i IHtv•• fHt a t t v 11 a c , "' tlft , . , ,. . ... " n t u t • " • " "'"'' a1•1•, •"•llf• ,,. tmt uu,eaiun• • • uo ,...,, w c, w r v 1 11 . a u A ,u M r r t '"' lll! 1 t ,11. r t r o 1 1
O l t A I H f tl rttnW I M C lflU ,,, •111,- IHlf"• .. tllOJlf
I
bg reduces g:i.s porosit_:-'. However, g25 porosity xruty be � impor
t=t factor in other � of ostings. The best v.';J.y to minim.�
ur-.soundncs:s resulting from r;:i.s evolution is to combine the ,'"Uioc.s
me:ins of -.voiding g:is 2-bsorption with sui::able subsequc:::it de
g�g procedures desc:1oed in a �ter .sec!:ion.
Fi� :t-Seciioll or • Cut Part Tile sourc=s of the � will provide the found.ryxr.:i.n 'With a l:: ey
Showin.; roroaitr f'ou,blr
Ca...-ed 'by Caa £....,lulion. to t.�e ,�ous me:u:JS whereby the a.bsorption of this gas c::i.n be
Dunn; Soticil!ic:alioa m;nj::n:�ed It is difficult to rate the rel:itive impcrtance of these
d.i.fferc:nt sources of � becaase the conditions will vary cons:ide:r
ably from &y to 6y in the foundry. The following is a. desc::-ip
tion of th� sources of moisture and hydrogeD and the methods of
mi.ni..r:ni:in g hydrogen absorption from them.
Thembl.c:n
Products of Coml:,ustion
Gas Porosity cont:tin '
of controlling� in slumioom
C2Stin is e:it@v §ple �
on}y one g:u. bydr-ogc:n. u
involved. ·ci.d the principal � of this ,:..S U moisture-• C accom- "
solubility of hydrogen in solid :uuminum is :um0$t nil. When the
alloy melts, sohibility of tlie hydrogen incre::uc:s somcwh:lt :i.nd
cootinucs to ino-e2se r.a.pidly with 2n inc:rc:i.sc in te:mpe:-:i.h.m!..
'When a g--_s-cont:i.ming rnelt soudi5c:s too slowly, the dCO"C25-
bg so1u'::lility of the hydrogen ousc:s it to prccipibte to form
pi.::ihole::s, Fig. !, ;i.nd mic:-opcrosity. When the o:t.ide sl:in on :LU
::Llumin= melt is broken, the melt readily rea� with moistu..-e in
to form ;i.luminum oxide ::Lnd :i.tomic: or �cent hydrogen which
:s a!J-=dy :i.c"..lve ch cmiolly ::i.nd which is re:idily :md r.ipidly
di::solved by the 2luminum melt. Atmospheric Moisture
Mo�ture occurs n=itur:i.lly in tlie :i tmos-phere :ind ,-:tries from ::i
Sou.recs o f Hy dro;;cn :rn d Mctuocls o f fr:iction of :i gr:i.in per C\.lbic foot of ::iir in d ry clim=itcs to 12 or
Avoidin� G:i.s Absorption 13 gr:iins per cubic foot in hot humid wc:ithcr. It is :i common
The !o-:.ndrpi:i.n should be :iw:ire of the sources of gas 2nd t�e CX?C---icnce th::it the problems of g:u unsoundne::s in .luminum
l':lcthoc.s of ::i.voicing g:i.s :ibsorption. No dei;::i.�ing procedure m.-iy c:utings incrc.-ise with the �bsolute humidity. This source of g:u
be rcq,u i:-ed in :ubscqucnt opcr.itions if g-::i.s :ibsorption is mini is p:u-tiC\.ll:irly import�nt during the tr:msfc:r of aluminum rnclt.s
mb:d :ind if i;::i.s porosi:-y is not :1 m:ijor bctor in determining or during :i.ny other mct::il h:mdling oper:ition in which the oxide
:i ccept.:i.blc c:u'..ing qu::i.li:-y. In die csting. the npid r.ite of cool- lilm is broken :ind the mdt is permitted to cont:ict the �trnos
phcrc. In :i given geo�phical loc1ity. tlie only means of avoid-
70
71
- ___,
A StrikoWestofen Company
I
STAN DARD LONG LIFE HEATING ELEMENTS
FEATURES Dynarad® continuous duty, high temperature rated heating elements,

with tens of thousands in service, are unsurpassed in operating life
I
I
and reliability since first introduced in 1983. The durability and per
formance of Dynarad heating elements has never been equaled, an
enviable record that enables Dynarad to back its elements with the
I
industry's best warranty.
I
DAMAGE RESISTANT
PARALLEL ELEMENT WIRING
I
All heating elements in Dynarad furnaces are independently parallel
wired and fused instead of series-connected like old style heating
element arrays. With series wiring, if one element burns out, all
I
elements in the series string immediately stop working. But if a
Dynarad parallel wired element sustains damage, all others remain in
operation! This common sense design gives Dynarad furnaces the
I
highest up-time reliability in the industry.
"THERMOS BOTTLE"
MULTI-LAYERED LINING I
I
Dynarad furnaces use a computer optimized, multi-layered lining
system designed with Dynarad's own custom software to cut heat
losses like a thermos bottle. Old-fashioned monolithic refractories
I
are eliminated to boost furnace efficiency and save energy dollars.
I
HEAVY DUTY CONSTRUCTION
Dynarad furnaces are built to handle the severe conditions often
I
found in foundries and die casting plants. Features like extra heavy,
warp-proofplate steel furnace covers (3/4" for larger furnaces, ½" for
smaller), heavy welded steel base and sidewall construction, and a
rugged steel "hat" ring to protect the top of the crucible are standard
on all Dynarad furnaces.
I
REPEAT ORDERS FROM DYNARAD USERS
EASY INTERNAL ACCESS
The crucible and self-supporting, vertically installed heating ele
I
I
PROVE AGAIN AND AGAIN ments are easily accessible by removing only the furnace cover.
DYNARAD® FURNACES Side panel access is not required so Dynarad furnaces can be posi
ARE THE MOST RELIABLE tioned close to casting equipment or other furnaces or pit mounted
without sacrificing internal accessibility.
MELTERS AVAILABLE TODAY! I
I
I MS SERIES STATIONARY FURNACES
I MODEL
MS-175
MS-260
MELT RATE*
175 lbs/hr
260 lbs/hr
CAPACITY
325 Ibs
550 Ibs
WIDTH
43"
46"
HEIGHT
41 "
41 "
I
MS-260W 260 lbs/hr 625 Ibs 46" 41 "
MS-400 400 lbs/hr 700 Ibs 53" 45"
MS-400W 400 lbs/hr 1 ,000 lbs 53" 45"
60" "
MS-500 500 lbs/hr 1 ,200 lbs 45"
I
MS-500W 500 lbs/hr 1 ,700 lbs 60" 5
4 "
MS-600 600 lbs/hr 2,600 lbs 67" 45"
MS-700 700 lbs/hr 2,600 lbs 72" 53
MS-1000 1 ,000 lbs/hr 4,200 lbs 72" 70"
*Rates are based on continuously melting aluminum at full power in
I a clean, hot crucible at 1300°F with cover closed.
DYNARAD® MODEL MS-600 WITH SPLIT PNEUMATIC

BUTTERFLY CRUCIBLE COVER
I MT SERIES TILTING FURNACES
I MODEL
MT-260
MT-260W
MELT RATE*
260 lbs/hr
260 lbs/hr
CAPACITY
500 Ibs
575 Ibs
WIDTH
64"
64"
DEPTH
63"
63"
HEIGHT
44"
44"
I
MT-400 400 lbs/hr 650 Ibs 71" 70" 48"
MT-400W 400 lbs/hr 950 Ibs 71 " 70" 48"
MT-500 500 lbs/hr 1 ,150 lbs 78" 77" 48"
MT-500W 500 lbs/hr 1 ,700 lbs 78" 77" 48"
87" 85" 48"
I
MT-600 600 lbs/hr 2,200 lbs
*Rates are based on continuously melting aluminum at fulltf/wer in a
clean, hot crucible at 1300°F with cover closed. Batch me ting rates
may be less depending on charge makeup and percent utilization.
I Dynarad's rugged MT Series tilting furnaces feature heavily

reinforced furnace frames for distortion free tilting to prevent
I crucible shifting and crack

ing. Double acting hydraulic
cylinders with safety valves
I
prevent uncontrolled return
if hydraulic lines are dam
aged. Unique "on-demand"
hydraulic power package
I starts and stops automatically,

eliminating endless running
and oil overheating.
MODEL MT-600 TILTING FURNACES PROVIDE
CLEAN, HIGH QUALITY ALUMINUM FOR
I
PRODUCING PREMIUM QUALITY PISTONS
I
EC SERIES STATIONARY FURNACES
STANDARD HEIGHT MELTING FURNACES

MODEL MELT RATE• CAPACITY WIDTH HEIGHT
EC-600 250 lbs/hr 600 Ibs 46" 42"
EC-700 325 lbs/hr 700 Ibs 51" 42"
EC-950 380 lbs/hr 950Ibs 56" 42"
EC-1100 450 lbs/hr 1 , 1 00 lbs 63" 42"
EC-1500 475 lbs/hr 1 ,500 lbs 63" 42"
EC-2400 540 lbs/hr 2,400 lbs 72" 42"
*Rates are based on continuously melting aluminum at full power in
a clean, hot crucible at 1300°F with cover closed.
PNEUMATIC DISHED HEAD CRUCIBLE COVER CAN BE CLOSED

ON PROTRUDING CHARGE MATERIAL IN THIS MODEL EC-2400
LOWBOY™ LOW PROFILE

MELTING FURNACES
MODEL MELT RATE* CAPACITY WIDTH HEIGHT
EC-500LB 200 lbs/hr 500 Ibs 46" 36"
EC-575LB 250 lbs/hr 575 Ibs 51 " 36"
EC-750LB 300 lbs/hr 750 Ibs 56" 36"
EC-825LB 350 lbs/hr 825 Ibs 63" 36"
EC-11 50LB 360 lbs/hr 1 , 1 50 Ibs 63" 36"
EC-2000LB 400 lbs/hr 2,000 lbs 72" 36"
*Rates are based on continuously melting aluminum atfull power in
a clean, hot crucible at 1300"F with cover closed.
IT'S EASIER TO DIP OUT WITH LARGER LADLES

FROM THIS MODEL EC-750LB LOWBOY MELTER
STRETCH™ EXTRA CAPACITY

MELTING FURNACES
MODEL MELT RATE* CAPACITY WIDTH HEIGHT
EC-750S 250 lbs/hr 750 Ibs 46" 48"
EC-900S 325 lbs/hr 900 lbs 51 " 48"
EC-1 250S 380 lbs/hr 1 ,250 lbs 56" 48"
EC-1475S 450 lbs/hr 1 ,475 lbs 63" 48"
IVIDE EC-2000S 475 lbs/hr 2,000 lbs 63" 48"
EC-3000S 540 lbs/hr 3,000 lbs 72'' 48"
�s *Rates are based on continuously melting aluminum atfull power in
a clean, hot crucible at 1300°F with cover closed.
POUR MORE CASTINGS FROM THE SAME FLOOR SPACE WITH

THIS EC-750S STRETCH EXTRA CAPACITY MELTING FURNACE
. . .. . - ·· ·· •• · ••· · -···-····--· ·-· - -··-··- -· · · - ·· - ··-··-·· - · ·- - -- - - - - · - ---- - - - - -- --- -· -· ---·- --··· - ·· · · · ·- ··· --- -- -- -- · - -· · · ·- · ·· - - · - -- --- - - -- ·· -- - --- ---- -· ·------ · · ···
To Cut Metal Losses

LET'S FACE FACTS ABOUT FUEL FIRED MELTING - DOLLARS & CENTS FACTS!
FACT All gas and oil flames produce water vapor - no matter how well tuned your burners may be!
FACT Water vapor and aluminum don't mix - in fact, they react explosively!
FACT Water vapor and molten aluminum will react in all fuel fired furnaces to produce dross
(aluminum oxide) and free gaseous hydrogen. Both are harmful to metal quality and cause
casting defects!
FACT Dross formation in fuel fired furnaces is substantial - it's a major expense which hurts your
profitability!
FACT The melting equipment you select will have a significant impact on your metal quality -
choose it carefully!
GOOD Aluminum casting producers report a 75% to 80% reduction in metal losses with Dynarad
NEWS! electric resistance melting. When the daily savings are multiplied by annual production and
today's aluminum prices, the yearly savings are significant!
ToAssure Maximum Up-Time ...

RELIABLE POWER CONTROL
---
Because Dynarad's unique heating element design requires no trans
formers or complex solid state SCR power supplies, Dynarad's
� power control panel is compact yet rugged and reliable. It is easily
installed and serviced by any plant electrician. The tight, dust-free
integrity of the NEMA 12 enclosure is maintained since no fans or
vents are needed to cool power control components.
POWER LEVEL SELECTOR

The optional Power Level Selector is a true load shedding demand
control system which positively limits KW demand to the power
level chosen. More than a simple solid state current limiter, the
Power Level Selector reduces utility demand charges, regardless of
the type of demand meter used by the utility, and extends heating
element life. The Power Level Selector instantly converts a melter
MS/EC SERIES CONTROL PANEL WITH
POWER LEVEL SELECTOR to a superheater to a highly efficient holder and back again.
Available as portables
and custom designs . . .
MS & EC SERIES PORTABLE FURNACES
Dynarad will set up any furnace for portable use to quickly accom
modate alloy changes or maintain production when fixed furnaces
break down. Portable "packages" include lifting channels for fork
trucks, or eyebolts, chains and spreader bars for crane lifting. Control
panel is attached and prewired to furnace. Heavy duty electrical
cable with a welder type plug and mating receptacle are provided.
CUSTOM DYNARAD FURNACE CONFIGURED TO MATCH UNIQUE

"FOOTPRINT" FOR LEADING ELECTRIC MOTOR MANUFACTURER
CUSTOM DESIGN FURNACES

Dynarad specializes in the design and construction of
custom furnaces with unusual shapes and configurations
to accommodate limir;;,J floor space, unique floor plan
"footprints", special casting machine requirements, etc.
DYNARAD® MODEL EC-2400 SET UP FOR The picture above shows just one of many possibiJities.
PORTABLE USE WITH A FORK TRUCK
If you have special melting or holding furnace needs, let
us hear from you.
ACCESSORIES
■ CRUCIBLE COVERS - Dynarad offers a large selection of

crucible covers including pneumatically operated dished head
covers, pneumatic split Butterfly covers, pneumatic hinged cov
--• STRIKO
ers, split manual covers and various custom designs.
■ ALTERNATE POWER SUPPLIES - Dynarad's exclusive DYNARAD
Piggyback™ power supply combines the best in 100% solid
state control with the time proven durability of a rugged con A StrikoWestofen Company
tactor backup system to virtually eliminate power supply
downtime. In addition, all furnaces are available _with reduced
power ratings for holding and/or superheating applications.
■ PROGRAMMABLE TIMERS can be provided for reducing the
StrikoWestofen GmbH StrikoDynarad
PO Box 59 09 575 Whitney Street
0-65049 Wiesbaden
temperature setpoint at night, reducing on-peak demand during Tel.: +49(0)6134 / 207-6
San Leandro, CA 94577 , USA
Tel.: + 1 (510)638 2000
the day, or for simply starting the furnace in the early morning. Telefax: +49(0)61 34 / 207-877 Telefax: +1(510)639 4564
■ WHEELS. AND QUICK DISCONNECTS easily retract fur e-mail: info@wiesbaden.strikowestofen.com e-mail: info@strikodynarad.com
naces from casting machines or molding lines.

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NOTE: THIS DRAWING IS CONFIDENTIAL Drawn B Date
This document Is transmitted solety for the
REV DATE DESCRIPTION DEFAULT y Matt Smith 4-1 1 -201 1 ..
-��.!..!.�9
purpose or aiding lhe trans.action of business TOLERANCES
@ -8
be,_n RAYTEQ LLC end 1he n,cipient and
must be �d upon request. Al drawfngs. Material Finlsh
lnforrnetk>n, llsts of materia., and data lncludng .x = ± .1 N/A N/A I
all designs and concepts contained hereon ere
lhe sole propeny of RAYTEQ LLC and may not
.xx = ± .06
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I
be reproduced or copied In whole or In part nor
IN-CABINET RETROFIT FOR EC-1 500
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3RD ANGLE
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STEP 3 (CON4) 1 9/A, 1 2/8, 5/C
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STEP 5 (CON6) 1 7/A, 1 0/8, 3/C
STEP 6. (CON7) 1 3/A, 6/8, 20C
NOTE: THI$ DRAWING 1$ CON�IOENTIAL. Drawn By

4- 1 1-201 1
Date
This document Is transmitted solety for the
REV I DATE DESCRIPTION DEFAULT Matt Smith
()U'))0Se of aidng Iha transaction of busineM
between RAYTEQ LLC and the raclplanl and
TOLERANCES AV
R ... ....T EQ. '
mus! be returned upon request. AJI drawings, Q -El
@ Material
N/A
Finish
NIA ....... .........
lnf0nnallon, lists of materiab and d3ta lncWng .x = :1: .1
all designs end coocepts contelned hereon a�
the sole prQpefty ot RAYTEO LLC end may not
.xx = :1: .06
be reproduced 0< copied In whole 0< In pen nor .XXX = :1: .005 ITitle
IN-CABINET RETROFIT FOR EC-1 500
3RD ANGLE
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� wntu,n consent of RAYTEQ U.C.
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StrikoDynarad

MELTING AND HOLDING FURNACE

MELTING AND HOLDING FURNACE

Section Page No.

II Routine Melting and

8. Removal of Packing Materials

C. Locating and Mounting Furnace and Controls

Tilting furnace frames must be solidly anchored to floor or platform. It is not

2. [nterconnect Control Panel and Furnace - Again referring to the electrical

[ a) Inside diameter - Crucible ID should correspond with the ID of the furnace

l straightedge across top of furnace frame and measure height from

11. Installing Bath Thermocouple

I. Initial Electrical Check

Refer to the electrical schematic diagram to determine if the furnace is wired in

h) "Delta" connection - The highest ammeter reading should approximately

l Furnace is now ready for regular melting operations.

II ROUTINE MELTING AND HOLDING OPERATIONS

I . Element temperature limit - As stated in the previous section. the element

l RESULT. DO NOT REMOVE THIS SIGN."

l through the crucible in time to melt each charge.

[ 6. Controlling temperature overshoot

a) Why does temperature overshoot? - The large heat of fusion of aluminum

Temperature control instruments are designed to react to temperature

., ) Add a predetermined amount of ingot to the furnace after the Bath

This method has the added advantage of maximizing average melting

F. Power Level Control (Optional)

C i . 1-Iolding Use Only

a) Reduce holding temperature - The bath temperature pyrometer should be

I. l Jsing Fluxes in Electric Resistance Furnaces

I . Introduction - Because of the nature and purpose of reactive chemical fluxes.

2. Definition - Reactive fluxes are defined as solid. liquid or gaseous chemical

4. Examples of reactive fluxes include exothermic surface dross treatment

l All electrically conductive components including heating elements. lead wires.

l subject to attack from reactive chemical fluxes.

Solid powdered or granular "cover" fluxes should be used only with

J . Furnace Shutdown - The shutdown procedure is very simple. Metal is ladled or

III Fl iRNACE MAINTENANCE

a) Why crucibles should be scraped - The crucible should be scraped on a

c ) Repeat as needed - Crucibles should be scraped on a regular basis. usually

2. Crucible inspection - Non-metallic (e.g. silicon carbide) crucibles should be

If the crucible is to be permanently retired. heavy duty C-c!amps can be

I. Type K. Elements - Both furnace thermocouple assemblies use heavy gage

' Replacement of heating elements - Problems with cracked or broken crucibles

b) Hot replacement - Heating elements may be replaced from a

Equip personnel with high temperature gloves and protective insulating

A Control Panel Electrical Safety

a) Thermocouple failure - If the bath thermocouple protection tube is worn

Element temperature limit thermocouple

b) Result of failure - An open circuit thermocouple failure will result in the

c) Replacement - A defective thermocouple should be replaced. Refer to

I. Ground Fault Alarm

a) Description of operation - The Ground F ault Interrupter (GFI) senses

1r you find resistance ranging from a dead short to several thousand

l cause of the alarm and correct the problem.

l a) Introduction - This StrikoDynarad furnace is equipped with ammeters

b) Independent readings - Each ammeter independently reads the current in

d) Separately fused - Each heating element is separately wired and

c) Temperature changes - As with most resistance heating alloys. the

3. 1\bnorn1al an1111eter readings

I crucible shifting and crack