DCM - 3049 - Dynarad Owners Manual
DCM - 3049 - Dynarad Owners Manual
DCM - 3049 - Dynarad Owners Manual
ELECTRiC RESISTANCE
Electrical Schematic
Drawing Number D0179
DYNARAD CORPORATION
INSTRUCTION MANUAL
Version 1.5
TABLE OF CONTENTS
IV Troubleshooting 26
VI Index 36
-2-
INSTRUCTION MANUAL
I INSTALLATION
A. Inspecting Shipment
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
-3-
DYNARAD ELECTRIC RESISTANCE FURNACE
-4-
I INSTRUCTION MANUAL
'
their respective thermocouples at the furnace without
connection to any intermediate terminal strips or
spliced connections.
-5-
DYNARAD ELECTRIC RESISTANCE FURNACE
E. Accessories (Optional)
F. Installing Crucible
b) Crucible height
-6-
INSTRUCTION MANUAL
3. Installing crucible
-7-
\
DYNARAD ELECTRIC RESISTANCE FURNACE
-8-
I INSTRUCTION MANUAL
-9-
\
' I
If the GFI 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) .
-10-
INSTRUCTION MANUAL
A. Setting Instruments
-11-
DYNARAD ELECTRIC RESISTANCE FURNACE
C. First melt
-12-
INSTRUCTION MANUAL
I D. Continuous Melting
I faster melting.
I -13-
I DYNARAD ELECTRIC RESISTANCE FURNACE
I
3. Furnace utilization - Increase furnace "utilization"
to increase the average melting rate. Furnace utiliza-
I tion is defined as the time a furnace is actually
melting metal during a given production period divided
by the total time in that production period and is
I 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
-14-
INSTRUCTION MANUAL
-15-
I DYNARAD ELECTRIC RESISTANCE FURNACE
-16-
INSTRUCTION MANUAL
-17-
DYNARAD ELECTRIC RESISTANCE FURNACE
-18-
INSTRUCTION MANUAL
-19-
I~
DYNARAD ELECTRIC RESISTANCE FURNACE
-20- i:l
'I
----
------------- -----~
INSTRUCTION MANUAL
A. Crucibles
1. Scraping
-21-
DYNARAD ELECTRIC RESISTANCE FURNACE
3. Crucible Replacement
B. Thermocouples
-22-
INSTRUCTION MANUAL
C. Heating Elements
-23-
DYNARAD ELECTRIC RESISTANCE FURNACE
-24-
I INSTRUCTION MANUAL
I
(to catch any loose junctions caused by shipping vibration)
and thereafter on a quarterly basis. A "tug test'' consisting .rr
'
-25-
DYNARAD ELECTRIC RESISTANCE FURNACE
IV TROUBLESHOOTING
Don't rely on the door switch! Shut off and lock out
incoming power before opening the Control Panel door.
B. Thermocouples
-26-
--- --~~-
I INSTRUCTION MANUAL
C. Alarms
I 1. Ground Fault Alarm
-27-
DYNARAD ELECTRIC RESISTANCE FURNACE
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:
-28'-
INSTRUCTION MANUAL
D. Heating elements
-29-
DYNARAD ELECTRIC RESISTANCE FURNACE
-30-
INSTRUCTION MANUAL
-31-
I DYNARAD ELECTRIC RESISTANCE FURNACE
-32-
I INSTRUCTION MANUAL
-33-
I
I
Spare Parts List for Dynarad EC-1500 Furnace, Job # 1153
I
Thermocouples and Accessories Dyn. Part No. UM I
!
Heating Elements:
r Heating element 28" 277V flex lead.(inc. hardware)
1'3
301--75RP ea
I
I VI INDEX
Fluctuations, voltage 30
current 30
Alarms 27-30 Fluxes 17-20
I Ammeters, reading
Argon degassing
29,31
16-18
definition
non-reactive
17
17, 19
Batch melting, pyrometer reactive 17-20
I settings
Batch melting, maximizing
11 tablet
Fork channels, furnace
17, 19
4
utilization 13-14 Freon degassing 17, 19
safety 26 checking 31
Cover, furnace, proper
I sealing
Cover, pneumatic
7-8
6
designation
grouping
32-33
I filling at night
gasket
16
8, 17
replacement, cold
replacement, hot
23
24
inspection 21 rubber padding 3
installing 7 temperature change,
I overfilling
replacement 6I
17
7
effect
temperature limit,
30
9
Melt rate, maximizing
Metal leakage, thermo-
couple
13
26
Demand control 15 Moisture danger 12
Drying charge material 12 Nitrogen degassing 17, 19
Electric resistance, Overshoot, temperature 15
heating elements 29-33 Oxidation, heating
I Electrical connections,
tightening 25
elements
Packing, styrofoam
30
3
Electrical wiring check 6 Padding, elements, rubber 3
I Explosion hazard
First melt
12
12-13
Phase designation 31-32
I
'
-36-
Ji
VI INDEX (continued)
Pit installation 4
Pneumatic cover 6
Power failure 20
Power level switch 91 15
Protection tube, bath
thermocouple 8, 22-23
Protective coating,
heating elements 30-31
Pyrometer settings
9, 11, 33
element temperature
limit, setting
9, 13, 14, 28
Runout membrane 22
Runout pan 4
Salt fluxes 17-20
Seven day timer 11, 20
Shutdown 20
Steam, startup 12
Tablet degassers 17, 19
Temperature control
13-16, 33
Temperature overshoot 15
Testing,
electrical 5, 9-10, 31-33
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,
U-bolt clamp 8, 22
Tightening connections 25
Timer, seven day 11-12, 20
Utilization, furnace 14
Voltage fluctuations 30
Wye connection, current
readings 9
-37-
METAL BATH THERMOCOUPLE POWER CONTROLS
IDYNARADI ~
~~~II DIMENSION TABLE
Dz p,
!iii EB !iii MODEL D, P2
l
3 6"
EC-600 18 46 12'' 12
'~
12"
-~·~1t
~::::::.:7:
.:::.--c-:;;~.:
~~7'~~~~::~ ~~~:;;~.;~:~t;r!~~~;1;~~!~~~,,£111~:~~~E~~:t~!~ :=
.· . ~ I 1, I "'
[0
[DYNARADI
n'PE •A•
42"
~ P2 ~
ELEMENT PROTECTION
THERMOCOUPLE
DYNARAD:::~
.... ,,-·- ,..
1
~~~J!~l~!!~!~~~~~if~~!f§li:'~~~~~~;~ :::
~::.::;~~=~=,~~~-:::==-~~ ~77{::::~!~~:.:
olclftg the ~ of ~ ~ DYHARAD CORP~':::'
and tha r.clp"'"l a>cl ......t be nn..n.c! an . . _ L M ~.:.-.:~,
~ hlcrmoUoft <>no:! c!ota hdu<Sn9 oil c1a!9ns .....,(;<>'··:-
=~~~ ;:-
- I s ccntclnood l>r- ora tl>oo ~7 of D'I!Uo.RAD COR!'
~:)'h"'"an";".;:~=~:::.~
n\"'csta of O'I?IARAD COR?.
>f
lnclu~"'!l clloc:l- to aublcla
pcortl«o, clr.etly ar lndroctl7o not: can It be u..d lrr ·..
·:;_ _-· _.. i :.....1
SHIP VIA? _______________ _:~_:__ - ..... - II>& monufoeb.no of ony oqu!p,....l c1acr1>cc1 wlt.l>out lh•
..,.ark: ..-ttl., .......,, of D'I'NAAAD COR?. •
1/2' INSULATION
UNDER HAT RING
FURNACE COVER
INSULATION
FURNACE
CRUCIBLE COVER
HAT RING PLATE
.,
·.. WIRE CRUCIBLE
,.
:.: ..:
HARNESS
HEATING
~:·.:
ELEME:NT
·;.
,,
t
~~~
~~~ NOTICE
i~ This <locument ;, tronsmmed solely f« tho! pu~ ·
of aiding the ~ at business between
GRADED
i~~ DYNARAO CORP. o:>4 tho! recip;ent and must be FURNACE
returned on request. All drawings, information ond
I t~ data in<;lud;ng oil de$gns on<! concepts contained INSULATION
I !"·~ hereon ore !he P'operty at DYNNW> CORP. on<!
f'·' may not be r~UC*I « copied in whole or in port
nor oppropr;.,tedi to use(s) ;n any way detr;mentol to
J~
E'~
the inter.osts at ~ CORP. including d;se~o-
sure to outside parties, dir.ctly or indintetly, nor eon
~
it be used lor lhe manufacture at ony equipment de-
:>cribed without tile spec:ifJC written consent of
~t~
DYNARAO CORP.
(1:10)
,, h
DYN'ARAD '
TELEPHONE: (
510 638 2000
) -
FAX: (510) 639-45&4-
IN suLA TI0 N DE TAI L s A0132
.: ~ EC FURNACES , ~~._.
--- - - - - - - '"'~-···-·--~~ ..
r
I:
L~ SUPPORT NG.E <REF.)
~
-----·-t+--tt-
~~~ HEATER LEAD <REF.>
IIIRE LUG CIH
IIIRING HARNESS
<REF.>
DYNARAD
~LESS OTHERWISE SPEOFlED
(510) 638-2000
....c:us- FAX
.t:
(510) 639-456+
OINEHSIOHS Jfl:£ IN INCHES
...._ . . -
............
........................
~C:QlJP. . . . . . ~ . . . - -
__. ...........
........._
.......,c:r .t CftMirAIIO COIP. . . . !-:-~--;:~=-,.-:--~----,--:: Rf:V.
::::..z:~:>~'",Z:£_..:-'~DWI'SMOIIDHT
...............
~ .. - ----.........
........
~
"'*"""~-
--- .
.., ...............
- - 01EOCEI>""
~---.--., -- ---
,,_ 1-20-981 DRAWING
,_
-~,.
A0168
NO.
A
""llllll!!l!!l ~ ~ ~ ~---~--!'!111111111111~~--!!lillllllll!l.~ "-
;0-1 ... -
HEATING t:LEMENT
.
PROTECTION COVER
r,~-~-"-~
I
I
-tllif8±83±B@})frH
L--
L,'"-~-"- . . .
CUT OFF EXCESS
THREADED ROD
DYNARAD .
TOI.ERAHC£S:
1 I 291-0032 I 1 I HANGER ROD UNLESS OTHERWISE SPECIFIED
.....us • (51~~~
'* • (510) 639-~564
2 I 530-0005 I 1 I CERAMIC \J ASHER OINENSIONS ~ IH INO-IES
~
I DESCRIPTION DESCRIPTION SELECTION SETIINO. DESCRIPTION DESCRIPTION SELECTION SETIINO
~.o
-J
RATE MIN 0.00 ASP SAC IK>t-IE 10
ASETMIN 1.0 RATIO 1.0 ~
or BIAS 0
RSETRPM 0,5"" 1.0 SPTRACK IK>NE
or POWER UP l) L5 P MANUAL
MANRSET 0,0 SP HILIM HOQ 1000
PROP 002 1.0 SP LOLIM 0 1000
or ACT tOt~ REVERSE
GAIN 2 1.0 OUT RATE DISAOL
RATE2MIN 0.00 PCTIM UP 0
RSET2MIN 1.0 PCTIMDN 0
or OUTHILIM 100.0
RSET2RPM 1.0 OUTLOLIM 0
CYCSEC I ~Q 20.0 DROPOFF 0.0
CYC2SEC 20.0 OEADBAND 2.0
SECURilY - OVTHYST 0.5
* LOCKOUT
AUTO MAN
~-~lEW CALIB
ENAB
ENAB
FAILSAFE
MAN OUT
AVTOOlff
0.0
0.0 :./.. '
SP SEL 0.0 1.)
RUN HOLD ENAB PBorOAIN re. GAIN 0
-l
MINor RPM BPM MIN
SPRAMP SP RAMP DISABL 0
0
TIME MIN 3 OPTIONS AUXOVT DISADL
FINAL SP
SP RATE
-
DISADL
o1mA VAL
20mA VAL
0
0 J.
EUMRUP
EUMRDN
-- DIG IN I
DIG IN 2
IK>NE
NONE
v
0
J
SPPROO DISABL
can ComSTATI: DISAOL \
ADAPTIVE ADAPTIVE DISADL ComADDR 0
SPCHANG 10 SHEDTIME 0
KPG . 1.0 PARITY ODD
BAUD 300
ALGORITHM CONT ALG
INPUT2
PID A
DISABL
DUPLEX
LOOP BACK
-
DISABL -
~....
OVTALG
4-20RNO
IIMt' -
50PCT
SHEDMODE
SHED SP
LAST
TOLSP
l:
j
INPUT1 DECIMAL
OF
xxxx ALARMS A1S1 VAL so 90
UNITS NONE A1S2 VAL 0 90
INt 'TYPE 1; rc. II o-1omv A251 VAL s:o 90
XMrTTER LINEAR A2S2 VAL Q 90
IN1 HI ~'100 1000 A151TYPE OEIJ NONE
IN1 LO 0 A152TYPE NONE
BIAS IN1 0 A2S1TYPE oev NONE
FILTER 1 3 1 A2S2ll'PE NONE
.BURNOUT ~p NONE A1S1 H L HI
EMISSIV 0 A1S1 EV -
PWAFAEO 60HZ A1S2 H L HI
A1S2 EV
Lo
-HI <t
rO
INPUT2 XMmER2 LINEAR A2S1 H L
IN2 HI 1000 A2S1 EV
A2S2 HL
-HI j
IN2 LO 0
FILTER 2 1 A2S2 EV -
ALHYST 0.1
,'
A B c
X
POINT
A, B or C
INPUT TO
NEUTRAL
480 v X
3¢ YIELDS X
277 v
3 WIRE
SINGLE X X
PHASE
4 WIRE
X X
H H
NOTE: Units having no taps are recommended for this Zig-Zag connection. When only transformers with taps are available, refer to factory for
proper connection diagram.
Connection diagram (using 3 pieces of 1 phase, 60 hertz transformers connected zig-zag auto) for developing a neutral (4th wire) from a
3 phase, 3 wire supply. Dim~nsional information on page 13.
19
1-01
1-02
1-03
I ?Nru~~ r r r USER'S -480 VAC, 3 PHASE. 110 AMP SERVICE
~OUND9 I 1-51
1-52
1-53
TO UNE 1-21
1141 1142 1143 1144
1-35
1-36
1-37
1-38
TO UNE 1-13 TO UNE 1-13 FROM UNE 2-39 FROM UNE 2-39
1121 1122 2022 1122
~
2-ol 2-51
202 BKR
WHT 1 2521
2-o2 2-52
4
"GROUND FAUL r
2-03 RED
"UAIN SWITCH Ott 2-53 RED
BATH TEMP CONlROllER "GROUND FAULT AUX"
2-o4 2-54
HONEYWEll. MODEL NO. 2-62
UDCJ200
2-o5 2-24 2-55
2-09
1~~
2-59 260 AH
2022 TO T C EXTENSION WIRE
~ RUN T/C EXTENSION 2601
2-10 2-60 ALARM HORN
208 Ell WIRE IN SEPARATE CONDUIT
5 2111 RED
2-11 "ElEMENT lEMP UMir" 2-61
4
2-12 2-62
208 Ell
2-13
8 2131
7 ELEMENT OVER TEMP RaA Y 2-63
P&B KUP-14Ao45-120
(A!.M 1)
2-14 Z::ZQ. 2::2!. 2-56, 2-60 2-64
2-15
RED
GROUND FAULT RELAY 2-65
2-20,=
2-16 TO UNE c t:!QIE.: GROUND SHIELDS
2-66
1-16 CT2
AT RELAY END !l!lJ.l:,
2-17 2022 ::::::::::~HI@::h:::::: 2-67
TO UNE CT
2-18 1-16 CT 2-68
2-19 2-69
215 GFR 213 CR
11 2201 9 2202
2-20 MAIN CONTACTOR 2-70
12 1 D'tNARAO 31o-0023
2-21 1-12. 1-12. 1-12 2-71
2-34
2-35
2-36
I
2-37 NOTE:: AU. CONTROL
l=
WIRES RED EXCEPT
AS NOTED.
2-38
1122
2-39
TO UNE
'
TO UNE
2-51 2-51