Prevent Induction Melting Furnace Shutdowns with Water-Cooled Power Leads Maintenance - EMSCO, Inc.
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Prevent Induction Melting Furnace Shutdowns with Water-Cooled Power Leads Maintenance

November 29th, 2022

A common cause of induction melting furnace shutdown is the failure of the water-cooled power leads. In fact, over 90 percent of induction melting system problems involve water, and many of the problems boil down to a coil overheating due to restricted water flow in the power leads. Check out the maintenance tips below for your water-cooled power leads to keep your induction melting furnace running smoothly and optimize your heat rejection processes.

  1. Be sure to purchase the correct water-cooled power leads for your application:
    Your leads should yield high electrical efficiency and be manufactured with copper since they provide optimum contact and conductivity. Use leads that are rated at 101 percent electrical conductivity by the IACS.
  2. Search for failing power leads that impede flow:
    An inferior lead, or one that has begun to deteriorate from age, may develop “bird’s nesting” in the copper wires near the terminal. Failing power leads could trip your power supply and shut down your system, as well as cause your other consumables to age and deteriorate prematurely, such as your Bernoulli ring cables.
  3. Upgrade your water-cooled power leads:
    Coatings and coverings are available to provide the hose additional protection from molten metal, abrasion, and high temperatures. EMSCO offers Firesleeve, a non-asbestos power lead covering that withstands short-term exposure to 3,000ºF molten metal and long-term exposure to temperatures up to 500ºF.

A furnace’s water-cooled leads can produce unnecessary electrical losses if not properly maintained or configured. [1] Luckily, EMSCO, Inc. offers 24/7 induction furnace repairs in Ohio and beyond, should a furnace shutdown occur. We also offer induction melting furnace inspections to provide our customers with a report of issues that should be addressed to prevent future downtime, as well as a guide to induction furnace maintenance. Contact us today for information about our foundry induction furnace repairs, furnace rebuilds, and other foundry services!

References

  1. “Reduce Power Consumption Without Sacrificing Production”
    https://www.foundrymag.com/melt-pour/article/21925030/reduce-power-consumption-without-sacrificing-production

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