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Morganite Crucible Ltd
Built under licence by
Molten Metal Products Ltd
Tel: 01905 728200 Fax: 01905 767877
Morgan Mark IV/ V High Efficiency Electric Resistance
Bale Out Furnaces
Part 1
Operating and Safety Instructions
The Morgan Mark IV / V High Efficiency Electric
Resistance Bale Out Furnace is designed for melting and
holding aluminium and zinc alloys at casting temperature.
Maximum metal temperature approximately 850°C
(1562°F).
It is suitable for use with carbon bonded silicon carbide
basin type crucibles.
Raised by RDT Part 1 of 2
Approved RDT Sections 1 to 3
Date 03/05/12 Pages 1 to 15
Issue 1 FDI 1582BO
This document and the information it contains is the property of Morganite Crucible Limited (MCL). This document and the
information it contains may not be disclosed to any third party or copied for any purpose whatsoever without the prior written
consent of MCL nor may be used otherwise than for the purpose of operating equipment supplied by MCL.
© Morganite Crucible Limited 1999
Morgan Furnace Manuals are divided
into two separate parts
Part 1. Operating and Safety Instructions
Part 2. Installation, Commissioning,
Maintenance and Fault Finding
The Operating and Safety Instructions include
a simplified section which can be displayed
close to the furnace or its controls for easy
reference by the Operator.
This Manual contains Part 1
Operating and Safety Instructions
Sections 1 - 3
3
Index
1
1. General Safety 4
1.1 Hazard Precautions 4
1.1.1 Metal Charging 4
1.1.10 Furnace Testing 9
1.1.11 Fire Fighting and Appliances 10
1.1.12 Lighting 10
1.1.13 Fluxes, Modification and Degassing 10
1.1.14 Noise 10
1.1.16 Displayed Instructions 11
1.1.2 Risk of Burns 4
1.1.3 Protection of Eyes 5
1.1.4 General Protection Against Molten Metal Burns 5
1.1.5 Metal Leakage 6
1.1.6 Maintenance Work 7
1.1.8 Thermal Protection 9
1.2 Electrical Safety 7
2
2. Furnace Operation (Operator Level) 12
2.1 Charging solid materials 12
2.1 Temperature Controller 3
2.1.1 Display (see separate controller handbook) 3
2.1.2 Charging liquid materials 13
2.1.2 Temperature Depression 3
2.1.3 Charging solid metals to a melt 14
2.1.4 Flux Additions 14
2.2 Half, Auto, Full Control System 4
2.2.1 Half 5
2.2.2 Full 5
2.2.3 Auto 5
2.3 Control Panel Indicators (See Diagram) 6
2.3.1 Temperature Controller 6
2.3.10 Time Clock 8
2.3.11 Temperature Depression Switch (on side of control panel) 8
2.3.12 Optional spilt metal detector lamp. 8
2.3.2 Control On Indicator Lamp 7
2.3.3 Lining Limit 7
2.3.4 Mimic Run Lamps 7
2.3.5 Earth Fault Indicator Lamp/Button 7
2.3.6 Off/Timed/On Switch 7
2.3.7 Half/Auto/Full Switch 7
2.3.8 Analogue Displays 7
2.3.9 Isolating Switch 8
3
3. Basic Operation and Settings 2, 10
4
5
1. General Safety
This furnace has been designed and built to conform to the following key
standards:-
EN 746-1 Machinery Safety
BS 5885-1 Safety requirements for industrial gas burners
This is to ensure that the product complies with the essential safety
requirements implied by the CE Mark.
1.1 Hazard Precautions
The operation of metal melting furnaces is relatively safe when good practices
and safety precautions are adhered to. The following risk analysis with
recommended precautions should be noted:
1.1.1 Metal Charging
Under no circumstances must wet or damp charge material be added to a
molten bath. A serious explosion will occur should water vapour be trapped
beneath molten metal; only charge dry material to a molten bath. If charge
material is preheated prior to loading, the temperature must be above 100°C to
be sure that water has evaporated.
1.1.2 Risk of Burns
Operators should wear protection to the hands and arms to avoid burns
through contact with hot surfaces or metal splashing. Suitable gauntlets should
be supplied capable of withstanding heat and abrasion.
Assume that all surfaces, tools, rakes ladles etc are hot enough to cause
damage to human tissue. Those surfaces on the furnace are marked by
warning plates to alert persons to this risk. Other adjacent equipment may not
be marked.
6
1.1.3 Protection of Eyes
Operators and other personnel in the work area must wear suitable eye
protection. Spectacles or goggles must be designed and manufactured to a
specification suitable for molten metal splash and impact resistant to high
velocity projectiles.
1.1.4 General Protection Against Molten Metal Burns
Operators charging or discharging metal from furnaces must wear protective
clothing, gloves, foundry boots and face masks. Each item should be carefully
selected to ensure its suitability for the application
7
1.1.5 Metal Leakage
Provision must be made to safely captivate any metal that should discharge
from the furnace drain hole. A pit, capable of containing the full capacity of the
crucible lined with sand, should be located beneath the furnace drain hole.
Typical example (bale out shown):
8
1.1.6 Maintenance Work
Prior to carrying out maintenance work. Ensure it is safe to work. do not
remove any covers, earthing straps or conduits without firstly isolating the
electrical supply and locking off, to avoid inadvertent switch on.
Ensure that fuel isolating valves are closed before carrying out any
maintenance work.
Ensure the furnace is cool enough before removing cover plates.
Assume that all surfaces, tools, rakes ladles etc are hot enough to cause
damage to human tissue. Those surfaces on the furnace are marked by
warning plates to alert persons to this risk. Other adjacent equipment may not
be marked.
1.2 Electrical Safety
Access by personnel to conductors, terminals and other live components is
prevented by containment within earth bonded enclosure. The control panel
requires circuit isolation before the door can be opened. Other terminal boxes
are marked with International electrical warning symbols and requires the use
of a tool to gain access.
9
Furnace parts carrying electrical components are connected to a solid earth, which in
turn are wired to the supply earth.
Identification of Furnace Manufacture
Furnace Type
Serial Number
Fuel Type
Heat Input
Electrical Supply
Duty
The plate is permanently secured to the furnace body. The burner also carries
a rating plate.
Circuit protection is provided by thermal/magnetic circuit breakers, MCB's or
thermal fuses, appropriately sized to limit current to safe values and within
operational limits for cables and components.
Motors are protected by thermal overload relays to impose a limit at the rated
full load current.
Access to the control panel is prevented unless the isolator is switched off to
mechanically release the interlock. In most cases, all electrical supply is
removed when the isolator is ‘Open'. However, in some models a time clock
supply is retained. In this circumstance, a warning notice is displayed to advise
that some circuits remain ‘Live'.
10
1.1.8 Thermal Protection
Protection against furnace over temperature is provided by the chamber
temperature thermocouple. This is only effective when connected to a
policemen controller located within the control panel. Since this a body only
supply the controller must be supplied wit the control panel. The thermocouple
connections are located within the terminal box.
The chamber limit should be set to 1050°c.
Chamber
thermocouple
1.1.10 Furnace Testing
All furnaces are fully tested, with results recorded in the specified test sheet.
The correct operation of the certified flame failure device in particular, relates to
the safe operation of the gas burner.
11
1.1.11 Fire Fighting and Appliances
In the event of fire, do not use water based extinguishers which could be
hazardous due to electrical circuitry and molten metal. CO2 or powder type
extinguishers are the most appropriate for dealing with fires on or local to the
furnace.
Turn off the electrical supply at the isolating switch serving the furnace(s)
should fire occur.
1.1.12 Lighting
Adequate workshop lighting should be provided to facilitate safe working on the
furnace, particularly during fault finding or maintenance. Guidance to suitable
lighting levels can be found in British, European and other national standards.
1.1.13 Fluxes, Modification and Degassing
When carrying out metal fluxing, degassing or alloy modification using chemical
powders, tablets or tubes, follow the suppliers data sheets carefully. Prior to
use, read the Health and Safety Data Sheets and wear the recommended
protection to avoid inhalation of fumes or powders and to avoid contact with
eyes and skin.
1.1.14 Noise
The furnace design recognises the requirement to reduce airborne noise to a
minimum (5.5). The actual noise level will depend on the burner and fan
system employed, but in all cases should not exceed 90 DBA at 2 metres. In
most aluminium and zinc applications, the emission would be less than 85 DBA
at 2 metres. However, personal ear defenders should be provided if exposure
is long.
12
1.1.16 Displayed Instructions
It is recommended that key sections of the operator manual be extracted and
copied into a durable form for use by the operator. The simplified document
should be displayed on or near the control panel.
Included should be:-
i) Routine start up and shut down procedure.
ii) Emergency shut down procedure.
iii) Operational temperature range and recommended control settings.
1.1.17 Keeping a Log
It is also recommended that the operator or supervisor keep a log of furnace
faults or problems and details of any maintenance work carried out, particularly
those relating to health and safety.
13
2. Furnace Operation (Operator Level)
This section of the Product Manual deals with operator level and day to day
running of the furnace. This does not include the control cabinet since this is
outside MMP scope of supply.
2.1 Charging solid materials
• Open swing aside cover to allow charging of materials
• As soon as the crucible has reached red heat all over, add molten metal.
Prolonged preheating of an empty crucible is detrimental and will result
in shorter crucible life and higher fuel consumption
• Never introduce moist or wet charge materials into the crucible
• Use tongs to charge ingots or larger pieces of metal to avoid damage to
the crucible.
• Charge ingots or long pieces in a vertical position so that they may
expand upward
• When adding solid ingots, place vertically in the crucible to avoid
bridging or wedging the charge.
• Do not pack metal tightly in the crucible. Always allow sufficient space
for the metal to expand.
• Add light scrap to the crucible before heavy ingots
See fig 8
Note: Metal expands approximately seven times as much as the crucible.
Melt as quickly as possible. Avoid overheating the melt. Always melt to the
lowest possible temperature compatible with casting.
Avoid stewing the molten metal for long periods. Pour the metal immediately it
is ready. Empty the crucible as quickly as possible.
Avoid delay between heats and use the crucible for as many melts a day as
possible.
14
2.1.2 Charging liquid materials
Holding furnaces and crucible ladles are frequently charged with liquid metal.
To avoid thermal shock it is essential that the crucible is preheated to the same
temperature as the metal being poured.
Before charging ensure the temperature difference between the ladle and crucible is
no more than 20°c.
Pour metal into the crucible slowly, to avoid erosion to the crucible wall and impact to
the wall and base.
Do not pour liquid metal onto solid charge material. This will solidify on contact with the
solid charge then expand the charge and damage the crucible.
15
2.1.3 Charging solid metals to a melt
Avoid adding solid materials to an already moten crucible in quantities large enough to
freeze the melt (solidify). Never introduce Wet materials to a melt
2.1.4 Flux Additions
Where fluxes are used:
• Ensure the correct flux is used for the alloy being treated
• Ensure the correct flux is used for the required temperature
• Use the minimum quantity of flux to satisfy the metallurgical requirements and
add to the melt as late in the heat as possible
• Maintain accurate temperature control. Any unnecessary increase in
temperature will result in accentuated attack on the crucible and a drastic
reduction in crucible life
• Follow health and safety advice given by the flux supplier
2
3. Basic Operation and Settings
This section of the Product Manual deals with operator level and day to day
running of the furnace. The temperature controller and time switch will have
been pre-set in accordance with the detailed Engineering Level Instructions in
Part 2 Section 7. All other operating procedures can be controlled by means
of the switches mounted on the door of the control cabinet. There is no
requirement for entry into the cabinet at this operating level.
Basic functions would follow the following algorithm.
3
2.1 Temperature Controller
These instructions are based on the assumption that the Controller has been set up
and configured and is in User Mode. In User Mode, both the process variable value
(shown in the upper display) and the set point value (shown in the lower display) may
be viewed. The set point value may be adjusted by pressing the raise and lower
keys.
2.1.1 Display (see separate controller handbook)
For other settings refer to controller manual in part 2.
2.1.2 Temperature Depression
The main metal temperature controller has an additional second set point,
which will typically be set to 600oC – 650oC (1112oF – 1202oF) for aluminium
alloys, a temperature from which recovery to normal working temperature can
be achieved quickly, but give good energy economy and unattended safety
during periods outside production.
The temperature depression feature is used where the molten metal is held
liquid overnight. The time clock channel 2 is set to be active at a time after the
last casting shift has finished and set to deactivate at a set period before the
first casting shift the next working day. The time clock is a 7 day clock therefore
weekends can be covered if they are not worked.
The reserve set point is operated by Channel 2 of the time clock and if the
facility is required, will have been pre-programmed. With the temperature
4
depression switch selector switch set to off, the furnace operates continuously
around the main set point. When the facility is required, switch it to ‘on’, when
selection of lower reserve set point is made at the preset time set to switch on
the time clocks channel 2.
Typically the the switch is located on the right hand side of the control panel
with the Legend ‘Temperature Depression’.
TEMPERATURE
DEPRESSION
SWITCH
The reserve set point can be set on the main metal temperature controller and
can be found by pressing the page button until SP is displayed then
scrolling, with the scroll button through WKSP, SP1 to SP2. The reserve
set point is the value set against SP2.
2.2 Half, Auto, Full Control System
With this temperature control option, a 3 position switch selects the condition for
half and full power operation.
HALF/AUTO/FULL
SWITCH
5
2.2.1 Half
When the switch is set to the ‘half' position, ‘six' of the ‘twelve' heaters only are
powered subject to temperature control.
2.2.2 Full
When the switch is set to the ‘full' position, all twelve heaters are powered,
subject to temperature control.
2.2.3 Auto
When the ‘auto’ position is selected, full power (12 heaters) operation occurs,
up to the ‘Deviation Alarm’ setting of the metal temperature controller. At
temperatures in excess of the alarm setting and below the main set point, half
power (6 heaters) operates.
For example, with the deviation alarm set to 30oC (86oF) and a set point value
of 700oC (1292oF), full power will be applied up to 670oC (1238oF). At a
temperature of between 670oC (1238oF) and 700oC (1292oF) the furnace will be
powered with six heaters only.
This feature is to reduce temperature overshoot by reducing the power during
o o
the last 30 C (86 F) before set point is reached. The temperature controls PID
algorithm also cuts back the power on a time proportioned basis.
6
2.3 Control Panel Indicators (See Diagram)
All operating procedures can be programmed and monitored from the front closed
door of the cabinet. Furnace switching times from the time clock will have been pre-
programmed, therefore entry into the cabinet will not be necessary.
12
2.3.1 Temperature Controller
7
The controller is equipped with two LED displays; the upper display normally
shows the process value whilst the lower display shows the value of the set
point.
For details of operator/function controls, refer to manufacturers Operating
Instructions further guidance is also given in the second part of this
manual.
2.3.2 Control On Indicator Lamp
This is a white lamp which is illuminated when the isolating switch is on and the
control panel is energised.
2.3.3 Lining Limit
This is a lamp which is illuminated when the chamber temperature limit has
been reached. It indicates that the safe working temperature limit for the
furnace lining materials has been reached.
2.3.4 Mimic Run Lamps
These are a circle of 12 green LED lamps which are illuminated while the
furnace is on and indicate the well being of the furnace element panels. Should
an LED fail to illuminate it indicates that the element at that position in the
furnace is not drawing current. This could be due to a tripped MCB or a failed
element panel.
2.3.5 Earth Fault Indicator Lamp/Button
This is a red lamp with push button which is illuminated when the earth leakage
RCD trips. The push button allows testing of the earth leakage equipment
which should be tested on a daily basis. The Tip can be reset by switching off
the control panel at the main isolator and switching back on again.
2.3.6 Off/Timed/On Switch
This is a selector switch for commencement of furnace operation. Timed
selects start up and shut down controlled by Channel 1 of the time clock.
2.3.7 Half/Auto/Full Switch
This is a selector switch to allow selection of power to six elements only, (half)
or all twelve (full) subject to temperature control (Auto).
2.3.8 Analogue Displays
There are two visual analogue display dials; the left hand dial registers number
of furnace operation hours whilst the right hand dial registers number of crucible
8
operating hours.
2.3.9 Isolating Switch
This is the main on/off switch for energising/de-energising power to the control
cabinet.
2.3.10 Time Clock
A dual channel time lock is set to select furnace switch on and off times. It also
selects times at which the lower holding temperature is required.
There are 2 models that may be fitted depending on customer preference.
a) Lacron Micro
b) Theben TR636
Theben Lacron
The Lacron time clock (default option) is mounted inside the control panel and
may be set using the buttons on the front of the time clock. If the time clock has
been without power for some time it may be necessary to reactivate it by
pressing and holding the ‘C’ key with a pen or small screwdriver for 90 seconds.
After a further 90 seconds the clock will activate. Further programming
instructions are included in the second part of this manual.
The Theben time clock (customer request option) is mounted on the door of the
control panel. It may be set using the buttons on the front of the clock that are
protected by a clear plastic cover. The time clock is activated as soon as mains
power is supplied to the control panel. Further programming instructions are
included in the second part of this manual.
9
2.3.11 Temperature Depression Switch (on side of control panel)
This off/on switch selects the operation of temperature depression. See section
2.1.2
TEMPERATURE
DEPRESSION
SWITCH
2.3.12 Optional spilt metal detector lamp.
When this red lamp illuminates, it indicates that metal has entered the furnace
chamber and that action is required to investigate the cause. It may be just
accidental over filling or it could be a crucible failure. Variations of signalling are
available as additional options, such as audible alarms, and volt free contacts
to link into the telephone system.
The spilt metal is detected my means of 2 probes located in the drain hole.
Should a metal leakage occur a circuit is formed between the probes by the
metal.
A controller within the control panel detects the circuit made and energises a
relay that illuminates the lamp showing a metal leakage and also closes the a
circuit formed between volt free contacts such that an external alarm may be
triggered.
The power to the elements will also be automatically isolated to protect the
furnace and personnel, the furnace will switch off.
Should it be necessary to resume operation of the furnace the system masy be
10
overridden by disconnecting the probes at the drain hole.
11
3. Basic Operation and Settings
The following section is a simplified instruction covering the basic operation of
the furnace. Part 2 Section 7 covers detailed operating instructions.
Manual Automatic Event Operating Status Panel Colour
Operation Indication
Switch on supply Panel energised Panel live lamp White
and panel isolating
switch
Check temperature Upper display
controller settings = 0°°C
(max. operating Lower display
temperature 850°°C) = 850°°C
For automatic Time switch starts Furnace start-up Mimic run lamps 12 - Green
control of furnace, up furnace when sequence - LED
switch off/timed/on pre-set time is 12 elements
selector to timed (it reached Energised
is assumed that
timer has been
preset)
OR PID control Furnace switches Upper display
monitors time and from full to half, ie 6 = 800°°C
Half, auto, full temperature elements only Lower display
switch, set to auto automatically energised when = 850°°C
o
power 50 C alarm setting is
reached
Set point
temperature is Furnace switches Upper display Red LED
reached ie upper off to half power and = 850°°C
value matches is monitored Lower display Red LED
lower value automatically = 850°°C
according to
demand from PID
controller
For manual
operation of Automatic control
furnace, switch overridden
half/auto/full
selector to full
12
Manual Automatic Event Operating Status Panel Colour
Operation Indication
THEN
For manual Furnace switched Mimic run lamps 12 - Green
operation of on. Time clock LED
furnace switch overridden furnace
off/timed/on on sequence
selector to on 12 elements
energised
IF
Red
Earth fault RCD relay tripped Elements not Earth fault
energised because indicator lamp
RCD trips Mimic run lamp
not illuminated
THEN
Refer to Part 2
Section 10 for fault
finding
Otherwise if
furnace runs
To prevent Furnace switches 6 - Green
overshoot of set from full to half at
point temperature, controller alarm LED
furnace power can setting
be reduced by
selection of temp
control panel
If crucible pre- Locks furnace into 6 - mimic run Green
heating or drying continuous half lamps illuminated
out when low heat power setting 6 - mimic run
is required. lamps illuminated
Switch
Half/temp/full
selector to half
IF
Chamber Lining limit Furnace switches Lining limit lamp Red
temperature temperature control off
exceeds set limit is triggered by
(1070°°C) refer to chamber
Part 2 Section 6.2 temperature
of Manual exceeding set limit
(1070°°C)
IF
Metal leakage metal leakage Furnace switches Metal leakage
occurs controller is off lamp illuminates Red
activated
13
