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MANUAL OF OPERATION

for

FURNACE TYPE: VBQ-S-303648SHOP ORDER: 12069

SERIAL NUMBER: 16636

Prepared for: International Gear Corp.9000 Precision Dr.Indianapolis, IN 46236

Prepared by: C.I.Hayes Inc.800 Wellington Ave.Cranston, RI 02910

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W A R N I N G !

T H E G A S E S P R O D U C E D B Y OR U S E D I N T H I S E Q U I P M E N T MAY B E F L A M M A B L E OR H A Z A R D O U S .

P E R S O N N E L T H O R O U G H L Y T R A I N E D I NA T M O S P H E R E E Q U I P M E N T S H O U L DE A L L O W E D T O I N S T A L L ~ O P E R A T E ~ AND

A I N T A I N T H I S E Q U I P M E N T .

T H E P R O C E D U R E S O U T L I N E D I N 860 ( I N D U S T R I A L F U R N A C E S U S I N GA S AN A T M O S P H E R E ) I N A D D I T I O N T H E P R O C E D U R E S I N T H I S I N S T R U C T I O N

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5

10

15

20

25

2 .0

1.0 GENERAL INFORMATION.......... . • • . . • . . • . .4 1 .1 . Shipping Equipment. . . . . . . . . . . . . . . . . . . .4

11.2 . Damage C1 a im s . . .. . . . . . . . 4.3 . Additional Help.. ••••••••• ••••• •••• . •• . • 4

1 .4 . Specif icat ions.........1.5 . W arra n t y . . . .. . . . . 5

1.5 .1 . Terms of Liabi l i ty • • . . • • • • • • • • • • • . . • . • • • • • • • •• • . • 51.5 .2 . Limits of Liabi l i ty . • • • • • • • • • • • • • • . • • • • • • • • • • • • 51.5 .3 . EXCLUSION OF WARRANTY OF MERCHANTABILITY... . . 5

3.

4.

5.

6.

1.6 . Consequential Damages . . . . . . . . . . . . . . . . . . . .5 ATMOSPHERE INFORMATION: TECHNICAL ALERT. • • • • • • . . • • • • 6

2 .1 . Argon . . . . .....•. . 72 .2 . Nitrogen. . . 72 .3 . Propane . . . . . . . . . . . 82.4 . Methane.................... . 82 .5 . Natural Gas. . . . 92 .6 . Hydrogen...................... .9 2.7. Anhydrous Ammonia. • . • • • • . • • • • . • • • . • • • • .2.8. Dissociated Ammonia (See Hydrogen).. . . •••••. 10

DESCRIPTION OF THE VBQ.. . . . . . . . . • • • • • • • • . • • • • • • • . • • .123 .1 . Furnace . . . . . . . . . . . . . . 123 .2 . Vacuum Vessel s....... • • • • • • • • • • • . • • • • . . • • • .123 .3 . Front and Rear Heads. . • . • • • • • . • • . ••••• . •••• 12

3 .4 . Heating Chamber.. ••••••..•••• . . • . . • . • • . . 12

3 .5 . Heating Elements . . . . . . . • . . . • . .133.6. Water Cool ing. . •..•••...•• .•..•.. • . • • . 133 . 7 . Control Panel . . 13

3 . 8 . Power Suppl y............... . 13

3 .9 . Power Terminal s....... • • • • • • • • . • •••••• .133.10. Forced Convection Inert Gas Cooling ••••••••.•.••• 14

3.11. Furnace Load and Unload Mechanisms. . . . . . . • • • • • • • • 14

INSTALLATION OF THE VBQ FURNACE.... . . • • • • • • • • • . . • • • •••4.1 . Unloading and Rigging . • • . . • • • . • • • . • • . . • . • • • . • • •• • . • • • 15

4.2 . Un-Crating and Unpacking. . . . . . . • . . . • • • • • . • • • • 15

4.3 . Selection of the Furnace Site... • • • • • • • • • • . • • • 164.4. Furnace Pos i t i on i ng . . . . . . . . . . . . . . . . . . . • •.•••• 16

4.5 . Vacuum Tight Connections. . . . . ••• • • • • • • . • • . • 174.6 . Vacuum Pumping System.. . . . . • • . • • . • . • • • • • • 184.7. Hydraulic Pump Ins ta l la t ion . . •• . ••• • ••• 19

4.8. Compressed Air Supply Piping.. • • • • • • • . . ••• 19

4.9 . Nitrogen Backfil l Supply Piping. ••• . . • • • • • • . • • 19

4.10 . Natural Gas Supply Pip ing . . . . . . . . . . . • •.• 4.11. Water Supply Piping. . . • • • • • • • • • • • • • . . 20 4.12. Power Suppl y W ir ing . . .. . .. • • • • • • • • • • • • • • • • • • • • • • • • 214.13 . Thermocouple Ins ta l la t ion and Wiring. . • . • • • . • • 214.14. Profi le Thermocouple Feedthrou9h Assembly . . . . . . . . .224.15. Vacuum Sensor Tube Ins ta l la t ion . . . • . • • . 234.16. Instal lat ion Check List............. .23HEATING ELEMENT INSTALLATION AND REMOVAL.. ••• . • • • . 24

5 .1 . Eleinent

Remova1 • • • • • • • • • • • • • • • • • • • • • • • • • • •

.245 .2 . Element Ins t a l l a t ion . . . . . . •• • • • • • . . . 24 OPERATION. . . . . . . . . . . . . . . . . . . . . . . ..... . ...6. 1 . In i t i a 1 Sta r t UP Pro c e d u r e • • • .256 .2 . Motor Direction Check. . . . . . . . • • •• . • • . .• 256.3 . Hydraul ic System. . . . . . . ••.•••••..•••• .25

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6.4 . Vacuum Inteqritv Check . . . . . . . . . . . . . . . • . • ..... .266 .5 . Overtemperature Check . . . . . . . . . . . . . . . . . • . . • • • • • . • • • . 266.6 . Pressure and Vacuum Switch Set t ings . . . . . • • • • • 276.7. Conditions for s ta r t up--Automatic and Manual . . . . • • . • 276.8 . Start Up .....•...........................•..•....•••.28 6 .9 . Loading and running the VBQ-S Automat ical lv . . . . . . .286.10 . Loading, processing, and unloading the VBQ Manuallv .• 296 .11 . A larm s . . .. . .. . .. . .. . 30

6.12 . Burnout Cvcl e . . . . . . . • • • • • • • • • . • • • • • • • • .316. 13. Pu1se Ca r bur i z i ng • • . • • . • • • . . • • • • • • • .326.14. Furnace Shut down (automatic) •..••••••••••.••••.• 33

6.15 . Furnace Shut down (manual)•••••••••••••••••.

337. NITROGEN GAS FOR BACKFILL....... .• • . • • • • • • • • • • • • • • • • • • • • • • . 348. VAPOR PRESSURE GRAPH. . . . . . . . . . . . . . . . . . . . . . •••••••••• .359. MA I NTENANCE RE COMMENDAT IONS. • . • • • . • • • • • • • • • . • • • • • • .37

9 .1 . After Each Production Run . . . . . . . . . . . . . . • • • . . . • • • • 379.2 . Daily Maintenance... . ••••.•••••...•••••••.•379.3 . Weekly M ain te nan ce . . . . . .. . . .. . .. . .. . . .. • • . . . • • . • 389.4 . Monthly Maintenance • • . . • . • • • • . . • • • • • • • • • • . • • • • • . • 389 .5 . Semi-annual Maintenance. . . . . . ••• • •••••••••• 389.6 . General Maintenance... •••• . . • • • • • • • . • • • .39

10.11 TROUBLE SHOOTING........ . . . • • . . • • • • • • • • • • . • • . . 40

11. RECOMMENDED SPARE PARTS. . . . . . . . . . . . • • • . • ••• • • • • • • • • • . .42

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1.0 GENERAL INFORMATION

WARNING

Improper operation of th is equipment may resul t in propertydamage, personal injury, or death. This ent i re inst ruct ion

manual should be read pr ior to ins ta l l ing or operating th i sequipment.

This equipment was designed for a speci f ic process withspecif ic mater ia ls . Use for other purposes or with othermaterials may resul t in property damage, personal in jury, ordeath. Consult with C. 1. Hayes before modifying ei ther the

2 E m E E 2 m m m E 2 m 2 E j 1 1 1 i l l H 1 j ~ h ~ : : E ~ : ~ ~ : ~ : : I : : : E i l l : G 1 j ~ ~ : 1 j ~ m ~ ~ : : S : ~ : : : : : 1 ~ E ~ : ~ : ~ E m : ~ E ~ E ~ : 1 h ~ r E ~ : 1 S : m m 1 : ~ 1 : ~ 1 ~ m m ~ 1 1 ~ : : ~ 1 : ~ : : j 1 m 1 m 1 S : ~ : m : 1 ~ : ~ ~ 1 : U ~ : i l l : ~ : E f E : : : m m : 2 2 :1.1 . Shipping Equipment

C. 1. Hayes Inc. equipment is assembled at the factory and is

mechanically tes ted before shipment. Smaller furnaces areshipped as a uni t . Larger furnaces may be par t ia l ly dismantledand shipped in sect ions .

When the equipment arr ives at the plant the shipping l i s t shouldbe checked carefully to make certa in that a ll l is ted items areaccounted. C. 1. Hayes Inc. can replace items missing only i fthe omission is reported immediately upon receipt of theequipment.

1.2. Damage Claims

Carefully inspect the equipment on del ivery for any damage whichmay have occurred during shipment. A claim for res t i tu t ion fordamages can only be f i led against the shipping agent . Thecustomer should inform C. 1. Hayes Inc. of any damage so thatarrangements can be made for correct ion pending set t lement of aclaim.

1.3 . Additional Help

These ins truct ions may not cover al l deta i ls or variat ions inequipment, or provide for every possible s i tuat ion in connectionwith the ins ta l la t ion , maintenance, and operation of thefurnace. I f the customer or service engineer has added to ormodified the configuration of the furnace, addit ionalins truct ions regarding those modificat ions should be added tot his ma nua 1 •If further information is needed or part icular problems ar isewhich are not covered suff ic ien t ly , C. 1. Hayes Inc. or thenearest di s t r i c t off ice should be contacted. A timely reply canbe made only i f the complete name plate information and ser ia lnumber are included with a complete, detai led descr ipt ion of theproblem.

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1.4. SpecificationsHayes Furnace Type: VBQ-S-303648Serial Number: 16636Maximum Operating Temperature 2000"F/1093"CAtmosphere: Vacuum and Nitrogen Gas, Propane CarburizingMax. Gross Load: 1500 l b s ~ Electr ical Rating

Furnace: 261 kilowatts , 460 vol t s , 328 A, 3 Phase, 60 HzControl: 2 kilowatts , 460 vol t s , 4.4 A, 1 Phase, 60 Hz

Auxiliary: 61 kilowatts , 460 vol t s , 77 A, 3 Phase, 60 Hz

1.5. Warranty

1.5.1.C.

Terms of Liabi l i tyI . Hayes Inc. warrants equipment and parts

manufactured by i t to be free of defects in materialsand workmanship for a period of ninety (90) days af te rreceipt by purchaser subject to the conditions below.Hayes' obligation under th is warranty is l imited torepair or replacement, at i ts option, any parts (exceptceramic type heating units such as "globars" and "hotrods" and refractory metals) which, upon examination by

Hayes, prove to be defective in materials orworkmanship provided that wri t ten notice is given toHayes within ten (10) days af te r discovery.

1.5.2. Limits of Liabi l i tyThis warranty does not apply where, in Hayes' judgment,the defect is due to causes beyond Hayes' control .This includes, but is no t l imited to , such things asservice or al tera t ion by someone other than an employeeof C. I . Hayes Inc . , negligence on the part of theuser, accident , and operat ion, maintenance, or storageunder other than normal and proper condit ions.

Hayes makes no warranty of equipment or parts notmanufactured by i t .

1.5.3. EXCLUSION OF WARRANTY OF MERCHANTABILITYTHE WARRANTY OF MERCHANTABILITY IS EXPRESSLY EXCLUDED;THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THEDESCRIPTION ON THE FACE HEREOF.

No agent, employee, or representative of C. I . HayesInc. has any authority to bind i t to any aff i rmation,representation, or warranty which is no t specif ical lyincluded herein.

1.6. Consequential DamagesC. 1. Hayes Inc. shall not be l iable for anyconsequential damages whatsoever.

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2.0 ATMOSPHERE INFORMATION: TECHNICAL ALERT

WARNING

TECHNICAL ALERT!ATMOSPHERE CONTAINING LESS THAN 16% OXYGEN

MAY CAUSE SERIOUS INJURY OR DEATH

All furnaces require the use of a non-life supporting backfil lgas. Also, nitrogen, argon, propane, methane, or hydrogen mayused during some phase of the heat t reat ing process.

be

Before entering a vessel or pit containing a vessel , theatmosphere must be purged with a ir to dissipate any trappedprocess gases. Use a suitable fan or blower to direct a stream ofa ir into these places for at least five minutes before enteringand continue to vent i la te freely while personnel are working inthese areas.

TOXIC RATING CODE

HAZARD COMMENTS

o NONE a . No harm under any conditionsHarmful only under unusual conditionsoverwhelming dosage

or

1 SLIGHT Causes readily reversible changesdisappear af te r end of exposure.

which

2MODERATE May cause both reversible

andi r revers iblechanges not normally severe enough to cause

death.

3 HIGH May cause permanentvery short exposure

injuty or death af te rto small quant i t ies .

4 UNKNOWN Effects are unknown

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2.1. Argon

DefinitionArgon is a colorless , inert gas which is heavier thana i r .

Hazard analysis Acute local 0Acute systemic 1 (by inhalat ion) Chronic local U

Chronic systemic U

Warning SymptomsArgon is a simple asphyxiant. The oxygen may bedisplaced to a level of 16% of the gas/a i r mixturebefore symptoms appear. Marked symptoms appear whenthe oxygen concentration has been reduced below 16%.Death will occur in minutes when oxygen content isbelow 10%.

Firs t symptoms are hunger and rapid respira t ion. Thisis followed almost immediately by diminished mentalalertness and impaired muscular coordination. Later ,

judgement is impaired and all sensations aredepressed. Emotional instabi l i ty and the rapid onsetof fat igue is often reported. As asphyxia progresses,there may be naussa, vomiting, pros t ra t ion , loss ofconsciousness, convulsions, deep coma, and death.

2.2. Nitrogen

DefinitionNitrogen is a colorless , iner t gas which is verys l ight ly l ighter than a i r .

Hazard analysisAcute local 0Acute systemic 1 (by inhalat ion) Chronic local UChronic systemic U

Warning SymptomsSimple asphyxiant. Pathology is s imilar to argon. Theoxygen may be displaced to a level of 16% of thegas/a i r mixture before symptoms appear. Markedsymptoms appear when oxygen concentration has beenreduced to below 16%. Death will occur in minutes whenthe oxygen concentration is below 10%.

Firs t symptoms are hunger and rapid respira t ion. Thisis followed almost immediately by diminished mentalalertness and impaired muscular coordination. Laterjudgement is impaired and a ll sensations aredepressed. Emotional ins tabi l i ty and the rapid onsetof fat igue is often reported. As asphyxia progresses,there may be nausea, vomiting, pros t ra t ion , loss ofconsciousness, convulsions, deep coma, and death.

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2.3. Propane

Definit ionPropane is a color less gas with a s l ight odor, and isheavier than a i r .

Hazard analysis Acute local 0Acute systemic 1 (by inhalat ion)

Chronic local UChronic systemic 2

Warning SymptomsPrimary inhalat ion hazard is due to displacement ofa i r . See effects of simple asphyxiants argon andnitrogen for descript ion of symptoms.

Primary hazard is explosiveness of a i r /gas mixture. DO

NOT USE NEAR OPEN FLAME OR HEAT!

Propane is easi ly oxidized and can react explosively inthe presence of oxidizing substances .

2.4. Methane

Definit ionMethane is a colorless , odorless (odorant sometimesadded), t as te less gas, very s l ight ly heavier than a i r .

Hazard analysis Acute local 0Acute systemic 1 (by inhalat ion) Chronic local 0Chronic systemic 0

Warning SymptomsPrimary inhalat ion hazard is due to displacement ofa i r . See effects of simple asphyxiants argon andnitrogen for descript ion of symptoms.

Primary hazard is explosiveness of air /gas mixture. DO


Methane is more easily oxidized than propane and canreact explosively in the presence of oxidizingsubstances .

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2.5. Natural Gas

DefinitionNatural gas is colorless , odorless (odorant sometimesadded), ta s te less , and very s l ight ly heavier than a i r .

Hazard analysis Acute local 0Acute systemic 1 (by inhalat ion) Chronic local 0

Chronic systemic 0Warning SymptomsPrimary inhalat ion hazard is due to displacement ofa i r . See effects of simple asphyxiants argon andnitrogen for descript ion of symptoms.

Primary hazard is explosiveness of air /gas mixture. DO


Natural gas is more easily oxidized than propane andcan react explosively in the presence of oxidizingsubstances.

2.6. Hydrogen

DefinitionHydrogen is a colorless , odorless gas, much l ighterthan a i r .

Hazard analysis Acute local 0Acute systemic 1 (by inhalat ion) Chronic local 0Chronic systemic 0

Warning SymptomsPrimary inhalat ion hazard is due to displacement ofa i r ; however, hydrogen very rapidly disperses into thea ir except in gas t ight areas . See effects of simpleasphyxiants argon and nitrogen for descriptions ofsymptoms.

Primary hazard is explosiveness of air /gas mixtures.DO NOT USE NEAR OPEN FLAME OR HEAT!

Hydrogen is easily oxidized and can react explosively

in the presence of oxidizing substances. Hydrogennormally burns with a color less flame.

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2.7. Anhydrous Ammonia

Definit ionAnhydrous ammonia, a color less gas with a strong,pungent odor, is l ighter than a i r . I t is usuallyt ransported l iquefied by compression.

Hazard analysisAcute local

I r r i t an t 3

Ingestion 3Inhalat ion 3Acute systemic UChronic local

I r r i t an t 1Chronic systemic U

Warning SymptomsAmmonia is an extreme i r r i t an t to skin, eyes, nose, andthroat . Flood affected areas immediately with copiousquant i t ies of clean water and continue f looding for atleas t 15 minutes.

Ammonia is a toxic inhalant; excessive inhalat ion cancause severe damage to the lungs. Remove pat ient atonce to uncontaminated area.

Ingested oral ly , ammonia is highly toxic . I f pat ientis conscious, give him large quant i t ies of water.

Ammonia is not in i t se l f a f i re hazard, since i t isnonflammable under 1200°F; however, i f ammonia leaksin an area heavily exposed to heat, EVACUATE THE WORK

AREA AND ANY AREA DOWNWIND FROM FIRE. Anyf i re - f igh te rs will need sel f -contained breathingapparatus and full protective gear .

2.8. Dissociated Ammonia (See Hydrogen)

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ALL FURNACES THAT USE A PROTECTIVE ATMOSPHERE, A COMBUSTION SYSTEMGIVING OFF FLUE GASES, OR GIVE OFF VAPORS OR OTHER CONTAMINANTS FROM

THE WORK MATERIALS BEING PROCESSED, REQUIRE THE CUSTOMER TO PROVIDE AVENTILATION SYSTEM TO REMOVE THE GASES AND CONTAMINANTS FROM THEFURNACE AND BUILDING TO A SAFE LOCATION. THE VENTILATION SYSTEM

SHOULDBE

PROPERLY SIZEDAND

POSITIONED SOIT

PREVENTS THEABOVE

GASESAND CONTAMINANTS FROM ENTERING THE BUILDING WHERE OPERATING AND OTHERPLANT PERSONNEL ARE LOCATED. THE COLLECTION HOODS AND PLENUMS MUST

NOT BE CONNECTED TO THE FURNACE VENTS OR FURNACE PROPER AND MUST BE

ADEQUATELY SPACED AWAY FROM THE FURNACE TO ALLOW SUFFICIENT ROOM

DILUTION AIR TO ALSO ENTER THE VENTILATION SYSTEM. THE PROPER SPACINGAND ROOM AIR DILUTION PREVENTS DRAFTS FROM CAUSING ABNORMAL ATMOSPHERECONDITIONS IN THE FURNACE EQUIPMENT AND PROVIDES FOR DILUTION OF THEVENTED GASES TO A SAFE LEVEL. CONTACT YOUR INSURANCE CARRIER OR LOCALGOVERNING MUNICIPALITY FOR SAFE DILUTION LEVELS.

EXTREME CARE MUST BE TAKEN TO PREVENT THE ABOVE ATMOSPHERE GASES,COMBUSTION PRODUCTS, AND CONTAMINANTS OF PROCESSED WORK MATERIAL

FROM COMING INTO CONTACT WITH THE PLANT PERSONNEL. MANY OF THESEGASES AND CONTAMINANTS CAN CAUSE PERMANENT INJURY OR DEATH AFTERVERY SHORT EXPOSURE TO SMALL QUANTITIES.

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3. DESCRIPTION OF THE VBQ

3.1.

3.2.

3.3.

3 .4 .

Furnace

The VBQ furnace is unique in that i t is a combination vacuum

furnace, controlled atmosphere furnace, and an a ir furnace.

*NOTE

HIGH SPEED STEELS ARE NOT TO BE INCLUDED, SINCE THE MAXIMUM

CONTINUOUS OPERATING TEMPERATURE OF THE VBQ IS 2000

0 F •

Vacuum Vessels

The Hayes Model VBQ-S is a single stage heat t reat ingfurnace which may be used for carburizing and hardening tools tee ls . The furnace consists of a horizontal inner vesselsurrounded by an outer water jacket . A rear mounted fancirculates the inert gas backfil l through the work loadduring the cooling cycle.

Front and Rear Heads

The loading end of the furnace consists of a water cooleddished head with a rectangular sl iding door which is sealedto the door frame by an '0 ' r ing. The rear water cooleddished head supports the gas ci rcula t ing fan and the heatexchanger.

Heating Chamber

The heating chamber is a s teel framework fabricated withappropriate structural members and covered with a heavysteel mesh screening.

A high puri ty ceramic f iber blanket of suff ic ient thicknessfor the maximum operating temperatures is mounted on thein ter ior walls of the cage, forming the actual heatingchamber.

The high puri ty ceramic blanket does not contain any organicconsti tuents , thus posing no threat to the furnace or thework being heat t rea ted .

The ceramic blanket used is a highly eff ic ient thermalinsulator , having low thermal conductivi ty, low heatstorage, and is resis tant to thermal shock.

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3.5. Heating Elements

The furnace is heated by horizontally mounted ceramicelements that have been f ired from two special ceramicmixtures t such that only that sect ion within the heatingchamber will heat to control temperature.

3.6. Water Cooling

Water is circula ted to the furnace areas t heat exchangers t

and access heads to maintain proper operating temperatures.The flow is controlled by an automatic water control ler .

3.7. Control Panel

The control panel is equipped with a ll of the necessarycontrol instruments and switches t mounted and clearlylabeled according to their functions.

3.8. Power Supply

Power to the furnace elements is supplied by a free standingpower pack containing the variable output transformers t

regulated by a s tep- less amplif ier t controlled by aproportional control ler connected to a thermocouple in theheating chamber.

3.9. Power Terminals

Power is brought into the heating chamber through terminalfeed-throughs. These terminals are elec t r ica l ly insulatedfrom the chamber and are equipped with vacuum seals .

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3.10. Forced Convection Iner t Gas CoolingThis system cons is ts of a baff le plug located at the rear ofthe heating chamber which opens with the heating chamberfront doors during the cooling cycle. The gas ci rculat ing

fan is surrounded by the finned coiled heat exchanger. Theiner t gas c i rcu la tes through the heat exchanger, along thewater cooled vessel walls through the open front door, thework load and the rear baff le plug.

Furnace Load and Unload Mechanisms

This cons is ts of two pusher and puller heads attached tocaptivated chains and drive sprockets . The heads areadvanced and re tracted by a drive system consis t ing of ahydraulic motor and a direct ional valve.

Numerous sensing devices are provided to establ i sh a smoothand consis tent operat ion.

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4. INSTALLATION OF THE VBQ FURNACE

4.1. Unloading and Rigging

Immediately check the shipping l i s t against the itemsreceived for missing equipment. Notify the shipping agentand C. I . Hayes Inc. immediately of any shortages.

If possible, leave sections crated and on shipping skids andmove into furnace area. I f the sections must be uncrated to

allow movement through the building, take care that thef langes, piping, etc. are suitably protected from damage.

I f ins ta l la t ion is no t to take place immediately, place thefurnace and components in a cool, dry, dust f ree , enclosedstorage area.

Many of the furnace surfaces are ground and polished.Excessive humidity in the storage area may resul t inrust ing of these surfaces .

After storage the polished surfaces should be checked,any rust removed, and the surfaces re-polished

Contact C. I . Hayes Inc. for recommended storageprocedures i f prolonged storage is ant icipated.

CAUTIONFailure to properly store the furnace may void the warranty.

4.2. Un-Crating and Unpacking

NOTEOne method of moving the dished heads is to pick them up , whilethey are s t i l l protected, by the holes provided.

Exercise extreme care in unloading the dished heads. They cannot

be set on the i r polished f langes.

Carefully uncrate sections and check items received againstthe shipping l i s t .

Check careful ly for shipping damage, especially those itemsfrom crates that are broken or appear to have been subjectedto rough handling. Control instruments should be carefullyexamined for broken indicat ing needles, cracked or brokenglass , and disconnected wiring. Notify the shipping agentand C. I . Hayes Inc. of any shortages or damagesimmediately.

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4.3. Selection of the Furnace Site

With reference to the Overall print , select a location thatwill allow ample space around the furnace for ins ta l la t ionof the pumping systems, loading and unloading operations,and maintenance.

The location must also provide suff ic ient space foroperation and maintenance.

NOTEAs the maintenance space around the furnace is reduced, heatingchamber removal wi 11 become more diff icul t .

Allow enough room around the loading end of the furnace forvessel door movement and work handling.

4.4. Furnace Positioning

When raising the vessel , a sl ing is recommended (the l i f t ingeyes on top were for assembly at C.l . Hayes). For any ofthe other equipment use the l i f t ing points provided. All ofthe heavier items have been provided with l i f t ing holes or

eyes to make positioning of these items safer and easier .

Be careful not to damage finished surfaces of flanges,piping, and wiring with chains, hooks, cables, or otherrigging equipment.

Level the vessel using the hearth as a reference from frontto rear and from side to s ide. Correct leveling isnecessary to permit sat is factory mating of the other furnacecomponents. A sp i r i t level and straightedge or an opticalleveling device may be used.

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4.5. Vacuum Tight Connections

NOTE

SATISFACTORY SEALING OF AREAS SUBJECTED TO VACUUM CONDITIONS CAN

ONLY BE ACCOMPLISHED BY CAREFUL ASSEMBLY. A RECOMMENDED

PROCEDURE FOR MAKING THE BOLTED FLANGE TYPE CONNECTIONS FOLLOWS.

Clean the "0" ring or sealing disc and the two matingsurfaces with a clean rag and acetone. Make sure the

surfaces are "squeaky clean" and are kept clean duringassembly.

Remove any rust on the flanges with fine emery paper. Anysmall nicks or burrs should be removed with fine emery clothand oil by rubbing along the circumference of the flange.

It is necessary to resurface scratched or gouged flanges.Contact C. I. Hayes Inc. for resurfacing information ifrequired.

CAUTION

DO NOT NOT ASSEMBLE BADLY SCORED, SCRATCHED, OR NICKED SURFACES.NEITHER THE SEAL NOR THE VACUUM GREASE WILL CORRECT A SEALINGPROBLEM. REPAIR AND REASSEMBLY OF DAMAGED VACUUM SEALS BY

C.I.HAYES INC. SERVICE REPRESENTATIVE MAY RESULT IN A CHARGE TO

THE CUSTOMER.

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Apply a l ight coat of si l icone vacuum grease to the f langesurfaces to prevent rust during operat ion. Wipe off excessso that only a l ight film of grease remains.

Apply a l ight film of s i l icone vacuum grease to the "0" ringor sealing disc. Wipe off excess so that only a l ight filmof grease remains.

Place the "0" ring or sealing disc in posi t ion.

Secure the flanges together by t ightening bol ts in a"cr isscross" pattern as fol lows:

1 Firs t hand t ighten a ll of the bol ts .2 Then t ighten the bolt in the 12 o'clock posi t ion.3 Then the bolt in the 6 o'clock posi t ion.4 Then the bolt in the 9 o'clock posi t ion.5 Then the bolt in the 3 o'clock posi t ion.6 Continue th is pattern unti l a ll of the bol ts are

secured.

Throughout the assembly process keep constant check on theposit ion of the "0" ring or disc to be sure i t has not moved

out of posit ion.

Vacuum Pumping System

1 Prepare flanges and "0" ring or sealing disc asdescribed in the section on Vacuum Tight Connections.

2 With the sealpiping to the

in posi t ion,main chamber

assembleport .

and bolt vacuum

3 With vacuum seals and vacuum piping inf langes together as described above.

place, bolt the

4 Move the mechanical booster system into posit ion andlevel i t so that the pump intake port i s d i rect ly inl ine with the vacuum piping f lexible connector. Withthe vacuum seal in place, bolt the f langes together asdescribed in the section above.

5 Bolt the mechanical booster system to the f loor .

6 Connect the electr ical leads from the pumping systemthe main disconnect switch box. Check that thero ta t ion of the pump motor is correct . Re-wire forcorrect ro ta t ion i f necessary.

to

7 Make upsystem.

the water piping to

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the mechanical booster

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4.7. Hydraulic Pump Ins ta l la t ion

CAUTION

The hydraulic f lu id recommended for use with th is equipment isHoughto Safe #620 Fire Resistent Hydraulic Oil.

1 Reconnect the in le t and outle t hydraulic tubingand outle t connections of the main vessel .

to the in le t

12

Make i n i t i a l connections f inger t ight .Placement of the hydraulic pumping unit willdetermined by the length and posit ion of the

betubing.

2 Move the hydraulic unit into posit ion and level i t .that the posit ion selected will not pu t undue s tra intubing connections during operat ion.

Insureon the

3 Attach the hydraulic tubingthe furnace.

to the in le t and outle t ports on

4 Securely t ighten all hydraulic tubing connections.

5 Bolt the hydraulic unit to the f loor .

6 Reconnect the electr icalthe main junction box.

leads from the hydraulic motor to

7 Check the hydraulic f luid level and add f lu id i f necessary.

4.8. Compressed Air Supply Piping

1 Pipe the compressed a i r supply to the compressed a ir in le tof the furnace. Compressed a ir pressure must be maintainedat 100 PSIG ±10%. The a ir must be both clean and dry.

2 Leave the shutthe furnace is

off valve in the supply l ine closedready to be placed in operat ion.

unti l

4.9. Nitrogen Backfil l Supply Piping

1 Pipe the nitrogen backfil l supply to thefurnace. Use piping of the same size orin le t connection at the furnace.

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in le t on thelarger than the

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NOTEBACKFILL GAS MUST BE METALLURGICAL GRADE.

2 A vacuum leakproof shut off valve in the backfil l supplyl ine near the furnace is provided. Close this valve andleave i t closed until the furnace is ready for operat ion.

3 The backfil l gas pressure must be regulated to 15 PSIGmaximum.

An incorrect regulator or small piping will resul t in extendedbackfill time.

C 8 U I I Q ~ MAKE CERTAIN THAT ALL CONNECTIONS ARE VACUUM TIGHT AND THAT THEREARE NO LEAKS IN THE BACKFILL SUPPLY PIPING. LEAKS MAY ALLOW AIRTO ENTER THE SYSTEM WHEN THE BACKFILL LINE IS AT SUB-ATMOSPHERICPRESSURE. THIS WILL HAVE A DETRIMENTAL EFFECT ON THE OPERATIONOF THE EQUIPMENT AND TO THE WORK BEING PROCESSED.

4 A pressure gauge is insta l led between the backfil l supplyand the shut off valve at the furnace to enable a pressurecheck of the backfil l l ine for leaks.

4.10. Natural Gas Supply Piping

Pipe the natural gas supply to the inle t on the furnace.Use piping of the same size or larger than the inle tconnection at the furnace. Natural gas pressure at thefurnace is maintained at 20 psig.

4.11. Water Supply Piping

1 Pipe the furnace make-up water inlet piping to the watersupply.

2 Check that the water supply piping to the mechanical pump,hydraulic heat exchanger, furnace and quench vessel havebeen connected.

C 8 U I I Q ~ Be certain that a ll piping is complete and leak proof.

* * W 8 B ~ 1 ~ G * * m m m m m m ~ ~ m n m w ~ m m m m w m ~ m W m m m m H m ~ E ~ m m m m W m m ~ m m ~ m m m m n I T 2 I T T I m H m E I T E E E H H W m ~ ~ ~ ~ ~ ~ ~ ~ ~ m H E E E E m E E H H H H H ~ ~ m ~ E E E E H m ~ E ~ ~ ~ E m m E m n H m ~ ~ E ~ m H H H H E ~ ~ ~ E H H H ~ H

AN OPEN DRAIN COLLECTOR IS USED TO PREVENT PRESSURE BUILD-UP INTHE COOLING SYSTEM. 00 NOT PIPE FURNACE DRAINS DIRECTLY INTO THEPLANT PIPING, BYPASSING THE OPEN COLLECTOR SYSTEM

I f the use of the drain col lector , as supplied with the furnace,is impractical , contact C. 1. Hayes Inc. for furtherinst ruct ions.

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4. 12. Power Supply Wiring

MAKE SURE CONNECTIONS ARE MADE TIGHTLY. LOOSE CONNECTIONS OFHIGH CURRENT CARRYING CONDUCTORS MAY RESULT IN SEVERE HEATING.OXIDATION. ARCING. AND MELTING OF CONDUCTORS.

1 Check that the supplied voltage and frequency are the same

as the furnace design. Contact C.I .

Hayes Inc.i f

there isany variat ion from the design requirements.

2 Connect the power supply to the main disconnect switch. andfrom the main disconnect switch to each sub systemdisconnect switch.

4.13. Thermocouple Instal lat ion and Wiring

1 Coat the threads of the thermocouple gland nut with glyptoland insert the thermocouple into the port to i t s full depth.through the heating chamber insulat ion. and thread intoport .

I f a thermocouple ceramic insulator has been provided.insert i t through the heating chamber insulation beforeinserting thermocouple.

C 8 U I I Q ~ DO NOT OVER TIGHTEN THE GLAND NUT. TIGHTEN ONLY A LITTLE OVERFINGER TIGHT!

2 Connect the thermocouple lead wires from the instrumentcontrol panel to the thermocouple port on the furnace.

C 8 U I I O ~ DO NOT RUN THE THERMOCOUPLE LEAD WIRE WITH CONTROL OR POWERWIRING. ERRATIC OPERATION AND LOSS OF TEMPERATURE MAY RESULT.

3 Thermocouple lead wire is polarized and color coded. Thecolor of the lead depends on the type of thermocouplesupplied. Identify the posit ive and negative leads of thethermocouples provided.

Negative Leads:The negative

wiremay be red.

brown.or some other color with a red or white t race.

Positive Leads:The posit ive wire may be yellow. black.or white.

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4 Attach the thermocouple leads to the thermocouple junctionblock terminals maintaining correct polar i ty .

4.14. Profi le Thermocouple Feedthrough Assembly

NOTE

In order to permit temperature profi l ing of the furnace,auxiliary thermocouple feedthroughs have been mounted in the sideof the loading end of the furnace chamber. Below is a suggestedmethod of connecting those feedthroughs to the customer's prof i le

thermocouples.

1 Release the flange clamps and remove the blind sealingf lange and centering r ings .

2 Clean the thermocouple feedthroughs of all grease and otherforeign matter.

3 Three wire thermocouple feed throughs have been providedwith thermocouple plug connectors at tached. Nine cer t i f iedtype 'K ' thermocouple assemblies with jacks are provided.refer to drawing A-12069-01 for posit ioning of thermocoupleassemblies.

4 Clean the centering rings and l ight ly coat the i r sealing "0"rings with vacuum grease.

5 Remove lead wire plugs and pass lead wire through the feedthrough ports . Reconnect plugs to lead wires. Place thesealing rings and feed throughs on the mounting f langes.

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6 Securely clamp the feedthroughs in place.

7 Connections outs ide the furnace should be made with anAmphenol 78-S8 octal tube socket with an Amphenol 3-24 plugcap to the prof i l ing instrument. Observe the correctpolar i ty and numerical sequence.

8 Connections inside the furnace can be made by connecting thelead wire plugs and thermocouple jacks together . When notin use, the lead wire and plug may be rol led and stored inthe feed through port sides or the feed throughs and leads

may be removed and the blind flanges ins ta l led .

4.15. Vacuum Sensor Tube Ins ta l la t ion

Coat the threads of the sensor tubes with glyptol and inser tinto proper locat ions .

4. 16. Ins ta l la t ion Check List

NOTEPlease check the following pr ior to making arrangements for af ie ld service engineer to complete the ins ta l la t ion and place thefurnace into operat ion.

1 Shortages and/or shipping damages have been reported.

2 The furnace has been properly leveled.

3 All flanges have been assembled correct ly .

4 All services are supplied to the furnace (water, compresseda i r , nitrogen, elec t r ic i ty , e tc . ) . Be sure that theelectr ical supply is adequate to handle the load placed bythe furnace. The nitrogen backf i l l should be suff ic ient forat leas t one week of furnace operat ion. Compressed a ir mustbe supplied at 100 PSIG ±10%. The a ir must be both clean

and dry.

5 Vacuum leak detect ion equipment is avai lable in the plant orin the immediate vic in i ty . A helium mass spectrometer typeleak detector is required.

6 I f tools and electr ical meters are not avai lable for theservice engineer to use, please notify the C. I . Hayes Inc.f ield service manager.

7 A spare set of heating elements, element terminals , andthermocouples should be on hand.

8 Specif ic ins ta l la t ion problems not covered suf f ic ien t ly bythese ins truct ions should have been resolved through contactwith C. I . Hayes Inc.

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5. HEATING ELEMENT INSTALLATION AND REMOVAL

5.1. Element Removal

WARNING

BE CERTAIN THAT THE MAIN ELECTRICAL DISCONNECT SWITCH IS IN THE"OFF" POSITION BEFORE PROCEEDING WITH ANY ELECTRICAL WORK ON THISUNIT. DO NOT TOUCH THE FUSES WITHOUT FIRST DISCONNECTING POWER.

WARNING

THE GASES USED IN THE OPERATION OF THIS FURNACE ARE HAZARDOUS.BE CERTAIN TO OPEN ALL VESSEL DOORS AN D DIRECT A STREAM OF AIR,WITH A FAN OR BLOWER, THROUGH THE FURNACE FOR AT LEAST TENMINUTES BEFORE ENTERING THE VESSEL.

1 Unbolt and lower the element port covers.

2 Using the expansion tool provided, remove the Globarclamps and carefully unwrap the braid connector.

3 Slide the used or broken Globar straight out holdingthe insulation tube in place.

4 If the electr ic feed through is in the way, remove jamnuts and push the connecting rod into the feed through.

Element Instal lat ion

1 Slide the new Globar straight through the element port ,being careful not to knock insulation out on theopposite side.

2 Wrap braid connector around Globar end and, using theexpansion tool , slip the connecting clamp over thebraid.

3 Having insta l led the Globars, perform a continuitycheck between each element and ground. I f theresistance is not close to inf in i ty , look for contactbetween the connecting braid and the heating chamber,or perhaps a misplaced insulating tube.

4 Clean element port and cover flanges. Clean andre-grease "0" rings.

5 Swing the cover into place and t ighten the bol ts .

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6. OPERATION

WARNING

The safe operation of vacuum furnaces depends on the furnacebeing ei ther at vacuum or f i l led with inert gas whenever i t isabove 200 0 F. Any action which introduces an oxidizing gas oragent into a heated vacuum furnace poses a damage hazard to the

: m : : H H : H : : H ~ : W : ~ : : m : m : U : : ~ : : : H m : ~ : : ~ E : H m : E : : S : ~ : : ~ : : m : ~ : : ~ : : ~ : : m : ~ : H : : ~ : : m : S : m : ~ : : m : : : : : ~ E ~ : : H : ~ E 8 : ~ H H U : : S : m : ~ E m : ~ : : ~ E n : : : : : H : H H H : H E E E E : : : : n : n : n : : : : H m : H m : m H6.1. In i t ia l Star t Up Procedure

1 Open the main a ir supply valve to the systempiping, valves, and f i t t ings for leakage.

and check

2 Check the primary andf i t t ings for leakage.

secondary nitrogen piping, valves, and

3 Check theleakage.

natural gas supply piping, valves and f i t t ings for

4 With all control panel selector switches in

"AUTO" or "CLOSED" posi t ion, close the mainswitch.

the "OFF" or

fused disconnect

6.2. Motor Direction Check

1 Energize the vacuum booster system by pressing the VACUUMPUMP START push button and turning the BLOWER ON selectorswitch to ON. Check the motor for proper ro ta t ion andcorrect i f necessary.

NOTEThe mechanical roughing pump is equipped with a gas bal las tvalve. I f , af te r a period of operat ion, the normal low pressure

usually accomplished by th is pump becomes unobtainable, open thegas ballast valve. Operation for at leas t an hour with thebal las t valve open and the furnace vacuum valve closed willusually correct the problem. The oil level of vacuum pumpsshould be checked frequently, especially during bal las toperat ions. Refer to the pump manual for the completemaintenance procedure.

2 Energize the hydraulic pump motor s t a r t e r switch bydepressing the "START" push button. Check the motor forproper

ro ta t ionand correct i f necessary.

6.3. Hydraulic System

1 Bleed the Hydraulic System.

2 Once the hydraulic unit is energized, the a ir must be bledfrom the hydraulic system at each of the internal hydrauliccylinder connections.

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- - - - - - -

3 Close the appropriate flow control valve ful ly ,tubing connector, and then slowly open the flowvalve to force the a ir from the l ine .

loosen thecontrol

4 I f no f luid is released in short order, close the valve andinsert a small diameter rod into the end of the solenoidvalve to move the spool lef t or r ight . Then slowly open theflow control valve to bleed the l ine .

5 Tighten hydraulic tubing

control valve.

connector and close the flow

6 Repeat steps 3system.

through 5 for each hydraulic cylinder in the

6.4. Vacuum Integrity Check

1 Turn the CONTROL POWER selector switch to ON.

When the CONTROL POWERNOTE

switch is turned ON, the alarm horn willsound. Silence i t by depressing the ALARM SILENCE push button

2 With the furnace chamber heat vessel empty, close the door.

3 Using the vacuum valve control, evacuate the chamber toultimate vacuum. Note the time i t takes to evacuate thechamber.

4 The chamber is now at ultimate vacuum.

Turn the "VACUUM VALVE" selector switch to the "AUTO"posit ion, closing the valve and isolating the chamberfrom the vacuum system.

NOTENote the rate of pressure r ise in the vessel . The rate of r ise

should not be greater than 10 microns per hour. If the rate ofpressure r ise is excessive, and a leak is not otherwise apparent,a helium mass spectrometer type leak detector must be employed tolocate the leak.

6.5. Overtemperature Check

1 The overtemperature protection instrument should bechecked for correct operation following the componentmanufacturer's inst ruct ions.

C 8 U I I Q ~ALL WORK, WORK BASKETS, TRAYS, AND FIXTURES MUST BE PROPERLYDEGREASED PRIOR TO VACUUM FURNACE PROCESSING TO ASSURE OPTIMUMRESULTS. OIL RESIDUES BETWEEN PROCESSED PARTS WHICH NESTTOGETHER CAN CAUSE CARBURIZATION AND ALLOYING OF PARTS ATELEVATED TEMPERATURES.

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6.6. Pressure and Vacuum Switch Sett ings

1VSA is set to 28" Hg. vacuum.1VSB iss e t to 12" Hg.2VS(a) is set to carburizing level (24" Hg).2VS (b) iss e t a t 14" H9 •

VG1 is set to the AUTO VAC control set point. VG2 is set to 500 microns.

1PS is set to 5 psig.

6.7. Conditions for s tar t up--Automatic and Manual

The furnace is at ambient temperature and pressure.The cooling water is be flowing to the furnace and to theheat exchanger.The drive is retracted. The furnace door is closed.The external t i l t is down.The internal t i l t is up.A load is on the t ransfer (hot) turn table and in a positionto load the furnace.

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6.8. Start Up

1 Turn CONTROL POWER ON.2

34

The program on the programmer is selected for carburizing;therefore. turn the CARB GAS OFF-ON selector switch to ON.Bring the furnace up to 1600 a F.Select the process program.

6.9 . Loading and running the VBQ-S AutomaticallyPress the LOAD VBQ button on the Materials Handling System.

Once the load is in the furnace. press RUN on the DCP 511 onthe furnace control panel.The furnace chamber will pump down to 400 microns and theload will heat to the desired temperature.When the heat cycle is complete. the furnace will backfil lto 12" Hg.The internal and external doors will open.The Furnace heat will cut off and the heat exchanger waterwi 11 go on. The cool ing fan wi 11 s ta r t .

The HEATING CYCLE COMPLETE l ight will go on.The cooling fan will stop. The heat exchanger water will gooff .The UNLOAD FURNACE l ight will go on.

Use the Materials Handling System to unload the VBQ.

CAUTION

DO NOT TOUCH THE MANUAL CONTROLS (EXCEPT FOR EMERGENCY STOP)WHILE THE FURNACE IS IN AUTOMATIC OPERATION.

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6. 10 . Loading, processing, and unloading the VBQ Manually

Co12345

nditionsTheTheTheTheThereis

for Manual Loadfurnace is at temperaturefurnace is at atmosphericexternal t i l t is down.internal t i l t is up .

is a load on the t ransferin position to load the fur

p

na

ressure

(hot) turnce.

table and i t

Manually loading the furnace

NOTEClearly labeled selector switches are provided for each of theseoperat ions.

1 Open the external door.2 Open the internal doors.3 Load the furnace, using the TRANSFER ADVANCE.4 Retract the t ransfer .

5 Close the internal door.6 Close the external door.

Start ing the program cycle

Open the vacuum valve by turning the AUTO VAC CONTROL OFF-ONswitch to ON.A) The furnace chamber pumps down to 500 microns.B) The Heating cycle s t a r t s , following the DCP

program selected .C) The heating cycle runs i t s course.D) The furnace backfi l ls to 12" Hg.E) The internal door and fan plug open.F) The furnace eat goes off , the heat exchanger comes

on, and the cooling fan goes on.G) The cooling cycle runs i t s course.H) The cooling fan turns off and the heat exchanger

water goes off .H) The fan plug closes .I) The UNLOAD FURNACE pilot l ight goes on.

Manually unloading the work1 Backfil l the furnace to atmospheric pressure leaving

nitrogen flowing during the unloading of the furnace.

WARNING

~ ~ W m m m m m ~ m m m m w m m m m m ~ m m m m m m ~ ~ m w m ~ m m m m m n m m m m m m m m ~ ~ m m m m m ~ ~ m ~ m ~ m m m ~ m m m m m m m m ~ m m m m ~ m m m m m m m m m m m m ~ m ~ W m W H m m m m m W m m m m Exercise caution and use appropriate protective gear whenunloading the furnace. The nitrogen discharging from the

furnace is both hot and unbreatheable, and the work load is quitehot.m ~ m m m m ~ m m ~ m m m m m m ~ m m m m m w m m m m m m m m m m m m m m m m m m m ~ m m m m m m n m ~ m m m m m m ~ [ [ ~ m m H H m m ~ H H H m H m E H m E H m m m H H H m H ~ m m H H H H m H E H H H H H H H m H m ~ E H H H

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2 Open the internal door. (Note: the internal door is

should already be open. Check to confirm that theinternal doors are open.) .

3) Advance and retract the t ransfer to unload the furnace.

To reheat a load manually1 The UNLOAD FURNACE l ight goes on .2 Change the operating temperature for process on the

DCP.3 Change the unload quench temperature.

4Star t the programmer.

Alarms

The alarm wi 11 sound t furnace heat wi 11 shut off t and theappropriate alarm l ight will go on for the followingcondit ions:

Furnace overtemperatureLoss of cooling water flow--furnace.

The alarm will sound and the appropriate alarm l ight will goon for the following condit ions:

Loss of cooling water flow--heat. Loss of cooling water flow--heat exchanger.

* Silence the alarm by pressing the ALARM SILENCE pushbutton. The ALARM SILENT pi lo t l ight will go on.

* The appropriate ALARM l ight will stay on until thealarm condition is corrected.

The alarm will also sound i f during a carburizing eyelet thecarburizing gas pressure switch indicates low pressure.This will close the carburizing gas safety shutoff valve.

NOTECarburizing gas cannot be admitted below 1400°F.

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6. 12. Burnout Cycle

Periodically, the heat chamber must go through a burnout cycle.The burnout alarm will sound for the ent i re burnout cycle. Thesequence of the burnout cycle is as follows:

Backfil l the heat chamber to atmospheric with N2 •

Open the external load door.Close the internal door.Set the programmer to 1200°F.Turn the selector switch BURNOFF OFF-ON to ON.

At the conclusion of burnout, turn the selector switchBURNOFF OFF-ON to OFF.

C t l U I I Q ~ Stay clear of the front door during the burnout cycle, asflames may r o l l o u t of the heat chamber.

NOTE

Adjust the a ir flow to that amount which will not exceed theamount that would over heat carbon deposits and cause damageto the heating cage mater ia ls .

NOTEThe burnout time can be adjusted i f i t is determined that 5minutes is not long enough to suff ic ient ly clean the heatcage.

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6.13. Pulse CarburizingThe purpose of the pulsator is to enable sat is factorycarburizing at lower part ia l pressures than are currentlyemployed with the conventional, primary/secondary backf i l lmethod of carburizing.

We recommend using the following guidelines when operatingthe uni t :

1 The propane l ine pressures must be 20 psig minimum.

2 The2VS(a)

switch controls the carburizinggas part ia l

pressure. Trials indicate that a setpoint range of of 30"24" Hg. is sat i sfactory for most appl icat ions.

3 In some appl icat ions , such as with closely racked work orrandomly or ientated (shovel loaded) work an increase incarburizing part ia l pressure may be required. Ourexperience suggests that operation in the 30" to 24" Hg.range should be adequate. Operation of the unit in excessof 18" Hg. is not recommended as severe soot deposi t ion wi 11resu l t . 30" to 24" Hg. should be adequate on spaced par tsand outside diameter (00) only carburizing. Dense loads mayrequire somewhat higher pressures, possibly up to 18" Hg.

In no ins tance should the setpoint be higher than 18" Hg.In a ll cases, the lowest possible pressures should be used.

4 The pulsator 's timer controls the accumulation and re leasetimes of the system. In i t i a l set t ings include a releasetime of 0.3 seconds (ON time) and an accumulate time of 20seconds (OFF time) of propane flow. The correctaccumulate/release times and flow ra te re la t ionship isobtained when a decrease in flow ra te is observed pr ior tothe pulsator 's solenoid opening.

5 An evacuation time is used to remove gas from the heatchamber when the preset carburizat ion level is reached. The

evacuation timer is in i t i a l ly set for three minutes af te rwhich the pulse cycle will resume unti l the carburizinglevel is again obtained.

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6.14. Furnace Shut down (automatic)To shut down the furnace use the following procedure:

1 After the las t work load has been pulled from the heatchamber, press the CYCLE STOP push button, located on thecontrol panel. Confirm that the external and internal doorsare closed.

2 Turn the MODE selector switch to MANUAL.

3 Evacuate the furnace to 10" Hg.4 Close the vacuum valves.5 Turn the HEAT selector switch to OFF.6 Allow the furnace to cool to below 300"F, then close the

main water supply valve.7 Turn the CONTROL POWER selector switch to OFF.8 Press the STOP push button for the vacuum and hydraulic

pumps.9 Shut off the MAIN nitrogen and a ir supplies.

6.15. Furnace Shut down (manual)To shut down the furnace use the following procedure:

1 Remove the las t work load has been pulled from the heatchamber.

2 Close the internal and external doors.3 Evacuate the furnace to 10" Hg.4 Close the vacuum valves.5 Turn the FURNACE HEAT selector switch to OFF.6 Allow the furnace to cool to below 300 Q F, then close the

main water supply valve.7 Turn the CONTROL POWER OFF-ON selector switch to OFF.8 Press the STOP push button for the vacuum and hydraulic

pumps.9 Shut off the MAIN nitrogen and a ir supplies.

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7. NITROGEN GAS FOR BACKFILL

The recommended source for backf i l l gas is bulkl iquid . The minimum analys is of nitrogen backfi l l gasshould be:

Puri ty: 99.998%Maximum Water Content: 10.5 ppm 10.5 Mg/cu.lDewpoint: -76 D FMaximum Oxygen Content: 2 ppm typo

The above specif ica t ions are as ordered from the suppl ier .Contamination may occur during shipping, on-s i te storage,and delivery to the furnace.

The flow ra te will backf i l l the furnace from operatingpart ia l pressures to 12" mercury vacuum in the desired timespan.

The nitrogen suppl ier must posit ion a pressure regulatorr ight at the in le t to the furnace nitrogen system and mustprovide the required pressure at that point .

A qualif ied suppl ier of nitrogen will ass i s t you in theselection of a bulk storage tank and select ion of the properregulator .

NOTEThe piping that carries nitrogen from the bulk tank to thefurnace must be hard soldered· · using type L copper tubing andwrought f i t t ings . CONVENTIONAL THREAD PIPING IS NOT TO BE USED.

· ·Hard solder can be 95 t in /5 lead or a s i lve r solder .

High pressure cylinder gas <commercial grade) has been usedby some customers, but i t is not recommended as

discolorat ion of work may resul t . However, thespecif ica t ions for high pressure gas are as follows:

Purity: 99.9%Maximum Water Content: H2 0: 34 ppm; O2 : 1000 ppm<1/10%)Dewpoint: -60 D F

NOTEArgon and neon are not included in the purity percentages and mayrun as high as 300 ppm.

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8. VAPOR PRESSURE GRAPH

The vapor pressure graph on the next page is provided forthe convenience of the metal lurgis t or engineer developing avacuum heat t reat ing process.

The chart should be used to determine the l ikel ihood thatthe process developed will cause undesirable vaporizationfrom and/or deposition of metals onto the work beingprocessed.

Additional information is avai lable from the EngineeringDepartment, C. I . Hayes Inc.

07/05/1990 (35)

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VAPOR PRESSURE CURVES

=-- , - - - - , - - - , - - - , - - - . , . - - . . . - - - - - . - - - , r - - - , - - - . , . - - . . . - - - - - , - - r - - - - . - - - -= 108

10

1 : : : : : I - - - t - - t - f - t + - - t - H + - - - - t : f - - - ¥ - - H - - - - h h - I - 7 ' ' - + - ' ' + ~ ' ' - t ~ + . . y . - - - + - ~ ' F - - - + - - - : : : : : : ! 10 1

Cl+---- . f - - -#-+h_---- jo ..........i L - - i o ~ - - - + - - ~ t - - , I I I ' " t - - _ _ _ . I I ' - - - + - - . . . . . . . . . . - j 10-

1 o

:I: o

- -5 2o I0 1 : : : = - - - - j f - t r - - - + - J - ~ t - - - - J ' + - - I t - - - . f _ f + - : ~ ' - t - _ r _ + t + - - + - - J < - - - - ~ - - - - b ' T _ - + - _ _ _ : : ~ - - - : : : : : : ! 10 EE ..

EQ)

I = - - f - - t - - - - ' - - " i j ~ - t - t - + _ t f - - - b f - f _ _ _ r + f - - * f - J f _ t - - - - - t - . _ + _ T - n ~ - - + - ~ ' t - - - + - - - : : : : : l I0-3 IIIIIIQ)

41 - - - - - H + ~ ' - - I + - - t + - - _ t f j f - - H r . . - - , _ r + _ . . L . . . J y c - - t - - - - 1 - - r - t _ _ : f _ 1 f - - - 7 ' f - - + - - - + - - - : : : : : l 1 Ii:

b f + - H r - . . , f - t - - I + - - - J l f t - + H r . . . . . r - : t - I ' - f - - + - - I - - - t i ~ ~ _ / - - - t - i ! : . . . . - - + - - + - - - + - - - : : : : : l l 0- 5

-:'-fi:f--+---+-"f-t---J,+-_+_+--+--t--+_--:=j 10- 6

1 : ± - - f - + - + - - - + - t - t + J h ~ - i - - t ~ H - + _ - - + - - t _ + _ - - + - , f _ + t - - + _ - _ + _ - - _ + _ - _ + - _ = : l 1-7

+ - - H - - - + + - - t + - - t - - t t - - - t H ' - - + - - - + - - + t - - ~ ' _ _ t _ 1 - _ + - - + _ - _ + _ - - _ + _ - _ + - _ = : l 1 0- 8

1= I - - / f - -- - f j f- - - f -jH - r t - - -+ t f - - + - - - + -+ - I - - -t ' -- - 1 - - _+ - -+_ - _+_ - - _+_ - _+ - _= : l IO-9

10-1 1 : : : : f - - + - - _ + _ - H - t t - - + - + ~ - + + - - + _ - - t - - - t - - - - + - - - - - 4 - - + - - - - + - - + - - - + - - - : : : : : l 1 0-

10

a-Melting Point--- Estimated Curvef ! - - + - - - + - , f - - + - - - - h f - ! - . . . ! . . f - - _ + _ - - - j 4 - - I - - - 1 - - - - - t - - - t - - - - + - - _ + _ - - - + - ~0- 11

10-15 10-12

0 ~ - - : : 2 ~ 0 : - : 0 : - - - = 4 ~ 0 " ; : : " 0 - - - : : 6 : - ; O ~ 0 : ; - - ~ ~ - - ; - ; 1 0 : : " ; 0 : : : 0 ~ ; - ; 1 2 ; ' ; : O ; - ; : 0 : ; - - 1 ; - ; ; 4 - ' ; ; 0 ~ 0 : - - ; - 1 ~ 6 ~ O ' ; : ; : O - - ; - I ; ; " 8 0 ~ 0 ; : : ; - - - ; : ; 2 - ; : t O ' ; : ; : O - ; : ; 0 - - - - ; : ; 2 * 2 ' ; : ; : 0 ' ; : ; : 0 ~ 2 ; : : - 4 + 0 ; : : - 0 : : : : - - 2 ; : : - 6 ; : ! - ; 0 " " 0 : : : - - : 2 ~ 8 ~ 0 ~ 0 : - - : : 3 , . . " J 0 0 0 Temperature,OC

-Vapor pressure vs. temperature

BOO \ N E L L I NG TON AVE .

C R A N S TO N , R. I. 02910

LP.-6-72-1M PRINTED IN U.S.A.

8/7/2019 C735572


9. MAINTENANCE RECOMMENDATIONS

H H : : 1 : : : : H H : : : : : : E H : : H H H : : H H H : H : H H : H : : : : : : : m : : H H H H 1 : : : H m : m : m ~ ~ ~ ~ ~ ~ ~ : j : j : H : : ~ : : : : : : : H H m 1 : H : H E : : : H : H : 1 : m H : H : H m H H H E : : : : m : H H H : H : H : H : H : : : : : THE GASES USED IN THE OPERATION OF THIS FURNACE CAN BEHAZARDOUS. BE CERTAIN TO OPEN THE VESSEL DOOR AND DIRECT ASTREAM OF AIR, WITH A FAN OR BLOWER, THROUGH THE FURNACE FORAT LEAST TEN MINUTES BEFORE ENTERING.

WARNING

BE CERTAIN THAT THE MAIN ELECTRICAL DISCONNECT SWITCH IS IN THE"OFF" POSITION BEFORE PROCEEDING WITH ANY ELECTRICAL WORK ON THISUNIT. 00 NO T TOUCH THE FUSES WITHOUT FIRST DISCONNECTING POWER.

BE SURE ALL ELECTRICAL POWER IS DISCONNECTED AND NITROGEN SHUTOFF VALVES ARE CLOSED BEFORE PROCEEDING WITH ANY MAINTENANCEPROCEDURE.

::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::........................................................................................................................................................................................................................................................................................

: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : ~ ~ ~ ~ ~ ~ : : ~ : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::;:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

ALL WORK DONE ON THE HEAT CHAMBER SHOULD BE DONE WITH THEFRONT HEAD ASSEMBLY REMOVED.

The freguency of these procedures is directly related to thefreguencY of process cycles. This schedule should be modified asfound necessary to conform to the operational requirements.Also, pumps, valves, motors, and instruments should be maintainedas outlined by the manufacturers of the components. Record a llmaintenance data for reference and guidance in set t ing up apreventative maintenance plan and to forecast replacement partsstock requirements.

9.1. After Each Production Run

Degrease all components following processing and beforereloading.

9.2. Daily Maintenance

Check the mechanical pump an blower oi 1 level. Themechanical pump should not be running when checking the oillevel. Refer to the mechanical booster pump system manual.

Ballast the mechanical pump for at least one-half hour.

Drain the condensate from the mechanical pump vent piping.

Check coolant flow to all areas. 07/05/1990 (37)

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9.6. General Maintenance

Whenever vacuum seals are disassembled the "0" ringsand mating surfaces should be cleaned with acetone andthen l ightly coated with si l icone vacuum grease beforeassembly. Tighten all bolts securely and periodicallyre-check for t ightness.

During shut downs or idle periods the furnace chambervacuum should be lef t at about twenty-eight inches ofHg. vacuum.

07/05/1990 (39)

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10.11 TROUBLE SHOOTING

Ma 1fun ct ion

E1e ct r ica 1

Mechanical

Vacuum valves

Vacuum instruments

Vacuum pressure

Heating

Problem Solution

Blown fuses Check for grounding condit ion.

Won't s tar t Check motor s t a r t e r switchposit ion and overload t r ips .

Rotationincorrect Interchange

two of thethreephases.

Seized pump Refer to the pump manual

proper maintenance.for

Pump deficient Ballas t pump while isolatedfrom chamber. I f not cured bythe action replace pump oi l .

Will not actuate Check a i r pressure. Check

wiring to solenoids.

Bypass leakage Check a i rand clean pressure. Dissemblevalve seats .

Contaminated Remove and clean thermocouple.Thermocouple

Unable to at ta in Pump defic ient . Contaminationultimate vacuum on internal surfaces. Oil

vapor satura t ion ofinsula t ion. Load outgassing.

Leaks in system Check with heliumspectrometer type

massleak

detector.

Vent exhaust Restr ict ion in pipe due topiping size of pipe versus pipe

length.

Furnace Check fusesElements Check for ground.Thermocouple Check for open ci rcu i t .Overtemperature Reset overtemperature

instrument.

07/05/1990 (40)

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Ma 1funct ion Problem Solution

Backfi l l Nitrogen Check pressure of backfil lgas. Solenoid may not be

energized.

Valve control Manual valves in backfi 11system may be closed.

07/05/1990 (41)

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11. RECOMMENDED SPARE PARTS

WARNING

equipment; use of other parts may resul t in damage, injury oreven death. For information on authorized replacement parts ,call C. I . Hayes Replacement Parts department.

C.I. Hayes Inc. does not stock a l l parts for a ll products which

makes immediate del iver i of some par ts impossible. Therefore,the following par ts should be ordered and held in your inventory:

SiC Heating Elements (matched sets of 6)High Purity Ceramic Fiber Insulat ionNichrome Wire FastenersMain Chamber "0" RingsHeating Element Terminal Insulators , Clamps, and AluminumBraid ConnectorsHeating Element Power Feed Through Insula torsTerminal Port Cap "0" RingsThermocouples

Thermocouple GlandsAlloy Hearth CartVacuum Gauge SensorsMeehan i ca 1 Pump Oi 1Hydraulic Pump OilBooster pump OilVacuum GreaseGlyptol Pipe Joint Coating

You should also stock par ts recommended by the manufacturers

of the components used on your Hayes equipment.

To assis t us in expediting your order, please give theser ial number as found on the equipment name plate and insect ion 1 .0 , General Information.

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--- - - - --- --- --- --- --- --- --- --- --- --- --- ------ --- --- --- --- ---

--- --- --- --- --- --- --- ---

--- --- ---- - - --- --- --- --- --- --- --- --- ---- - - --- --- --- --- --- --- --- --- --- --- --- --- ------ - - - --- --- --- --- --- --- --- --- --- --- --- ---

Set Point Type PID Group PID·1 PID·2 PID·3_. . - - - - _ . ~ - ~Set Point Range J5a to 1700

Proportional band .% . . . . . . . . . . po,____ P02____ P03____

Set Point Unit 102____ 103____

Guarantee BandReset time ·sec . . . . . . . . 10'____

Rate time ·sec . . . . . . . . dO'____ d02____ d03____

Ewent HYlterell1Controller Output Limits

Time Unit.Upper l imit .0/0 • . . • • • • • . . CO,____ C03____ C05____

Proportional Band to' f.. .% . . . . . . . . . . C02____ C04____ C06____

Number of PID GrouplLower limit

Linear Range L1mltl

Decimal position . . . . . . . . . . . . . . . . . . .C07_

Upper limit ••••••••••••••••••••• . •• COS____

Lower l imit . . • . . . . . . . . . . . . . . . . . . . . .C09____

Output Relay Cycle Time ·sec . . . . . . . . C'O____

NOTE: Alter al; 01 the 101l0wlng data is emered, press IPROGlto store it

SOAK G. SOAK TE PVE OEVE

Set se t RAMP EVENT se t se t PID Cye

PROG SEG Point Time Point Time Rate No. ON OFF Point Point No. No. ....i- -'L --- --..

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--- --- --- --- ----- --- /700 .it::L

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..fL._ --- LQtL .2JL

I i ! I I I I~ . . 4 - 4 " " ; ) - ~ - I I

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Process Control Dlvillon, 1100 Virginia Drive, Fort Washington, PA 1903.

Prlnled in us.. c PY rt 0hi , g , a ~ - Hone .... 11 InC.A '< 0

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Heating EiementInstallation Guide

Remember, element breakage can occur during installation, as well as during

operation, if proper care is not used when installing them. It is also important that you besure that the element is the correct type and size for the furnace you are installing it in.

If the element or elements you are replacing are series connected they should be

matched by resistance or amps to within ±5%. The amperage of new elements is

marked on the right cold end and in magic marker at the end of each box.

.

STEP 1: While furnace is under power, ascertain which element or elements need replacing. This can be donevisually or with a clamp-on ammeter connected to the element strap to check for current flow. SHUT OFF

POWER AND LOCK-OUT SWITCH FOR SAFETY REASONS.

STEP 2: Remove c-clamps with clamp tool and take straps off from element ends.

STEP 3: Inspect clamps to make sure thC'! they have not lost tension due to excessive heat. If they have. theyshould be replaced. Inspect aluminum straps for fraying and/or oxidation. If they exhibit these problems. theyshould be replaced. .

STEP 4: Remove element from furnace by carefully pulling it straight out. If element is broken, each part will haveto be removed from each side of the furnace.

8/7/2019 C735572


: Inspect the terminal tubes in the furnace to be sure they are not broken. If they are, replace them.

STEP 6: Check the alignment and the straightness of the terminal holes thru the refractory walls. If they arenot true they should be corrected. Any binding of the heating e lement can cause breakage during heat-up or

operation due to expansion or movement of the furnace walls. Slide the element straight through the furnace. Avoid

hitting the opposite walls. Don't force the elements into terminal holes or put any unnecessary stress on them.

STEP 7: Center the element in the chamber so no portion of the heating section is in the refractory wall. This can

be done by measuring the cold end length sticking out of the furnace shell and make sure they are both equal.STEP 8: Lightly pack the open space around the element with Fiberfrax bulk fiber. The Fiberfrax should only go

back into the terminal hole 1 to 1V2 inches. Also lightly pack Fiberfrax into end of element to a depth of one inch..These will cut down on heat loss through terminal holes.

STEP 9: Carefully re-connect straps and clamps to element. Be sure that there is enough s lack in straps to

allow for element expansion. Also check that there is sufficient clearance between clamps and furnace shellto prevent electrical contact between the two.

STEP 10: Remove safety lock-out and turn power back on. Visually inspect the g low of the elements. if the

elements can be seen in the furnace. to verify heat output and correct operation. Check terminal connections

visually to insure no arcing is taking place between the element and the strap.

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CERAMI·C HEATING

ELEMENTS

INTRODUCTION

This instruction manual is designed to familiarize you with ceramic 'r

heating elements. I t covers element installation and operating pro-

cedures required to obtain maximum element service. Although

the manual deals with elements installed in furnaces, the same

procedures hold true for other heating applications.

The Leader.••

'-

H A V E SC . I . M A Y E S I N C .

800 Wellington Avenue, Cranston, RI I (401) 467·5200

8 ~ 1 I . ' i " : ;JJOj]

REV 4/29/8

'""'" ....... --- . _

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"

"

TABLE OF CONTENTS

Page

General Description . 1

Inspection . 1

Effects of Atmosphere on Ceramic Heating Elements . 1

Use of Matched Ceramic Heating Elements .'. 2

Mounting and Handling Instructions . 3

Installation:

Attached Terminal Type Elements 5

Diagram 4

Attached Terminal Type Elements in Ceramic Tubes. . . . . . . . . . . . . . . . . . . . . . . . . 7

Diagram , - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Attached Terminal Type Elements with Atmosphere Seals. . . . . . . . . . . . . . . . . . . . . 9

Diagram 8

Detached Terminal Type Elements (Angle Mounting) . . . . . . . . . . . . . . . . . . . . . . . . 11

Diagram 10

Detached Terminal Type Elements (Straight-Through Mounting). . . . . . . . . . . . . 13

Diagram 12

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If matched elements are used properly, they willgenerally give about the same life so that whenone element fails (barring accidents), there is not

enough life left in the other element to troubleabout, especially if uninterrupted production is an

important factor.

MOUNTING AND HANDLING

INSTRUCTIONS

Pick up the elements with tW9 hands, as the

weight of an unsupported end may cause breakage.

Do not knock or jar the elements, as they are

extremely fragile; often the slightest tap, jar, or

tension will break the element.

Do not pack insulating fiber around the terminalstoo tightly, as the elements must be able to movefreely during expansion. Fiber packing is used toprevent heat or atmosphere drafts and not to sealcompletely.

Have no undue weight or strain on the ends ofthe elements.

Use the recommended connections and voltageswhen starting new elements. Do not boost the

. voltage to heat the furnace rapidly, as this willshorten element life.

Shock mounts, capable of supporting the fullweight of the furnace, should be used whereheavy Hoar shocks from impact tools would otherwise be transmitted to the heating elements.

If one or more elements break or require replacement after operating for some time at increasedvoltage, all the elements in that circuit should be

replaced. One basic reason for the failure or shortlife of ceramic heating elements is the practiceof installing one new element in a circuit tooperate with others of different resistances.

A factor in determining the life of ceramic heating elements is the number of times the elementsare heated from ambient to operating temperature.To increase element life, the furnace should be

"idled" above 1300°F. during periods of inactivity.

Once a detached terminal heating element hasbeen heated, it should not be twisted or disturbed

until it is replaced. The heating section pins andterminal sockets fuse together; over this fusing, adielectric coating is formed. If this fusing is broken,it may be difficult to re-establish a good electricalconnection. Do not re-use detachable terminalswith new heating sections without first removingthe dielectric coating. This may be done by sand·hlasing or by tWisting a broken heating elementin the socket to grind it clean.

-3

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ArTACHEO TERMINAL. TYPE" ELEMENTS

FIBRO(/S CERAMIC P A P E ~ J:"{JRtVACE SHELl.

Tf2.AtJS,re II:" LUrnac:1Z-

f:'/I3ROOS CERAMIC ,t:"/8E

£LEM£/ IT TERMIIV

TERMINAL ClAM

TEl?MIN AI. 8RAI

J:"VRNACE SHELl .

TERMINAL 8RAID CERAMIC FIBER.

TERMINAl.

SECTIO

8/7/2019 C735572


INSTALLATION - ATTACHED TERMINAL TYPE ELEMENTS

. Place the element in the support trough provided.

(The trough resembles a steel tube that has been

split lengthwise to form a "U" shaped channel.)

Insert both the element and the trough into the

terminal port, across the heating chamber, andthrough the opposite terminal port. Hold the ele-

ment in place, and carefully withdraw the trough.

Center the element in the furnace so that its ends

extend an equal distance out each side of the

furnace. Install heating elements that have both

terminals on the same end so that their entire heat-

ing section protrudes into the heating ~ h a m b e r . Fold a piece of fibrous ceramic paper (manufac-

tured by The Babcock & Wilcox Company, Johns-

Manville Corporation, or The Carborundum Com-

pany) to form a pad about six inches long of suffi-

cient thickness to support the element in the center

of the terminal port. Raise the element, and slide

the pad under its terminal end. Repeat this proce-

dure at the opposite end of the element. Loosely

pack insulating fiber around both terminal ends,

forming an effective seal and at the same time

providing for element expansion and contraction.

A restriction of element movement may result inits breakage. "

Attach the aluminum braid connectors to the ter-

minal ends, using the clamps and clamp tool pro-

vided. Refer to the wiring print when making

these connections. Maintain adequate electrical

clearance between the CO!lIlectiO!1S and the furnace

shell, and do not impose any unnecessary weight

or strain on the elements.

To remove used heating elements: unfasten the

aluminum braid connectors from the terminal ends,

remove the insulating fiber packing; and then with-

draw the elements.

I f the elements are replaced when the furnace is

at temperature, allow the element to heat slowly

to furnace temperature by gradually inserting it

through the heating chamber. A sudden change in

element temperature may result in breakage.

-5

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A T T A C H G ' O TERM INA l TYPE ELEMENTS

IN CERAMIC TUBES

~ / ~ J f OtiS CEAAH/C.(

PAPZl l

/G SECT/O/{

) ( )< )< ".,,11 "It ll'Y,.ll )eX'",.. .,. ) f , . ) ; ' )0 ) I ' ~ t »)1 2r ' I t)lJ-

C E R A M I C TUSE

-0.fi1

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IN CERAMIC TUBES

Tube Installation:

Insert an installation rod (either wood or metal)

through the. gland ports. Carefully slip the ceramic

tube over the rod, and slide the tube along the

rod and out through the opposite port. Two men

will be required to support the rod and slide the

tube into position.

Fold a piece of fibrous ceramic paper to form a

pad that will support the lower half of the tube.

The pad should be about six inches long and of

sufficient thickness to support the tube midway

in the port. Install one of these pads under each

end of the tube, and insert a similar pad over the

top of the tube on each end. Do not pack the tube

sotightly th;t its movement

isprevented whilethe furnace is being heated. After the furnace has

heen heated and dried out, an atmosphere-tight

seal should be made by packing insulating fiber

between the tube and port and sealing the area

with a coating of The Carborundum Company's

TIigidizer \ViE liquid or equivalent.

Tube Replacement:

Should a tube fail during operation, it will be

necessary to remove the atmosphere from the fur

nace. Remove the corresponding element, and ex

amine it for damage caused by atmosphere attack.

Pass a metal rod through the tube to support it

during removal. Remove the insulation at each

end of the tube; then, carefully withdraw. the tube.

The removal and replacement of tubes should be

made while the furnace is at temperature, allow

ing the tube to heat slowly to furnace tempera

ture by inserting it gradually through the heating

chamber.

Element Installation:

Insert the element in the ceramic tube, using the

installation trough prOVided. Fold a piece of

fibrous ceramic paper, forming a pad about six

inches long Of sufficient thickness to elevate the

element slightly above the center of the tube.

Raise the element, and install a pad under each

end of the element. The elementis

located slightlyabove the center of the tube to prevent contact

should the element sag dUring operation. Fold a

similar pad, and install it over the top of the ele

ment, allOWing for element movement during

heating. Using the clamps and clamp tool pro

vided. attach the aluminum braid connectors to

the terminal ends. Refer to the wiring print .when

making these connections. Maintain adequate

clearance between the connections and furnace

shell, and do not impose any unnecessary weight

or strain on the elements. At the completion ofthe drying out process, insulating fiber should be

packed in the spaces formed by shrinkage of the

fibrous ceramic paper.

Element Replacement:

Should the element fail during operation and the

ceramic tube remain intact, it is possible to replace

the element without removing atmosphere from

the furnace. Remove the electrical connections

and packing at each end; then, carefu1ly withdraw

the element. Do not insert cold rods or pokers intothe hot tube, as thermal shock may result in tube

breakage. I f searching for element particles is

necessary, be sure that the metal rod is inserted

gradually. . ,,,.

Place a pa d of fibrous ceramic paper b e t w ~ ~ n the

leading end of the element and tube. Slide the

element and pad through the t_ube at a speed of

approximately two inches per minute. Slowly in

serting the element will allow the element to heat

to the tube temperature, preventing element or

tube breakage from thermal shock. When the in

sertion is completed, install the packing, and make

the necessary electrical connections.

-7

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ATTACHED TERMINAL TYPE ELEMENTS

WITH ATMOSPHERE SEALS

FIBROUS CERAMICI

RETAINING

r ' . . . , ,£ F F r r, " " " IFF ;CS P R IN G

'R c "'1fyUfP=- ::.:6jr-----1- J ~ ~ ~ = = = = = ~ ~ : = ! : ~ ~ ~ ~ f : ~ ~ ~ F 4 1 ~ , , ~ ~ , ~ " \ ~ ~0• ..a·t ; l m Q = . . : ~ Pr ' ----

TEc€M

PAPEi!. Il:.J'MJ$lr

~ / B R O U S FIBROUS C

~ U R N A C £ S

8/7/2019 C735572



WITH ATMOSPHERE SEALS

Place the element in the support trough provided,

and insert both into the terminal port, across the

heating chamber, and through the opposite port.

Holding the element in place, carefully withdraw

the trough. Center the element in the furnace so

that its ends extend an equal distance out each

side of the furnace.

Fold a piece of fibrous ceramic paper, forming a

pad about six inches long of sufficient thickness

to support the element in the center of the ter-

minal port. Raise the element, and slide the pad

under its terminal end. Repeat this procedure at

the opposite end of the element. L90sely pack

insulating fiber around both terminal ends to form

an effective seal and at the same time provide forelement expansion and contraction. A restriction

of element movement may result in breakage.

Place the fibrous ceramic washers, retaining ring,

and spring over the end of the element. Compress

the spring against the retaining ring, and attach

the terminal braid and terminal clamp so that the

spring is held in compression by the terminal

clamp. Repeat this procedure at the other end of

the element. Two men will be required to per-

form these operations, one to make the seal and

terminal connections and the other to hold the

element in place until operations at both ends of

the element are completp.d.

Remove used elements from the furnace by re-

moving the terminal clamps, springs, retaining

rings, fibrous ceramic washers, and insulation from

both ends of the element; then, withdraw the

element.

I f the elements are replaced when the furnace is

at temperature, allow the element to heat slowly

to furnace temperature by gradually inserting it

through the heating chamber. A sudden change

in element temperature could result in breakage.

-9

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8/7/2019 C735572


INSTALLATION - DETACHED TERMINAL TYPE ELEMENTS

Angle Type Mounting

In the removal of old elements, first remove the

aluminum braid connectors. The locking bolts on

the terminal pressure clamps at the rear of the

furnace should then be released and the clamps

swung out of the way. The rear terminals shouldbe removed from the rear. Remove the elements

from the chamber by working through the front

door. First slide the element an inch or two into

the rear terminal hole so that the front is clear of

its terminal block; then, gently work the front of

the element toward and out the front door. The

side terminals should be removed after the rear

terminals and heating elements have been re-

moved. (The importance of this sequence can be

seen by referring to the diagram which shows the

pin type ends of the element recessed in the socketof the angle terminal.) After the elements and

terminals have been removed, the terminal bricks

and tubes should be inspected and repaired or

replaced if necessary. Any slag or foreign matter

should he removed before the installation of new

elements and terminals.

To install new clements and terminals, the side

terminal must be put in position first. On the outer

end of the angle terminal, there is an arrow which

indicates the position of the socket. This arrow

should point toward the rear of the furnace. The

position of the socket must be checked by looking

through the rear terminal tube with a trouble

light illuminating the chamber. The element

should now be placed into postion by working

through the front door. First slide the element

an inch or two into its line of position; then, slide

it forward into the side terminal socket. Handle

. the element with care, and do not force. After the

element has been placed in the socket of the side

terminal, place the rear terminal in the rear tube

against the end of the element. These installationsare best accomplished if one man holds the ele-

ment centered in the socket of the side terminal,

and another man installs the rear terminal. After

the rear terminal has been inserted, a transite

insulating washer should be placed against the

end of the terminal and the terminal pressure

clamp swung into position. Center the washer

and clamp on the terminal, and apply pressure tothe clamp. Only pressure necessary to hold the

terminal firmly against the heating element need

be applied. The rear terminal should then be held

and the element turned until it seats itself in the

terminal sockets and a good contact is established.

Increase the initial pressure by closing the clamp

completely, releasing it approximately 3/16" for

element expansion and contraction, and locking it

by means of the locking bolt.

The terminal ports, rear and side, s110uld be lightly

packed with insulating fiber. Roll a quantity of

fiber between the palms of the hands, forming a

soft roll about 1/4" in diameter long enough to go

a little more than once around the terminal. The

roll should be wrapped around the terminal, close

to the port, and pushed in around the terminal.

This roll will fill the gap between the terminal

and tube, thereby preventing heat drafts, infiltra-

tion of air, and loss of atmosphere. Only a single

roll should be used, and it should not be packed

so tightly that the terminal cannot move in andout freely to allow for element expanSion and

contraction. (The terminal must be able to remain

in continuous contact with the heating element.)

After the elements have been installed, they

should be rotated by hand through the front door

opening to be sure that they are properly centered

in their sockets; then, check clearances at the

spring clamps. The aluminum braid connectors

may now be attached to the outer ends of the

terminals with clamps. The Wiring print should

be referred to when making these connections.

Care should be taken to have adequate electrical

and mechanical clearances from the furnace shell.

-It

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IJETACHED TERMINAL TYPE ELEMENTS

STI?AI6HT THI?OUGJI MOUNTING

7rnMINABRAID

TERMINAL

8/7/2019 C735572


INSTALLATION - DETACHED TERMINAL TYPE ELEMENTS

Straight-Through Mounting

.When removing old elements, first remove the

aluminum braid connectors. Next, the locking bolt

on the terminal pressure clamp at the side of the

furnace should be released and the clamp swung

out of the way. A fixed bracket at the oppositeside prevents the removal or replacement of the

terminals from this side unless the bracket is re-

moved. To eliminate the necessity of removing

brackets, a special installing trough is furnished

which can be entered at the free side to bridge

the furnace chamber. The elements and terminals

can be supported on this long trough and removed

or replaced quite readily. Clearance for manipu-

lathg the trough must be equal to the full length

of the element and terminal assembly. I f this

amount of clearance is not available, it may benecessary to remove the fixed bracket and work

both sides. After the elements and terminals have

been removed, inspect the terminal bricks and

tubes, and repair or replace i f necessary. Remove

any slag or foreign matter before installing new

elements and terminals.

To install new elements and terminals, the in-

stalling trough should be placed in position. The

element and terminals must be inserted in this

order: terminal/element/terminal. Take care to

see that the sockets in the terminals face towardthe heating element. After the first terminal of the

terminal/element/terminal combination is against

the fixed bracket, a slight holding pressure may

be exerted by hand on the other terminal and the

installing trough removed. A transite insulating

ring should then be placed against the end of the

terminal and the terminal pressure clamp swung

into position. The clamp should be centered on

the terminal and pressure applied to the clamp.

Only pressure necessary to hold the terminal firmly

against the element need be applied. Turn the

element until it seats itself in the terminal socketsand a good contact is established. The proper

pressure should now be estabilshed by closing the

clamp completely, releasing it approximately 3/16"

for element expansion and contraction, and lock-

ing it by means of the locking bolt of the clamp.

The terminal ports should be packed with insu-

lating fiber. A quantity of fiber should be rolled

between the palms of the hands to form a soft roll

about 1/4" in diameter long enough to go a little

more than once around the terminal. This roll will

fill the gap between the terminal and the tube,

thereby preventing heat drafts, infiltration of air,

and atmosphere loss. Only a single roll should be

used, and it should not be packed so tightly that

the terminal cannot move in and out freely to

allow for element expansion and contraction.

(The terminal must be able to remain in con-

tinuous contact with the h e ~ t i n g element.)

After the elements have been installed, rotate

them by hand to make sure that the elements are

properly centered in their sockets; then, clearancesof the spring clamps should be checked. Attach

the aluminum braid connectors to the outer ends

of the terminals with clamps. The wiring print

should be referred to when making these connec-

tions. Take care to have adequate electrical and

mchanical clearances from the furnace shell. .

c735572

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