Frequently Asked Questions (FAQs)

Inductotherm Corp. is part of the Inductotherm Group. Inductotherm Group brings together some 40 companies strategically located around the world all sharing a focus on serving the metals and materials industry. All are leaders in their respective disciplines. Inductotherm Corp. designs and manufactures the most advanced induction melting, heating, holding and pouring systems for virtually all metal and material processing.

Yes. Inductotherm Corp. is part of the Inductotherm Group. Inductotherm Group brings together some 40 companies strategically located around the world which all share a focus on serving the metals and materials industry and all are leaders in their respective disciplines. For a complete list of all the Inductotherm Group companies, visit www.inductothermgroup.com.

If your industry needs heat… Let's meet! Induction technology can help a wide range of industries and Inductotherm Group companies are able to help in almost every case.

One of the major advantages that Inductotherm can offer its customers is the Inductotherm Group. Inductotherm Group companies provide a wide variety of equipment and services that allow every industry to process metals from melting through casting, heating, rolling, drawing, forming and shaping into their final products. Contact your District Manager who can help connect you with the sister company that can best serve your needs.

Induction furnaces do not have a limit to the temperature they can melt and/or heat. However, the refractories and materials that contain the heated or melted material have limitations. The highest temperature typically reached in open air is about 3300°F for a platinum melt. In controlled atmospheres, heating of graphite can achieve temperatures in excess of 5000°F.

Induction equipment can melt/heat virtually all metals and materials including, gray and ductile iron, steel, copper and copper-based alloys, aluminum, zinc, reactive metals, precious metals, silicon and graphite. If the material to be heated is electrically conductive and resistive, it will couple with the magnetic field and can be heated, inductively. In the cases where the material is non-conductive, a susceptor may be used to provide the energy to heat non-conductive materials.

Always check with your District Manager to confirm if any changes to the melt system are required. The melt system may have been designed specifically to melt most efficiently either ferrous or non-ferrous applications and, therefore, may require modification to handle materials it wasn't originally designed for with the same efficiency and productivity. Note that your refractory supplier should be contacted to make certain your refractories are appropriate for the metal you are melting.

Our corporate headquarters is located in Rancocas, NJ, and we manufacture and assemble equipment at this location for both domestic supply and export. In addition to our facility in the U.S., we have additional manufacturing facilities in 17 other countries around the world for installation into their local regions. Additional locations for service, parts and repairs are in place around the world so that we can truly provide you with the best service and support in the industry, wherever and whenever you may need it.

Inductotherm is part of a larger family of companies, the Inductotherm Group. We have sister companies which manufacture high-quality equipment for a variety of applications, including heat treating, welding, mass heating, etc. We would be happy to connect you with the company that can best help you meet your needs.

We can connect our equipment to any typical 3-phase electrical power-distribution system. A transformer may be required to step the voltage up or down depending on the source voltage.

To date, we have built the following: 85 tonne tilting coreless furnace; 320 tonne stationary coreless furnace; and 250 tonne channel furnace. But we see no limits to what can be supplied.

With normal maintenance, virtually forever. However, as with any technology, you reach a point where the new technology gains in efficiency, reliability and support and so new equipment should be investigated to keep your operation competitive.

We have 21 manufacturing facilities in 18 countries and an additional 29 service locations worldwide. We set the world standard for customer service and support so that no matter where you are, we're there too.

Inductotherm has over 28,000 melting and pouring systems installed in 115 countries. This number continues to grow to satisfy our customers' growing markets, and we continue to grow with them. Every day we continue to develop new and better applications from A to Z (aluminum to zinc) to support the metals and materials industries worldwide.

Our systems are designed to have minimal downtime and so most costs will be from consumables and not spare parts.

In one word – Value. We manufacture the highest quality equipment that is built to the strictest standards. When you invest in Inductotherm equipment, you are provided with a system that will give you the best melt rates available which in turn provide you with the best return on your capital investment. When comparing 'cost per ton', Inductotherm equipment beats the competition every time. Our equipment truly does provide you with the competitive edge and will increase your bottom line.

Our shipping address and physical location is 10 Indel Avenue, Rancocas NJ 08073 USA. Our mailing address is 10 Indel Avenue, P.O. Box 157, Rancocas NJ 08073-0157 USA. While Inductotherm is headquartered in Rancocas, New Jersey, we have manufacturing and service facilities in 18 countries which helps us to set the world standard for customer service. Depending on your location, you can reach out to any of our facilities.

Our Customer Service Departments around the world provide service 24 hours a day, 365 days a year. You can call our toll-free technical support hotline 1.888.INDUCTO or 1.800.257.9527 here in the U.S.A. anytime and speak with a fully qualified and knowledgeable member of our service team for quick and professional assistance. Our standard office hours are Monday thru Friday from 7:30 am to 5:30 pm EST.

When single-phase alternating electric current (AC) from an induction power unit flows through a coil made of copper tubing, an electromagnetic field is produced that induces an alternating current to flow in the metal charge inside the furnace. Resistance to that current flow produces heat that rapidly causes the metal to heat or melt.

Combustion furnaces and induction furnaces produce heat in two entirely different ways. In a combustion furnace, heat is created by burning a fuel such as coke, oil or natural gas. The burning fuel brings the interior temperature of the furnace above the melting point of the charge material placed inside. This heats the surface of the charge material and the refractories, causing the metal to melt. Induction furnaces produce their heat cleanly, without burning fuel. The current flow in the metal causes it to heat and melt from within itself. With induction, you heat the charge directly, not the surrounding space.

In an induction furnace, the metal charge material is melted or heated by current generated by an electromagnetic field. When the metal becomes molten, this field also causes the bath to move. This is called inductive stirring. This constant motion naturally mixes the bath producing a more homogeneous mix and assists with alloying. The amount of stirring is determined by the size of the furnace, the power put into the metal, the frequency of the electromagnetic field and the type/amount of metal in the furnace. The amount of inductive stirring in any given furnace can be manipulated for special applications if required.

The highest electrical efficiency ever available coupled with tremendous reliability.

Because technology continues to advance, we highly recommend that you contact your District Manager to review efficiency/support enhancements. While your system may be running, it may not be as efficient as today's equipment and upgrading may greatly enhance your safety and productivity as well as efficiency.

There are many new products and upgrades that can be added to your system to increase its productivity, safety, and reporting capability with minimal investment so it is a good idea to keep in contact with your District Manager for our latest technologies. Another good resource is our website. It is updated frequently with our latest products, upgrades, news and articles, and we suggest you navigate through the site often.

We will be happy to send you additional information on our equipment and a quote. Please fill out the on-line form, or contact us by some other manner, so that we can better understand your project goals.

It's best to refer to the refractory manufacturer/supplier for their recommendations on selection, installation, sintering and maintenance of the refractory. They will have the most current information on the specifications and performance characteristics of your specific refractory material.

You must contact your refractory provider and completely understand the type of refractory and how it will be affected by your particular application. Contact the induction furnace supplier as well to make certain the refractories being considered are compatible with the design of the equipment.

All material being charged into the furnace must be completely dry and care should be taken so that the charge continues to feed into the furnace properly. If the charge hangs up due to interlocking or bridging, the metal below can superheat and erode the refractory, causing molten metal to penetrate to the coil. Automated charging systems should be used whenever possible because they significantly enhance safety by permitting furnaces to be charged remotely, keeping the foundry worker at a distance or behind protective barriers. Charge materials such as enclosed containers, propane tanks, gas cylinders, shock absorbers, aerosol cans, sheared tubing or pipe, and similar materials must never be charged into a furnace.

In a coreless furnace, the entire bath functions as the induction heating area. A copper coil encircles a layer of refractory material and a powerful electric current travels through the coils creating a magnetic field that penetrates the refractory and quickly melts the metal charge material inside the furnace. In a channel furnace, induction heating takes place in the "channel," a relatively small and narrow area at the bottom of the bath. The channel passes through a laminated steel core and around the coil assembly. The electric circuit is completed when the channel is filled with molten metal. Hotter metal leaving the channel circulates upward, raising the temperature of the entire bath. Foundries typically use channel furnaces to hold and dispense molten metal whenever it is needed.

We manufacture a variety of coreless induction furnaces (i.e., Heavy Steel Shell Furnaces, Small Steel Shell Furnaces, Dura-Line® Furnaces, Rollover Furnaces and Mini-Melt® Furnaces) as well as Crucible-type furnaces (i.e., Acutrak® Furnaces, Lift-Swing Furnaces and Push-Out Furnaces) so that, regardless of the size or application of your molten metal needs, we can customize a system for you. From small capacity, precision casting operations to the largest induction melting foundry, we have the right furnace for you.

Inductotherm is the principal supplier of induction furnaces and power supplies to the world's leading vacuum system manufacturers and precision investment casters, alloy manufacturers and anyone needing the highest quality molten metal. Inductotherm Vacuum Furnaces are designed specifically for operation in high vacuum environments and include vacuum-adapted construction methods and the industry's most advanced coil and connector dielectric insulation technologies and procedures.

Inductotherm Corp. supplies vacuum induction equipment including induction power supplies, furnaces, coils, shunt packages, and power transmission components. However, a complete vacuum system, including components such as chamber and vacuum pumps, would be supplied by a vacuum system supplier or system integrator.

Monitor the conductivity of the water. If the conductivity should exceed 10 µmhos/cm (or µsiemens), replace the deionizer cartridge. If the conductivity should ever exceed 100 µmhos/cm, flush the system with deionized water until the conductivity has returned to the recommended levels. Add industrial-grade inhibitors and additives-free glycol as needed for freeze protection. Also, due to differences in ethylene and propylene glycol, it is important to use the one for which your system was designed.

Take a small sample of the cooling fluid and use a standard automotive anti-freeze tester to measure the freeze protection level.

There are numerous reasons why this may be occurring. One possibility is that there is a leak in the system. Find and repair any leaks. If there are no leaks, the cause may be that fluid is added while the system is off. Adding glycol to the system while the pumps are off will result in high concentrations of glycol at the fill point while none is distributed to the rest of the system. Run the pumps to circulate the fluid before testing the concentration. Also, always be sure that the tower diversion valve is open when glycol is added so that the mixture can flow through the tower. If this is not done, the tower may remain full of 100% water while the rest has the correct concentration of glycol.

The system is most likely already full. The fill valve will automatically close when the pre-charge pressure is reached. At this point it will not allow more fluid to be added to the system. Some fluid will need to be removed before more can be added. The excess fluid can be collected in a mixing tank where glycol is added, then pumped back into the system.

The throttle valve may not be set correctly. With the pump running, adjust the throttle valve (first valve after pump discharge) until proper pressure is reached.

There may be air trapped in the system. If so, use air bleed valves to purge air from the system. This is more effective if the system is turned off for a while to allow small air bubbles to accumulate in the system high points. Extreme cases may require the use of an air separator. If this does not help, additional expansion capacity may be required and additional expansion tanks can be added to the system.

It is possible that there is a closed isolation valve somewhere in the system. Check to make sure that all main piping valves are completely open and that any by-pass or throttling valves are properly adjusted. If this does not work, you can also check to see if there is a clogged strainer or other obstruction in the piping. Flush the strainer or remove and clean. You may also want to refer to the piping diagram and ensure that the piping is not too small or that the piping runs are too long. The motor nameplate for wiring requirements should also be checked to be sure that the motor voltage and frequency is correct.

Checking the current melt rate and line kVA draw versus what it was when it was new will show efficiency level. If you need assistance, please contact your District Manager who can provide you with additional assistance. Periodic preventative maintenance service as outlined in the manual supplied with the equipment is recommended to ensure equipment is working at peak efficiency.

The control board monitors the power requested by the operator and controls the firing of the SCRs or IGBTs in order to maintain the requested power throughout the melting/heating process. Additional sensors provide feedback to the control board to ensure the system operates within the design limits.

Capacitor manufacturers have made tremendous strides in providing designs with a long life. However, capacitor life is still very much a function of the cooling water temperature. Verifying proper operation of your recirculating water system will do more than anything else to ensure maximum capacitor life.

We have specific replacement solid-state power supplies for all of these older technologies that offer increased efficiency, reliability and repairability over these older technologies as SCR and IGBT technology continues to advance.

Induction furnaces are a single-phase AC device. The power supply takes standard 3-phase 50 or 60 Hz power available from the utility companies and converts it into single-phase power at the most desirable frequency for the application.

Absolutely. We would be happy to upgrade all or part of your existing melt system based on your requirements.

Based on the type of power supply and the application it was built for, a finite number of furnaces can be connected through mechanical and/or electrical switch systems to the power supply system.

Inductotherm service personnel are highly trained and experienced on our particular equipment. They may not be sufficiently versed in the specific aspects of another manufacturer's equipment to offer the same level of effectiveness they bring to working on our equipment.

Please refer to www.inductothermgroup.com for contact information for the Inductotherm facility closest to you.

By locating the IP (Inductotherm Part) number which, whenever possible, is listed on the part itself. Part numbers can also be identified by referring to the drawings or the spare parts list that was supplied with the equipment or by sending a digital picture to our Inside Sales Dept. for assistance. Our experienced Inside Sales staff can identify parts using a verbal description or a photograph. Always have your unit's serial number handy.

All units are shipped with a data plate that includes the serial number. This is usually located on the outside of the unit or inside the control door. Many units will also have an aluminum plate with the serial number etched into it, riveted to the frame of the equipment.

We will be happy to compile a list of spare parts for your particular equipment, taking into account its type and age that will help ensure minimum downtime for you.

There is no way to evaluate the life of electronic components. That is why we always recommend that an adequate supply of spare parts be maintained at each foundry location.

Our standard warranty is 12 months from commissioning or 18 months from shipment, whichever occurs first.

We don't recommend it. You should maintain your system's high level of quality, reliability, safety and performance by using only recommended and authorized OEM parts. Failure to do so will void equipment warranty and can cause equipment malfunctions, resulting in equipment and/or property damage, including risk to personnel.

Charging equipment, scrap dryers and preheaters, computer control systems, water recirculating systems and ARMS® (Automated Robotic Melt Shop) Systems to replace your operators on the melt deck with automated systems adapted to foundry operations are often installed in modern foundries.

It will greatly depend on the type of existing equipment. Contact Inductotherm through the website or via phone and one of our technical sales staff will get in touch with you.

EMSCO and Inductotherm Corp. are separate companies in the Inductotherm Group. EMSCO is a reliable repair company that works on all induction melting equipment regardless of the OEM (Original Equipment Manufacturer). Inductotherm Corp. services, repairs and upgrades everything that we build, but only Inductotherm equipment. It is always beneficial to contact your OEM since they are often best equipped to provide you with the latest technological upgrades for your equipment.

It depends on the condition of the power leads. It may be less expensive to replace them. Note, however, that we offer a trade-in credit on used leads, regardless of condition.

It expedites the process if anything coming back has an RMR (Return Material Report) number attached to it. This tells our Receiving Dept. how to direct the part to achieve the fastest response possible. Please call our Inside Sales department so that we can arrange this for you.

It varies. We stock some smaller VIP® and VIP®-I™ power supplies along with a large inventory of parts (that include difficult to find and long lead time components) to ensure the fastest delivery time and maximum up-time at your installation should you need a spare part. Your District Manager can give you an estimated ship date on new equipment. Lead time on parts can be given to you by our Inside Sales Dept.

Once we have your order, we do our very best to manufacture your equipment as quickly as possible, without sacrificing any quality. The best way to shorten delivery times is to work closely with your District Manager and let us know your time restraints from the beginning.

Induction furnaces improve working conditions by making foundries cooler, cleaner and generally less hostile workplaces when compared to other methods of melting. They have not, however, eliminated the dangers inherent in working close to molten metal. Because of this, we always insist that all employees read and understand all safety and equipment manuals before operating or maintaining the equipment. Most companies find that the amount of training required when switching to induction is more than acceptable.

Induction furnaces make today's foundries safer and more productive than at any time in history. Sadly, many of the accidents that have occurred could have been prevented by observing common-sense safety precautions and following basic safety rules. For this reason, we developed the Induction Foundry Safety Training Kit and have made it available for free to all foundries, whether they have Inductotherm equipment or not. To request a Safety Training Kit, click here.

Yes. We offer all types of training. You can send your employees to Inductotherm (Rancocas, NJ) to take part in a general training class or a training class can be configured specifically for your equipment and held at your facility or ours. Training is available for safety, maintenance, operation and induction basics. Contact our Training Director at training@inductotherm.com for more specific information.

The Inductotherm Safety Fundamentals Guide advises you to stay well away from induction equipment if you have any artificial implants, particularly a cardiac pacemaker. The safe distance will depend on many factors including the size and type of the furnace and power supply and the size and type of the implant. No one with an implant should work directly on, or near, any induction equipment. For more information, visit www.inductotherm.com/Safety.htm.

Bridging can be minimized by using proper charge materials and by making sure the different sizes of charge material are added correctly. If a bridge occurs, power must be turned off immediately and all personnel must be evacuated from the furnace area until enough time has elapsed to allow the molten metal to cool and solidify. For more information, visit www.inductotherm.com/Safety.htm.

Personnel working (and all visitors) in proximity to molten metal must wear appropriate Personal Protective Equipment (PPE) as required by OSHA, based on an assessment by foundry management to determine if hazards are likely to be present. In addition to wearing PPE, automated systems should be used whenever possible to distance the workers from the furnace and molten metal splash. For more information, visit www.inductotherm.com/Safety.htm.

The ground detector is a primary safety device. The ground and leak detector system for use with most coreless induction furnaces and power supply units is crucial to safe melting and holding operations. The system, which includes both a ground detector module associated with the power supply and a ground leak probe, located in the furnace (except in removable crucible furnaces), is designed to provide important protection against electrical shock and warning of metal-to-coil penetration, a highly dangerous condition that could lead to a furnace eruption or explosion. For more information, visit www.inductotherm.com/Safety.htm.

The ground detector is a primary safety device. The system, which includes both a ground detector module associated with the power supply and ground leak probe, located in the furnace (except in removable crucible furnaces), is designed to provide important protection. The ground leak probe which is used to detect a molten metal leak penetration through the refractory and penetrating the coil is not used with removable crucible furnaces since the crucible and the coil are separated by an air gap and there is no path for molten metal to reach the coil. For more information, visit www.inductotherm.com/Safety.htm.

Yes! Furnaces must only be operated with adequate, carefully maintained and dry spill pits. Without adequate pits, free-flowing spilled molten metal could flow across the foundry floor, endangering workers, damaging equipment and structures, and possibly causing a fire or explosion. They must be carefully maintained because metal poured into a pit where moisture, standing water, oils or other fluids are present could cause a potentially serious explosion. For more information, visit www.inductotherm.com/Safety.htm.

We refurbish and update used furnaces and power supplies to like-new condition. We will make the necessary upgrades to the equipment for your application, and it will pass through the same rigorous test procedures as any new system.

The power supplies and furnaces are designed to work together and may not be compatible with the furnace coil you have, the lining material you plan to use, or the metal you are melting. Although they may look the same on the outside, the internal components may be very different depending on the application. Inductotherm's Legacy Program covers: all equipment that was built 15 years prior to the current year; or equipment that is purchased by someone from a third party, regardless of age; or equipment still owned by the original purchaser but in a facility that had been closed and has been reopened or they have moved the equipment to a new facility. The Legacy Program was established to continue providing service and support to all Inductotherm equipment for the duration of its operation. Contact your District Manager for more information on our Legacy Program.

Inductotherm has established a Legacy Program dedicated to used equipment acquisitions, as described in the previous question. The Legacy Program is operated with your safety as the top priority. We will perform an on-site inspection of the equipment to verify the system is equipped with the latest safety features, evaluate whether the system is suitable for your intended purpose, and verify that we can properly support the equipment for you moving forward. Upon completion of the Legacy Program, you will be recognized and supported as a full customer of Inductotherm. Contact your District Manager for more information on our Legacy Program.

Most used equipment manufacturers purchase used equipment and then resell it "as-is" to the customer. Our used equipment is completely re-manufactured and re-qualified for the new application. Every component is removed, inspected and upgraded/replaced as required at our plant and fully tested to ensure that it is in like-new condition and will offer like-new performance.

We do take existing equipment as a trade-in. Please contact your Inductotherm District Manager for more information to determine the value of the equipment.

Purchasing used equipment from an auction or plant closure carries inherent risks. It may have unseen internal degradation or freeze damage, missing components (or components replaced with incompatible parts), or loose connections. Many may not be compliant with the latest NEC (National Electric Code), may not have necessary safety devices, or may not be suited for your intended use. Refurbished equipment purchased from Inductotherm does not carry any of those risks, since the equipment is updated, refurbished and completely retested specifically for you.