REFRACTORY RAMMING

MACHINE USER’S MANUAL

CONTENT:

1. INTRODUCTION

2. OPERATION

2.1 MANUAL OPERTION

2.1.1. BOTTOM RAMMING

2.1.2. WALL RAMMING

2.1.3. RAMMING PERIODS

2.2. AUTOMATIC OPERATION

2.2.1. CRANE INSTALLATION

2.2.2. PLC CONTROL

3. MAINTENANCE

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1. INTRODUCTION:

Induction furnace lining material’s lifetime

depends on dryness of refractory and homogenious

ramming, equal density without any decomposition.

There is a very big risk using pneumatic stick

type rammers and hammers manually for ramming

operation.

- If any space arise in the refractory while

ramming, there will be a pressured gas in this

space because of high temperature of melted

metal, it might explode and cause serious

damages, and pecuniary loss.

- Manually refractory ramming can not be done

with equal density and homogenious everytime.

So, it will shorten the lifetime of lining material

which means high refractory cost.

With IDEAL Refractory Ramming Systems, we

have been producing since 2006 with patent, and

constantly developing our product, we reduce these

risks to minimum. In one hand providing consistent

ramming, on the other hand saving of time.

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By our special pistons’ self-reaction strokes,

ramming is done directly to refractory in the bottom and

former in the wall wamming.

System works with pressured air. 6 bar pressured

air is required for ideal ramming operation.

IDEAL Refractory Ramming Machines consists of

two main units:

- Wall Ramming Machine - Bottom Ramming Machine

And other auxiliary equipments such as:

- Adaptor Flange For Bottom Ramming - Crane System - Automation System

We have 43 type various products range for

500kg. to 40t. capacity furnaces.

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2. OPERATION

- Clean inner side and around of the furnace, before

starting operation.

- Be sure all trashs removed which might mix into

refractory.

- Check coil mortar and grounding system.

- Open air valve of compressor, remove the

collected water, continue air flow until all moisture

fade away.

- On the air flow line, a little lubrication must be

applied by the assistance of conditioner.

- Check air flow lines, air volume is as important as

air pressure for machine’s operation.

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2.1. MANUEL OPERATION

2.1.1. BOTTOM RAMMING

- Calculate the refractory amount for bottom.

- Spread 15% more than calculated refractory

amount to the bottom. (Bottom thickness higher

than 400mm. must be rammed as two layers.)

- Step on to refractory or use an equipment to make

levellling and precompression.

- Plug bottom ramming machine air hose to

compressor.

- Hang bottom ramming machine to a crane and

lower down on refractory.

- Start operation with full air pressure. Lower down air pressure until you can observe the stoke, then continue operation.

- While the machine is operating, change the air flow

rate for a couple of times to acquire better density and avoide vacuum existance under bottom rammer plate.

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Attention: If bottom thickness does not reach to desired level, add more material and repeat ramming operation.

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2.1.2. WALL RAMMING

- Put former into the middle of furnace. Make sure its distance to furnace wall sides be equal.

- Fill the space between former and furnace with refractory until it reaches to top.

- Plug the air hose to wall ramming machine.

- Hang wall ramming machine to a crane, adjust the

position.

- Adjust the wall ramming machine pistons distance according to former inner diameter, and place it into the former.

- Pull the pins holding pistons and lower the

machine down. (it must not touch the ground)

- Wall ramming machine should be hanging. Start

operation with 2 bar air pressure, increase the

pressure up to 6 bar.

- When operations starts, pistons will stroke to former, at the same time machine will turn around its own axis.

- For effective strokes, distance of pistons to former

should be adjusted very well. Strong strokes will

make machine turn around its axis.

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- If pistons are hardly touching to former, their distance should be adjusted to outer. If pistons are working very near to former, and forcing the system, their distance should be adjusted to inner.

Attention: While making distance adjustmen of pistons, air flow must be stopped.

Wall ramming machine should be operated in

between 100mm. range according to our table (2.1.3.

ramming periods) , but this table shows only

approximate time values. While using the machine,

according to specifications of lining material, ideal values

will be determined by user. Continue wall ramming

operation until reaching 200mm. distance to top.

- While wall ramming operation continues,decreasing material should be filled with more refractory.

- The system must be stopped when it reaches to

200mm. distance from top. Top side operation must be made manually.

- After the operation is completed, pull pistons inside

by assistance of pulling rings. Take the machine out of former.

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VİNÇ

BOBİN

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2.1.3. RAMMING PERIODS

Furnace

Capacity

Bottom

Part

Former Conical

Part

Former Flat

Part

< 2 Ton 3 - 4 min. 1 - 1,5 min. 1 min.

2 - 5 Ton 4 - 6 min. 1,5 - 2 min. 1 min.

5 - 8 Ton 5 - 8 min. 2 - 2,5 min. 1 min.

8 - 25 Ton 8 -10 min. 2,5 - 3 min. 1,5 min.

Attention: This table shows only approximate values.

According to usage of the machine and specifications

of lining material, ideal values will be determined by

final user.

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2.2. AUTOMATIC OPERATION

- Certain values will be input to PLC to automatically

calculate:

Refractory amount used for bottom part Refractory amount used for wall part

- Ramming operation will be done automatically.

- For automatic operation:

Plug electric socket into power. Open the main switch on left. Choose the language from touchscreen.

Open Main Menu

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Open Refractory Calculation Menu

Input furnace inner and former dimensions.

Input specific weight of refractory. (If doesn’t know, please ask your refractory supplier)

After input the values, system will automatically calculate necessary refractory amount.

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Open Bottom Ramming Menu from Main Menu screen

Input desired ramming period for bottom part.

Input the necessary value for bottom ramming machine’s automatically move out after the operation is completed.

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Open Wall Ramming Menu from Main Menu screen

For automatic wall ramming, input the necessary values with the system’s redirection.

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Attention: Refractory filling method will be same with

manual ramming operation.

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2.2.1. CRANE INSTALLATION

- Assemble the metal sticks according to picture.

1.M16 Special Bolt, 2pcs. 4.Crane Hang Profile, 1pcs.

2.Crane Hang Stays, 2pcs. 5.M16 Special Bolt, 4pcs.

3.Centering&Fastening Shaft, 4pcs. 6.Former Subside Profile, 2pcs.

1 2 3

4 5 6

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2.2.2. PLC CONTROL

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3. MAINTENANCE

- Do not keep in dusty and moist condition.

- Lubrication must be injected from air flow

lines before running the system.

İDEAL DÖKÜMAHNE TEKNOLOJİLERİ SAN. TİC. LTD. İkitelli Organize Sanayi Bölgesi Biksan Koop. B1 Blok No:22 Başakşehir, İstanbul / TÜRKİYE Tel : +90 212 886 42 34 www.idealmodel.com.tr Fax : +90 212 886 49 20 info@idealmodel.com.tr