“Ground Detection in

Coreless Induction
Furnaces”
David A. Lazor
Technical Director

LECTROTHERM
North Canton, Ohio
Phone: 330-818-8080
fax: 330-818-8085
Email: lazor@lectrotherm.com

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 Ground Detection System
• Is the most important safety system on the
furnace
– Protects personnel
– Protects the Equipment
• Is often the most aggravating feature
• MUST be ensured to be properly installed
and verified to be in working order at ALL
TIMES

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 What is the Ground
Detection System?
• Monitors the leakage current from
the power circuit to ground
• Shuts down the power system when
the leakage current to ground raises
to a preset fault level

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 Main Types of Ground
Detectors
• AC Ground Detector
• DC Ground Detector

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 The Ground Detector
Operates per Ohms Law
I

+
Vsource R
-

V=IXR OR I=V/R
LECTROTHERM “Ground Detection in Coreless Induction Furnaces”
 AC Ground Detector
• Used on many older line frequency
systems
• Typically uses the AC voltage applied to
the furnace from its source, therefore it
only functions when the furnace power is
on
– This can allow the furnace to be turned-on into
a grounded condition
• Due to the requirement for an impedance
imbalance in the circuit it will not detect a
ground at the center of the power coil
LECTROTHERM “Ground Detection in Coreless Induction Furnaces”
AC Ground Detector
Set up

Cap
+
Power Vs
System Cap
-

Ground Detector CT

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

AC Ground Detector
Monitors ground current flow
due to impedance imbalance

Cap
+ (Vs / 2) fin
Power Hi Z
Vs
System Cap
- (Vs / 2)

Lo Z

Ground Detector CT

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

AC Ground Detector
Monitors ground current flow
due to impedance imbalance

Cap
+ (Vs / 2) fin
Power Hi Z
Vs
System Cap IGND
- (Vs / 2)
IGND IGND Lo Z

CT IGND IGND
Ground Detector

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 DC Ground Detector
• Used on Virtually all newer solid
state power supply systems and has
been retrofitted on older line
frequency systems
• Fully Functional with furnace power
on or off
– This can help prevent the power supply
from starting into a grounded condition

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

DC Ground Detector
Set up

Power
System

Ground Detector L Gnd Choke

VDC

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

DC Ground Detector

fin
Power
System
IGND

Ground Detector L Gnd Choke IGND IGND

VDC

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 DC Ground Detector
• Requires the use of an isolation
transformer to isolate the furnace
power circuit from any grounds that
may exist on the main power grid
feeding the system

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 Ground Detector with
Primary Isolation
Transformer
XFMR
HV SW CABLES
POWER CAP BUS
BANK COIL
SUPPLY

GD

Typical for High Power Installations

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

Ground Detector with Power
Supply / Capacitor Bank
Isolation Transformer
XFMR
SW CABLES
POWER CAP BUS
BANK COIL
SUPPLY

GD

Typical for Low Power Installations

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 Ground Detector with
Output Isolation
Transformer
XFMR
SW CABLES
POWER CAP BUS
BANK COIL
SUPPLY

GD

Special Installations

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 What Does the Ground
Detector Tell You When it
Trips?
• The output power circuit is grounded
somewhere on the monitored portion
of the system

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 What Causes a Ground
Current to Flow?
• Anything that is electrically
conductive and comes in contact
with a power circuit component and
ground at the same time on the
monitored portion of the circuit

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

Typical Sources for Ground
Current from Power Circuit
• Moisture in the refractory System
• Metal penetration from the melt back to
the coil
• Insulation breakdown
– Coil insulation
– Shunt / Yoke insulation
– Other Insulation used between the power
circuit and ground
• Conductive water hose
• High water conductivity
• Water hoses too short
LECTROTHERM “Ground Detection in Coreless Induction Furnaces”
 Ground Due to Moisture in
the Refractory System
• Wet / damp grout
• Wet / damp shunt/yoke
insulation

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 Ground Due to Moisture in
the Refractory System
• Wet / damp grout

Ground Detector

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 Ground Due to Moisture in
the Refractory System
• Wet / damp grout
IGND

IGND
Ground Detector

IGND
IGND

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 Sources of Moisture
• Grout not dried out before the refractory
was installed
• Castables used which were not pre-fired
• Lining (Typically < ½%)
• Condensation due to too low of a water
temperature through the coil
• Leaking water hose
• Leaking coil / or shunt/yoke water path

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

Why is it Difficult to Dry out
the Grout after the Fact?
•Closest point from coil to
ground (Furnace Floor)
•Point where water can
drip down and collect
•Most difficult area to get
“heat-in” to drive the
moisture out

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

To Avoid Nuisence Grounds
Due to Moisture
• Dry out the grout BEFORE the working
lining is installed
• Utilize pre-fired castables whenever
possible to minimize moisture from the
start
• Do not use shunt/yoke insulation that can
“wick” moisture
• Perform regular PM to make sure hose
clamps are tight
• Keep minimum water temperatures above
the dew point to prevent condensation
LECTROTHERM “Ground Detection in Coreless Induction Furnaces”
 Metal Penetration
fin

Ground Detector

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 Metal Penetration
fin

IGND
IGND
IGND
IGND IGND
Ground Detector

IGND IGND

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 Metal Penetration
Ground spider not in contact fin
with charge creates an open
circuit and disables the system
from detecting metal
penetration back to the coil

Ground Detector

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

Do Not Stick Tools in the
Furnace with Power On SHOCK

+
IGND IGND
Vs IGND
IGND
-

IGND
IGND
Ground Detector

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 Grounds Due to Water &
Water Hose

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 WATER & HOSE Grounded Water Pipe

Water
Coil Winding

Water Hose

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

Ground Detector
Grounded Water Pipe

Water

Water Hose

Coil Winding

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

Ground Detector
Grounded Water Pipe

IGND

IGND
Water
IGND
IGND

Water Hose

Coil Winding

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 To Minimize Ground
Problems Due to Water &
Hose
• Utilize only “Non-Conductive” Hose
approved by your equipment OEM or
Service company
• Do not make hose lengths shorter
than that recommended
• Maintain water system quality to
within the equipment manufacturers
specifications
LECTROTHERM “Ground Detection in Coreless Induction Furnaces”
 Grounds Due to Electrical
Insulation Failure
• Coil Insulation
• Shunt/yoke insulation
• Tracking due to contaminant build-up
on insulators
• Any other insulation used between
the power circuit and ground

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

The Ground Current is a Summation of all
the Paths to Ground
I1 Shunt Insulation to Ground

(+)
I2 Refractory to Ground

I3 Water Hose to Ground

Vac Coil
I4 Water to Ground

I5 Other paths to Ground

(-) IGND

IGND IGND

Ground Detector IGND

IGND = I1 + I2 + I3 +I4 + I5 + …….

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”
 The Ground Current Meter Can
Help Determine The Type of
Ground Experienced
• Meter does not stay steady and
continuously fluctuates randomly
with power on
– High probability that there is moisture in
the refractory system

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 The Ground Current Meter Can
Help Determine The Type of
Ground Experienced
• Meter is steady at a relatively high
level whether power is on or not
– Water conductivity may be too high
– Conductive water hose
– Water hose(s) may be too short

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 The Ground Current Meter Can
Help Determine The Type of
Ground Experienced
• Meter is normal and steady with
power off or low power levels, but
pegs and trips the power supply
when power is turned up
– High probability that there is an
insulation breakdown somewhere from
the power circuit to ground

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 The Ground Current Meter Can
Help Determine The Type of
Ground Experienced
• Meter is pegged all the time but drops to normal
when the ground wire from the ground detector is
disconnected from the grounding electrodes
embedded in the furnace refractory floor
– There is metal penetration through the refractory from
the molten bath back to the coil
• IF THE GROUNDING ELECTRODES IN THE BOTTOM
OF THE FURNACE DOES NOT CONTACT THE
MOLTEN BATH A METAL PENETRATION TO THE
COIL CANNOT BE DETECTED

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 The Ground Current Meter Can
Help Determine The Type of
Ground Experienced
• Meter is pegged all of the time and remains pegged
when the ground wire from the ground detector is
disconnected from the grounding electrodes embedded
in the furnace refractory floor
– Possibility that a power circuit component is solidly grounded
– CAUTION should be observed during this type of ground since
a metal penetration to the coil may still exist if either of the
following conditions occur:
• If the grounding electrode rod is not properly insulated from
the furnace floor and is grounded through contact with the
furnace floor
• A metal penetration has occurred where it contacts the coil
and is grounded through contact with part of the furnace
structure
• The bath is grounded through metal splash to the top of the
furnace
LECTROTHERM “Ground Detection in Coreless Induction Furnaces”
 FOR PROPER GROUND
DETECTOR OPERATION:
• Make sure the ground detector electrodes are
properly installed
– The grounding electrode rod must be insulated from
contact with the furnace floor structure
– The electrodes MUST always be in contact with the
molten metal…DO NOT BURY THEM UNDER
REFRACTORY
– The ground wire from the ground electrode rod at the
furnace floor back to the ground detector must be
insulated and installed such that it is protected and
not at risk from being damaged or broken

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 FOR PROPER GROUND
DETECTOR OPERATION:
• Make sure the ground detector is operating
properly
– The ground detector system should be tested at least
once a shift per the OEM’s recommendations to ensure
that the bath is grounded and that the ground detector
is functioning properly
• Use water hose that is non-conductive
• Keep water conductivity within the OEM’s
specifications
• The lower the conductivity, the lower the normal ground
current reading

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 FOR PROPER GROUND
DETECTOR OPERATION:
• Make sure hose lengths installed are no
shorter than that recommended by the
OEM for the system operating voltage

• Do not install the hot face refractory

material in the furnace unless the ground
leakage current is within normal limits

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”

 For Maximum Safety:

• Do not defeat the ground detector system

• Do test the ground detector system at
least once a shift
• Do not stick tools into the furnace with
furnace power on
• Do not take short cuts to bring a furnace
on line
• Do believe the ground detector

LECTROTHERM “Ground Detection in Coreless Induction Furnaces”