Indutherm Mini Casting MC16, Technical Documentation Manual

Page 1: ...t Amityville NY 11701 USA Technical Documentation Mini Casting unit MC16 Keep for future use Romanoff order service for consumables www romanoff com Romanoff technical service Tel 1 631 842 2400 servi...

Page 2: ...responsible 2017 07 24 All Edition 2017 RK 2018 01 29 All Edition 2018 RK 2019 10 16 All last changes RK This manual has been prepared in good faith by us Nevertheless should you find any mistakes or...

Page 3: ...iour in an emergency 2 9 3 Technical Data 3 1 4 Description of the system 4 1 4 1 Components of the system 4 1 4 2 Schematic representation 4 2 4 3 Connections on the backside 4 3 4 4 Set up in the va...

Page 4: ...as out 6 3 6 3 6 RS232 for service 6 4 6 3 7 LAN Ethernet or RJ 45 connector for service 6 4 6 3 8 USB socket B type for service 6 4 7 Operation 7 1 7 1 Safety advices for operation 7 1 7 2 Changing c...

Page 5: ...THERM Erw rmungsanlagen GmbH don t take liability for dam ages caused by faulty protection of power supply and or wrong con necting the supplies protective gas water compressed air There is no guarant...

Page 6: ...nufacturer 1 4 EC conformity Declaration of European Community conformity is attached to this manual 1 5 Observation of the product The management will provide you with a secure machine at state of th...

Page 7: ...the operating instructions That also contains observing of servicing and mainte nance regulations Set up operation and maintenance is only allowed to be carried out by trained qualified personal that...

Page 8: ...only allowed for workers skilled in the field of electricity The instruction manual has to be freely disposable at the location of the system The employees have to know the storage place Every person...

Page 9: ...tective gear Protective gear PPE includes heat resistant clothes heat resistant closed shoes heat resistant protective gauntlets protecting artery and face guard Caution Wear always for every process...

Page 10: ...attached safety marking meaning safety marking meaning Warning of dan gerous electrical voltages Wear heat resistant safety clothing Warning on hot surfaces Wear heat resistant protective gauntlet gl...

Page 11: ...jury or substantial property damage will result if proper precautions are not taken Warning Death serious injury or substantial property damage can result if proper precautions are not taken Careful M...

Page 12: ...pacemaker it is not allowed to approach or to be near to the machine Danger Danger to life are caused also by the fact that very hot and liquid metals solidify in cold liquids In this case may arise p...

Page 13: ...n retain their charge even after de activation of the system Keep the housing of the mini casting unit closed con tinually No work must be carried out on parts conducting high voltage Remove loose con...

Page 14: ...the means of transporta tion otherwise the system can fall from forklift truck With too small dimensioned or forks adjusted too narrowly there is danger for the system to fall from the means of trans...

Page 15: ...n Health risk for persons with cardiac pacemaker who ap proach the running system Instruct people Burn injury on hot surfaces or hot molten metal Teach people Danger of explosion because of dripping o...

Page 16: ...0 C Cooling water supply a 6 mm 2 5 5 bar min 1 5 liter minute max 6 dH Cooling water recoil a 6 mm pressureless Cooling water entry temperature 15 25 C 59 77 F Ambient temperature 10 35 C 50 95 F Rel...

Page 17: ...one housing Inside the housing there are mains cable microprocessor controlled induction generator DM type middle frequency transformer oscillating circuit capacities and pneumatic magnet valves The f...

Page 18: ...h lock Due to movement to the right the machine will cast 2 inductor housing The melting and casting process takes place here 3 control buttons Control the casting process See ch 4 6 4 LCD screen See...

Page 19: ...2 Gas out gas outlet 3 Protective gas input for protective gas 4 Vacuum connection for external vacuum pump 5 Water In input for cooling water 6 Water Out output for cooling water 7 mains cable electr...

Page 20: ...the heat and trans fers the energy to the metal 3 ceramic cover Protects the thermocouple against contamination with liquid metal or graphite 4 Flask adapter Adapter for various flasks and mould sizes...

Page 21: ...gram active program InduTest 1 program name Manual casting mode On the left side shown Temp Rise the set temperature even within a program Temp Lower the set temperature even within a program Power Ed...

Page 22: ...during the machine heats Manual Melting pressure start Automatic Start of the melting pressure Pressure starts after the washing cy cles Manual To start melting pressure you need to press the start bu...

Page 23: ...re and usually after consulta tion with the Indutherm service staff Display functions 000 00002 Selected parameter 000 Value of parameter is 2 which means here thermocouple type N TC N is activated V...

Page 24: ...water flow sensor 0 generator tem perature IGBT and actual machine state The rows Water flow 1 and Op are not used in MC16 The button Serv Service Print is without function Figure 9 Service Info Page...

Page 25: ...nction of these buttons you can see in display See chapter 4 5 2 too Generator Starts and stops heating with induction generator outside the automatic mode Start Starts selected program Second push st...

Page 26: ...ons are dental alloys and very reactive alloys like magnesium The melting charge is heated up by induction The special advantage of strong in ductive heating is that the melting temperature is reached...

Page 27: ...oned before a pressure impulse on top of liquid metal while inside there is still a vacuum makes the good form filling of this system This means the flask by itself is a reservoir of the vacuum As sma...

Page 28: ...g 0000 0000 0000 0000 0000 0000 0001 Washing while heating 0000 0000 0000 0000 0000 0001 0000 Melting pressure start Manual Manual Manual Manual Manual Manual Manual Melting pressure bar 1 00 1 00 1 0...

Page 29: ...rption of energy So it makes sense to place metal plates horizontal also bigger wires couple more energy in horizontal position Figure 13 typical application which not work Please also take notice tha...

Page 30: ...expands can disrupt the crucible Hint load complete amount of metal in cold crucible or charge only small pieces into molten metal Caution danger of squirting Direct melting is usually used for metal...

Page 31: ...nnector with crucible holder for using power control instead of tem perature control Another name is dummy plug The nominal temperature can be set with the buttons Temp and Temp The heat ing power is...

Page 32: ...4 16 Attention Do not use a thermocouple in direct heating process Energy will melt thermocouple If you use graphite crucible and thermocouple the output power must not exceed 50 1 7 kW Otherwise the...

Page 33: ...a short piece of main sprue is required Some hints for the topic tree making Make sprues as short as possible Diameter of sprues should be big enough to guarantee optimal feeding of the cast ings with...

Page 34: ...cific weight of the metal Metal Spec weight in g cm Water wax 1 00 Aluminium 2 70 Steel 7 85 Brass 8 40 Bronze 8 80 Silver 10 50 Nickel silver 8 40 Gold 333 10 90 Gold 585 13 70 Gold 750 15 20 Gold 90...

Page 35: ...l alloys Brass gold 8 9 10 kt some alloys gold 14 kt These alloys have a high content of zinc Some of the zinc evapo rates during the heating phase If vacuum is used in the melting chamber much more z...

Page 36: ...portant hint Pt melted in a standard Pt crucible is absorbing silicate out of the crucible material As more often you re melt same batch of metal as more silicate will be absorbed This makes Pt brittl...

Page 37: ...are often mixed with acid Disadvantage Very expensive Most difficult to remove After pouring the cuvette should cool and the investment mass is then removed roughly with a hammer A sand blasting machi...

Page 38: ...uid embedding compound is left under vacuum for a long time the bulk water is removed i e this mixing ratio will change The reason for this is that water under vacuum has a boiling point at room tempe...

Page 39: ...oss weight volume of cone and wax pieces must be subtracted To find out proper amount of water according to the instruction manual of investment ma terial Ratio given by instructions 100 40 100 40 570...

Page 40: ...low out of wax The firing cycle of gypsum bonded flasks has normally 3 phases Phase 1 Melting out of wax and steaming out remaining moisture of flasks very slowly This steaming out process should be d...

Page 41: ...s time bigger flasks more time Phase 3 Bringing flasks to casting temperature After reaching the casting temper ature in the furnace please give flask a rest of 30 60 minutes depending on size to ensu...

Page 42: ...ntal Depot about this investment material Standard burnout cycle for gipsum from investment to casting 6 5 hrs Resting time after investment 30 min in 2 hrs 2 5 C min to 300 C holding time 30 min in 2...

Page 43: ...d the holding time be extend ed to 60 min 4 20 Flask temperatures The casting temperature depends on metal alloy and style of castings High melting point of metal needs high flask temperatures thin an...

Page 44: ...and slurry temperature is 20 22 C Other flashing or finning Figure 22 other flashing or finning Cause Remedy Work cycle too long Investment begin ning to set while still under vacuum Ensuring the work...

Page 45: ...equipment is regularly serviced and adequate for the task Work cycle too long Investment begin ning to set while still under vacuum Ensuring the work cycle is not too long and slurry temperature is 2...

Page 46: ...chines Work time of investment not used up Ensuring the work time is used up and slurry temperature is 20 22 C Gas porosity Figure 26 gas porosity Cause Remedy Overheating the metal Reduce metal cast...

Page 47: ...surface of the in vestment De waxed too quickly Leave flask for at least 1 hour to achieve maximum strength before de waxing Flasks overheated during burn out Ensure maximum burn out temperature does...

Page 48: ...ithout restriction Incomplete burn out Increase the burn out time at 730 C If the flask is not properly burnt out it will be impermeable and not allow gases to escape when the metal enters the mould S...

Page 49: ...Flask has been heated too rapidly during de wax Do not exceed 150 C during de wax Wax will boil and erode investment surface Flasks overheated during burn out Ensure maximum burn out temperature does...

Page 50: ...ng transport device to avoid tilting of the system Please wear appropriate personal protective equipment PPE Let do transportation only by trained personnel There is no guarantee for damages because o...

Page 51: ...s voltage corresponds with the operating voltage of the system If the voltages do not match the system can be damaged 6 2 Mounting process Place the system on a clean and dry table horizontal The grou...

Page 52: ...On the installation site must be provided by a loop impedance meas urement of the detection of the switch off of the overcurrent protective device High leakage current This machine has a leakage curr...

Page 53: ...um pump with a suction capacity of at least 8 m h and a final pressure of 2 mbar should be connected via a tube of 8 mm in outside diameter Keep the tube short to avoid vacuum loss The pump should run...

Page 54: ...nnector for service Behind a black cover you ll find this plug to connect the machine to a network LAN local area network You can collect and store machine data with help of our data management softwa...

Page 55: ...using graphite crucibles and graphite moulds The heat of these parts is only visible when the temperatures are over 500 C Danger Risk of burns If metal is melted without the supply of protective gas...

Page 56: ...le Check glass inductor shield 7 2 2 Mounting Check crucible surface for damages and cleanliness before you start casting Put a small piece of quartz fleece in glass inductor shield Figure 35 quartz f...

Page 57: ...repare crucible with thermocouple Switch on mains switch booting takes about 10 seconds Fill in casting material Put in preheated flask 620 650 C Close and lock casting chamber secure Figure 38 safe h...

Page 58: ...t fault a warning appear in display You ll see the warning code in display 7 5 Troubleshooting Only an expert may open the system Trouble Cause Machine can t be switched on Missing mains supply Heatin...

Page 59: ...arried out when the system has been disconnected from the power supply pull the plug The capacitors may still be charged even after turning off the system The cabinet of the mini casting machine must...

Page 60: ...rning hazard because of leaking melted metal Remove thermocouple crucible and crucible shield Clean in ductor housing carefully with a vacuum cleaner Check compo nents before installing and replace th...

Page 61: ...nt After an exchange of components repair or extension are in EN60204 1 2006 A1 2009 defined tests to be performed Note The operator is in accordance with the Industrial Safety Regulation BetrSichV in...

Page 62: ...lated by the Environmental Pro tection Act and its regulations Deliver applied lubricants at the hazardous waste col lection point Spilled lubricants must immediately sprinkle with binder and dis pose...

Page 63: ...4 15 Figure 15 connector with crucible holder 4 15 Figure 16 hydrodynamic not proper style 4 17 Figure 17 tree with easy flow of wax and not 4 17 Figure 18 Indu Mix for MC16 4 22 Figure 19 firing cyc...

Page 64: ...or shield 7 2 Figure 37 further suggestions of casting programs 7 3 Figure 38 safe handling of lock 7 3 Figure 39 backside vacuumfilter 8 2 Figure 40 connection diagram 10 7 Figure 41 inductor chamber...

Page 65: ...ctive 2006 42 EG MRL in extracts Reference Directive 2006 42 EC EU Ab No L 157 24 of 9 June 2006 EN 60204 1 2006 A1 2009 Security of machines Electrical equipment of machines Part 1 General requiremen...

Page 66: ...her specified positions in an essentially free field over a reflecting plane with negligible environmental corrections EC Directive on Electromagnetic Compatibility Reference Directive 2014 30 EU EU A...

Page 67: ...Annexe sales romanoff com www romanoff com 2019 10 16 10 7 10 3 Connection diagrams Figure 40 connection diagram...

Page 68: ...read fur ther below 4 The last two digits are the actual state starting with _00 One example G19999_MC_00 This is the consumables list of machine no 19999 equipped as mini casting machine with deliver...

Page 69: ...2018 Please note At our Internetpage http www indutherm de webshop you can get after registration access to important data Figure 42 contact form webshop Until you can enjoy the ad vantages of the Web...