Indutherm VTC Series Instruction Manual
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Indutherm VTC Series Instruction Manual

Vacuum tilting casting machine
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Brettener Strasse 32
DE-75045 Walzbachtal
Germany
www.indutherm.de
Instruction manual for
Vacuum Tilting Casting machine
VTC series
Machine service no.
Indutherm order handling
Indutherm
consumables:
technical service
M17999 F
+49 7203 9218-40
+49 7203 9218-41
Tel.:
Tel.:
sales@indutherm.de
support@indutherm.de
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  • Page 1 Brettener Strasse 32 DE-75045 Walzbachtal Germany www.indutherm.de Instruction manual for Vacuum Tilting Casting machine VTC series Machine service no. Indutherm order handling Indutherm consumables: technical service M17999 F +49 7203 9218-40 +49 7203 9218-41 Tel.: Tel.: sales@indutherm.de support@indutherm.de Keep for future...
  • Page 2 This manual is the property of: INDUTHERM Erwärmungsanlagen GmbH Brettener Strasse 32 D-75045 Walzbachtal Germany Tel.: + 49 7203 9218-0 Fax: + 49 7203 9218-70 E-Mail: info@indutherm.de Unauthorised duplication, even partial, is not permitted. Walzbachtal, 20/10/2017. TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...

  • Page 3: Table Of Contents

    Contents Contents Contents .......................... 2 Introduction ......................1-1 General description of the VTC-Series ............1-1 Machine components ..................1-2 Technical data ....................1-3 General information ..................1-4 Putting into operation ................... 2-1 Set-up directions ....................2-1 Mains supply ....................2-1 Cooling water ....................

  • Page 4: Contents

    Contents Connection diagram .................... 7-1 Test result chart ....................8-1 Appendix ......................9-1 List of figures ....................9-1 CE-declaration ....................9-2 Software documentation .................. 9-4 TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...

  • Page 5: Introduction

    Introduction 1 Introduction 1.1 General description of the VTC-Series With this vacuum tilting machine, the melting charge is heated up by direct induction under protective gas or vacuum. The liquid metal is poured directly into a preheated flask or into a graphite or metal mould. The special advantage of inductive heating is that the melting temperature is reached rapidly, because the heat is directly generated in the metal.

  • Page 6: Machine Components

    Introduction 1.2 Machine components The machine consists of separate units built into one casing: Inside the casing, the following components are installed: mains supply, microprocessor controlled induction generator F type, motor to rotate inductor housing and mould chamber, medium frequency transformer, oscillation circuit capacities (capacitor boards), solenoid valves, pressure sensors for water and protective gas.

  • Page 7: Technical Data

    Introduction 1.3 Technical data VTC100V VTC200V VTC400V VTC800V 650 = 2 kg Pt Crucible volume in cm³ 505 = 4 kg St Crucible inclination in ° Melting performance in Frequency in kHz max. Ø 125 mm (5“) * 220 mm (8“) height Mould size Crucible temperature max.

  • Page 8: General Information

    As melted metal is processed with this machine (= temperatures up to ~ 2100 °C), the utmost care and attention has to be applied when working with the VTC series. The following necessary safety clothing is principally to be worn:...
  • Page 9 This machine was designed for use in closed spaces (indoors) and may only be used for the above-mentioned purpose.  Only original INDUTHERM consumable and spare parts are to be used.  The machine may not be modified in any way. Technical changes may only be affected with prior written permission of INDUTHERM GmbH.

  • Page 10: Putting Into Operation

    +/- 10 % (maximum) from the nominal value. The mains supply (at 3* 400 V AC) must at least be furnished with 20 A and 32 A delay-action fuses (max.). The machine is equipped with a 32 A-Ceekon-connector when leaving INDUTHERM. All 4 lines (L1, L2, L3, and PE) must be connected correctly.

  • Page 11: Vacuum

    Low vacuum pump Low vacuum pump: The pump supplied by INDUTHERM (optional) normally has a suction power of 40 m and an end pressure of 2 mbar. The vacuum connection is through a suction hose with an inner diameter of 13 mm at the rear side of the casing to the vacuum pump. Through the hoses inside the casing, the low vacuum pump is finally connected directly to the mould chamber.

  • Page 12: Gas Out

    Putting into operation NOTE: To achieve sufficient good vacuum level in daily process you have to possibly clean with vacuum cleaner the crucible and mould chamber after every melting and casting cycle. This is followed by wiping with clean cloths soaked with alcohol only. Oil-, water- or silicone-based cleaning agents must be strictly avoided.

  • Page 13: Temperature Measurement And Control

    Putting into operation 2.9 Temperature measurement and control Thermocouple Fig. 5: thermocouple The machine can operate with a thermocouple plugged in at the port inside the crucible chamber. Usually this thermocouple is used in combination with a graphite lined ceramic crucible to melt non-ferrous metals.
  • Page 14 Putting into operation Pyrometer Fig. 6: pyrometer The standard pyrometer delivered with the machine starts reading temperatures at 800 °C and can be used up to 2100 °C. It must be carefully mounted and connected on top of the front panel. Fig.
  • Page 15 550-600 °C on (depending on the metal/alloy). This is due to the low emission factors at those low temperatures. Several system parameters must be changed by the INDUTHERM service staff to make the machine work with that pyrometer and at those low temperatures. The standard machine is very powerful so that amongst other the maximum power must be reduced significantly.

  • Page 16: Crucible Materials And Crucible Shield

    ~ 1400 °C usually require the usage of bulk alumina or bulk zirconia crucibles. NOTE: Please refer to the list of available consumables and the INDUTHERM technical staff for more information on the suitability of crucibles for particular applications alternative crucible materials for melting of reactive metals which can be supplied on special request.

  • Page 17: Mould Chamber And Adapters

    Putting into operation 2.11 Mould chamber and adapters Moulds or flasks of different length and diameter can be used. Fig. 10: hat shaped adapter The starter set includes adapters suitable for a mould diameter of Ø 100 mm (4“). Adapters for both smaller and larger diameters are available, too.
  • Page 18 Putting into operation Fig. 12: spacers In order to allow for a secure mould movement and a safe seal of the two chambers, a set of spacers of different width is included in the starter set. These spacers accommodate for the mould length. Several spacers may be combined to fill up the full length of the clamp.

  • Page 19: Safety

    The machine has been developed for use in enclosed spaces and for the above mentioned application. Only original INDUTHERM consumables and spare parts are admitted for operation. It is not allowed to change or vary the system in any way. Technical changes need explicit written approval of INDUTHERM.

  • Page 20: Demands On Staff, Duty For Utmost Care

    Safety 3.2 Demands on staff, duty for utmost care Work on and with the machine is allowed to be accomplished by reliable, trained and instructed staff only. Responsibilities for the separate sections have to be regulated clearly which include operation, preparation, service and repair. Only authorized personnel may act at the system.
  • Page 21 Safety 3.3.1 Concept of safety Objective is the safety  of the staff against injuries  of the system against damage or standstill  of the environment against endangering The list of actions taken:  deployment of protective equipment like covers and main-switch with emergency stop function, ...
  • Page 22 Safety 3.3.4 Main switch with emergency stop function It is allowed to start the machine or operation only with proper emergency stop function. Caution! With the emergency stop function you can stop the machine in critical moments of health hazard. You help to diminish potential consequences of injury.

  • Page 23: Safety Marking

    Safety 3.4 Safety marking The following signal words are used in this document which are associated with safety markings for presentation of possible dangerous situations. Danger! Death, serious body injury 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.

  • Page 24: Safety Advices

    Safety 3.5 Safety advices Check always the condition of the system before you switch on the system. Examine the supply pipes and insulations if there are leaks and damages. Operate the system only if it is in proper and faultless shape. Operate the system never: ...
  • Page 25 Safety Danger! Danger for the eyes. Always place the gold coated foil for eye protection against thermal radiation on top of the inspection window of the crucible chamber. In addition wear safety goggles suitable for welding operations Danger! Danger because of touching parts conducting voltage.
  • Page 26 Safety Danger! At crucible temperatures over 100 °C the cooling water supply must be switched on. If it is not turned on, the inductor will be destroyed. If cooling water supply fails, the heating system immediately is turned off. Inspect the system for damage before putting back into operation again.
  • Page 27 Safety Danger! Lethal injuries happen because of false transport by forklift truck.  Pay attention of the right attachment of the means of transportation, otherwise the system can fall from forklift truck. The system must be lifted from the side only, because the center of gravity is located in front and towards the upper third of the machine.

  • Page 28: Residual Risks

    Safety 3.6 Residual risks risk characterisation risk reduction Health risk for persons with Instruct people. cardiac pacemaker who approach the running system. Burn injury on hot surfaces or Teach people. hot molten metal. Wear personal protective gear. Jet flame or explosion when Always melt with protective gas opening the lid of the melting at temperatures above 500 °C.

  • Page 29: Operation

    Operation 4 Operation 4.1 Operating elements VTC series: Display when starting the machine or during a melting process Fig. 13: main screen Top level = INDUTHERM VTC100V Actual machine status 1088 °C ° 1100 °C 4.5 kW 0.00 InduTest 2...
  • Page 30 Program setup == switch to the program set-up display for the actually selected program (here program 19) VTC series: Display during a “washing cycle” (= evacuation followed by backfill with protective gas) Fig. 14: display during washing cycle INDUTHERM VTC100V °C...
  • Page 31 Operation VTC- series: Program set-up display The software allows to define process parameters for example for different alloys or applications and to store them in 100 different programs. Fig. 15: program parameter page 1 Top level = Actual program status Bottom level = Selectors for different values...
  • Page 32 Operation ‘Flask’ Casting flask == two chamber system with differential pressure mould ingot == one chamber system with always similar pressure in both chambers; should be selected if the mould does not allow for a sufficiently good seal between the two chambers, which is frequently the case for ingot moulds ‘Manual’...
  • Page 33 Operation VTC-series: Program set-up display - second page Fig. 16: program parameter page 2 0001 Program 0020 s Vibration 0060 s Cooling time 0000 s Cooling time pressureless 0030 ° Heating off angle 0100 % Tilt speed 0 0040 ° Tilt angle 1 0060 % Tilt speed 1...
  • Page 34 Operation VTC series: system parameter display If you start from the main page and you press “Program setup“ for 5 seconds you get access to the system parameter level. Fig. 17: system parameter System Parameter Note: Please refer to the respective section 000: 00007 Temp.
  • Page 35 Operation VTC series: buttons below display Fig. 20: front panel buttons Manual area: decreases the generator output power increases the generator output power Generator Stop stops heating (not active during a running program) Generator Start starts heating Arrow to the left...

  • Page 36: Pre-Defined Casting Programs

    4.2 Pre-defined casting programs Several pre-defined programs with recommended parameters are stored for the standard VTC series and processing of conventional metals and alloys. Please refer to the INDUTHERM technical staff for assistance in choosing suitable process parameters for your particular alloy.
  • Page 37 Operation Programs pre-installed on VTC100V (-Ti) Fig. 21: pre-installed programs VTC100V(-Ti) VTC100V / VTC100VTi Material Steel Palladium Gold 18k CuBe Silver 925 Platinum 316 L Ingot Crucible Ceramic Ceramic Graphite Graphite Graphite Ceramic Temperature reading Pyrometer Pyrometer Thermo- Thermo- Thermo- Pyrometer couple couple...
  • Page 38 Operation Programs pre-installed on VTC200V (-Ti) Fig. 22: pre-installed programs VTC200V(-Ti) VTC200V / VTC200VTi Material Steel Palladium Gold 18k CuBe Silver 925 Platinum 316 L Ingot Crucible Ceramic Ceramic Graphite Graphite Graphite Ceramic Temperature reading Pyrometer Pyrometer Thermo- Thermo- Thermo- Pyrometer couple couple...
  • Page 39 Operation Programs pre-installed on VTC400V(-Ti)/VTC800V(-Ti) Fig. 23: pre-installed programs VTC400V/VTC400V-Ti VTC400V / VTC400V-Ti Material Steel CuBe Silver 925 Platinum Test 1 Test 2 316 L Ingot Crucible Ceramic Graphite Graphite Ceramic Ceramic Ceramic Temperature reading Pyrometer Thermo- Thermo- Pyrometer Pyrometer Pyrometer couple couple...

  • Page 40: Option: Melting Under Overpressure

    Operation 4.3 Option: Melting under overpressure In case the machine has been ordered with the option ‘melting under overpressure’ the parameter “melting pressure” can be varied from ‘-1.00’ up to ‘2.00’. This feature can be useful to minimize evaporation of volatile elements during melting. Melting under overpressure is only available for the setting “Casting mould”==’flask’...

  • Page 41: Castings In Manual Or Automatic Mode

    Operation 4.4 Castings in manual or automatic mode Before starting check chambers, crucible and crucible shield for dirt, residues or possible damages. It is recommended to use a vacuum cleaner for the entire inductor housing and mould chamber. Clean clothes with alcohol-based as opposed to water-, oil- or silicone based agents must be used for cleaning of the chambers, clamp, adapters and seals.
  • Page 42 Operation NOTE: In the manual mode, no cleaning of the atmosphere via evacuation of the chambers and backfill with protective gas is possible. (Also no overpressure during melting or after pouring can be applied.) In order to run automated atmosphere washing cycles in combination with the manual processing mode before the start of the heating process, a software program (for example test program 28) can be started with a pre-defined number of atmosphere ‘washing cycles before heating’.
  • Page 43 Operation A suggestion for a general casting process in automatic mode: Open cooling water and protective gas supplies. Switch on vacuum casting machine and vacuum pumps; for optimum performance always keep the vacuum pumps running for at least 30 min to heat Use a metal or graphite mould pre-heated to at least 100 °C.

  • Page 44: Possible Causes For Dissatisfying Casting Results

    Please note that INDUTHERM cannot be held responsible for dissatisfying casting results. In case you have problems with some alloys INDUTHERM tries to help you. But it is very important to achieve an exact description about your whole process. TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB...

  • Page 45: Consumable Parts

    Consumables 5 Consumable parts 5.1 Assembly drawing VTC100V Fig. 29: assembly drawing VTC100V TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...

  • Page 46: Assembly Drawing Vtc200V

    Consumables 5.2 Assembly drawing VTC200V Fig. 30: assembly drawing VTC200V flange connection,  40 mm TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...

  • Page 47: Assembly Drawing Vtc400V

    Consumables 5.3 Assembly drawing VTC400V Fig. 31: assembly drawing VTC400V TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...

  • Page 48: Assembly Drawing Vtc800V

    Consumables 5.4 Assembly drawing VTC800V Fig. 32: assembly drawing VTC800V TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...

  • Page 49: Consumables And Spare Parts List

    5.5 Consumables and spare parts list On the following pages the spare parts list for this particular machine is included. INDUTHERM is now using only machine specific spare parts lists, which contain all the information for your specific machine. The name is encoded. One example could be G12318_VTC_00 or G13095_VTC100V_00 If spare parts are replaced by new parts, the index will be incremented.
  • Page 50 Telephone no +49-7203-9218-40. Attention! Please understand that INDUTHERM has to support more than 3000 machines. We cannot sort spare parts only with your customer name. We always need your machine service number, to send you the correct spare part.
  • Page 51 Consumables This page will be replaced with G17999_00 (xxx = machine no.). _00 is version of spare parts list. Changes will be done with _01, _02, due to customer requirement Example: G17999_01 (second version of the list for machine 17999). TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...

  • Page 52: Service

    - Correct temperature reading is not possible in case of smoking metal during heating or melting. Other error and warning codes: see appendix Attention: On our website http://www.indutherm.de/webshop you can find examples how to troubleshoot errors. If you need help please contact: support@indutherm.de TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB...

  • Page 53: Maintenance

    Service 6.2 Maintenance A routine check / regular cleaning of the following is necessary (Caution: disconnect the machine first!): Daily (before casting): 1. Remove crucible and crucible shield. Carefully clean inductor housing, mould chamber, clamp, adapters etc. with a vacuum cleaner. Continue cleaning only with clean wipes and alcohol-based agents.

  • Page 54: Connection Diagram

    Connections 7 Connection diagram Fig. 35: connection diagram power section TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...
  • Page 55 Connections Fig. 36: connection diagram control TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...
  • Page 56 Connections Fig. 37: connection diagram temperature sensor TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...
  • Page 57 Connections Fig. 38: connection diagram digital input/output TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...
  • Page 58 Connections Fig. 39: connection diagram tilting unit TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...

  • Page 59: Test Result Chart

    Test result chart 8 Test result chart TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB VTC-series...

  • Page 60: Appendix

    Fig. 30: assembly drawing VTC200V ......................5-2 Fig. 31: assembly drawing VTC400V ......................5-3 Fig. 32: assembly drawing VTC800V ......................5-4 Fig. 33: Indutherm 3D hologram ........................ 5-5 Fig. 34: webshop - accessory part list ....................... 5-6 Fig. 35: connection diagram power section ....................7-1 Fig.

  • Page 61: Ce-Declaration

    Appendix 9.2 CE-declaration Manufacturer: INDUTHERM Erwärmungsanlagen GmbH Brettener Str. 32, 75045 Walzbachtal Product type: Vacuum-pressure-casting-machine VTC100V(-Ti)/VTC200V(-Ti)/VTC400V(-Ti)/VTC800V(-Ti) Machine type: 10096 or higher Serial number: Peter Hofmann Authorized to sign: We herewith declare that the machine named above corresponds to the essential safety and health requirements of the following EC directives because of its design and construction in the version which we have placed on the market.
  • Page 62 The declaration of conformity relates only to the machine in the state in which it was placed on the market; Parts and / or retrospective interventions carried out subsequently by the end user remain unaffected. The test protocols are stored at INDUTHERM Erwärmungsanlagen GmbH for 10 years. city/date/signatory: Walzbachtal/2017-10-20/Peter Hofmann, chairman TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB...

  • Page 63: Software Documentation

    Appendix 9.3 Software documentation The software documentation INDUTHERM article no. 86380000 with the error and warning codes starts on the next pages. For the F generator the software starts with 80000 xx = software index. Attention: On our new Internet page http://www.indutherm.de/webshop...

This manual is also suitable for:

Vtc100vVtc800vVtc200vVtc400v

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