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Brettener Strasse 32
D-75045 Walzbachtal
Germany
CC3000
VCC1000
Both pictures with options!
Technical Documentation
Continuous-Casting-Machine (V)CC1000 /
(V)CC3000 with PM-generator
Machine-service-no.
Indutherm order service
Indutherm
for consumables:
technical service
M17999 PM
+49 7203 9218-40
+49 7203 9218-41
Tel.:
Tel.:
sales@indutherm.de
support@indutherm.de
Keep for future use!
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Table of Contents
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Summary of Contents for Indutherm CC3000
- Page 1 Brettener Strasse 32 D-75045 Walzbachtal Germany CC3000 VCC1000 Both pictures with options! Technical Documentation Continuous-Casting-Machine (V)CC1000 / (V)CC3000 with PM-generator Machine-service-no. Indutherm order service Indutherm for consumables: technical service M17999 PM +49 7203 9218-40 +49 7203 9218-41 Tel.: Tel.: sales@indutherm.de support@indutherm.de...
- Page 2 © Instruction manual 2017-09-19 state: 19.09.2017 The manual is 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 Unauthorized duplication, even partial, is not permitted. Walzbachtal, 2017-09-19. TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_86025010_86025110.doc...
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Page 3: Table Of Contents
Contents Contents Contents ................... 3 General information ............1–1 Scope of delivery and responsibilities........1–1 Liability, warranty and guarantee ......... 1–1 Responsibility of operating company ........1–1 EC-conformity ..............1–2 Observation of the product ..........1–2 Safety ................... 2–1 Intended use ............... 2–1 Demands on staff, duty for utmost care ....... -
Page 4: Contents
Contents 6.3.5 Gas outlet ................6–3 6.3.6 Vacuumpump (mains socket 16 A) for VCC ......6–3 6.3.7 RS232 for service..............6–4 6.3.8 USB socket (universal serial bus) for service ...... 6–4 6.3.9 LAN-socket (Local Area Network) for service ...... 6–4 6.3.10 Internal modem (modem antenna) ........ -
Page 5: General Information
General information Scope of delivery and responsibilities The continuous casting machine (V)CC1000 or (V)CC3000 is deliv- ered complete. Please check delivery immediately after receiving the shipment if there are something missing or possible transport damag- es. Please tell the faults the shipping agency and your dealer. -
Page 6: Ec-Conformity
Operating company must ensure unauthorized person has no access to the system. Maintenance actions may only be done by authorized personnel or by service technicians from Indutherm. EC-conformity Declaration of European Community conformity is attached to this manual. -
Page 7: 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 admit- ted for operation. It is not allowed to change or vary the system in any way. Technical changes need explicit written approval of INDUTHERM Erwärmung-... -
Page 8: Demands On Staff, Duty For Utmost Care
Safety 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 must be regulated clearly which include opera- tion, preparation, service and repair. Only authorized personnel may act at the system. -
Page 9: Concept Of Safety
Safety Concept of safety 2.3.1 Objective is the safety: of the staff against injuries; of the system against damage or standstill and of the environment against endangering. The list of actions taken: deployment of protective equipment like covers and main-switch with emergency stop function, ... -
Page 10: Main Switch With Emergency Stop Function
Safety Main switch with emergency stop function 2.3.4 It is allowed to start the machine or operation only with proper emer- gency stop function. Caution! With the emergency stop function you can stop the machine in criti- cal moments of health hazard. You help to diminish potential con- sequences of injury. -
Page 11: Safety Marking
Safety Safety marking The following signal words are used in this document which are asso- ciated 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 12: Safety Advices
Safety 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 13 Safety Danger! Risk of burns. If metal is melted without the supply of protective gas, can cause a flash fire or explosion when opening the bell. Melt at temperatures above 500 °C always with protective gas. Use as a protective gas exclusively argon or nitrogen. Danger! Danger because of touching parts conducting voltage.
- Page 14 Safety Danger! Burning risk by leaking hot metal at protective gas failure. When protective gas failure of the sealing rod can no longer close properly. Through a check valve, the pressure is maintained in the lock cylinder. When pneumatically powered units are operated after a compressed air failure, molten metal can freely leak through the die.
- Page 15 Safety Danger! Lethal injuries happen because of false transport by forklift truck. Pay attention of the right attachment of the means of transporta- tion, otherwise the system can fall from forklift truck. The system must be lifted from the side only, because the centre of gravity is located in front and towards the upper third of the machine.
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Page 16: Residual Risks
Safety Caution! Danger for health because of inhalation of fibre particles. Store crucible shield and insulation in dustproof package. Remove the material just before installation. Don’t shatter crucible shield and insulation. Pack the materials immediately after removal dustproof and dis- pose the materials in this packaging Residual risks risk characterisation... -
Page 17: Technical Data
Technical data Technical data (V)CC1000 (V)CC3000 Crucible diameter in mm Crucible volume in cm³ (1) 1500 3400 Material weight 15 kg Ag, 22 kg Au 18 kt 30 kg Ag, 51 kg Au 18 kt Max. Die Ø in mm... -
Page 18: Description Of The System
System description Description of the system Components of the system The system consists of several modules are assembled in one hous- ing. Inside the housing there are: mains cable and mains filter, microprocessor controlled induction generator PM-type, middle-frequency transformer, ... -
Page 19: Schematic Representation
System description Schematic representation Figure 1: overall view pos. designation function bell with window Closing the inductor housing. inductor housing (cruci- In the inductor housing are: Induction coil ble chamber) crucible insulation and crucible press plate. Heat insulation material. - Page 20 System description pos. designation function drawing device Drawing device for continuous moving down of metal. Here in picture quattro drive water drain For let out condensed water in machine. front panel Control the process of the system. See chapter 7.4. printer Enables printing of casting report, list of program parameter or full systemparameter overview.
- Page 21 System description Figure 2: Front connection and additional control elements Pressure Draw Roll < Drawing roll > < pressed loose > pos. designation function Code plug Connection of the strand-end de- tection in continuous casting appli- cation. For granulating or sintering you have to connect right plug.
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Page 22: Backside Connections
Connection for PC via USB or Ethernet. Filter crucible Filter for vacuum in crucible area. Gas out Depressurization. Serial Inter- Connection for PC over Indutherm-RS232- face/RS232 cable (socket actual attached to internal modem). Vacuum pump Socket for plug from vacuum pump. -
Page 23: Setup Of The Crucible Chamber
System description Setup of the crucible chamber Figure 4: Setup of the crucible chamber position designation function metal filter C038 Brass filter for vacuum build up. thermocouple wall Thermocouple connector for wall measurement, only sec- ondary temperature measurement. thermocouple centre Thermocouple for the sealing rod centre measurement. -
Page 24: Additional Operating Elements
System description Additional operating elements Figure 5: die cooler Die cooler: Brass-part with water hoses. Here you can see the round shape. It is used for wire and tubes. Other option is rectangu- lar shape. Please look in Web-Shop for part C718. Figure 6: round die cooler Figure 7: vacuum die Vacuum die cooler:... - Page 25 System description Figure 10: main switch Main switch: The switch is used to turn the machine on and off. The switch has additional emergency stop function. Figure 11: oxidation protection Oxidation protection/reduce of oxidation: After casting this part is used to close the die outlet, when the starter bar is out and to protect the die against oxidation and burn out.
- Page 26 System description Figure 14: antenna of modem Modem with antenna: Enables INDUTHERM online diagnosis. The modem is inside. To achieve stable connections the antenna might be moved. The modem is connected, if the red led inside is flashing and Op. A at service page 2 show you value like Op.A = 10 to 25.
- Page 27 # 71225042 at (V) CC1000 # 71227042 at (V) CC3000 Advantage is a higher pulling force. Figure 22: Bending unit option Bending unit: For up to 5 wires (V) CC3000. # 71225031 at (V) CC1000 # 71227031 at (V) CC3000. TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_86025010_86025110.doc...
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Page 28: Special Options
System description Special options 4.6.1 Granulation tank Figure 23: granulation tank position designation function protective gas entry Here you can supply additional protective gas. water outlet Usual water outlet. O-Ring For sealing of the barrel without a gap. Inside barrel with lever Removable inside barrel with fast emptying function. fresh water input Control the fresh water input. -
Page 29: Hinged Window
System description 4.6.2 Hinged window Figure 24: option vacuum sealed hinged window position Designation function locking lever Lock the window. slide For refilling the crucible. protective gas supply Reducing the glass from fogging. TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_86025010_86025110.doc 4–12... -
Page 30: Refill System
System description 4.6.3 Refill system Figure 25: option refill system position Designation function control valves Allow the supply of protective gas into 3 areas. From above: a.) option hinged window b.) option refill system c.) in the vacuum pressure casting tank refill container Here the additional material can be filled in. -
Page 31: Description Of Function
System description Description of function The vertical continuous casting plant can be used to produce wires, sheets and tubes of different dimensions from precious metals, alu- minum alloys or other suitable metals. For this purpose, the molten material is first melted inductively by means of a protective gas at- mosphere and then drawn by means of a drawing device through a die. -
Page 32: Transport
Transport Transport Danger! Lethal injuries with wrong transport by fork lift truck. Take care of the right position using transport device to avoid tilting of the system. Pick up the system only from the side, because centre of gravity is in the upper front third. -
Page 33: Mounting And Commissioning
Mounting and commissioning Mounting and commissioning Safety advices for mounting Danger! Only experts may work at the electrical equipment. Danger! Observe the mains supply to requirements of the local electricity supply company, the VDE and the local electricity company. Close the system always via the 5-pin power plug to the power sup- ply. -
Page 34: Apply Supply Connections
The system is supplied with a 32 A CEE plug for (V)CC1000 and (V)CC3000 with 63 A CEE plug. The system may only be connected via this 5-pin power plug to the power supply. The on-site to install socket must be equipped with appropriate fuses (slow). All 4 lines (L1, L2, L3 and PE) must be connected correctly. -
Page 35: Protective Gas
Mounting and commissioning Warning: The cooling water is continuously running through the (V)CC even in case the mains switch is off. 6.3.3 Protective gas The protective gas only nitrogen or argon may be used with a purity status of at least 99.9 %. The supply is affected via a compressed air hose having an inner diameter of 6 mm. -
Page 36: Rs232 For Service
Internal modem (modem antenna) The machine is equipped with a modem on mobile phone base. This can be used by Indutherm service for read outs from the induction generator, which may be useful for debugging and fine-tuning your machine. The free use is valid for 10 years with occasional use. -
Page 37: Operation
Operation Operation Safety advices for operation Caution! Examine all consumables, insulations and hoses before switching on. Check for damages and cleanliness, especially crucible, sealing rod, die and insulations. Operate the system only when it’s free of damages. Warning! Risk of burning on hot surfaces and hot metal (until ~ 1500 °C). -
Page 38: Changing Casting Parts
Operation Warning! Bodily harm by burning. Before you switch on the system fix the protective cover in front the die cooler. An absence of the protective cover will lead to danger during casting of burns if liquid metal squirts, ... -
Page 39: Mounting
Operation 7.2.2 Mounting > Install “new” crucible, die and possibly “new” insulations but don’t fix them. > Apply a thick layer of Hydrokollag in the crucible bottom cone. > Put the die in the cone and push it with together with physical strength. -
Page 40: Front Panel
Operation Front panel 7.3.1 LCD screen after mains switch on Figure 30: Main Screen Upper area = actual °C machine state 0010 15.0 °C Die Schmelz- 0010 Temp 100% 2.0 mm Draw 0.00 0.5 s Pause Crucible 100% 0.0 mm Reverse 0 N Draw 0.0 s Pause... - Page 41 Operation Detail Name Set area Description 20…100 100 % Draw rotation speed of roll in draw direction 0.1…9.9 2.0 mm Draw draw length in millimetre 0.0…9.9 0.5 s Pause stop time in seconds 20…100 100 % Reverse rotation speed in reverse direction 0.0 mm Reverse 0.0..(9.8)
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Page 42: Cc-Info-Page
Operation 7.3.2 CC-Info-page Figure 31: Info screen CC Info 25.0 °C Die Waterinput 24.5 °C Die Wateroutput 2.3 l/min Die Waterflow Haupt- Return Service Λ – TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_860 7-10 25010_86025110.doc... -
Page 43: Predefined Casting Programs
Operation 7.3.3 Predefined casting programs Figure 32: pre-set casting programs (V)CC1000/(V)CC3000 Material Test Program No. Temperature °C 0010 Power (Crucible) 0100 Mode Die Temp Set temperature (Die) °C Set power (Die) 0100 Set water temperature 0020 (Die) CC Draw velocity... -
Page 44: System Parameter
Please refer to the explanations for the parameters in the attachment software documentation. The ad- justed values should be changed with care and usually after consulta- 000: 00002 tion with the Indutherm service staff. Temp. Sensor 0 Type Haupt- Service Λ –... -
Page 45: State Level
Operation 7.3.5 State Level By pressing the ‘Service’-button once, you see the software ID, generator number and machine number. Figure 34: Service-Info-Page 1 Service Info Page 1 800.0098 SW-ID.Build (Apr 29 2016 09:34:29) PM0089 Generator No. (SER ETH USB) M16069 Machine No. Service Service Print... -
Page 46: V)Cc Front Panel Below Display
Operation 7.3.6 (V)CC Front panel below display Figure 36: Front panel below display Control element Function Crucible temp. The set temperature can be adjusted using the "+" or "-" keys. The setting range is from 10 ° C to 1300 ° C when an N-type thermocou- ple is used. -
Page 47: Casting
Operation Arrow up As long as you press this button the material will be pushed up- wards. Auto Draw The automatic drawing cycle (draw-pause-reverse) will be switched on/off with this button. Wash (VCC) Allows a complete vacuum build-up with subsequent flooding of the induction chamber by means of protective gas. - Page 48 Operation Program selection: You can program 80 casting programs, 10 granulating and 10 sinter programs. One pre-defined program with recommended parameters is stored for CC series. Pro- gram-place is 18. This one test program from IN- DUTHERM for system check without heating power. Various dimensions of wire, sheet or tube can be produced with this machine.
- Page 49 Operation Take off the round metal plate by removing the two brass nuts. Loosen the screw of the die-cooler from the left side with the Allen key. Figure 38: die cooler Remove "old" crucible, die and, if necessary, drawing roller. Check the crucible and the die for scratches.
- Page 50 Operation Insert the drawing bar into the die (about 8 cm) and tighten the roller. Tighten the metal plate. Install thermocouples. Dip the drawing bar into separating graphite for about 5 cm and let dry (Graphite spray or Hydrokollag). Open cooling water and compressed air supplies. Turn the mains switch. Set the desired casting program (1 to 99 programs available).
- Page 51 Make a mark, for example with a wa- terproof marker. Attention: All these steps you can see in a CC3000 video on our website www.indutherm.de or on YouTube if you type in CC3000. Make familiar with this video first.
- Page 52 Die temperature in °C 600 Note: At our webpage www.INDUTHERM.de you’ll find a train- ing video of former model CC3000 with P-generator. Recommendation INDUTHERM: Before you do your first drawing with your material let run the test program 18 at room temperature with cold starter bar.
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Page 53: Granulating
To produce granules of different diameters, it is sufficient to change screw-fit in the crucible bottom. For granulating you have to install granulating unit and put in attached plug for granulat- ing. Figure 44: Program INDUTHERM VCC1000 parameter granulat- Operation mode: Grain Upper area = pa- °C 0.00... - Page 54 Operation Suggestion for a granulating process: 1. Switch on cooling water, compressed air and protective gas supply. 2. Fill the granulating tank with water until overflow. 3. Switch on (V)CC at the mains switch. 5. Please press ‘Generator-Start’ in left area of front panel. Protective gas will be applied automatically at temperatures over 500 °C.
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Page 55: Casting Reports
Operation Casting reports As you know a good casting result depends from many causes: investing material, used alloy, de-wax-process and of course from the INDUTHERM casting machine and its set- tings. Advice: Save your casting reports right from the beginning. -
Page 56: Troubleshooting
Webshop. You’ll find error document typing in the ‚Exxx‘-number. Please replace W with E for search. Service If you need technical support from company INDUTHERM, we’d like to have following information of your machine at first contact: Service No. M17999 PM below mains switch or ... -
Page 57: Maintenance
Maintenance Maintenance Safety advices for repair and maintenance For reliable use and highest work accuracy use is regular mainte- nance and service of your system a prerequisite. The necessary working steps are summarized in this chapter and should be carry out in time. - Page 58 Maintenance Warning! Risk of injury. Make pressurized plant parts at zero pressure before work is carried out there. Warning! Slipping on the floor in the area around the plant, if lubricants or sol- vents were spilled. Clean the floor with dirt immediately! Discard the cleaning cloths in the collecting means made available.
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Page 59: Maintenance Schedule
Maintenance Maintenance schedule Follow the maintenance schedule to obtain the functionality of the system. Daily (before casting) Warning! Burning hazard because of leaking molten metal. The system must not be operated without a sealing rod for security reasons. The tip of the sealing rod must stay in the pouring opening even when sealing rod is open. - Page 60 Maintenance Figure 49: air filter of vacuum pump Every year If you use tap water for cooling water-system, then pump about 25% citric acid solution for about an hour through the system. Af- terwards the system should be thoroughly flushed with clean wa- ter and checked for possible leaks.
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Page 61: Repair
Maintenance Repair The system must be repaired only by authorized personnel. Never try to repair the system yourself. Incorrect repairs can lead to health problems or damage to the equipment. *Directive 2009/104/EG of the European Parliament and of the Council of 16 September 2009 concerning mini- mum safety and health protection for the use of work equipment by workers at work (sec- ond individual Directive within the meaning of Article 16 paragraph 1 of Directive 89/391 / EEC). -
Page 62: Dismantling And Cleaning Up
Dismantling and cleaning up Dismantling and cleaning up Warning! Permanent skin damages after touching lubricant or sol- vent of every description (long term effects). Avoid touching lubricants, solvents and coolants. Wash the sprinkled skin parts thoroughly. Wear protective gauntlets when using lubricants, solvents and coolants. -
Page 63: Annexe
Annexe Annexe 10.1 List of figures Figure 1: overall view ..............4–2 Figure 2: Front connection and additional control elements ... 4–4 Figure 3: backside of the vacuum pressure casting machine ..4–5 Figure 4: Setup of the crucible chamber ........4–6 Figure 5: die cooler ................ - Page 64 Annexe Figure 36: Front panel below display ..........7-14 Figure 37: two thermocouples ............7-16 Figure 38: die cooler ..............7-17 Figure 39: conical reamer ............. 7-17 Figure 40: Hydrokollag ..............7-17 Figure 41: drawing bar ..............7-19 Figure 42: strand-end detection ............ 7-19 Figure 43: granulating crucible ............
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Page 65: Ce-Declaration Of Conformity
INDUTHERM Erwärmungsanlagen GmbH Brettener Str. 32, 75045 Walzbachtal Product type: Continuous-casting-machine Machine type: (V)CC400, (V)CC1000, (V)CC3000 Serial number: 15072 or higher Authorized to sign: Peter Hofmann 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 66 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/2017-09-19/Peter Hofmann, chairman TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_860 10-4 25010_86025110.doc...
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Page 67: Test Result Chart
Annexe 10.3 Test result chart TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_860 10-5 25010_86025110.doc... -
Page 68: Connection Diagrams
Annexe 10.4 Connection diagrams Figure 51: connection diagram – power part TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_860 10-6 25010_86025110.doc... - Page 69 Annexe Figure 52: connection diagram – control TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_860 10-7 25010_86025110.doc...
- Page 70 Annexe Figure 53: connection diagram – temperature sensor, digital I/O TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_860 10-8 25010_86025110.doc...
- Page 71 Annexe Figure 54: connection diagram – power part VCC3000 TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_860 10-9 25010_86025110.doc...
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Page 72: Cooling Water Circuit
Annexe 10.5 Cooling water circuit Figure 55: cooling water circuit TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_860 10-10 25010_86025110.doc... -
Page 73: Cut Drawing Vcc
Annexe 10.6 Cut drawing VCC Figure 56: Cut drawing die cooler Ø110 Figure 57: Cut drawing die cooler Ø070 1 graphite crucible 2 crucible shield 209x177x275 3 crucible bottom insulation 4 die insulation 5 die for wire 6 crucible press insulation 7 crucible cover 8 sealing rod TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_86... - Page 74 Annexe Figure 58: Cut drawing die cooler Ø050 Figure 59: Cut drawing die cooler Ø120x30 Figure 60: Cut drawing die cooler Ø160x40 TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_860 10-12 25010_86025110.doc...
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Page 75: Consumable And Spare Parts List
Annexe 10.7 Consumable and spare parts list INDUTHERM is now using only machine specific spare parts list, which contain all the information for your machine. At following page, the spare parts list for this machine will start. The item number of the consumables list is composed by following parts: ... - Page 76 Annexe Please replace this page with G17999_00. TechDoku_CC1000_VCC1000_CC3000_VCC3000_GenPM_GB_860 10-14 25010_86025110.doc...
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Page 77: Error And Warning Messages
Error and warning messages Software-Documentation starts at next pages. The label of the bilingual documentation is “generator_documentation_80000xxx_customer_DM_F_PM_Gen.pdf”. Please note: At our Internetpage http://www.indutherm.de/webshop you can get prac- tical help for troubleshooting. Figure 61: contact form Webshop Until you can enjoy the ad- vantages of the Webshop you have to apply for an access.