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Summary of Contents for Indutherm MC60V
- Page 1 9 Deforest Street Amityville, NY, 11701 Technical Documentation Mini Casting unit MC60V Romanoff order service for Romanoff consumables: technical service www.romanoff.com Tel.: +1-631-842-2400 service@romanoff.com Keep for future use!
- Page 2 Revision Revision Date chapter Reason responsible 2018-02-06 Edition 2018 2019-01-08 last changes This manual has been prepared in good faith by us. Nevertheless, should you find any mistakes or ambiguities, please let us know. Furthermore, we are grateful for comments and suggestions sales@romanoff.com | www.romanoff.com 2019-01-08...
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Page 3: Table Of Contents
4.5.1 MC60V screen when starting the machine ......4–5 4.5.2 MC60V modify program screen ........... 4–6 4.5.3 MC60V modify system parameter ........4–7 4.5.4 MC60V State-Level (Service Info Page 1 + 2) ..... 4–8 Front panel buttons ............. 4–9 Functional description ............4–10 Casting programs for MC60V (05.12.2016) ....... -
Page 4: Contents
Contents 4.13 Notes on the properties of some metal alloys ....4–16 4.14 Investment material ............4–17 4.15 Investment process ............4–18 4.16 Determination of the powder / water partial quantities ..4–19 4.17 Recommendations for flasks ..........4–20 4.18 Preheating of the flasks ............. - Page 5 Contents 10.4 Cut diagram of the replacement parts ........ 10-7 Consumable – and spare parts list ........10-7 10.5 10.6 Software documentation with error messages ....10-9 sales@romanoff.com | www.romanoff.com 2019-01-08...
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Page 6: General Information
General information Scope of delivery and responsibilities The mini casting machine MC60V is delivered complete. Please check delivery immediately after receiving the shipment if there is something missing or possible transport damages. Please tell the faults the shipping agency and your dealer. -
Page 7: Ec-Conformity
General information Operating company has to ensure unauthorized person has no ac- cess to the system. Maintenance actions may only be done by authorized personnel or by service technicians from manufacturer. EC-conformity Declaration of European Community conformity is attached to this manual. -
Page 8: 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 9: 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 have to be regulated clearly which include oper- ation, preparation, service and repair. Only authorized personnel may act at the system. -
Page 10: Concept Of Safety
The list of actions taken: deployment of protective equipment like covers and mains switch; you can unplug the mains plug as an emergency stop. The wall socket for the mini-casting unit MC60V must be freely accessible. water-cooled inductor housing;... -
Page 11: Safety Markings On The Unit
Safety 2.3.4 Safety markings on the unit A necessary condition for safe dealing with and undisturbed running of the machine is the knowledge of safety instructions and industrial safety regulations. At the machine casing the following safety markings are attached. safety meaning safety... -
Page 12: 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 13: 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 14 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 15 Safety Warning! Danger of explosion. Dripping liquid metal can’t be excluded. The set-up place (table) and the floor beneath the system should be made of non-flammable material. As well there shouldn’t be stored inflammable materials within a radius of 5 metres. Attention! At crucible temperatures over 100 °C the cooling water supply must be switched on.
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Page 16: Residual Risks
Safety Caution! Observe regulations for the mains supply written from the responsible electric power supply company, the associa- tion VDE and the local electric power station. Inappropriate connecting can lead to injuries and dam- ages of the machine. Caution! Danger for health because of inhalation of fibre particles. ... -
Page 17: Technical Data
Technical Data Technical Data MC60V Crucible volume 50 cm³ (practically 38 cm³) Pressure range in melting cham- -1 to 2 ber in bar Crucible temperature in °C max. 1300 Melting performance in kW Mains supply 230 V, 50 or 60 Hz Fuse protection in A 4.45... -
Page 18: Description Of The System
System description Description of the system Components of the system The system consists of several modules assembled in one housing. Inside the housing there are: mains cable, microprocessor controlled induction generator DM-type, middle-frequency transformer, oscillating circuit capacities and ... -
Page 19: Schematic Representation
System description Schematic representation Figure 1: overall view Position Description Function tilting handle with Due to movement to the right the machine will lock cast. inductor housing The melting and casting process takes place here. control buttons. Control the casting process. See ch. 4.6. LCD screen See chapter 4.5 top plate with... -
Page 20: Connections On The Backside
System description Connections on the backside Figure 2: backside of the mini-casting machine Position Description Function of the connection vacuum filter filters the vacuum Gas out gas outlet Protective gas input for protective gas Vacuum connection for external vacuum pump Water In input for cooling water Water Out... -
Page 21: Set-Up In The Vacuum Chamber
System description Set-up in the vacuum chamber Figure 3: set-up with crucible Position Description Function thermocouple type N Allows a temperature measurement up to 1300 °C. ceramic cover Protects the thermocouple against contamination with liquid metal or graphite. ceramic crucible with In this crucible the graphite contains the heat and trans- graphite inlet fers the energy to the metal. -
Page 22: Front Panel Display
System description Front panel display 4.5.1 MC60V screen when starting the machine Figure 4: screen with mains supply Temp. Prog. °C 0010 inner area: ac- 0.00 Temp. InduTest 1 Prog. tual values Program Manual Power Prog. outer area: op- Edit... -
Page 23: Mc60V Modify Program Screen
System description 4.5.2 MC60V modify program screen Figure 5: program 0018 Program InduTest 1 parameter Λ 0010 °C Temperature 0100 % Heating power middle section with 0000 Washing before heat program parame- 0000 Washing while heat Manual Melt. press. start –... -
Page 24: Mc60V Modify System Parameter
Decreases the value. Main page Display returns to main menu. 4.5.3 MC60V modify system parameter If you start from the main page and you press „Program setup“ for 5 seconds you get ac- cess to the system parameter. Figure 6:... -
Page 25: Mc60V State-Level (Service Info Page 1 + 2)
If you press „Serv.“-button again, you’ll see cooling water flow (sensor 0), generator tem- perature (IGBT)and actual machine state. The rows ‘Water flow 1’ and ‘Op.’ are not used in MC60V. The button ‘Serv. (Service) Print’ is without function. Figure 8: Service-Info-Page 2 Service Info Page 2 1.3 l/min. -
Page 26: Front Panel Buttons
System description Front panel buttons Figure 9: front panel From left to the right Button Function Stop Stops active program. 6 push buttons left Function of these buttons you can see in display. See chapter and right from display 4.5.1 too. Generator Starts and stops heating with induction generator outside the automatic mode. -
Page 27: Functional Description
(eg commercially available copper or silver), de- gassing of the molten metal under vacuum is possible. The INDUTHERM mini casting machine MC60V is suitable to cast all kind of metals into moulds or into investment flasks. Exceptions are dental alloys and very reactive alloys like magnesium. - Page 28 System description All functions are linked with the turning of the chamber: immediately after pouring metal into the flask, over pressure comes automatically. As mentioned before, a pressure impulse on top of liquid metal, while inside there is still a vacuum, makes the good form-filling of this system.
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Page 29: Casting Programs For Mc60V (05.12.2016)
System description Casting programs for MC60V (05.12.2016) Figure 10: predefined casting programs MC60V Material Silver Yellow Test 1 Test 2 gold 18k Crucible Graphite Graphite Graphite Graphite Temperature read- Thermo- Thermo- Thermo- Thermo- couple couple couple couple Program No. Temperature* °C... -
Page 30: Temperature Control
System description Temperature control To use the temperature controller a thermocouple type N article no 13400016 up to 1300 °C (parameter P.000 - must be set to 0002) has to be connected to the socket inside the casting chamber. Very important is that you use the thermocouple together with the thermocouple protection cover article no 132000046. -
Page 31: Tree Making
This is best for cutting off the casting pieces after casting process. On MC60V this tree is more a bush, pieces are fixed on the button cone directly. Only a short piece of main sprue is required. -
Page 32: To Find Out The Weight Of The Metal
System description 4.11 To find out the weight of the metal All rubber bases must be determined on a scale. Write exact weight on this rubber bases by a felt pen. After mounting the tree, take the total weight. Deduct the rubber base weight from the total weight = net wax weight. -
Page 33: Using Already Cast Material
System description 4.12 Using already cast material Because of high costs casters do not like to use every time fresh alloy. For some alloys customers mix “second hand metal” up to 50 %, mainly Au, Ag based alloys. Please pay attention to following: ... -
Page 34: Investment Material
System description 4.14 Investment material Generally, there are three types of investment: Gypsum-bonded investment materials for metal temperatures up to 1250 °C. (Flask tem- perature up to 730 °C) These are standard investment materials for gold, silver, bronze, etc. These investment materials are stirred with water and the investment is easy to re- move by quenching in water. -
Page 35: Investment Process
After filling the flask: give slurry 1-hour time to become totally solid. No moving of the flask, place in on a quiet place without vibration. Afterwards: remove rubber base. Figure 15: Indu Mix for MC60V sales@romanoff.com | www.romanoff.com 2019-01-08 4–18... -
Page 36: Determination Of The Powder / Water Partial Quantities
System description 4.16 Determination of the powder / water partial quantities Determining amount of powder per flask this formula is helpful: Volume of flask in cm³ x 1.4 = amount of powder in grams For example flask ø 8 x 8 cm r²... -
Page 37: Recommendations For Flasks
To reach this temperature starting at 300 °C, ramp should be 4 °C/min = process takes around 2 hours. On bigger flasks (starting at 150 °C, we recom- mend to select ramp 5 °C/min. Duration in the furnace: for small flasks like MC60V around 1 hour, on bigger flasks up to 5 hours. - Page 38 Figure 16: firing cycle for MC60V Casting temperature Zeit in h Firing cycle for MC60V, gypsum bonded investment material This “gentle” firing cycle needs maximum 7 hours, so from wax to casting it will take only one day. sales@romanoff.com | www.romanoff.com 2019-01-08 4–21...
- Page 39 Time in h RAPID firing cycle for flasks MC60V gypsum bonded investment material Caution: In case of a “gentle”-firing cycle all amenities of the investment material are pre- vented from damage. A rapid firing cycle doesn’t take care on these amenities. Already aged investment powder or thus of lower quality can react because of gruff handling with cracks.
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Page 40: Flask Temperatures
System description 4.19 Flask temperatures The casting temperature depends on metal alloy and style of castings. High melting point of metal needs high flask temperatures, thin and delicate pieces with long flow ways too. Low melting point of metal needs lower flask temperatures, heavier massive pieces too. Ask metal supplier about their recommendation. -
Page 41: Collection Of Spoiled Castings
System description 4.20 Collection of spoiled castings Horizontal flashing or finning Figure 18: horizontal flashing or finning Cause Remedy Incorrect powder / water ratio (too much Using correct amount of water (espe- water). cially important with vacuum investing machines). - Page 42 System description Bubbles - Complete Spheres Figure 20: bubbles - complete spheres Cause Remedy Investment too thick. Too little water. Use correct powder / water ratio. Vacuum pump/ tank faulty. Ensure equipment is regularly serviced and adequate for the task. ...
- Page 43 System description Water marking Figure 22: water marking Cause Remedy Incorrect powder / water ratio (too much Use correct amount of water (especially water). important with vacuum investing ma- chines). Work time of investment not used up. Ensuring the work time is used up and slurry temperature is 20 –...
- Page 44 System description Rough Surfaces Figure 24: rough surfaces Cause Remedy Rough waxes. Use less release agent on the rubbers. This can be caused by excess of tal- cum. Use only a trace of talcum. Never use silicon spray. ...
- Page 45 System description Incomplete castings Figure 26: incomplete castings Cause Remedy Metal or flask too cold. Please increase casting temperature. If the metal or mould is too cold, the metal will freeze before complete- ly filling the mould. ...
- Page 46 System description Blisters, spalling Figure 28: blisters, spalling Cause Remedy Flask has been heated too Do not exceed 150 ºC during de-wax. Wax will rapidly during de-wax. boil and erode investment surface. Flasks overheated during burn Ensure maximum burn out temperature does not out.
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Page 47: Transport
Transport Transport Danger! Injuries because wrong transport. Take care of the right position using 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 of failure to comply transport regulations. -
Page 48: 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 electricty sup- ply company, the VDE and the local electricity company. Use always the 2-pin power plug with safety contacts for connecting the system to the mains supply. -
Page 49: Apply Supply Connections
A power plug with earth contacts is supplied with this machine. All three lines (L, N and PE) must be connected correct- The wall socket of the mini-casting unit MC60V must be freely acces- sible. 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. -
Page 50: Protective Gas
Mounting and commissioning 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 effected via a compressed air hose having an inner diameter of 6 mm. The inlet pressure should be at least 6 bar and must not exceed 8 bar. -
Page 51: Rs232 For Service
Mounting and commissioning 6.3.6 RS232 for service At this plug behind a black cover our modem (item no. 71000320) or our serial cable (50500060) can be connected for service issues. ̉ L AN, Ethernet or RJ-45 connector for service 6.3.7 Behind a black cover, you’ll find this plug to connect the machine to a network (LAN-local area network). -
Page 52: Operation
Operation Operation Safety advices for operation Caution! Examine all consumables, insulations and hoses before switching on. Check for damages and cleanliness, especially crucible and glass shield. Operate the system only when it’s free of damages. Warning! Risk of burning on hot surfaces and hot metal (until ~ 1300 °C). -
Page 53: Removal
Operation 7.2.1 Removal > Open the top plate of the casting chamber. > Remove “old crucible”. 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 32: quartz fleece in inductor shield The crucible should be sitting easily on the quartz fleece. -
Page 54: Recommendation For A Casting Process
Operation Recommendation for a casting process Figure 34: further suggestions of casting programs Suggestions Material Yellow gold 14k Crucible Graphite Temperature reading Thermo- couple Program No. Temperature °C 1080 Heating power 0100 Washing before heating 0000 Washing while heating 0001 Melting pressure start Manual Melting pressure... -
Page 55: Error Diagnosis
Low generator output Additional error messages see software-documentation. Service If you need technical support from company INDUTHERM Erwärmungsanlagen GmbH, we’d like to have following information with first contact: Service No. M19999 DM on the left front side of machine or ... -
Page 56: 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 have to carry out in time. -
Page 57: Maintenance Schedule
Maintenance Warning! Slipping on the floor in the area around the plant, if lubricants or sol- vents were spilled. Clean the dirty floor immediately! Discard the cleaning cloths in the collecting means made available. Maintenance schedule Follow the maintenance schedule to obtain the functionality of the system. -
Page 58: Repair
Maintenance Every year Cooling water system with about 25 % citric acid rinse for about an hour. Then system thoroughly flush with clean water and check for possible leaks. This cleaning-supply cycle is highly de- pendent on the hardness and cleanliness of the cooling water. ... -
Page 59: 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 60: Annexe
Figure 13: hydrodynamic not proper style ........4–14 Figure 14: tree with easy flow of wax and not ....... 4–14 Figure 15: Indu Mix for MC60V ............ 4–18 Figure 16: firing cycle for MC60V ..........4–21 Figure 17: Rapid firing cycle ............4–22 Figure 18: horizontal flashing or finning ........ -
Page 61: Ce Declaration Of Conformity
Annexe 10.2 CE Declaration of conformity Manufacturer: INDUTHERM Erwärmungsanlagen GmbH Brettener Str. 32, 75054 Walzbachtal, Germany Product type: Mini-casting machine Machine type: MC60V Serial number: 16265 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 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 for 10 years. city/date/signatory: Walzbachtal/2019-01-08/Peter Hofmann, chairman sales@romanoff.com | www.romanoff.com...
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Page 63: Connection Diagrams
Annexe 10.3 Connection diagrams Figure 37: connection diagram sales@romanoff.com | www.romanoff.com 2019-01-08 10-6... - Page 64 Figure 38: inductor chamber Consumable – and spare parts list 10.5 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.
- Page 65 Software-Documentation starts at next pages. The label of the bilingual documentation is “generator_documentation_80000xxx_customer_DM_F_PM_Gen.pdf”. xxx is the software state. Please note: At our Internetpage http://www.indutherm.de/webshop you can get after registration access to important data. Figure 39: contact form webshop Until you can enjoy the ad- vantages of the Webshop you have to apply for an access.
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