ROMANOFF Indutherm VC 680V Product Manual
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ROMANOFF Indutherm VC 680V Product Manual

Full automatic casting machine
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Indutherm VC 680V
Full Automatic Casting Machine
Product Manual
3/15/24 Romanoff.com • Sales@romanoff.com • 631-842-2400
Page 1 of 71

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Summary of Contents for ROMANOFF Indutherm VC 680V

  • Page 1 Indutherm VC 680V Full Automatic Casting Machine Product Manual 3/15/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 1 of 71...

  • Page 2: Table Of Contents

    Contents 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Contents Contents ...................3 General information ............1–1 Scope of delivery and responsibilities ........1–1 Liability, warranty and guarantee ......... 1–1 Responsibility of operating company ........1–2 EC-conformity ..............1–2 Observation of the product ..........

  • Page 3: Contents

    Contents 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Mounting and commissioning .......... 6–1 Safety advices for mounting ..........6–1 Mounting process ..............6–1 Apply supply connections ............ 6–2 6.3.1 Power supply ..............6–2 6.3.2 Cooling water ..............6–2 6.3.3 Compressed air ..............
  • Page 4 Contents 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Repair ..................8-5 Dismantling and cleaning up ..........9–1 Annexe ................10–1 10.1 List of figures ..............10–1 10.2 CE-Declaration of conformity ........... 10–3 10.3 Test result chart ..............10–5 10.4...

  • Page 5: General Information

    General 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine information General information Scope of delivery and responsibilities The vacuum pressure casting machine VC680V is delivered com- plete. Please check the delivery immediately after receiving the ship- ment if there are something missing or possible transport damages.

  • Page 6: Responsibility Of Operating Company

    General 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine information Damages caused by disregard, wrong interpretation and non- compliance with specifications in this manual will lead to expiration of guarantee for this system. Responsibility of operating company The operator has to meet with national accident preventing regula- tions and technical regulations.

  • Page 7: Safety

    Safety 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Safety Intended use Operational safety of the vacuum pressure casting machine is only guaranteed at intended use. The casting machine serves exclusively for melting, pouring and vac- uum casting of commercially available precious metals and of copper- or aluminium-alloys.

  • Page 8: Demands On Staff, Duty For Utmost Care

    Safety 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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 op- eration, preparation, service and repair.

  • Page 9: Concept Of Safety

    Safety 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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 pollution.

  • Page 10: Main Switch With Emergency Stop Function

    Safety 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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.

  • Page 11: Safety Marking

    Safety 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Safety marking The following signal words are used in this document, which are as- sociated 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.

  • Page 12: Safety Advices

    Safety 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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.
  • Page 13 Safety 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Warning! Maintenance and servicing of the machine only when the system is disconnected from the mains supply (Pull out mains plug). Advice! Don’t disconnect mains plug while machine is running or in standby.
  • Page 14 Safety 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Danger! Threat of health injury by escape of medias from damaged hoses. Danger of system damages.  Remove loose connections. Replace damaged hoses immediate- ly. Perform work only when mains plug is pulled out.
  • Page 15 Safety 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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 centre of the pouring hole even when sealing-rod is open.

  • Page 16: Residual Risks

    Safety 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Caution! Observe regulations for the mains supply written by 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.

  • Page 17: Technical Data

    Technical data 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Technical data VC680V   3.5 kg/Au crucible volume (1) 245 cm Max. Ø 125 mm (5“) * 240 mm (9.4“) height flasks special option 260 mm (10”) height Max.
  • Page 18 Technical data 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine  granulation tank (with 2 cooling system or fresh options water with Ø 8 mm input, Ø 21 mm outlet)  sinter unit  S-crucible noise emission 75 dB (A) (1) These are standard values which can be optionally changed.

  • Page 19: Description Of The System

    System description 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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 and mains filter, ...

  • Page 20: Schematic Representation

    System description 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Schematic representation Figure 2: overall view pos. designation Function bell with window Closing the inductor housing. inductor housing (cruci- In the inductor housing are: ble chamber)  Induction coil ...

  • Page 21: Backside Connections

    System description 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Backside connections Figure 3: backside of the vacuum pressure casting machine pos. designation Function Modem Connector for modem antenna. Compressed air Compressed air supply input. Protective gas Protective gas supply input.

  • Page 22: Setup Of The Crucible Chamber

    System description 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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 socket Thermocouple connector for wall measurement if you work (option) with centre measurement additional (option).

  • Page 23: Feeder System

    System description 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Feeder system Figure 6: refill system position designation function feeder grain Metal detector for detecting metal. When metal is present, the light detector at the detector goes on and if no metal is present, the light from the sensor is off.

  • Page 24: Additional Gas Tank

    System description 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Additional gas tank Figure 8: additional gas tank position designation function additional gas tank Accumulator for protective gas for rapid pressure build-up in the crucible. safety valve ̣...

  • Page 25: Special Options

    System description 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Special options 4.7.1 Centre- and wall measurement (Dual measurement) Figure 9: option – dual measurement 3/15/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 25 of 71...

  • Page 26: Granulation Tank

    System description 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 4.7.2 Granulation tank Figure 10: granulation tank position designation function protective gas entry Here you can supply additional protective gas. water outlet Usual water outlet for water hose with diameter 21 mm.

  • Page 27: Hinged Window

    System description 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 4.7.3 Hinged window Figure 12: 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.

  • Page 28: Flask Height With 260 Mm (10'') With 'Special-Pin' 711143214-10

    System description 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 4.7.5 Flask height with 260 mm (10‘‘) with ‘special-pin’ 71114321 Figure 14: standard 240 mm Figure 15: Pin-option Figure 16: possible height 260 mm 71114321 3/15/24 Romanoff.com • Sales@romanoff.com • 631-842-2400...

  • Page 29: Transport

    Transport 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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 30: Mounting And Commissioning

    Mounting and commissioning 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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.

  • Page 31: Apply Supply Connections

    Mounting and commissioning 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Apply supply connections 6.3.1 Power supply The electrical connection may only be performed by a specialist. Note the information specified on the nameplate rated voltage or frequen- The 3-phase power supply may differ max.

  • Page 32: Compressed Air

    Mounting and commissioning 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Figure 19: Waterflow Wateroutput in a A water flow bucket 2.3-2.5 liters / minute should be measured. Please also check the Measure the machine for dry con-...

  • Page 33: Gas Outlet

    Mounting and commissioning 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine The oil filter and the exhaust filter should be replaced at every second oil change. For detailed information, please also refer to the operating manual in maintenance of the vacuum pump.

  • Page 34: Usb Socket (Universal Serial Bus)

    Mounting and commissioning 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 6.3.9 USB socket (universal serial bus) Here, the machine can be connected to a PC. Use the data manage- ment software provides by Indutherm to read system data and casting programs.

  • Page 35: Operation

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Operation Safety advices for operation Caution! Examine all consumables, insulations and hoses before switching on. Check for damages and cleanliness, especially crucible and insulations. Operate the system only when it’s free of damages.

  • Page 36: Changing Casting Parts

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Attention! 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.

  • Page 37: Front Panel

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Front panel 7.3.1 LCD screen after mains switch on Figure 24: main screen upper area = INDUTHERM VC680V Actual state of ma- chine 12.0 °C (0718) 1100 °C 0 °C Flask...

  • Page 38: Program Change

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 7.3.2 Program change page 1 Figure 25: Program parameter page 1 0010 Program Bronze 1150 °C Temperature 0001 Washing while hea ng At Start Insert Flask/Ingot upper area = Pa- -1.0 bar...
  • Page 39 Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Flask Casting ‘Flask’ flask without flange – two chamber system with mould differential pressure. ‘Flask Fl’ Flask with flange (differential pressure) ‘Flask HSC’ under development ‘Ingot’ One chamber system with always similar pressure in both chambers;...
  • Page 40 Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 7.3.3 Program change page 2 Figure 26: Program parameter page2 0010 Program Bronze 0060 s Vibra on Vibra on Sweep 0150 s Cooling me upper area= pa- 0000 s...

  • Page 41: Predefined Casting Programs

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 7.3.4 Predefined casting programs Figure 27: pre-set casting programs VC680V Material Bronze Yellow Yellow Alumini- Brass gold gold 14 kt 18 kt (with zinc) Crucible Graphite Graphite Graphite...

  • Page 42: System Parameter

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 7.3.5 System parameter If you start from the main page and you press ‘Program Setup’ for five seconds you get access to the system parameter level. Figure 28: System parameter...

  • Page 43: State Level

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 7.3.6 State Level By pressing the ‘Service’-button once, you see the software ID, generator number and machine number. Figure 29: Service-Info-Page 1 Service Info Page 1 800.0096 SW-ID.Build (Mar 10 2016 15:14:42) F0936 Generator No.

  • Page 44: Vc680V Front Panel Below Display

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 7.3.7 VC680V Front panel below display Figure 31: Front panel below display Manual control: Generator By this button you can start heating from generator. Switched on genera- Start tor regulate for the set temperature (see above ‘temperature’).

  • Page 45: Protective Gas Flow

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine system is installed, which monitors a swivelled out vacuum chamber. You can deactivate the warning W077 by pressing the button ‘sealing rod’ for 3 seconds. This is useful when you want to clean an empty warm cruci- ble, but the vacuum chamber is swivelled out.
  • Page 46 Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine mance always keep the vacuum pump running for at least 30 min to heat up (The vacuum pump attached to the casting machine switch on by itself in pro- gram with selected washing or low vacuum).
  • Page 47 Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Temperature: ca. 100 °C over melting temperature of the alloy (Consider the recommendation of the alloy manufacturer). Melting pressure: +0.00 Melting time: Casting pressure: +0.60 Casting pressure start:...

  • Page 48: Possible Causes For Dissatisfying Casting Results

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Possible causes for dissatisfying casting results Dissatisfying casting results can have various causes and, depending on the material, can have various effects. The following "check list" is to help find the different causes: 1.

  • Page 49: Flask Structure

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Flask structure Figure 33: sectional view of flask Figure 34: flask without flange and holes Note: The principle of the machine is based on the high gas flow through the machine. Please use only flasks with holes on the side.

  • Page 50: Granulating

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Granulating Before starting check crucible, sealing rod and crucible insulation for dirt residues/possible damages. It is recommended to use a vacuum cleaner for the entire inductor. The metal filter (left of the sealing rod) should be taken out and cleaned with compressed air.
  • Page 51 Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Figure 36: Program parameter granulat- 0020 Program Granulate ing page 1 1150 Temperature 0001 Washing while hea ng Later Not used Upper area = pa- 0.00 bar Mel ng pressure...
  • Page 52 Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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 VC680V at the mains switch.

  • Page 53: Casting Reports

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Figure 39: granulating insert Take out insert. Pour out the water. Take out material. 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.

  • Page 54: Error Diagnosis

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 7.10 Error diagnosis There are two types of disturbances.  Error and  warnings. Whenever an error occurs the heating stops, and an error code will be on display.

  • Page 55: Diagram Casting Flasks Without Flange

    Operation 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 7.12 Diagram casting flasks without flange Figure 42: Flasks without flange Possible reasons of losing vacuum: O-Ring of vacuum chamber is not OK. Flask top surface is not flat enough.

  • Page 56: Maintenance

    Maintenance 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Maintenance Safety advices for repair and maintenance For reliable use and highest work accuracy use a prerequisite is regu- lar maintenance and service of your system. The necessary working steps are summarized in this chapter and have to be carried out in time.
  • Page 57 Maintenance 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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.

  • Page 58: Maintenance Schedule

    Maintenance 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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.
  • Page 59 Maintenance 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Figure 45: 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 flush the system thoroughly with clean water and check for possible leaks.

  • Page 60: Repair

    Maintenance 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Figure 47: red CEE-plug For electrical testing or maintenance, the machine must be separable from the power supply via the red CEE plug, as described in chap. 6.3.1 Installation re- quired.

  • Page 61: Dismantling And Cleaning Up

    Dismantling and cleaning up 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 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.

  • Page 62: Annexe

    Annexe 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Annexe 10.1 List of figures Figure 1: Sensor #84400010 ............1–1 Figure 2: overall view ..............4–2 Figure 3: backside of the vacuum pressure casting machine ..4–3 Figure 4: Setup of the crucible chamber ......... 4–4 Figure 5: Illustration of the self-rotating rubbing mechanism ..
  • Page 63 Annexe 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Figure 34: flask without flange and holes ........7–15 Figure 35: crucible without hole ............. 7-16 Figure 36: Program parameter granulating page 1 ......7-17 Figure 37: Program parameter granulating page2 ......7-17 Figure 38: adapter for flask chamber ..........

  • Page 64: Ce-Declaration Of Conformity

    Annexe 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 10.2 CE-Declaration of conformity Manufacturer: INDUTHERM Erwärmungsanlagen GmbH Brettener Str. 32, 75045 Walzbachtal Product type: Vacuum-pressure-casting-machine Machine type: VC680V Serial number: 18230 or higher Authorized to sign: Peter Hofmann...
  • Page 65 Annexe 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine EN ISO 13850:2006 Safety of machinery Emergency stop function – Principles of design EN ISO 13857:2008 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs...

  • Page 66: Test Result Chart

    Annexe 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 10.3 Test result chart 3/15/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 66 of 71...

  • Page 67: Connection Diagrams

    Annexe 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 10.4 Connection diagrams Figure 48: connection diagram – power part 3/15/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 67 of 71...
  • Page 68 Annexe 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Figure 49: connection diagram – control 3/15/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 68 of 71...
  • Page 69 Annexe 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine Figure 50: connection diagram – temperature sensor, digital I/O 3/15/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 69 of 71...

  • Page 70: Assembly Drawing Vc680V

    Annexe 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 10.5 Assembly drawing VC680V Figure 51: Assembly drawing with wall measurement VC680V C081 Attention: The numbers like C008 are placeholder for the posi- tion in the machine. The article number to order this piece is 8 digits and listed in your machine specific...

  • Page 71: Consumable And Spare Parts List

    Annexe 78-4100 Indutherm VC 680V - Fully Automatic Vacuum Gold Casting Machine 10.6 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.

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