DENTAURUM Compact Megaplus User manual

Instructions for use
REF 090-620-00
EN

2
Contents
1. Declaration of Conformity ..................................................................................................................17
2. Machine description ..................................................................................................................... 18–19
3. Safety instructions ..............................................................................................................................20
3.1. Correct use ............................................................................................................................................20
3.2. Hazard warning symbols ........................................................................................................................20
3.3. Warranty and liability .............................................................................................................................20
3.4. Owner responsibility ..............................................................................................................................20
3.5. Personnel responsibility ..........................................................................................................................21
3.6. General advice on operating safety ........................................................................................................21
3.7. Significant dangers ................................................................................................................................21
3.8. Disposal .................................................................................................................................................21
3.9. Delivery .................................................................................................................................................22
4. Description of the induction casting machine megapuls compact ..............................................22
4.1. Function ................................................................................................................................................22
4.2. Unit construction ...................................................................................................................................22
5. Installation ..........................................................................................................................................23
5.1. Positioning the machine .........................................................................................................................23
5.2. Preparations in advance for water installation ........................................................................................23
5.3. Preparations in advance for electro installation .......................................................................................23
6. Operation and use ..............................................................................................................................23
6.1. Inserting the casting ring and adjusting and balancing the casting arm ..................................................23
6.2. Starting the melting process ..................................................................................................................24
6.3. Starting the casting process ...................................................................................................................25
6.4. Opening the casting machine lid and removing the casting ring .............................................................25
6.5. Switching the machine off .....................................................................................................................25
6.6. Using the „Stop“ button .......................................................................................................................25
7. Cleaning and maintenance ................................................................................................................25
7.1. Cleaning the water supply inlet ..............................................................................................................25
7.2. Cleaning the machine ............................................................................................................................26
7.3. Handling the melting crucible ................................................................................................................26
8. Correcting faults .................................................................................................................................27
9. Spare parts ..........................................................................................................................................28
10. Functional diagram .............................................................................................................................28
11. Technical data ......................................................................................................................................29

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1. Declaration of Conformity
EC-Declaration of Conformity
DENTAURUM GmbH & Co. KG
Turnstr. 31
75228 Ispringen
hereby declares that the design and construction of the laboratory equipment described
below, including the version marketed by us, comply with the basic regulations governing
safety and health as stated in the EC Guidelines. This declaration will become invalid if the
laboratory equipment is modified or altered in any way without our prior consent.
Description of unit: Megapuls Compact
REF 090-620-00
Type of unit: Induction Casting Machine
Start with Unit No.: 140-002 051
EC guidelines: 98/37/EC Guideline for machine
Applied unified standards: EN 746-T1/T3
EN 60204
EN 60519-1
EN 292-1
EN 292-2
Applied national standards
and technical specifications
Date and manufacturers signature: 01.01.2010 -----------------------------------------
Signatory: - i.V. Dipl. Ing. (FH) K. Merkle -
Production Manager Mechanic
Printing Date: 14.10.15

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1 Automatic circuit breaker 2x16 A
2 Mains connection socket 230V for water table
3 Mains connection 230 V 50/60 Hz
Fig. 1: Back of machine with connections
Fig. 2: View from above 8 Power display
10 Alloy selection switch
12 "START" button
14 "CASTING" switch
9 Melting display "HEATING"
11 "READY / ERROR" display
13 Potentiometer for heating
15 Locking indicator
Fig. 3: control panel
2. Machine description
7 Mains switch
4 Protective glass
5 Control panel
6 „STOP“ button

54
Fig. 5: The water filter is fitted at the fresh water inlet
16 Balancing weights
19 Tightening lever for casting ring
21 Insert for casting ring
17 Star-shaped nut to lock the
casting arm
18 Induction coil
20 Insert for melting crucible
Fig. 4: Casting chamber with centrifugal arm

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3. Safety instructions
Caution Read through the instructions for installing and operating the unit carefully before
switching it on.
3.1. Correct use
The induction casting machine megapuls compact is designed solely for use in dental laboratories for
melting all conventional dental metal alloys, excluding titanium and titanium alloys, and then casting by means of
centrifugal force. Any other use or related improvisation of the machine is regarded as misuse. The company
Dentaurum, GmbH & Co. KG is not liable for damage resulting from misuse.
Correct operation also includes following these instructions for use carefully and making sure machine inspection
and maintenance is carried out on a regular basis.
When a Dentaurum product is finally no longer in use the disposal regulations of that particular country apply.
Dentaurum or the dental trade is available to answer questions regarding the correct disposal of any specific
product.
3.2. Hazard warning symbols
In the instructions for use, the following warning symbols were used:
Warning Suggests possible danger to life or health of persons.
Ignoring this warning may result in serious harm to health or even fatal injury.
Caution Suggests a possibly dangerous situation.
Ignoring this warning may result in slight personal injury or damage to equipment .
iNote General information regarding the machine.
3.3. Warranty and liability
Our general terms for sale and delivery apply. Warranty and liability to persons or machinery is not applicable when
attributable to one or more of the following points:
• Incorrect operation, use, assembly and maintenance of the machine
• Misuse of the machine
• Operation of the machine despite defect safety fixtures or incorrectly fitted or faulty safety and protective
precautionary measures
• Failure to follow the advice in the instructions for use regarding transport, storage, assembly, operation and
maintenance of the machine
• Failure to monitor working parts
• Personally conducted alterations to the build of the machine
• Unauthorized repairs.
3.4. Owner responsibility
The owner may only permit those persons to use the machine who
• Have been trained to use the machine and are familiar with the safety precautions
• Have read and understood the safety advice and instructions for use
• Have been instructed in the relevant accident prevention precautions.

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3.5. Personnel responsibility
Before use, all persons wishing to operate the machine are obliged to
• Abide by the standard instructions regarding working safety
• Read and understand the safety precautions and instructions for use and sign in confirmation.
3.6. General advice on operating safety
• Do not make any alterations to the machine.
• Only use the machine if it is in perfect working order.
• Keep your workplace clean. An untidy workplace can increase the possibility of accidents.
• Do not place your hand into the machine whilst it is in motion. Wait until the casting arm has stopped moving
before opening the lid. The casting chamber cannot be opened during the casting process.
• For your own safety use only materials and accessories which are recommended in the instructions for use.
The use of other materials can increase the possibility of injury for the operator and is regarded as misuse.
• Always make sure the machine is switched off and the mains plug has been pulled out before maintenance.
3.7. Significant dangers
Warning The machine functions using high frequency electromagnetic waves! The machine
must not be operated by persons wearing a pacemaker.
Warning There is a danger of burning if the melting crucible and the casting ring is touched.
Always remove the hot casting ring after casting using appropriate tongs!
Warning
Danger of Fire! Never leave any flammable objects in the melting and casting chamber.
Warning Always look through protective glass to observe the molten material.
Warning Only the metals named in section 3.1 may be melted. Light metals such as
aluminium, magnesium and titanium in particular can lead to dangerous situations
during melting and casting.
3.8. Disposal
iNote This symbol indicates that products marked with it should not be disposed of together with
household garbage. The legislator disallows commercial customers to return electronic waste
via municipial collection points. Further information is available through Dentaurum or the den-
tal trade.

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3.9. Delivery
1 High frequency casting machine megapuls compact - 230 V REF 090-620-00
1 Instructions for use with declaration of conformity
1.5 m Fabric reinforced fresh water hose with connection piece 3/4´´, inner diameter 8 mm
1.5 m Water outlet hose inner diameter 8 mm
2 Crucibles
1 Mains cable
4. Description of the induction casting machine megapuls compact
4.1. Function
The megapuls compact is an easy to operate induction casting machine in a compact and space saving construc-
tion, which can be used to melt all dental alloys (exception: titanium and titanium alloys) and subsequently cast
into a casting ring. It is equipped with manual operation and gradual heating adjustment and can be
used universally. The machine functions using an energy transmission principle, a transformer, creating the
so-called induction heating method. When the high frequency magnetic field is switched on, a secondary electrical
current flows through the metal by means of induction. This converts into heat and causes the metal to melt.
The eddy current created within the molten metal causes the molten mass to become thoroughly mixed.
The subsequent centrifugal force which casts the molten material into the form also helps with
homogenisation.
The megapuls compact‘s outstanding characteristics are:
• High melting power with low energy consumption
• Homogeneous melting and casting method
• Low material wastage
• Extra work is reduced
• Easy to operate
• Space saving construction
• Friendly service.
4.2. Unit construction
The high frequency generator, which is surrounded by steel sheet housing, is the heart of the machine and
complies with electromagnetic compatibility requirements. The HF generator produces an electromagnetic field
and heats and mixes the molten metal to create a homogeneous molten mass. The induction coil (Fig. 4, Pos. 18)
is cooled by water which prevents it from overheating.
• The melting crucible and casting ring can both be placed into the casting arm (Fig. 4) within the melting and
casting chamber. The casting arm is equipped with weights to maintain a well-balanced and smooth run.
• The heating element, the induction coil (Fig. 4, Pos. 18), is situated in the base of the chamber and can be raised
into position by pressing the „START“ button (Fig. 3, Pos. 12) after having adjusted the casting arm.
• The melting process is started by closing the lid and can be observed through the protective glass integrated
within the lid (Fig. 2, Pos. 4).
• The melting process is completed by pressing the „CASTING“ button (Fig. 3, Pos. 14).

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5. Installation
5.1. Positioning the machine
The chosen area must have a solid base. The machine must be positioned onto a stable and level table. The
location must be clean and if possible free from dust.
Caution Leave at least 20 cm distance between the casting machine and other objects. This will
ensure sufficient air circulation.
Furnaces or other machines which generate heat should not be located directly next
to the casting machine.
5.2. Preparations in advance for water installation
The water supply pipe which runs from the stopcock (Fig. 5) to the spout at the back of the machine must be
made from a fabric reinforced, fresh water pressure hose with a 3/4“ connection thread at each end. The water
outlet pipe, which runs from the hose nipple (Fig. 5) at the back of the machine to the siphon or allows the water
to run directly into the domestic sewer, must be a hose with a diameter of 8 mm. The water should be able to drain
away without resistance
Caution Before connecting, please check the water pressure in the water supply network. It
should be a minimum of 3 bar up to a maximum of 8 bar even during summer. If the
water pressure is too low, a cool water circulation unit must be set up. If the water
pressure exceeds 8 bar, a pressure reducing valve must be added to the water supply
pipe.
Caution If the water supply network is known to carry sediment or pollution then it is neces-
sary to fit a filter in order to avoid a water guard dysfunction.
5.3. Preparations in advance for electro installation
The machine must be connected to a 230 V mains supply, the plug socket must contain a 16 A K fuse or a 16 A
slow-blow fuse.
Caution Any maintenance work at the plug socket or mains supply may only be carried out by
an electrician.
6. Operation and use
6.1. Inserting the casting ring and adjusting and balancing the casting arm
Once the machine has been successfully installed, operation can be started. Before each casting, the casting arm
which holds the melting crucible and casting ring must be brought into a balanced position.
iNote It is advisable to adjust the balancing weights before the wax has completely burned out in
order to prevent the casting ring from cooling too much.
• First, open the tap to the cold water supply.
• Switch the machine on at the mains switch (Fig. 2, Pos. 7)
• Once the water is circulating properly, the „READY / ERROR“display (Fig. 3, Pos. 8) will light up green.
• Place the melting crucible with the metal to be cast into the crucible insert (Fig. 4, Pos. 20) within the casting
arm. Always preheat the melting crucible in the furnace without metal first!
• Place the preheated casting ring into the casting ring insert (Fig. 4, Pos. 21) and secure using the tightening lever
(Fig. 4, Pos. 19).

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• The casting ring arm should then be balanced out with the weights. Loosen the star-shaped nut (Fig. 4,
Pos. 17) and by turning the balancing weights (Fig. 4, Pos. 16) on the spindle, balance out the casting arm.
Re-tighten the star-shaped nut and remove the casting ring. This adjustment is usually carried out before the
actual melting process has begun.
Caution The star-shaped nut must be securely tightened! Otherwise the casting arm or
machine itself may become damaged during the casting procedure.
6.2 Starting the melting process
Once the casting arm has been correctly balanced and the wax pattern in the casting ring has been entirely
burned out, the actual melting procedure may begin.
iNote The hot casting ring can either be placed into the casting chamber directly before the melting
procedure is started or after the metal in the crucible has been melted (pre-heating function).
This prevents the casting ring from cooling down too much. It is advisable to pre-heat the alloy
if larger amounts of metal are to be melted.
iNote When melting gold-colored precious alloys, use a ceramic crucible with a graphite insert. When
melting silver-colored precious alloys, use only the ceramic crucible. This also applies to
palladium base alloys. Vitrify the crucible with melting powder prior to use.
iNote The potentiometer „HEATING“ (Fig. 3, Pos. 13), for the heat rate and the duration of the pre-
heating function must be adjusted individually for each type and amount of metal alloy so that
the melting does not occur entirely to 100% during pre-heating.
• Turn the potentiometer „HEATING“ (Fig. 3, Pos. 13) to choose the melting degree required. Select the power so
that, depending on which metal alloy is to be melted, the process takes less than one minute but more than 30
seconds. If there is a large amount of metal to be melted, then the process may take longer than
60 seconds. If a graphite crucible is in use within the ceramic crucible, reduce the heating power considerably so
that the graphite crucible may heat up slowly and therefore melt the precious metal gently.
• Select the spinning duration with the alloy selection switch „GOLD/OTHER ALLOYS“(Fig. 3, Pos. 10). When
„GOLD“ is selected, the spinning time increases. When „OTHER ALLOYS“is selected, the machine runs at maxi-
mum acceleration strength and the spinning time is reduced.
• Position the casting arm over the induction coil until an acoustic signal can be heard.
• Press the „START“ button (Fig 3, Pos. 12) to raise the induction coil.
• Close the casting chamber lid, the melting process begins and the melting display „HEATING“ (Fig. 3, Pos. 9)
lights up.
• Observe the melting metal by looking through the protective glass. When the metal is almost completely
molten, the casting ring can be inserted.
• Place the hot casting ring into the insert (Fig. 4, Pos. 21) using suitable tongs and clamp securely.
• Once the lid is closed, the melting process continues immediately. It is possible to turn the potentiometer for
heating (Fig. 3, Pos. 13) up or down during the melting process to correct the efficiency.
iNote The melting process can be stopped by pressing the red „STOP“ button (Fig. 2, Pos. 6) (see also
chapter 6.6).
Caution Fire Hazard! Very high temperatures can be reached during the melting process in the
casting chamber.

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6.3. Starting the casting process
When the metal is completely molten, press the casting switch „CASTING“ (Fig. 3, Pos. 14). The electric motor
accelerates the casting arm. The centrifugal force causes the molten metal to flow into the hot casting ring.
6.4. Opening the casting machine lid and removing the casting ring
Once the casting arm has completely stopped rotating, the lid may be opened and the casting ring removed.
Caution Risk of burns during removal of hot casting ring! The casting ring and crucible must
only be removed using suitable tongs and additional protective gloves.
Caution Do not forcefully open the lid! The casting chamber lid is locked during the casting
process and as long as the casting arm is still in motion.
6.5. Switching the machine off
To switch the machine off, close the casting chamber lid and turn off at the mains switch (Fig. 2, Pos. 7).
iNote Do not switch the machine off to cool down between casting procedures. It may only be
switched off at the mains switch after the last casting has taken place.
iNote The machine itself automatically turns the water supply off. There is no need to turn the tap off
manually after every casting, however if the machine stands for a longer period of time e. g.
over the weekend, then the main tap must be closed.
6.6. Using the „STOP“ button
During correct operation it is not necessary to use the „STOP“ button (Fig. 2, Pos. 6). It is only used when the
working procedure is faulty due to a malfunction or disorder.
The „STOP“ button (Fig. 2, Pos. 6) causes the current working procedure e.g. melting the metal, to be cancelled
immediately and the induction coil to descend.
7. Cleaning and maintenance
Warning Always switch the machine off and remove the plug from the mains supply during any
servicing or maintenance work. When service or maintenance work is carried out,
always ensure a second person with electrical knowledge is nearby. Many repairs may
only be carried out by authorized personnel or by the Dentaurum Service Team.
7.1. Cleaning the water supply inlet
Every 6 months the water filter in the fresh water inlet (Fig. 5) must be cleaned:
• Whilst the machine is still on, close the water stopcock in the laboratory. This way the circulating water within
the machine is no longer under pressure.
• Then switch the machine off and remove the plug from the mains supply.
• After the water supply has been closed and the machine has been switched off, unscrew the fresh water
pressure hose from the machine (Fig. 5).
• Close to the machine, within the fresh water connection is a fine filter which can be removed using tweezers
(Fig. 5). Clean the fine filter under running tap water with the aid of a brush or in an ultrasonic unit.
• Replace the cleaned fine filter back into the opening in the fresh water connection and screw the fresh water
pressure hose back on. Make sure the seal between the fresh water connection and the connecting piece of the
hose is in place.
• Always check if the connection is tight before switching the machine back on and opening the water
stopcock again.

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7.2. Cleaning the machine
Wipe over the machine every now and then with a damp cloth. Do not use any strong detergents or tools for
cleaning. Remove any casting residues or deposits from the casting arm immediately after casting and check for
good mobility. Regularly remove deposits from the casting chamber. Always ensure meticulously that no metal
pieces land in the coil rails.
7.3. Handling the melting crucible
In order to achieve excellent casting results, please observe the following points:
• Store the crucible (REF 090-611-00) in a dry and dust-free environment where it cannot be knocked.
• Check the crucible after every casting for possible damage or wear. Crucibles which are cracked or damaged may
no longer be used.
• Carefully remove residues from the crucible. Remove large pieces of residue using tweezers and then blow clean
with compressed air.
• Mark each crucible on the outside using a graphite pencil in order to indicate which alloy has been melted
inside.
iNote Use one crucible for each different alloy.
• It is the crucible material characteristics which forces the ceramic industry to work with large discrepancies. For
this reason it may occur that the crucible gets stuck in the clamp. It is possible to make it fit by filing the crucible.
Due to the delivery conditions of the ceramic industry it is not possible to determine an average lifespan or
guarantee against damages to the ceramic crucibles during transport.
The following crucibles are suitable for the induction casting machine megapuls compact:
Ceramic crucible 10 pieces REF 090-611-00
Graphite insert 10 pieces REF 090-615-00

1312
8. Correcting faults
The casting machine is equipped with an error warning system. The following errors can be the cause of a fault:
Error Reason Correction
"READY/ERROR" display
(Fig. 3, Pos. 11) lights up
red
The water circulation has been stopped,
flow guard is possibly defect,
water pressure too low
Machine is overheated due to poor
air circulation
Machine is overheated due to too
many castings
Check water circulation
Replace flow guard
Check water pressure
Leave a space of 20 cm between the casting
machine and the next piece of equipment
or wall
Integrated thermo protection device
interrupts the melting function for 5 min
A maximum of 15 castings may be
undertaken in succession
With the water circulation unit switched on
max. 7 castings then 10 min rest!
No LED lights up after
switching on.
Automatic circuit breaker at the back of the
machine is switched off
Mains supply is off
Mains switch is defect
Switch the automatic circuit breaker on
Check mains supply
Replace mains switch
No LED lights up after
switching on.
Mains adapter fuse defect
Mains adapter defect
Check the fuses and replace them if
necessary
Mains adapter must be replaced
(call customer service)
The induction coil cannot
be raised
The casting arm has not been correctly
positioned
The position of the casting arm has not been
recognised by the integrated light barrier
The motor or fuse for the lift mechanism is
defect
START" button is defect
Switch for the lower end position is defect
Bring the casting arm into position
(Confirmation with acoustic "peep" signal)
Light barrier defect (call customer service)
Motor must be replaced
(call customer service)
"START" button must be replaced
(call customer service)
Switch for the lower end position must
be replaced (call customer service)
The melting procedure has
taken place but when the
"CASTING" button is
pressed, nothing happens
The control system is defect
The induction coil has not been completely
lowered
The induction coil is mechanically blocked
Casting motor is defect
Switch for the upper end position is defect
Electric control must be replaced
(call customer service)
Check the fuses and change if necessary,
the motor for the lift mechanism is defect
(call customer service)
Clean the induction coil rails
Motor must be replaced
(call customer service)
Switch for the upper end position must
be replaced (call customer service)
If you are not able to correct the fault using this table, please call your relevant service technician or call Dentaurum
Technical Service – Machines directly.
Phone: + 497231 / 803 - 211 I
[email protected]

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9. Spare parts
Ceramic crucible 10 pieces REF 090-611-00
Graphite insert 10 pieces REF 090-615-00
Protective glass 1 piece REF 908-271-00
10. Functional diagram

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11. Technical data
Mains voltage 230 V
Mains frequency 50/60 HZ
Max. power consumption 2.4 kW
Average power consumption 1.5 kW
Starting torque 0...21 Nm
Min. melting quantity 15 g precious alloy, 15 g CoCr, NiCr, Pd
Max. melting quantity 100 g precious metal, 70 g CoCr, NiCr, Pd
Max. power output 2.2 kW
Cooling water flow 1 l/min
Ambient air temperature for operation 15...40 °C/59…104 °F
Storage temperature 5...40 °C/41…104 °F
Max. relative ambient humidity 70 %
Measurements [width x height x depth] 560 x 425 x 630 mm
Weight 55 kg

Turnstr. 31 I 75228 Ispringen I Germany I Phone + 49 72 31 / 803 - 0 I Fax + 49 72 31 / 803 - 295
www.dentaurum.com I [email protected]
989-898-02 Printed by Dentaurum Germany 09/19/C/R1-8
DENTAURUM
QUALITY
WORLDWIDE
UNIQUE
For more information on our products and services, please visit www.dentaurum.com
Date of information: 09/19
Subject to modifications
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