Heraeus Heracast iQ User manual

Heracast®iQ
Operating instructions
Casting Machine Heracast®iQ
Dateiname: W14040_66036086_02_BA Heracast iQ_GB_V01_X4
SAP-Nr: Version
66036086 GB-02 HK-Toolbox-Nr: W14040 Format: Falzmaß: 420 x 280 mm 210 x 280 mm
Projektmanager:
Michael Helken HKG-Version: V01, 0.AK Datum HKG Freigabe 27.08.2015
HKG-Layout W14040_66036086/02 BA
Heracast_iQ_GB
EURO / Pantone Sonderfarben Druckverfahren: Digitaldruck
C M Y K varnish DieCut var.Data

3
1 Scope of applicability .................................................................................................................................... 5
1.1 General ............................................................................................................................................................. 5
1.2 Designation and type of machine ......................................................................................................................... 5
1.3 EU Statement of conformity ................................................................................................................................ 5
1.4 Instructions on using the unit safely .................................................................................................................... 6
1.4.1 Explanation of Symbols ...................................................................................................................................... 6
1.5 Warning pacemakers .......................................................................................................................................... 6
1.6 Transport damage .............................................................................................................................................. 6
1.7 Operator‘s obligations ......................................................................................................................................... 6
1.8 Unit book .......................................................................................................................................................... 7
1.9 Safety information ............................................................................................................................................. 7
2 Useinaccordancewithspecications ............................................................................................................. 8
2.1 Working rules .................................................................................................................................................... 9
3 Description (of the unit) ................................................................................................................................. 9
3.1 Features ........................................................................................................................................................... 9
4 Scope of delivery / original equipment ............................................................................................................. 9
4.1 Scope of delivery ............................................................................................................................................... 9
4.2 Original equipment .......................................................................................................................................... 10
5 Structure and function ................................................................................................................................ 10
5.1 Control and display elements ............................................................................................................................ 10
5.1.1 Description “Total view Heracast iQ” ................................................................................................................. 10
5.1.2 Description “Interface” .................................................................................................................................... 11
5.1.3 Description “Supply connections” ..................................................................................................................... 11
5.1.4 Description “Front panel with control keys and display” ....................................................................................... 12
5.1.5 Description “Partial view open chamber” ........................................................................................................... 13
6 Location and installation .............................................................................................................................. 13
6.1 Transport ........................................................................................................................................................ 13
6.2 Unpacking ...................................................................................................................................................... 13
6.3 Set-up ............................................................................................................................................................ 14
6.4 Mains connection ............................................................................................................................................ 14
6.5 Compressed air supply ..................................................................................................................................... 15
6.6 Filling the cooling system ................................................................................................................................. 15
6.7 Room ventilation ............................................................................................................................................. 15
7 Operations .................................................................................................................................................. 16
7.1 Putting into operation ...................................................................................................................................... 16
7.2 Putting out of operation .................................................................................................................................... 16
7.3 Errors and causes ............................................................................................................................................ 17
8 Working with the Heracast iQ ....................................................................................................................... 19
8.1 Setup main menu – casting (diagram) ................................................................................................................ 19
8.2 Description main menu – casting (diagram) ........................................................................................................ 19
8.3 Setup menu (diagram) ...................................................................................................................................... 20
8.3.1 Description Table 1. “Setup” ............................................................................................................................ 20
8.4 Service menu (diagram) .................................................................................................................................... 21
8.5 Description Service menu (diagram) .................................................................................................................. 21
8.5.1 Description Table 2. “Service” .......................................................................................................................... 22
9 Melting and casting ..................................................................................................................................... 23
9.1 General ........................................................................................................................................................... 23
9.2 Heraeus spruing system .................................................................................................................................... 23
9.3 Suitable investment materials ........................................................................................................................... 23
9.4 Premelting ...................................................................................................................................................... 23
Table of Contents

4
9.5 Casting ........................................................................................................................................................... 24
9.5.1 Graphite insert ................................................................................................................................................ 24
9.5.2 Ceramic crucible ............................................................................................................................................. 24
10 Alloys ......................................................................................................................................................... 25
10.1 Gold casting and high gold content ceramic bonding alloys
Universal and silver-palladium alloys ................................................................................................................. 25
10.2 Reduced precious metal ceramic bonding and palladium-based alloys .................................................................. 25
10.3 CoCrMo and non-precious metal alloys ............................................................................................................... 25
10.4 Titanium and aluminium-containing alloys .......................................................................................................... 26
10.5 Description of alloy database ............................................................................................................................ 26
10.5.1 Enter new alloys .............................................................................................................................................. 27
10.5.2 Casting of alloys .............................................................................................................................................. 29
10.5.3 Deleting datasets ............................................................................................................................................. 29
11 Spruing system ........................................................................................................................................... 30
11.1 Melt characteristics of Heraenium CE and Heraenium EH .................................................................................... 30
11.1.1 Preparations .................................................................................................................................................... 30
11.1.2 Premelting (phase 1, 2, 3) ................................................................................................................................ 30
11.1.3 Insert the casting mould ................................................................................................................................... 30
11.1.4 Main melt ....................................................................................................................................................... 30
11.2 Melt characteristics of Heraenium alloys ............................................................................................................ 31
12 Maintenance ............................................................................................................................................... 32
12.1 Maintenance and care ...................................................................................................................................... 32
12.1.1 – daily ............................................................................................................................................................ 32
12.1.2 – weekly (or after 100 castings) ........................................................................................................................ 32
12.1.3 – annually (or after 3.000 castings) ................................................................................................................... 32
12.1.4 – after 30.000 casting or after 3 years ............................................................................................................... 33
12.2 Tests .............................................................................................................................................................. 33
12.3 Maintenance ................................................................................................................................................... 33
12.4 Disposal .......................................................................................................................................................... 33
12.4.1 Disposal of old equipment according to WEEE .................................................................................................... 33
13 Repair / Maintenance work ........................................................................................................................... 34
13.1 Exchanging the pump oil .................................................................................................................................. 34
13.2 Exchangingthepumplter............................................................................................................................... 35
13.3 Exchangingthelterinthevalvebox................................................................................................................. 35
14 Exchanging the cooling water ....................................................................................................................... 35
15 Technical data ............................................................................................................................................ 36
15.1 Rating plate .................................................................................................................................................... 36
16 Circuit diagrams .......................................................................................................................................... 37
16.1 Compressed air ................................................................................................................................................ 37
16.2 Water circulation ............................................................................................................................................. 37
16.3 Terminal assignment ........................................................................................................................................ 38
17 Alloys ......................................................................................................................................................... 39
18 Control information Heracast iQ .................................................................................................................... 40
19 Service ....................................................................................................................................................... 41
19.1 Service agents / Contact in the countries ............................................................................................................ 41
20 Document history ........................................................................................................................................ 42
Table of Contents

Operating instructions
Casting Machine Heracast®iQ
5
1 Scope of applicability
1.1 General
Combilabor®is a registered trademark of Heraeus Kulzer GmbH.
Author 42415SCH
These working instructions apply to:
Order No. Type Features Date
66004331 Heracast iQ integrated water cooling and vacuum pump 2015-08 / 66036086/02
1.2 Designation and type of machine
Designation of the machine: Type of machine: Serial number.:
Induction casting machine Heracast iQ Heracast iQ from 2093
1.3 EU Statement of conformity
Herewith we, Heraeus Kulzer GmbH,
Grüner Weg 11, 63450 Hanau (Germany),
conrmthatthefollowingunitduetoits
intended use and the version marketed by us
corresponds to the relevant basic safety and
health requirements of the EC guideline.
This statement will become invalid in case
ofanymodicationoftheunitthatisnot
co-ordinated with us.

6
1.4 Instructions on using the unit safely
1.4.1 Explanation of Symbols
Symbol Accompanying word(s) Explanation
CAUTION! Safety-relevant chapters and sections in these working instructions
have been marked with this symbol.
NOTE! Information within the working instructions
on the optimum use of the unit.
HOT SURFACE! Hot surface risk of getting burned.
HIGH FREQUENCY! Caution high frequency.
Not to be used by persons with pacemakers.
WARNING! Warning:
Caution High frequency.
CHANGE! Important:
Changes have been made to this paragraph.
Please read carefully.
CERTIFICATE Registrationcerticateaccordingtotheministryofhealth
of the Russian federation.
1.5 Warning pacemakers
WARNING!
Not to be used by persons with pacemakers Read working instructions prior to use! We cannot accept any
guarantee claims or assume liability if the machine is used for other purposes as stated or for damage
resulting from non-compliance with these working instructions!
1.6 Transport damage
Please check the unit for transport damage and, if necessary, report the damage to the forwarder within 24 hours after receiving
the unit. Under no circumstances, work with a damaged machine.
1.7 Operator‘s obligations
Inadditiontocomplyingwiththestatutoryregulationsspeciedbythemanufacturer,theoperatormustensurethestatutory
obligations are observed and implemented in the workplace, i.e. he must train his personnel and comply with industrial safety
legislation and any other regulations or laws in force.

Operating instructions
Casting Machine Heracast®iQ
7
For working on and with the machine, the operator must draw up written instructions in understandable form and give these
to his employees in their own language. These instructions must be based on the operating manual and written in light of the
work to be performed.
1.8 Unit book
Werecommendyoukeepaunitbook.Alltestsaswellasallessentialworks(e.g.repairwork,modications)mustbe
documented in this book.
1.9 Safety information
With these laboratory units the safety concerning the protection of persons, the environment and the material to be processed
mainly depends on the behaviour of the persons operating the unit.
Prior to operation read the working instructions carefully, adhere to the information provided in order to avoid errors and
damage, in particular damage to the health.
In addition to the information in these working instructions, relevant national laws and guidelines must be observed for setting
up and operating this unit (technical connection requirements of the electrical supply companies, etc.).
HOT SURFACE!
The metal surface around the casting chamber heats up during continuous operation.
Do not touch this surface.
When casting and in particular when handling melted metal face guards, gloves and aprons must be worn.
Cleaning must always be carried out when the unit is cool.
NOTE!
Due to the waste gases released during working, adequate ventilation must be provided.
WARNING!
This symbol warns of the dangers of electric voltage. In the case of non-compliance the result of an electrical
shock with all known effects can be death. When inspecting the housing cover this safety symbol is visible
on the free surface on the operating unit. Please observe the safety instructions when carrying out servicing.
Works at the electrical equipment of the unit must only be performed by the authorised Heraeus service and
in the safe condition (voltage cleared).
CAUTION!
Power cable and plug must be checked for damage prior to operation.
If any damage exists, the unit must not be connected to the mains.
A damaged mains connecting cable may only be replaced by a mains connecting cable of the same type by the
authorised Heraeus service.
Works at the electrical equipment of the unit may only be performed by adequately trained service companies and in the safe
condition (voltage cleared).
Only permissible original spare parts must be used. The use of different parts holds unknown risks and must be avoided
at any rate.
Proper function and safety of the unit are only guaranteed if the required tests, maintenance and repair work have been
performed by Heraeus Kulzer service agents or by personnel adequately trained by the manufacturer.
Heraeus Kulzer GmbH will not accept any liability for damage to the unit resulting from inexpert repair which has not been
performed by Heraeus Kulzer service agents or if no original spare parts/accessory parts have been used during the exchange of
these parts.

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CAUTION!
It is essential that the following safety instructions are adhered to
Fully close the locking lever before the start (push into the end setting). If the closed lever is not closed
overdeadcentrethereisariskthatthelevercouldipopenifpressurised.Thegivesrisetotherisk
of impacts and the danger of hot gases or melted metal splashing out.
When casting and in particular when handling melted metal face guards, gloves and aprons must be worn.
Cleaning must always be carried out when the unit is cool. The unit must always be supervised when in
operation.
Theoretically a control error can accidentally start a rotation.
This can lead to crushing via the locking lever.
Switch off the unit when not in use!
A self test also initiates an automatic rotation cycle.
Do not work in the area of the locking lever when the unit is switched on. Always keep this closed.
Don‘t place any objects under the chamber!
2 Useinaccordancewithspecications
The induction casting machine Heracast iQ is a laboratory unit for casting all precious metal and almost all non-precious and
CoCr alloys for dental applications with a liquidus temperature of 500 °C up to > 1600 °C.
The unit is not suitable or intended for casting pure titanium or beryllium-containing alloys!
CAUTION!
Processing of beryllium-containing alloys is hazardous to health!
Casting of these alloys is performed at the user‘s risk! Heraeus Kulzer GmbH will not accept any liability
for any health damage that may have been caused by casting such alloys!
Casting of titanium- or aluminium-containing alloys is performed in special working steps.
See paragraph 10.4 “Titanium and aluminium-containing alloys”.
Precision castings with alloy quantities of up to 130 g in the graphite crucible and 100 g in the ceramic crucible are possible.
Alloy quantity for CoCrMo and non-precious metal bonding alloys in the ceramic crucible: up to 60 g.
NOTE!
We recommend the exclusive use of original Heraeus Kulzer crucibles which are especially matched with this
type of application. The use of other materials leads to the exclusion of guarantee claims in case of damage to
the unit or the molten material. In view of the various causes for faulty castings, we do not grant any guarantee
for such cases.
 Normally,theunitissuitabletobesetupandoperatedinthefollowingelds:Commercialandindustriallaboratories,
schools, universities, hospitals, etc. The unit has been designed for continuous operation.
The pressure control is technically set to 3.5 bar on the unit and by means of a safety valve set to a pressure of 3.7 bar.

Operating instructions
Casting Machine Heracast®iQ
9
2.1 Working rules
CAUTION!
Personal protective equipment such as hand, face and body protection must be worn;
jewellery must be taken off prior to working.
CAUTION!
Do not use the unit for the following activities:
The unit must not be used for melting and casting beryllium-containing alloys (hazardous to health!).
Do not use the unit for melting, drying or thermal treatment which may lead to the release of combustible
gases and vapours which burn with air or which may form a hazardous, injurious or explosive mixture.
The unit is not suitable for thermal treatment of hazardous or health-hazardous materials
(e.g.dusts,bres,liquids,solids).
The unit must not be used to heat up food.
3 Description (of the unit)
3.1 Features
Reliable and material-appropriate melting and casting under vacuum.
Temperature control via electronic power control and time.
Long lifetime of ceramic and graphite crucibles.
NOTE!
In order to avoid errors and problems during working we would like to ask you to read these working instructions
carefully and store them at a place ready to hand. Additional information on vacuum pressure casting can be
obtained upon request. Phone No. of Customer Service, see paragraph 19 „Service“
4 Scope of delivery / original equipment
Check that all components are in perfect condition on delivery of the machine.
If you wish to make a complaint, contact your supplier.
4.1 Scope of delivery
1x HeracastiQ,workinginstructions,testcerticate
1 x Filling hose with connector and container
1x Mufeholder
1 x Pressure hose 13 mm, incl. 2 hose clamps and a socket 13 mm
2 x Door signs Caution! High frequency. “Not to be used by persons with pacemakers”
HIGH FREQUENCY!
Attach the supplied adhesive pictorial symbols “Not to be used by persons with pacemakers” to all entrances
to the unit service room.

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4.2 Original equipment
1 x Small alloy spoon
1 x Box cont. small melting powder pellets
1 x Spruing aid - plexiglass half-pressing
1 pack 6 pcs ceramic crucibles for CL-IG / IM / I95 / Heracast iQ / EC
1 pack 6 pcs ceramic crucibles NPM-crucibles for CL-IG / IM / I95 / Heracast iQ / EC
1 x Crucible box CL-IG / IM / I95 / Heracast iQ / EC
1 pack 10 pcs graphite inserts for CL-IG / IM / I95 / Heracast iQ / EC
3 x each Casting ring (X3, X6, X9)
1 x each Cone former (X3, X6, X9)
5 Structure and function
5.1 Control and display elements
2
1
4
5
6
3
7
5.1.1 Description “Total view Heracast iQ”
1Front panel with control elements
2Viewing glass casting chamber
3Front limit switch chamber lock
4Locking lever – casting chamber (with carrying handle) and bow
5Viewing glass for oil level of the pump
6 Holderforspecialtoolmufelift
7Filter cover air supply

Operating instructions
Casting Machine Heracast®iQ
11
8
10
9
11
5.1.2 Description “Front panel with control keys and display”
8Display
9Adjustment knob
10 Keyboard
11 Main switch
12
5.1.3 Description “Interface”
12 Port (RS 232 is used only for servicing)

12
16
13
14
17
18
15
5.1.4 Description “Supply connections“
13 Mains connection
14 Compressed air connection
15 Graduated viewing glass for cooling water level
16 Connectiontoll/emptythecoolingwatertank
17 Fans
18 Rear limit switch

Operating instructions
Casting Machine Heracast®iQ
13
22
19
20
21
23
24
27
25
26
5.1.5 Description “Partial view open chamber”
19 Viewing glass casting chamber
20 Ceramic crucible
21 Graphite insert
22 Shielding plate
23 Mould support
24 Chamber gasket
25 Mould
26 Adjustable screw for size of mould
27 Clampingdevice,guideandsnap-inlockingdeviceforxationofthemould
6 Location and installation
6.1 Transport
Carefully transport the unit horizontally to prevent the pump oil from leaking and damaging the unit. Packings and units must
not be stacked! Shocks must be avoided! If there is a risk of frost during the transportation of the unit, all of the cooling water
must be removed from the unit. This is not to be carried out using a plastic bottle. Please notify the service technicians.
For dimensions and weight refer to paragraph 15 “Technical data”.
6.2 Unpacking
Remove straps. If required, screw in the carrying handles at the corners of the unit.

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6.3 Set-up
Please screw one of the handle on the casting chamber.
Location: Table with load bearing capacity of at least 80 kg.
Table area: (w x h x d) 100 x 50 x 60 cm.
The casting machine must be placed on a solid, skid-proof surface (laboratory desks, racks) so that a horizontal safe position
is ensured. The surrounding temperature may amount to 40 °C.
Air inlet and outlet openings in the housing of the unit (rear and lower surface) must not be covered or blocked. Minimum
distance to the wall: 100 mm.
CAUTION!
Follow the instructions below absolute
The rear side of the unit must be at least 100 mm away from the wall to avoid blocking the air outlet
of the built-in fan.
There must be no combustible materials, e.g. newspapers and similar, present near the casting machine
and in particular under the unit.
Do not lean on the chamber.
There must not be any objects within the turning range (horizontal and vertical) of the chamber.
During turning movement do not touch / operate / hold chamber and lock.
During operation – turning movement of the chamber 90° downwards!
Do not reach under the chamber with your hand or arm when the unit is switched on.
 Donotplaceammablematerialunderneaththecastingchamber.
To transport the unit, leave the carrying handle under the chamber. Do not lift the unit at the chamber!
Risk of damaging the unit!
Risk of damage and injury in case of non-adherence!
Minimum distances to adjacent areas or pieces of equipment:
Operating instructions Casting Machine - Heracast iQ
15
6.3 Set-up
Please screw one of the handle on the casting chamber.
Location: Table with load bearing capacity of at least 80 kg.
Table area : (w x h x d) 100 x 50 x 60 cm
The casting machine must be placed on a solid, skid-proof surface (laboratory desks, racks) so that a horizontal safe
position is ensured. The surrounding temperature may amount to 40 °C.
Air inlet and outlet openings in the housing of the unit (rear and lower surface) must not be covered or blocked. Minimum
distance to the wall: 100 mm
CAUTION!
Follow the instructions below absolute
■The rear side of the unit must be at least 10 cm away from the wall to avoid blocking the air outlet of the built-in fan.
■Do not place flammable material underneath the casting chamber.
■To transport the unit, leave the carrying handle under the chamber. Do not lift the unit at the chamber! Risk of
damaging the unit!
■There must not be any objects within the turning range (horizontal and vertical) of the chamber.
■During operation - turning movement of the chamber 90 ° downwards!
■During turning movement do not touch/operate/hold chamber and lock.
■Do not reach under the chamber with your hand or arm when the unit is switched on.
■There must be no combustible materials, e.g. newspapers and similar, present near the casting machine and in
particular under the unit.
■Do not lean on the chamber.
■Risk of damage and injury in case of non-adherence!
Minimum distances to adjacent areas or pieces of equipment:
Fig.: 6 Minimum distances
6.4 Mains connection
Mains: 200 – 250 V (AC), 1 P / N / PE, 50/60 Hz, according to VDE requirements and those of your local
electricity board.
Mains fuse: Separate safety fuse 16 A inert or safety cut-out fuse C 16 A.
Mains connection: The unit should not be connected via a connection fault current circuit breaker.
Iftheuseofafaultcurrentcircuitbreakerisspeciedbythelocalelectricityboard,type30mA
should be used.

Operating instructions
Casting Machine Heracast®iQ
15
6.5 Compressed air supply
NOTE!
The compressed air must be clean and dry!
Line pressure min. 4 bar, max. 7 bar! Higher line pressure (even short-term) can result in damage to the inner valves!
Toavoidthis,anoptionalpressurereducerltercombinationmustbeused.OrderNo.66005499.Thepressurereducer
includes accessories for unit mounting or wall mounting.
 Incaseofmoistcompressedairawaterseparator/ltermustbeinterconnected.OrderNo.66005499.
Line cross-section (inner) min. 10 mm.
 Rapidpressurisation(<1.5sec.)isessentialforthemouldllingbehaviour.
Non-compliance can result in faulty castings. The use of a separate compressed air tank (< 10 mm) in the direct vicinity
of the casting machine is recommended for small line cross-sections. Order No. 66008921.
NOTE!
Any guarantee claims shall be excluded in case of malfunctions or damage resulting from inadequate
compressed air supply!
6.6 Filling the cooling system
Forsafetyreasonstheinnercoolingsystemisonlyprelledwithasmallquantityofantifreezeandanticorrosionagent.
Tollthesystemcompletely,theenclosedbottlemustbeused!Forthispurposeopenthecapofthebottleandllthe
container with tap water (do not use distilled water). Connect the hose to the connection piece at the rear side of the unit.
Hold the bottle well above the unit. Press the plastic bottle slightly and shortly. Due to the difference in height the unit
willbelledautomatically;ifrequired,makeaholeinthecontainer!Waituntilthebottleisemptyandremovethehosefrom
thell-inconnectionpiece.Screwthelidoffthebottleandllthebottlewithwateragain.Connectthebottletothelling
hoseandcontinuouslycheckthellinglevelofthereservoir(pos.15paragraph5.1.4„Description“Supplyconnections”)
ontherightsideduringllingup.Ifthewaterlevelhasreachedthevalue„MAX.“,stopllingandremovethellinghose.
For this purpose activate the unlocking lever above the connection with a tool, if required.
CAUTION!
Donotlloverthe„MAX.“marking.Riskofdamaging!
Afterinitialoperation,thecoolingwaterlevelmustbecheckedagainandtheunitmustbelledupwithpuretapwater.
For maintenance work it has turned out to be helpful to reuse the empty plastic bottles to empty the cooling water tank;
please do not discard these bottles.
6.7 Room ventilation
Theroominwhichtheunitisoperatedmusthavesufcienttechnicalventilation.Theunitmustnotbeoperatedinrecesses
that can not be ventilated. If several units are to be placed in one room, special ventilation measures may be required
(e.g. zone ventilation).

16
7 Operations
The following pages are to provide basic information and hints which are essential for successful and error-free working.
Please observe the order of the working steps.
Mostly, casting errors can not be attributed to the machine.
Normal production mode
The staple is monitored for safety during closing, the closing lever must thereby be closed over dead centre. A self opening
istherewithruledout.Withapositionbeforedeadcentre,thepressurereservoircanineventofanerrornotbefullyipped
open by the pressurisation, as this is retained by a clamp.
7.1 Putting into operation
The locking lever is checked for function when it is switched on. If this request does not appear on the display or an
automatic start of the test cycle is triggered after the main switch is switched on, errors have occurred in the safety
inspection. Do not continue to operate the unit, switch it off and notify the service technicians immediately.
1. Turn on the compressed air supply for the unit
2. Main switch “On” ( I )
When the machine is switched on the request “Safety check chamber locking mechanism – Please open and close
chamber by hand!” appears after welcome display.
If the chamber was open then it must be closed.
If the chamber was closed it must be opened and then closed again.
The vacuum pump evacuates the chamber. Then the chamber is turned automatically and pressurisation is started.
Prior to turning back the chamber into the basic position, the chamber is deaerated automatically.
In case of a defect or an error, a respective message is displayed. Once the test run has been successfully completed,
the unit is ready for operation.
CAUTION!
If an error can not be eliminated, please contact the responsible service agent. The addresses can be found
on the paragraph 19 “Service” of these instructions.
Unauthorised opening of the machine include unknown risks and are not permissible.
7.2 Putting out of operation
Remove crucible and mould from the chamber.
Let the unit cool down for approx. 3 min. before switching it off (then turn off the cooling water supply).
Switch off the unit; unplug the unit if it is not to be operated for longer periods.
Remove contamination from the crucible and the chamber.

Operating instructions
Casting Machine Heracast®iQ
17
7.3 Errors and causes
If a malfunction occurs during the test run or during operation, the error is shown in the display:
Error resp. warning message Warning Error Time delay
UDC too high > 210 V > 212 V 50 ms
IDC too high > 16.5 A > 17 A 50 ms
Internal temp. too high > 50 °C > 60 °C 500 ms
Internal temp. too low < 10 °C < 5 °C 500 ms
Oscillator temp. too high > 65 °C > 70 °C 500 ms
Oscillator temp. too low < 10 °C < 5 °C 500 ms
Coolant temperature too high > 55 °C > 60 °C 500 ms
Coolant temperature too low < 10 °C < 5 °C 500 ms
PDC too large > 2050 W > 2100 W 1 s
15V supply too high > 15.90 V > 15.99 V 1 s
15V supply too low < 13.50 V < 13.00 V 1 s
Deviation of set-actual power If – after 3 s – deviation > 5 %
conditions:
• if graphite crucible
• if chamber in basic position
If – after 3 s – deviation > 5 %
conditions:
• if graphite crucible
• if chamber in basic position
• if in self-test
3 s
Vacuum is not reached Vacuum > 500 mbar after 15 s Vacuum > 500 mbar after 25 s
or if in “automatic test mode”
vacuum > 50 mbar after 45 s
Various time windows
Check compressed air Additional message with
vacuum error
Additional message with
vacuum error
Pressure too high If pressure > 3.5 bar after 4 s
and after completing the
pressure startup phase
If pressure > 3.7 bar after 4 s
and after completing the
pressure start-up phase
4 s
Pressure too low If pressure < 2.9 bar after 4 s
and after completing the
pressure startup phase
If pressure < 2.7 bar after 4 s
and after completing the
pressure start-up phase
4 s
Chamber movement Chamber has not reached target
position after 4 s (difference
more than 15 digits from the
set end pos.)
4 s
Chamber open Chamber open (caused by limit
switch), displayed only under
following conditions:
• vacuum or
• pressure or
• chamber movement
Check of crucible For graphite crucible only:
if after 3 s UDC > 180 V
(graphite crucible weight < 7 g)
3 s
Pressure build-up too slow Pressure < 2.9 bar after 4 s 4 s
Error while reading the EEPROM EEPROM does not respond
EEPROM checksum error CRC checksum error while
reading the EEPROM
EEPROM data error Incorrect data while reading the
EEPROM
Error ADC If no reply of A/D converter for
more than 20 ms
20 ms
Errormemoryoverow More warnings available than
can be displayed
More errors available than can
be displayed

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Error resp. warning message Warning Error Time delay
Monitoring (control) of energy Automatic deactivation after
300000 Ws = 300 kWs
(e.g. 2 KW *2:30 min)
Calculated by formula
Check pressure sensor If during self test or in auto-
matic test mode, an ambient
pressure of < 700 mbar or
> 1200 mbar is measured
Self-test not successful If changeover to casting menu
is intended and self-test is not
successful
Memory test Error while checking the
program memory
Chamber position If chamber position exceeds
permissible adjustment range
(+/– 15 digits)
Watchdog Unauthorised abortion of
program
Waterow Conditions:
• error continues > 4 s
• level 0, no monitoring
• level 1, if flow < 200 ml
• level 2, if flow < 450 ml
• level 3, if flow < 600 ml
4 s
Pressure release too slow If air-pressure inside chamber
> 0.2 bar 4 s after pressure
release
4 s
Leakage If at pre-set vacuum level at
least 30 mbar drop within 5 s
or during pressurisation at least
0.3 bar drop within 5 seconds
5 s
Non-symmetric start of power supply
units
Output difference (voltage):
power supply 1 / 2 > 10 V
2.5 s
No start of power supply unit Output UDC 1 < 10 V (e.g. 0V)
and UDC2 > 20 V (e.g. 100 V)
or converse
2.5 s

Operating instructions
Casting Machine Heracast®iQ
19
8 Working with the Heracast iQ
After switching on and successful completion of the Auto-Test, the user is automatically directed to the main menu.
In this menu additional options are available For alloy entry see paragraph 10.5 “Description of alloy database” to
paragraph 10.5.3 “Deleting datasets”.
8.1 Setup main menu – casting (diagram)
Operating instructions Casting Machine - Heracast iQ
20
8 Working with the Heracast iQ
After switching on and successful completion of the Auto-Test, the user is automatically directed to the main menu. In this
menu additional options are available For alloy entry see paragraph 10.5 "Description of alloy database" page 28 to
paragraph 10.5.3 "Deleting datasets" page 31
8.1 Setup main menu - casting (diagram)
Fig.: 7 Setup main menu
Gold casting alloy High-gold content
bonding alloy PD-based alloys
Gold-Pd-alloys NPM/CoCrMo alloys
Casting
Casting
Graphite Ceramic
Casting menu
Main melt
automatic Premelt Main melt
Turning
manual
Turning
automatic
Main melt
manual
Turning
manual
Premelt
Quit
Back to parameter setting
Casting menuStop Stop
Enter liquidus
temperature
Quality
Enter
delay time
Gold casting and
universal alloys High gold content bonding alloys Pd-based alloys and Gold-Pd alloys NPM / CoCrMo alloys
8.2 Description main menu – casting (diagram)
The crucibles “graphite” or “ceramic” can be selected with the adjustment knob. For this purpose turn the knob to the left
or the right until the marking “*” marks the desired value.
Conrmyourselectionbyslightlypressingtheadjustmentknob(actionpoint).
Proceed identically in the menu „Enter quantity/liquidus temperature“. The values can be increased or lowered by turning
theadjustmentknobtotheleftorright.Thevaluesarealsoconrmedherebypressing.
All pre-set data are displayed in the “Casting menu”. To adjust a different vacuum value, also turn the knob to the left or the
right (without pressing).
Start the premelt now by pressing the key under the menu item “VS”. Press “Stop”keyafternishingthepremelt.

20
The main melt can always be carried out automatically or manually.
– Automatic main melt / automatic turning chamber is motor-driven turned (after a given or calculated delay time).
– Manual main melt / manual turning chamber is turned motor-driven (decision of the operator).
Thedecisionforautomaticormanualoperationmodedependsonvariousfactorsandisnallymadebytheoperatordepending
on the alloy that is used.
8.3 Setup menu (diagram)
Table 1. Setup
Language Temperature Weight Vacuum Contrast Currant signal Port
German °C g mbar xx % ON OFF Modemcong.
English °F Dwt mmHg ON OFF Modemcong.
French in Hg
Spanish
Italian
U.S.A.
8.3.1 Description Table 1. “Setup”
ThesettingsintheSetupmenuallowindividualcongurationoftheusersurfacewithcountry-anduser-specicconditions
and are mainly performed using the adjustment knob.
The individual menus can be selected one after the other by turning the adjustment knob. The current menu item is marked
by “*”. To select the options of a menu item, the adjustment knob must be pressed slightly.
Values can now be adjusted according to your wishes. If you want to end the settings of a menu item, press the adjustment
knob again. By turning the adjustment knob to the left or right, you can select another menu item.
The Setup menu can be quit in two ways:
– Save
All your Setup changes will be saved and run.
– Cancel
The Setup changes you have made will be deleted and the unit maintains its previous settings.