Indutherm ROMANOFF VC480V Guide

Technical Documentation
Vacuum-Pressure-Casting-Machine
VC480V
Keep for future use!
9 Deforest street
Amityville, NY, 11701 USA
Romanoff.com
Romanoff order service for
consumables:
www.romanoff.com
Romanoff
technical service
Tel.: [phone]
[email protected]

Revision
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revision
date chapter reason responsible
06.02.17 all Edition 2017 DV, KS, RK
12.10.17 all last corrections RK
This manual has been prepared in good faith by us. Nevertheless, should you find any
mistakes or ambiguities, please let us know. Furthermore, we are grateful for comments
and suggestions.
© Instruction manual 2017-10-16 state: 16.10.2017
The manual is property of: INDUTHERM
Erwärmungsanlagen GmbH
Brettener Straße 32
D-75045 Walzbachtal
Germany
Tel.: + 49 7203 9218-0
Fax: + 49 7203 9218-70
E-Mail: [e-mail]
Unauthorized duplication, even partial, is not permitted.
Walzbachtal, 2017-10-16.

Contents
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Contents
Contents.............................................................................................3
1 Generalinformation................................................................1–1
1.1 Scope of delivery and responsibilities .....................................1–1
1.2 Liability, warranty and guarantee ............................................1–1
1.3 Responsibility of operating company ......................................1–1
1.4 EC-conformity ........................................................................1–2
1.5 Observation of the product .....................................................1–2
2 Safety ....................................................................................2–1
2.1 Intended use .........................................................................2–1
2.2 Demands on staff, duty for utmost care .................................2–2
2.3 Protective measures .............................................................2–2
2.3.1 Concept of safety .................................................................2–3
2.3.2 Protective gear ......................................................................2–3
2.3.3 Safety equipment ..................................................................2–3
2.3.4 Main switch with emergency stop function ............................2–4
2.3.5 Safety markings on the unit ...................................................2–4
2.4 Safety marking ......................................................................2–5
2.5 Safety advices .......................................................................2–6
2.6 Residual risks......................................................................2–10
2.7 Behaviour in an emergency.................................................2–10
3 Technicaldata........................................................................3–1
4 Descriptionofthesystem.......................................................4–1
4.1 Components of the system ...................................................4–1
4.2 Schematic representation .....................................................4–2
4.3 Backside connections ..........................................................4–3
4.4 Setup of the crucible chamber ..............................................4–4
4.5 Special options .....................................................................4–5
4.5.1 Centre- and wall measurement (Dual measurement) ...........4–5
4.5.2 Granulation tank ...................................................................4–6
5 Transport ...............................................................................5–1
6 Mountingandcommissioning................................................6–1
6.1 Safety advices for mounting ..................................................6–1
6.2 Mounting process ..................................................................6–1
6.3 Apply supply connections ......................................................6–2
6.3.1 Power supply ........................................................................6–2
6.3.2 Cooling water ........................................................................6–2
6.3.3 Compressed air .....................................................................6–2
6.3.4 Protective gas .......................................................................6–2
6.3.5 Vacuum .................................................................................6–3
6.3.6 Gas outlet .............................................................................6–3
6.3.7 Vacuumpump (mains socket 16 A) ........................................6–3

Contents
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6.3.8 RS232 .................................................................................6–4
7 Operation ...............................................................................7–1
7.1 Safety advices for operation ...................................................7–1
7.2 Changing casting parts ..........................................................7–2
7.2.1 Removal .................................................................................7–2
7.2.2 Mounting ................................................................................7–2
7.3 Front panel .............................................................................7–3
7.3.1 LCD screen after mains switch on ..........................................7–3
7.3.2 Program change page 1 .........................................................7–4
7.3.3 Program change page 2 .........................................................7–6
7.3.4 Predefined casting programs .................................................7–7
7.4 System parameter ..................................................................7–8
7.4.1 State Level .............................................................................7–9
7.5 VC480V Front panel below display ......................................7–10
7.6 Protective Gas flow ..............................................................7–11
7.7 Casting .................................................................................7–11
7.8 Possible causes for dissatisfying casting results ..................7–14
7.9 Flask structure .....................................................................7–15
7.10 Granulating ...........................................................................7-16
7.11 Error diagnosis ......................................................................7-18
7.12 Troubleshooting ....................................................................7-18
7.13 Diagram casting flasks without flange ...................................7-19
7.14 Diagram casting flasks with flange ........................................7-19
7.15 Service ..................................................................................7-19
8 Maintenance ............................................................................8-1
8.1 Safety advices for repair and maintenance...............................8-1
8.2 Maintenance schedule .............................................................8-3
8.3 Repair ......................................................................................8-5
9 Dismantlingandcleaningup....................................................9–1
10 Annexe ..................................................................................10–1
10.1 List of figures........................................................................10–1
10.2 CE-Declaration of conformity ...............................................10–2
10.3 Test result chart ...................................................................10–4
10.4 Connection diagrams ...........................................................10–5
10.4.1 Connection diagram machine with 3x 400 V .........................10–5
10.4.2 Connection diagram machine with 3x 230 V .........................10–8
10.5 Water cooling circuit .............................................................10–9
10.6 Assembly drawing VC480V ................................................10–10
10.7 Consumable and spare parts list .........................................10-11
10.8 Error and warning messages ..............................................10-13

General
information
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1 General information
1.1 Scope of delivery and responsibilities
The vacuum pressure casting machine VC480V is delivered com-
plete. Please check delivery immediately after receiving the shipment
if there is something missing or possible transport damages. Please
tell the faults the shipping agency and your dealer.
1.2 Liability, warranty and guarantee
The company INDUTHERM ErwärmungsanlagenGmbH take liability,
warranty and guarantee according to the legal regulations.
The vacuum pressure casting machine is built to be state-of-the-art
and in compliance with the accepted safety regulations. Nevertheless,
can improper installation and non intended using lead to danger and
damages.
INDUTHERM ErwärmungsanlagenGmbHdon’t take liability for dam-
age caused by untrained personnel operating the machine.
For damages because of demonstrably misusing of machine or be-
cause of abnormal behaviour no liability will be taken by IN-
DUTHERM ErwärmungsanlagenGmbH!
INDUTHERM ErwärmungsanlagenGmbHdon’t take liability for dam-
ages caused by faulty protection of power supply and/or wrong con-
necting the supplies (protective gas, water, compressed air).
There is no guarantee for consumables by INDUTHERM Erwärmung-
sanlagen GmbH.
Company INDUTHERM ErwärmungsanlagenGmbH can not and will
not take responsibility for all consequential damages caused by
above mentioned circumstances.
This operating manual is of the technical state at printing date. All
rights reserved regarding technical changings and different equip-
ment.
Damages caused by disregard, wrong interpretation and non-
compliance with specifications in this manual will lead to expiration of
guarantee for this system.
1.3 Responsibility of operating company
The operator has to meet with national accident preventing regula-
tions and technical regulations.
Operating company is allowed to let operate machine by trained and
trustworthy personnel only.
Operating company has to make sure the system is supervised by
personnel which is trained at this device.
Operating manual must be kept right next to the system.

General
information
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Operating company has to ensure operating personnel has read and
understoodthe manual before they are going to use the machine.
Operating company has to ensure unauthorized person has no ac-
cess to the system.
Maintenance actions may only be done by authorized personnel or by
service technicians from Indutherm.
1.4 EC-conformity
Declaration of European Community conformity is attached to this
manual.
1.5 Observation of the product
The management will provide you with a secure machine at state-of-
the-art.
Please let us know immediately if there are:
failures at safety measurement devices,
failures during production,
modified parameter settings,
difficulties in using the system,
accidents or near accidents and
remarks for improvement of the manual.

Safety
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2 Safety
2.1 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. The specified temperature ranges must be com-
plied with.
Every other use of the overall plant or parts is considered as not in-
tended.
Unauthorized modifications of the plant are prohibited because of
reasons for safety! CE declaration of conformity expires with modifi-
cation.
Intended use includes reading, knowing and obeying the operating
instructions. That also contains observing of servicing and mainte-
nance regulations.
Set up, operation and maintenance is only allowed to be carried out
by trained qualified personal that has read and understood all docu-
ments.
The plant may affiliate only to the specified media. Supply voltage
and input respectively output pressure have to be observed to the
given device labelling accordingly.
The machine has been developed for use in enclosed spaces and for
the above mentioned application.
Only original INDUTHERM consumables and spare parts are admit-
ted for operation.
It is not allowed to change or vary the system in any way. Technical
changes need explicit written approval of INDUTHERM Erwärmung-
sanlagen GmbH.
The casting machine must not be placed in areas with explosive at-
mospheres.
Predictable abuse:
Warming of human body parts on hot surfaces.
Heating and casting of others then the mentioned metals.

Safety
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2.2 Demands on staff, duty for utmost care
Work on and with the machine is allowed to be accomplished by
reliable, trained and instructed staff only. Responsibilities for the
separate sections have to be regulated clearly which include oper-
ation, preparation, service and repair.
Only authorized personnel may act at the system.
The machine may never be operated by personnel under influence of
reflex diminishing medicine or people not able to work because of ill-
ness or disorder.
Running of the system has to be always supervised by trained staff.
Personnel which have to be trained und introduced to this job or with-
in in the course of vocational training may work only under permanent
observation of a person experienced with the machine.
Work on the electrical equipment is only allowed for workers skilled in
the field of electricity.
The instruction manual has to be freely disposable at the location of
the system. The employees have to know the storage place.
Every person working at the system has to read and apply the in-
struction manual especially the safety advices. The personnel have to
read and understand the chapters referring to safety aspects for the
particularly components of the machine. Please read before begin-
ning the work.
Please control the personnel for paying attention to all facts of safety
and danger prevention.
2.3 Protective measures
This operator’s guide contains all important advices to operate the
system secure.
Basic prerequisite for safe dealing and trouble-free running of this
system is the knowledge of fundamental safety advices and industrial
safety rules.
In commercial facilities you have to regard the accident prevention
regulations of the professional association for electrical systems and
tools.
When operating the system escape gases / vapours. These are con-
sumable parts dependent applications you use and the molten mate-
rial. The plant operator must provide a suitable on site and the current
standards and laws appropriate exhaust system.
The internal regulations of industrial safety are to be observed.

Safety
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2.3.1 Concept of safety
Objective is the safety:
of the staff against injuries;
of the system against damage or standstill and
of the environment against endangering.
The list of actions taken:
deployment of protective equipment like covers and main-switch
with emergency stop function,
safety switch that is used to ensure that the plant can be operated
only with the swivelled vacuum pressure casting tank;
water-cooled inductor housing,
duty of wearing personal protective equipment (PPE),
affix safety markings on the installation,
create safety advices in the manual.
2.3.2 Protective gear
Protective gear (PPE) includes:
heat-resistant clothes,
heat-resistant, closed shoes,
heat-resistant protective gauntlets protecting artery and
face guard.
Caution!
Wear always for every process step the right protective gear.
2.3.3 Safety equipment
The safety of the machine is only guaranteed if all safety equipment is
proper installed and working proper. Don’t use the system without the
safety equipment!
Disassembling safety equipment is only allowed with locked main-
switch. Install every part of the safety equipment after repair. Perfect
function has to be checked.
Caution!
Safety equipment protect from unintentional access of the staff to
danger spots. They prevent possible injuries. Never manipulate the
safety devices!

Safety
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2.3.4 Main switch with emergency stop function
It is allowed to start the machine or operation only with proper emer-
gency stop function.
Caution!
With the emergency stop function you can stop the machine in criti-
cal moments of health hazard. You help to diminish potential con-
sequences of injury.
> Don’t manipulate the emergency stop equipment.
> Don’t obstruct the way to the emergency stop equipment.
2.3.5 Safety markings on the unit
A necessary condition for safe dealing with and undisturbed running
of the machine is the knowledge of safety instructions and industrial
safety regulations.
On the front of the machine casing the following safety markings are
attached.
safety
marking
meaning safety
marking
meaning
warning of dan-
gerous electrical
voltages
wear heat resistant
safety clothing
warning on hot
surfaces
wear heat resistant
protective gauntlet
gloves protecting
artery
forbidden for
persons with
pacemaker
wear face guard
Warning of hand
injuries.
wear protective
shoes
Advice
Keep the safety markings always clean. Replace the markings if they
aren’t recognizable. Observe the warnings and commands. Don’t
expose yourself careless to dangerous situations.

Safety
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2.4 Safety marking
The following signal words are used in this document which are asso-
ciated with safety markings for presentation of possible dangerous
situations.
Danger!
Death, serious body injury or substantial property damage willresult
if proper precautions are not taken.
Warning!
Death, serious injury or substantial property damage can result,if
proper precautions are not taken.
Careful!
Minor personal injury can result if proper precautions are not taken.
Attention!
Property damage can result, if proper precautions are not taken.
Information/advice
Here you get information and advices to carry out the following activi-
ties effective and safe.

Safety
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2.5 Safety advices
Check always the condition of the system before you switch on the
system. Examine the supply pipes and insulations if there are leaks
and damages. Operate the system only if it is in proper and faultless
shape.
Operate the system never:
if there are malfunctions,
if it is showing damage or
after heavy transportation stress.
The system has to be constantly controlled when running to be able
to recognize and avoid dangerous situations. The system may not run
if it is unsupervised.
Do never change, remove or close the safety valves inside the ma-
chine.
Danger!
Danger to life because of strong electromagnetical fields
(induction). For persons with pacemaker it is not allowed
to approach or to be near to the machine.
Danger!
Danger to life are caused also by the fact that very hot and liquid
metals solidify in cold liquids. In this case may arise physical and
chemical reactions that have to be previously analysed by the user.
During this it can emerge physical and chemical reaction, which is to
be evaluated by the operator. For example, can with aluminium hap-
pen an explosion of hydrogen gas during hydrolysis.
Warning!
Risk of burning on hot surfaces and hot metal
(until ~ 1500 °C). Wear always personal protective
equipment when you work with the machine.
Utmost caution during using graphite crucibles and
graphite moulds. The heat of these parts is only visible
when the temperatures are over 500 °C.

Safety
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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.
Switch off for pulling out or putting in mains plug.
Danger!
Risk of burns. If metal is melted without the supply of protective gas,
can cause a flash fire or explosion when opening the bell.
Melt at temperatures above 500 °C always with protective gas. Use
as a protective gas exclusively argon or nitrogen.
Danger!
Danger because of touching parts conducting voltage.
Work on the electrical equipment is only allowed for au-
thorized qualified staff.
Access to the electrical distribution box is only allowed
for authorized qualified staff with tool.
Work on the electrical equipment is only allowed when
the system is disconnected from power supply (pull out
power plug).
The capacitors can retain their charge even after de-
activation of the system.
Keep the housing of the vacuum pressure casting
machine closed continually.
No work must be carried out on parts conducting high
voltage.
Remove loose connections.
Replace immediately damaged scorched or slightly
burned cables. Perform work only when mains plug is
pulled out.
Cables may not wedge in or rather squeezed. Cables
have to be laid in a way that they not become a trip-
ping hazard or can be not damaged.

Safety
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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.
Hoses may not wedge in or rather squeezed. Hoses have to be
laid in a way that they not become a tripping hazard or can be not
damaged.
Danger!
Burning risk by leaking hot metal at protective gas/compressed air
failure.
When protective gas failure of the sealing rod can no longer close
properly. Through a check valve, the pressure is maintained in the
lock cylinder.
Press after a protective gas/compressed air failure, no pneumatic
units (e.g.: cylinder).
Warning!
Risk of burns:
burns because of squirting liquid metal,
burns at hot surfaces (important here: like new insulations).
Warning!
Danger of explosion.
Dripping liquid metal can’t be excluded.
The floor beneath the system must be made of non-flammable mate-
rial. As well there must not be stored inflammable materials within a
radius of 5 metres.
Attention!
At crucible temperatures over 100 °C the cooling water supply must
be switched on. If it is not turned on, the inductor will be destroyed. If
cooling water supply fails, the heating system immediately is turned
off. Inspect the system for damage before putting back into operation
again.

Safety
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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.
With built-in and closed sealing rod the according cylinder must have
a gap to the lower end stop or the pouring hole is no longer proper
sealed.
Danger!
Lethal injuries happen because of false transport by forklift truck.
Pay attention of the right attachment of the means of transporta-
tion, otherwise the system can fall from forklift truck. The system
must be lifted from the side only, because the centre of gravity is
located in front and towards the upper third of the machine.
With too small dimensioned or forks adjusted too narrowly there
is danger for the system to fall from the means of transportation.
Wear appropriate personal protective equipment (PPE).
Move the system only by skilled personnel qualified for transpor-
tation jobs.
For damages resulting from non-compliance of regulations in transit
there is no assertion possible for warranty claims.
Warning!
Health risk because of lifting heavy weight.
Lift and transport the granulating tank only by two persons. Don’t try
to transport the tank by yourself. There is danger of permanently
healthy damages because of physical overload.
Warning!
Risk of injury.
Make pressure leading system parts depressurized before you carry
out servicing.
Warning!
Risk of slip on the floor around the installation in case someone had
spilled lubricant or solvent.
Clean the floor from dirt immediately! Dispose cleaning tissues in the
particular collecting boxes.

Safety
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Caution!
Observe regulations for the mains supply written from the
responsible electric power supply company, the associa-
tion VDE and the local electric power station.
Inappropriate connecting can lead to injuries and dam-
ages of the machine.
Caution!
Danger for health because of inhalation of fibre particles.
Store crucible shield and insulation in dustproof package.
Remove the material just before installation.
Don’t shatter crucible shield and insulation.
Pack the materials immediately after removal dustproof and dis-
pose the materials in this packaging
2.6 Residual risks
risk characterisation risk reduction
Health risk for persons with
cardiac pacemaker who ap-
proach the running system.
Instruct people.
Burn injury on hot surfaces or
hot molten metal.
Teach people. Wear personal pro-
tective equipment.
Danger of explosion because of Fill the tub with sand.
dripping of liquid metal in a wa-
ter filled steel tub during melting
of aluminium or aluminium-
alloys.
Jet flame or explosion when
opening the lid of the melting
chamber in case of melting
without protective gas.
Always melt with protective gas
at temperatures above 500 °C.
Tilting and toppling of the sys-
tem due to improper transporta-
tion.
Consider shipping instructions.
2.7 Behaviour in an emergency
The personnel working at the facility must be trained about the behav-
iour in an emergency.
All persons who are working with the machine must be informed of
the possibility of rapid standstill of the plant.

Technical data
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3 Technical data
VC480V
crucible volume (1) 170 cm32.5 kg/Au
flasks Max. Ø 130 mm (5“) * 260 mm (10“) height
Standard: Ø 125, 100, 90, 80, 70 mm
highest working temperature (2) Max. 1400 °C with type S thermocouple
(only with high-temperature insulations)
power 8 kW
mains 3 x , 50 or 60 Hz
3 x 208 V, 50 or 60 Hz (option)
fuse protection 16 A
25-32 A (230 V)
short circuit current max 5.0 kA
thermocouple
Type K (NiCr-Ni; max. 1200 °C) or
Type N (NiCrSi-NiSi; max. 1300 °C) or
Type S (PtRh-Pt; max. 1500 °C)
cooling water supply
2 x Ø 8 mm, fittings with 1/4“ thread
2.5 - 5 bar,
min. 130 l/h,
max. 6 °dH
water output Pressureless
cooling water input temperature 15 - 25 °C / 59 – 77 °F
ambient temperature 10 - 35 °C / 50 – 95 °F
relative humidity 20 - 80 %
compressed air supply
1 x Ø 6 mm, fitting with 1/4“ thread
8 bar,
without oil
protective gas supply 1 x Ø 6 mm, fitting with 1/4“ thread
8 bar, pure N2or pure Ar
vacuum 1x Ø 13 mm, fitting with 1/4“ thread,
0 - 20 mbar absolute, min. 21 m³/h
overpressure in the induction
chamber max. 1,5 bar
Weight in kg ca. 120
dimensions in mm
(Wide x Depth x Height) 500 x 760 x 1450
Options granulation tank
sinter unit
S-crucible
Noise emission 75 dB (A)
(1) These are standard values which can be optionally changed.
(2) in a special configuration

System
description
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4 Description of the system
4.1 Components of the system
The system consists of several modules assembled in one housing.
Inside the housing there are:
mains cable and mains filter,
microprocessor controlled induction generator F-type,
middle-frequency transformer,
oscillating circuit capacities,
pneumatic (magnet-) valves,
pressure regulator for pressure of the sealing rod cylinder and
pressure regulator for protective gas.
The front plate contains:
front panel for control of the granulating process.
To the melting system belongs:
inductor housing, water cooled with inductor, crucible, insulations,
sealing rod unit, thermocouple,
bell hinged, water-cooled and
vacuum chamber, watercooled;
flask lift,
vacuum chamber lift,
vibration unit,
granulating tank (option) and
sinter unit (option).

System
description
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4.2 Schematic representation
Figure 1: overall view
pos. designation Function
1 bell with window Closing the inductor housing.
2 inductor housing (cruci- In the inductor housing are:
ble chamber) Induction coil
crucible
insulation
3 vacuum chamber With water cooling inlet and outlet.
4 flask lift Enables lifting of tank.
5 lift for vacuum chamber Enables lifting of vacuum chamber.
6 front panel Control the process of the system.
7 Bell lock With pressure build up in the vacuum chamber this rod will se-
cure the handle against unintentional opening.
8 Mains switch with
emergency stop func-
tion
Switch on and off the vacuum pressure casting machine. Imme-
diate interrupt of power in emergency.
5
1
2
3
6
4
7
8

System
description
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4.3 Backside connections
Figure 2: backside of the vacuum pressure casting machine
4 5 6 7 8 Figure 3: details of connections
9 10 11 12 13
1 Side door Storage area for manual.
2 Back door Service access (only for experts for open with tool)
3 Serial Interface/RS232 Connection for PC over Indutherm-RS232-cable (socket
actual attached to internal modem).
4 Power supply Power supply of the vacuum pressure casting machine.
5 Vacuum pump Socket for plug from vacuum pump.
6 Protective gas Protective gas supply input.
7 Compressed air Compressed air supply input.
8 Water Input Cooling water supply input.
9 Vacuum For the hose from the external vacuum pump.
10 Gas out Depressurization.
11 Water Output Cooling water outlet.
12 Filter flask Filter for vacuum in the flask chamber.
13 Filter crucible Filter for vacuum in crucible area.
14 Identification plate Important information about machine.
1
1
2
3
14