Indutherm VTC Series User manual

Instruction manual for
Vacuum Tilting Casting machine
VTC series
Brettener Strasse 32
DE-75045 Walzbachtal
Germany
www.indutherm.de
Machine service no.
M17999 F
Indutherm order handling
consumables:
Tel.: [phone]
[email protected]
Indutherm
technical service
Tel.: [phone]
[email protected]
Keep for future reference!

Revision
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
1
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 October 2017
State: 20.10.2017
This manual is the 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]
Unauthorised duplication, even partial, is not permitted.
Walzbachtal, 20/10/2017.
Revision
Date
chapter
reason
responsible
21.07.11
all
new publication first edition
KS, SK, OM, RR, DV
15.02.16
all
version 01 from VTC-Ti-manual
RK, JFB
24.06.16
all
corrections
RK, JFB
19.10.17
all
last changes
RK

Contents
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Contents
Contents..........................................................................................................................2
1Introduction..........................................................................................................1-1
1.1 General description of the VTC-Series............................................................1-1
1.2 Machine components.......................................................................................1-2
1.3 Technical data .................................................................................................1-3
1.4 General information .........................................................................................1-4
2Putting into operation...........................................................................................2-1
2.1 Set-up directions..............................................................................................2-1
2.2 Mains supply....................................................................................................2-1
2.3 Cooling water...................................................................................................2-1
2.4 Protective gas (argon or nitrogen) ...................................................................2-1
2.5 Vacuum............................................................................................................2-2
2.6 Gas out............................................................................................................2-3
2.7 RS232 Connector / USB connector.................................................................2-3
2.8 Internal modem................................................................................................2-3
2.9 Temperature measurement and control ..........................................................2-4
2.10 Crucible materials and crucible shield .............................................................2-7
2.11 Mould chamber and adapters..........................................................................2-8
3Safety ..................................................................................................................3-1
3.1 Intended use....................................................................................................3-1
3.2 Demands on staff, duty for utmost care...........................................................3-2
3.3 Protective measures........................................................................................3-2
3.4 Safety marking.................................................................................................3-5
3.5 Safety advices .................................................................................................3-6
3.6 Residual risks ................................................................................................3-10
3.7 Behaviour in an emergency situation.............................................................3-10
4Operation.............................................................................................................4-1
4.1 Operating elements .........................................................................................4-1
4.2 Pre-defined casting programs..........................................................................4-8
4.3 Option: Melting under overpressure...............................................................4-12
4.4 Castings in manual or automatic mode..........................................................4-13
4.5 Possible causes for dissatisfying casting results ...........................................4-16
5Consumable parts ...............................................................................................5-1
5.1 Assembly drawing VTC100V ...........................................................................5-1
5.2 Assembly drawing VTC200V...........................................................................5-2
5.3 Assembly drawing VTC400V ...........................................................................5-3
5.4 Assembly drawing VTC800V ...........................................................................5-4
5.5 Consumables and spare parts list....................................................................5-5
6Service.................................................................................................................6-1
6.1 Troubleshooting...............................................................................................6-1
6.2 Maintenance ....................................................................................................6-2

Contents
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7Connection diagram ............................................................................................7-1
8Test result chart...................................................................................................8-1
9Appendix..............................................................................................................9-1
9.1 List of figures ...................................................................................................9-1
9.2 CE-declaration.................................................................................................9-2
9.3 Software documentation..................................................................................9-4

Introduction
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1 Introduction
1.1 General description of the VTC-Series
With this vacuum tilting machine, the melting charge is heated up by direct induction
under protective gas or vacuum. The liquid metal is poured directly into a preheated
flask or into a graphite or metal mould.
The special advantage of inductive heating is that the melting temperature is reached
rapidly, because the heat is directly generated in the metal. During the melting process,
the metal is thoroughly mixed by means of a magnetic field, ensuring a homogenous
mixing even when using raw materials. The metal is poured by simultaneous tilting of
the inductor housing and the mould chamber.
A two colour pyrometer reads the exact temperature and the controller regulates the
power output of the generator to control the set temperature.
The machines of the VTC-series are suitable for melting steel, non-ferrous or precious
metal alloys.
The melting process is fast which is of high importance for melting of reactive metals in
order to minimize the time for oxidation or reactions with crucible material. The
machines of the VTC-series can work with a very clean atmosphere, by applying a
vacuum and possibly repeated evacuation and back-fill steps using high purity
protective gas.

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1.2 Machine components
The machine consists of separate units built into one casing:
1. Inside the casing, the following components are installed:
- mains supply,
-microprocessor controlled induction generator F type,
- motor to rotate inductor housing and mould chamber,
- medium frequency transformer,
-oscillation circuit capacities (capacitor boards),
- solenoid valves,
- pressure sensors for water and protective gas.
2. The front panel consists of:
-main switch,
-switch for fine vacuum pump,
-pyrometer,
-operating panel for control of melting and casting cycles,
-printer.
3. The casting unit consists of:
-inductor housing = crucible chamber (water cooled),
inductor, ceramic crucible and crucible shield;
- mould chamber (water cooled) and vibration unit.
4. The rearside contains:
- inputs for the media supply and
- vacuumfilter.

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1.3 Technical data
VTC100V
VTC200V
VTC400V
VTC800V
Crucible volume in cm³
25
145
290
650 = 2 kg Pt
505 = 4 kg St
Crucible inclination in °
10
10
5
5
Melting performance in
kW
12
15
20
20
Frequency in kHz
18
15
12
12
Mould size
max. Ø 125 mm (5“) * 220 mm (8“) height
Crucible temperature
max. 2100 °C (standard pyrometer)
Mains supply
3 * 400 V/32 A, 50 or 60 Hz
Cooling water supply
2.5 - 5 bar/at least 300 l/h
Cooling water recoil
without pressure
Cooling water entry
temperature
15 –25 °C
Room temperature
10 –35 °C
Relative atmospheric
humidity
20 –80%
Protective gas supply
8 bar, pure N2or pure Ar
Vacuum
low vacuum pump: 2 - 20 mbar max., 40 m³/h
Recommended pump
29 m³/h
40 m³/h
Weight
approx. 280 kg
Dimensions in mm
(width * depth * height)
950 * 1050 * 1500

Introduction
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1.4 General information
Safety information
In order to ensure a constant, ideal performance of the machine and to ensure safe
working conditions, the user has to observe the following safety measures:
The complete electrical wiring is to be performed only by qualified and specially
trained personnel.
Check the machine and the supply devices regularly on possible damages.
When opening cabinet/casings or when removing parts (exception: when this is
possible by hand), certain parts under electric power can cause danger. If opening
up the machine is necessary (before maintenance, change of machine settings,
repair or exchange of parts) the machine must be cut off the mains voltage. If
working on the opened machine is inevitable, only qualified trained personnel aware
of the danger caused hereby and aware of the relevant regulations may be
instructed to do this work.
Capacitors in the machine can still be charged even when the machine’s mains
supply is switched off.
When it seems that the machine can no longer be worked safely it has to be taken
out of production and secured against further unintentional use. The following
incidents indicate that safe working is no longer possible:
- the machine is visibly damaged;
- the machine does not function;
- uncommonly heavy wear from transportation.
The safety valves placed inside the machine casing may not be removed, closed or
altered in any way.
As melted metal is processed with this machine (= temperatures up to ~ 2100 °C),
the utmost care and attention has to be applied when working with the VTC series.
The following necessary safety clothing is principally to be worn:
- fireproof clothes,
- fireproof closed shoes,
- fireproof gloves and
- safety goggles.
Special caution is essential when working with graphite crucibles and graphite dies
because these are only visibly hot at temperatures above 500 °C!
In commercial enterprises the regulations for the prevention of accidents of the
relevant authority for electrical machinery are to be followed.
People with pacemakers must not be near the machine while it is running.

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A trained responsible personnel has to supervise work with this machine.
Use as determined/liability
This casting machine is designed and manufactured to comply with the latest technical
knowledge and according to approved safety regulations. When not putting into
operation correctly or not using the machine as determined, however, danger and
damages may occur. Therefore we suggest reading carefully and completely this
manual before putting the machine into operation and to follow the instructions given
therein:
This machine is only to be used for melting and casting of metals and alloys.
This machine may only be connected as mentioned in this manual. The mains
supply as well as in- and outgoing pressures are to be provided as stated on the
machine label.
This machine was designed for use in closed spaces (indoors) and may only be
used for the above-mentioned purpose.
Only original INDUTHERM consumable and spare parts are to be used.
The machine may not be modified in any way. Technical changes may only be
affected with prior written permission of INDUTHERM GmbH.
Damages caused by disregard or false interpretation of the contents of this
instruction manual result in an immediate expiration of the machine guarantee.
This instruction manual is conforming to the latest technical condition of the
machine when printed. Technical changes and fittings subject to change.
INDUTHERM GmbH cannot and will not take responsibility for any damages
resulting of the above mentioned.
This instruction manual may not even partially be reproduced (photocopy, micro
film, computer processing etc.) without prior written permission of INDUTHERM
GmbH
.

Putting into operation
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2 Putting into operation
After delivery, immediately check if the machine is complete and if there are any
transportation damages. In the case of damages, please contact at once supplier or
forwarding agent.
2.1 Set-up directions
The machine should be placed on clean and dry ground. The ground should be even,
solid and levelled. The rear side of the machine must remain freely accessible to
ensure sufficient circulation of cooling air. The cooling air temperature must not exceed
35 °C and must not be contaminated. Only after all supply and connecting systems
have been connected, the machine may be put into operation.
2.2 Mains supply
Only trained personnel may connect the machine. Please pay attention to the nominal
voltage and frequency stated on the machine label. The 3-phase current may differ
+/- 10 % (maximum) from the nominal value. The mains supply (at 3* 400 V AC) must
at least be furnished with 20 A and 32 A delay-action fuses (max.). The machine is
equipped with a 32 A-Ceekon-connector when leaving INDUTHERM. All 4 lines
(L1, L2, L3, and PE) must be connected correctly.
Check the rotating direction of the vacuum pumps (option). If the direction is wrong,
2 phases of the mains connection are connected incorrectly and must be exchanged
(This only applies for rotary current vacuum pumps).
2.3 Cooling water
Use two hoses with an inner diameter of 13 mm for the cooling water. The water
entry pressure must be at least 2.5 bar and must not be more than 5 bar. The water
drainage must be without pressure. The water entry temperature must be above 15 °C
and must not exceed 25 °C. The concentration of lime in the water must not be more
than 60 mg CaO/l. The cooling water must not be contaminated.
2.4 Protective gas (argon or nitrogen)
Purity to be no less than 99.95% must be used as protective
gas. For melting of reactive metals higher purity Argon
99.996% is recommended. Use a compressed air hose with
an inner diameter of = 6 mm. The inlet pressure must be
8 bar. A constant pressure regulator must be used.
Fig. 1: pressure regulator