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
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
2
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
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
3
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
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
1-1
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.

Introduction
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
1-2
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.

Introduction
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
1-3
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
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
1-4
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.

Introduction
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
1-5
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
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
2-1
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

Putting into operation
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
2-2
2.5 Vacuum
The standard vacuum pump configuration is a low vacuum pump. The mains supply to
the machine is provided via the connection on the bottom rear side of the VTC
machine. Please contact INDUTHERM for any alternative configuration.
The low vacuum pump is switched on manually by pressing the button ‘vacuum pump’
on the display. It is also automatically turned on if a program is started. The pump
should always be turned on 30 min before use in order to heat-up and reach best
performance. When putting into operation, check the motor rotation direction (direction
of arrow). Oil level and air filters should be checked weekly.
Fig. 2: vacuum pump
Fig. 3: mains switch
Fig. 4: front panel buttons
Low vacuum pump:
The pump supplied by INDUTHERM (optional) normally has a suction power of 40 m3/h
and an end pressure of 2 mbar. The vacuum connection is through a suction hose with
an inner diameter of 13 mm at the rear side of the casing to the vacuum pump. Through
the hoses inside the casing, the low vacuum pump is finally connected directly to the
mould chamber.
The first oil change should be done after 100 working hours. Later on, we recommend
changing it regularly every 500 - 2000 working hours, depending on the working
process, though at least every 6 months. Recommended oil type: HD30/SAE30
(approx. 0.5 l).
The oil filter should be replaced on every second oil change. For more detailed
information please refer to the instruction manual for the vacuum pump.
Low vacuum pump

Putting into operation
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
2-3
NOTE: To achieve sufficient good vacuum level in daily process you have to possibly
clean with vacuum cleaner the crucible and mould chamber after every melting and
casting cycle. This is followed by wiping with clean cloths soaked with alcohol only.
Oil-, water- or silicone-based cleaning agents must be strictly avoided.
All seals of the chamber lids must be cleaned similarly careful and regular.
Cleaning (degreasing) of melting material is highly recommended and is essential for
achieving good end-vacuum.
2.6 Gas out
Pressure release output. This output must be open all the time.
2.7 RS232 Connector / USB connector
At the RS232 connector a serial cable article no. 50500060 can be connected. If you
want to use this connector internal cable backside to generator has to be mounted.
Actually internal modem use this connector at generator. At the USB (Universal Serial
Bus) port a standard USB cable can be connected. The connections can be used by to
read data for service or Research & Development purposes or for software updates.
2.8 Internal modem
The machine is also equipped with a built-in modem for service purposes. The antenna
must be connected at the rear side.

Putting into operation
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
2-4
2.9 Temperature measurement and control
Thermocouple
Fig. 5: thermocouple
The machine can operate with a
thermocouple plugged in at the port
inside the crucible chamber. Usually
this thermocouple is used in
combination with a graphite lined
ceramic crucible to melt non-ferrous
metals. It must be covered with a
ceramic thermocouple shield. It must
be placed inside the crucible as near
as possible to the crucible wall.

Putting into operation
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
2-5
Pyrometer
Fig. 6: pyrometer
The standard pyrometer delivered
with the machine starts reading
temperatures at 800 °C and can be
used up to 2100 °C. It must be
carefully mounted and connected on
top of the front panel.
Fig. 7: alignment of pyrometer
A laser spot can be activated by
pressing a button on top of the
pyrometer. It is used to check the
correct alignment of the
pyrometer. It must be in line with the
small circular glass window of the lid
of the crucible chamber and the
metal in the crucible. The spot must
be in central position of this
window. During a heating operation
the window is flushed with protective
gas to minimize deposition of dust,
which would impact the accuracy of
the pyrometer measurement.
Fig. 8: ceramic crucible with crucible holder
The pyrometer is usually used in
combination with ceramic crucibles to
process high melting metals / alloys,
or other metals which can not be
used with graphite crucibles due to
carbon contamination.
The “dummy” connector must be
plugged into thermocouple port. It
must be oriented in such a way that it
also mechanically fixes the position of
the ceramic crucible. The machine
software automatically recognizes
whether a pyrometer or thermocouple
is installed.
Laser spot of pyrometer
must be in central position
of the window.

Putting into operation
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
2-6
NOTE: As an alternative option, the machine can be equipped with a low-T pyrometer
which starts reading at 500 °C up to 1100 °C. However, it reliably operates only from
550-600 °C on (depending on the metal/alloy). This is due to the low emission factors at
those low temperatures. Several system parameters must be changed by the
INDUTHERM service staff to make the machine work with that pyrometer and at those
low temperatures. The standard machine is very powerful so that amongst other the
maximum power must be reduced significantly.

Putting into operation
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
2-7
2.10 Crucible materials and crucible shield
In addition to a graphite-lined crucible for melting of non-ferrous metals/alloys, several
different ceramic crucibles are available and included with the starter set.
Ceramic crucibles are available in different sizes (length) even for the same inductor
size. It is recommended to always use the shortest crucible length possible for the
respective metal amount.
Fig. 9: protective quartz crucible shield
All crucibles always MUST be used
in combination with a protective
quartz crucible shield, which
thermally insulates the crucible
against the inductor. It also protects
the inductor and the inductor housing
in case of crucible breakage and
molten metal leaking from a broken
crucible.
The starter set includes a coated silica-based crucible particularly suitable for steel
melting operations. It also includes coated silica-based crucibles for even higher melting
metals/alloys like platinum. The coating is made of zirconium-dioxide (zirconia). For
best performance the crucibles must be cleaned and re-coated. This is done at best
after each melting operation following the instructions for the coating slurry, which is
also included in the starter set.
All of these silica-based crucibles, even if coated, are suitable only for short term
melting operations. Long-term melting operations (like for example for alloying purposes
starting from raw materials) at temperatures above ~ 1400 °C usually require the usage
of bulk alumina or bulk zirconia crucibles.
NOTE: Please refer to the list of available consumables and the INDUTHERM technical
staff for more information on
-the suitability of crucibles for particular applications
-alternative crucible materials for melting of reactive metals which can be
supplied on special request.

Putting into operation
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
2-8
2.11Mould chamber and adapters
Moulds or flasks of different length and diameter can be used.
Fig. 10: hat shaped adapter
The starter set includes adapters
suitable for a mould diameter of Ø
100 mm (4“).
Adapters for both smaller and larger
diameters are available, too.
The “hat”-shaped adapter must
always be placed on top of the mould
with a graphite gasket in between.
The mould with adapter must be
inserted accurately inside the mould
chamber so that the adapter slides
into the clamp.
Fig. 11: clamp movement
During the melting process the clamp
moves sideways. First, this moves
the mould into the right position for
pouring near to the crucible spout.
Second, the adapter and mould then
effectively seal the crucible chamber
against the mould chamber. Only a
good seal allows application of
different gas pressures in the two
chambers.

Putting into operation
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
2-9
Fig. 12: spacers
In order to allow for a secure mould
movement and a safe seal of the two
chambers, a set of spacers of
different width is included in the
starter set. These spacers
accommodate for the mould length.
Several spacers may be combined to
fill up the full length of the clamp.

Safety
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
3-1
3 Safety
3.1 Intended use
Operational safety of the plant for vacuum casting is only guaranteed at intended use.
The vacuum casting machine serves exclusively for melting and pouring of metals and
alloys. The specified temperature ranges must be complied with.
Every other use of the overall plant or parts is considered as not intended.
Unauthorized modifications of the plant are prohibited because of reasons for safety!
Intended use includes reading, knowing and obeying the operating instructions. That
also contains observing of servicing and maintenance regulations.
Set up, operation and maintenance is only allowed to be carried out by trained qualified
personal that has read and understood all documents.
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 admitted for operation.
It is not allowed to change or vary the system in any way. Technical changes need
explicit written approval of INDUTHERM.
Predictable abuse:
Warming of human body parts on hot surfaces.
Heat of moist inserts or casting in insufficiently dried moulds.

Safety
VTC-series
TECHDOKU_VTC_SERIE_GB_86096010.DOC 20.10.2017 JFB
3-2
3.2 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 operation, 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 illness 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 within 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 instruction manual
especially the safety advices. The personnel has to read and understand the chapters
referring to safety aspects for the particularly components of the machine. Please read
before beginning the work.
Please control the personnel for paying attention to all facts of safety and danger
prevention.
3.3 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.
The internal regulations of industrial safety are to be observed.