Indutherm MU200 User manual

Instruction Manual for
Melting Machine
MU200 to MU 1200
F generator
INDUTHERM Erwärmungsanlagen GmbH
Brettener Strasse 32
D-75045 Walzbachtal
Germany
Tel.: [phone]
Fax: [phone]
e-mail: [email protected]
OPERATING_MANUAL_MU200_MU1200_F_GENERATOR.DOC 02.05.2014 KS

86070012_OPERATING_MANUAL_MU200_MU1200_F_GENERATOR 22.09.2011 KS page 2
Contents
1. Introduction........................................................................................................................3
1.1. General description of the MU melting machines........................................................3
1.2. Machine components ..................................................................................................3
1.3. Technical data.............................................................................................................4
1.4. General information.....................................................................................................5
2. Putting into operation.........................................................................................................7
2.1. Set-up directions..........................................................................................................7
2.2. Mains supply................................................................................................................7
2.3. Cooling water...............................................................................................................7
2.4. RS232 connector.........................................................................................................7
3. Operation...........................................................................................................................8
3.1. Operating elements .....................................................................................................8
3.2. Casting ........................................................................................................................9
4. Service.............................................................................................................................10
4.1. Trouble shooting........................................................................................................10
4.2. Maintenance..............................................................................................................11
5. Connection diagram ........................................................................................................12
5.1. MU200 single phase..................................................................................................12
5.2. MU200- MU1200 three phase ...................................................................................13
6. Appendix..........................................................................................................................14
6.1. Consumables and spare parts list .............................................................................14
6.2. Assembly drawing MU-series ....................................................................................16
6.3. Spare part options for MU-series...............................................................................18
6.4. Declaration of Conformity..........................................................................................20
6.5. Software documentation............................................................................................22

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1. Introduction
1.1. General description of the MU melting machines
With this melting machine, the melting charge is heated up by induction.
The special advantage of inductive heating is that the melting temperature is reached rapidly,
because the heat is directly generated in the metal and in the crucible. During the melting
process, the metal is thoroughly mixed by means of a magnetic field, ensuring a homogenous
mixing even when using new alloys.
Installing the thermocouple in the crucible bottom allows an exact temperature measuring and
also the output of the unit is controlled in such a way that the set temperature remains
constant.
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 and mains fuses (automatic cut-out)
- microprocessor controlled induction generator F-type
- medium frequency transformer
- oscillation circuit capacities
2. The front panel consists of:
- operating panel for control of melting cycles
3. The ca sting unit consists of:
- inductor, crucible, insulation parts, thermocouple

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1.3. Technical data
MU200
single phase
MU200
three phase
Crucible volume
155cm3 2,3 kg/Au
Useable capacity
75% of maximum volume
Crucible temperature
max. 1200 °C
max. 1400 °C
Melting performance
3,5 kW
6,0 kW
Mains supply
1x230V / 20A
3 * 400 V/16A, 50 or 60
Hz
Cooling water supply
2.5 - 6 bar/at least 200 l/h
Cooling water recoil
without pressure
Cooling water entry temperature
15 –25°C
Room temperature
10 –35°C
Relative atmospheric humidity
20 –80%
Weight
approx. 58 kg
Dimensions (width * depth * height)
500 mm * 500 mm * 900 mm
MU 400
MU 700
MU 900
MU1200
Crucible volume
400 cm3
6 kg/Au
700 cm3
9 kg/Au
900 cm3
13 kg/Au
1200 cm3
18 kg/Au
Useable capacity
75% of maximum volume
Crucible temperature
max. 1500 °C with type S thermocouple
Melting performance
10 kW
12 kW
15 kW
15 kW
Mains supply
3 * 400 V/25 A, 50 or 60 Hz
Cooling water supply
2.5 - 6 bar/at least 200 l/h
Cooling water recoil
without pressure
Cooling water entry temperature
15 –25°C
Room temperature
10 –35°C
Relative atmospheric humidity
20 –80%
Weight
approx. 58 kg
Dimensions (width * depth * height)
500 mm * 500 mm * 900 mm

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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 is 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 1500 °C), the
utmost care and attention has to be applied when working with the Machine. The following
necessary safety clothing is principally to be worn:
- fireproof clothes
- fireproof closed shoes
- fireproof gloves
- 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.
A trained responsible personnel is to supervise work with this machine.

86070012_OPERATING_MANUAL_MU200_MU1200_F_GENERATOR 22.09.2011 KS page 6
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 precious metals normally used
for the production of jewellery.
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 effected
with INDUTHERM GmbH’s prior written permission.
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 conform 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.

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2. Putting into operation
On 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 level. 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 must at least be furnished with 20 A and
maximum with 32 A delay-action fuses (at 3* 400 V AC). The machine is equipped with a 32
A-Ceekon-connector when leaving INDUTHERM. All 5 lines (L1, L2, L3, N, PE) must be
connected correctly.
2.3. Cooling water
Use two hoses with an inner ø of 8 mm for the cooling water. The water entry pressure must
be at least 2.5 bar and must not be more than 6 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.
Caution: As long as the crucible temperature is above 100°C, the cooling water supply must
be open; otherwise the inductor insulation could be destroyed. In case the cooling water
supply stops while there is still a hot crucible inside the machine, the crucible must be removed
once.
2.4. RS232 connector
At this connector our modem article no. 71000320 or the serial cable article no. 50500060 can
be connected

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3. Operation
3.1. Operating elements
- Temperature:
Normally, the actual crucible temperature is indicated here. When pressing the buttons
“+” or “–“ the indication changes to the set-point value (nominal value) for at least 5
seconds. An active set-point value is indicated through an illuminated red decimal point.
The set-point value can be altered with the buttons “+” or “-“.
- Water:
This signal lamp illuminates when the water entry pressure is more than 2 bar. If the
water pressure is too low, the signal light extinguishes and the generator is stopped
after some seconds. The display shows error and there is an acoustic error signal.
- Program:
It is possible to store up to 20 temperature values (0-19). To store a new value:
1. Select a program number (0-19) with the pushbuttons '+' or '-' (field Program).
2. Adjust the temperature value with the pushbuttons '+' or '-'
(field Crucible Temperature).
3. Press the pushbuttons '+' and '-' (field Program) simultaneously at least 1 second.
Now the new temperature value is stored.

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- Power:
-Button Start / Stop:
The generator is turned on/turned off with this buttons. The turned on generator
regulates principally to the adjusted nominal temperature (see Crucible-Temperature).
-Button + / -:
The maximum generator power is selected with this buttons
At the side of the operating panel:
- Mains Switch:
The machine is switched on/off by turning the mains switch.
3.2. Casting
Before starting check crucible and crucible insulation for dirt residues/possible damages. It is
recommended to use a vacuum cleaner for the entire inductor.
A suggestion for a general casting process:
1. Open cooling water supply.
2. Switch on melting machine.
3. Set the desired melting temperature on the digital temperature controller and start
generator (button 'Start').
4. Wait until material is molten.
5. Turn generator off (Button 'Stop') an remove crucible with the help of tongs.
Comment: All these steps you can see in our official customer CD
article no. 81100010. There you can see all steps in a
video.

86070012_OPERATING_MANUAL_MU200_MU1200_F_GENERATOR 22.09.2011 KS page 10
4. Service
4.1. Trouble shooting
Only trained personnel should open the machine.
The machine cannot be turned on:
- when there is no mains supply
The heating cannot be turned on:
- when there is no cooling water supply, error code “E012”
- when thermocouple is not in place or defective, indication crucible temperature “OFbE”
- when generator is running hot (error code "E021"
- other error, error code "Exxx"
Incorrect temperature indication:
- thermocouple is not programmed correctly, see appendix
Low generator output:
- nominal value of temperature control too low
Other error codes: see appendix

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4.2. Maintenance
A routine check/regular cleaning of the following is necessary: (Caution: disconnect the
machine first!):
Daily (before casting):
1. Remove thermocouple, crucible and insulation materials, carefully clean inductor
housing with a vacuum cleaner. Before reinstalling the above parts, check those and
replace if necessary.
Annually:
Depending on the water quality, the cooling system should be cleaned with 25% citric acid.
The cooling system should be treated with this acid for approx. 1 hour. Then clean the system
thoroughly with pure water and check on eventual leakages.
1. Tighten all electric wirings, especially those for power current.
2. Tighten all connections of water-cooling.

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5. Connection diagram
5.1. MU200 single phase

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5.2. MU200- MU1200 three phase

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6. Appendix
6.1. Consumables and spare parts list
At following side the spare parts list for this machine will start.
INDUTHERM is now using only machine specific spare parts lists, which contain all the
information for your machine.
The name is encoded. One example could be G12447_MU_00
If spare parts are replaced by new parts, the index will be incremented. This ensures that you
always receive the latest version of consumables and spares. To be sure that the data is
correct, INDUTHERM and our sales partners or end customers must work together.
G13xxx show you only the spare part that wears off. In the web shop you will find other lists
that might help you:
name
function
where to find
optional spare
parts
list shows parts for: e.g.
high temperatures and
special alloys
replacement
parts
parts that might go defective
during the years of
operation
accessory parts
parts that might help you to
operate your machine
Genuine INDUTHERM parts are clearly marked with our 3D hologram.

86070012_OPERATING_MANUAL_MU200_MU1200_F_GENERATOR 22.09.2011 KS page 15
If you open the accessory part list, you will see this screen:
Attention!
To order parts or to receive your order list as PDF file please contact your
local sales partner.
For direct customers, please contact our order department
E-mail
[e-mail]
Telephone no
[phone].
Attention!
Please understand that INDUTHERM has to support more than 3000
machines. We cannot sort spare parts only with your customer name. We
always need your machine service number, to send you the correct spare
part

86070012_OPERATING_MANUAL_MU200_MU1200_F_GENERATOR 22.09.2011 KS page 16
6.2. Assembly drawing MU-series

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This page will replaced with G05xxx_00 ( xxx = machine no.).
_00 is version of spare parts list. Changes will be done with _01, _02, due
to customers requirements
Example: G05003_01 (second version of the list for machine 05003).

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6.3. Spare part options for MU-series
Possible crucible option on INDUTHERM MU200
up to 1100°C
h
Øi
volume
hole
application
10077008
115
40
144
yes
standard crucible
up to 1500°C
h
Øi
volume
hole
application
10077160
115
40
144
no
very high temperature, no
temperature measurement
Possible crucible option on INDUTHERM MU400
up to 1100°C
h
Øi
volume
hole
application
10073022
115
65
381
yes
standard crucible
up to 1600°C
h
Øi
volume
hole
application
10073902
115
65
381
no
very high temperature, no
temperature measurement
Possible crucible option on INDUTHERM MU700
up to 1100°C
h
Øi
volume
hole
application
10071010
147
76
666
yes
standard crucible
up to 1400°C
h
Øi
volume
hole
application
10071900
139
57
354
no
high temperature, no temperature
measurement
10071901
139
57
354
yes
high temperature,
up to 1600°C
h
Øi
volume
hole
application
10071902
139
57
354
yes
very high temperature, no
temperature measurement

86070012_OPERATING_MANUAL_MU200_MU1200_F_GENERATOR 22.09.2011 KS page 19
Possible crucible option on INDUTHERM MU900
up to 1100°C
h
Øi
volume
hole
application
10074019
163
78
778
yes
standard crucible
up to 1400°C
h
Øi
volume
hole
application
10074902
163
72
663
yes
high temperature,
up to 1600°C
h
Øi
volume
hole
application
10074904
163
72
663
no
very high temperature, no
temperature measurement
Possible crucible option on INDUTHERM MU1200
up to 1100°C
Øo
Øi
volume
hole
application
10075010
127
96
1302
yes
standard crucible 15,5 mm wall
10075900
127
110
1710
yes
crucible for high volumes but very
short lifetime due to 8,5mm wall
up to 1400°C
Øo
Øi
volume
hole
application
10075903
116
96
1302
yes
high temperature, smaller wall,
shorter lifetime,
10075906
116
96
1302
no
high temperature, smaller wall,
shorter lifetime,
10075907
116
86
1045
no
high temperature, 15mm wall
10075910
116
86
1045
yes
high temperature, 15mm wall
up to 1600°C
Øo
Øi
volume
hole
application
10075909
116
96
1302
no
very high temperature, smaller wall,
shorter lifetime,

86070012_OPERATING_MANUAL_MU200_MU1200_F_GENERATOR 22.09.2011 KS page 20
6.4. Declaration of Conformity