Indutherm MC60V Guide

Technical Documentation
Mini Casting unit MC60V
9 Deforest Street
Amityville, NY, 11701
USA
Keep for future use!
Romanoff order service for
consumables:
www.romanoff.com
Romanoff
technical service
Tel.: [phone]
[email protected]

Revision
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2
Revision
Date
chapter
Reason
responsible
2018-02-06
All
Edition 2018
RK
2019-01-08
All
last changes
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

Contents
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Contents
Contents...........................................................................................3
1General information............................................................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
2Safety...................................................................................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 Safety markings on the unit.................................................2–4
2.4 Safety marking....................................................................2–5
2.5 Safety advices.....................................................................2–6
2.6 Residual risks......................................................................2–9
2.7 Behaviour in an emergency.................................................2–9
3Technical Data ....................................................................3–1
4Description of the system ..................................................4–1
4.1 Components of the system..................................................4–1
4.2 Schematic representation....................................................4–2
4.3 Connections on the backside ..............................................4–3
4.4 Set-up in the vacuum chamber............................................4–4
4.5 Front panel display..............................................................4–5
4.5.1 MC60V screen when starting the machine..........................4–5
4.5.2 MC60V modify program screen...........................................4–6
4.5.3 MC60V modify system parameter.......................................4–7
4.5.4 MC60V State-Level (Service Info Page 1 + 2).....................4–8
4.6 Front panel buttons.............................................................4–9
4.7 Functional description.......................................................4–10
4.8 Casting programs for MC60V (05.12.2016).......................4–12
4.9 Temperature control..........................................................4–13
4.10 Tree making......................................................................4–14
4.11 To find out the weight of the metal ....................................4–15
4.12 Using already cast material...............................................4–16

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4.13 Notes on the properties of some metal alloys....................4–16
4.14 Investment material...........................................................4–17
4.15 Investment process...........................................................4–18
4.16 Determination of the powder / water partial quantities.......4–19
4.17 Recommendations for flasks.............................................4–20
4.18 Preheating of the flasks.....................................................4–20
4.19 Flask temperatures ...........................................................4–23
4.20 Collection of spoiled castings............................................4–24
5Transport.............................................................................5–1
6Mounting and commissioning ...........................................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 Protective gas.....................................................................6–3
6.3.4 Vacuum...............................................................................6–3
6.3.5 Gas out...............................................................................6–3
6.3.6 RS232 for service................................................................6–4
6.3.7 LAN, Ethernet or RJ-45 connector for service.....................6–4
6.3.8 USB-socket (B-type) for service..........................................6–4
7Operation.............................................................................7–1
7.1 Safety advices for operation................................................7–1
7.2 Changing casting parts .......................................................7–1
7.2.1 Removal..............................................................................7–2
7.2.2 Mounting.............................................................................7–2
7.3 Recommendation for a casting process ..............................7–3
7.4 Error diagnosis....................................................................7–4
7.5 Troubleshooting ..................................................................7–4
7.6 Service................................................................................7–4
8Maintenance.........................................................................8-1
8.1 Safety advices for repair and maintenance...........................8-1
8.2 Maintenance schedule.........................................................8-2
8.3 Repair..................................................................................8-3
9Dismantling and cleaning up ..............................................9-1
10 Annexe................................................................................10-3
10.1 List of figures......................................................................10-3
10.2 CE Declaration of conformity..............................................10-4
10.3 Connection diagrams.........................................................10-6

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10.4 Cut diagram of the replacement parts ................................10-7
10.5 Consumable –and spare parts list.....................................10-7
10.6 Software documentation with error messages....................10-9

General
information
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1–1
1 General information
1.1 Scope of delivery and responsibilities
The mini casting machine MC60V is delivered complete. 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 Erwärmungsanlagen GmbH 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 Erwärmungsanlagen GmbH don’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 Erwärmungsanlagen GmbH!
INDUTHERM Erwärmungsanlagen GmbH don’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 Erwärmungsanlagen GmbH 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.
Operating company has to ensure operating personnel has read and
understood the manual before they are going to use the machine.

General
information
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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 manufacturer.
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 mini casting machine is only guaranteed at
intended use.
The mini casting machine serves exclusively for melting, pouring and
vacuum casting of commercially available precious metals and of
copper- or aluminium-alloys. Dental alloys and high reactive alloy like
magnesium can’t be melted. The specified temperature ranges must
be complied 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! The declaration of conformity will expire with modi-
fication.
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.
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 mains
switch; you can unplug the mains plug as an emergency stop.
The wall socket for the mini-casting unit MC60V must be freely
accessible.
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 in power supply free
state (mains switch in off-position, mains plug disconnected and
placed in sight). 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 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.
At 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.
Read instruction
manual.
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 will result
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.
Danger!
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.

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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.
Warning!
Risk of burning on hot surfaces and hot metal
(until ~ 1300 °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.
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.

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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
mains plug).
The capacitors can retain their charge even after de-
activation of the system.
Keep the housing of the mini-casting unit closed con-
tinually.
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.
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.
Warning!
Risk of burns:
burns because of squirting liquid metal and
burns at hot surfaces.

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Warning!
Danger of explosion.
Dripping liquid metal can’t be excluded.
The set-up place (table) and the floor beneath the system should be
made of non-flammable material. As well there shouldn’t 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.
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.
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!
Danger of burns by leaking liquid metal.
Warning!
Health risk because of lifting heavy weight.
Lift and transport the machine only by two persons.
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
specific collecting boxes.

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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 the vacuum chamber insulation in dustproof package.
Remove the material just before installation.
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.
Danger of explosion because of
dripping of liquid metal in a wa-
ter filled steel tub during melting
of aluminium or aluminium-
alloys.
Fill the tub with sand.
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 installation must be trained about the
behaviour in an emergency.
All persons who are working with the machine must be informed of
the possibility of rapid standstill of the device.

Technical
Data
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3 Technical Data
MC60V
Crucible volume
50 cm³ (practically 38 cm³)
Pressure range in melting cham-
ber in bar
-1 to 2
Crucible temperature in °C
max. 1300
Melting performance in kW
3.5
Mains supply
230 V, 50 or 60 Hz
Fuse protection in A
16
Abduct current in mA
4.45
Thermocouple
Type N (NiCr-Ni), max. 1300 °C
Cooling water supply
Øa 6 mm, 2.5 - 5 bar /
min. 1.5 liter/minute, max. 6 °dH
Cooling water recoil
Øa 6 mm, pressureless, maximum 70 °C (158
°F)
Cooling water entry temperature
15 - 25 °C / 59 - 77 °F {to prevent condensation:
20 - 25 °C / 68 –77 °F}
Ambient temperature
10 - 35 °C / 50 - 95 °F
Relative humidity
20 - 80 %
Protective gas supply
Øa 8 mm, argon or nitrogen, 6-8 bar
Vacuum
Øa 8 mm, min. 8 m³/h, 0.1 mbar abs.
Weight in kg
ca. 32
Dimensions in mm
(Wide x Depth x Height)
400 x 450 x 450
Maximum melting temperature
type N (NiCr-Ni): 1300 °C
Noise emission in dB (A)
72

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,
microprocessor controlled induction generator DM-type,
middle-frequency transformer,
oscillating circuit capacities and
pneumatic (magnet-) valves.
The front plate contains:
front panel for control of the casting process.
To the melting system belongs:
inductor housing, water cooled with inductor, crucible, insulations
and thermocouple.

System
description
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4.2 Schematic representation
Figure 1: overall view
1
3
4
5
6
2
7
Position
Description
Function
1
tilting handle with
lock
Due to movement to the right the machine will
cast.
2
inductor housing
The melting and casting process takes place
here.
3
control buttons.
Control the casting process. See ch. 4.6.
4
LCD screen
See chapter 4.5
5
top plate with
handle
Locks the inductor housing.
6
lock
Locks the system for safety reasons and to
allow overpressure.
7
mains switch
Machine will be turned on and off here.

System
description
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4.3 Connections on the backside
Figure 2: backside of the mini-casting machine
8
10
9
7
6
5
4
3
2
1
Position
Description
Function of the connection
1
vacuum filter
filters the vacuum
2
Gas out
gas outlet
3
Protective gas
input for protective gas
4
Vacuum
connection for external vacuum pump
5
Water In
input for cooling water
6
Water Out
output for cooling water
7
mains cable
electrical connection for machine
8
RS232 connection
connection for PC or modem for service issues
9
Ethernet
connection for Ethernet-cable (RJ45) for service
10
USB-B-socket
connection of USB cable for service issues