Pi dental SILVERCAST User manual

Pi dental Fogászati Gyártó Kft.
Tel.: [phone] 2234 / 221 2077 fax: [phone]
85 Szugló St. H- 1141 Budapest,Hungary
www. pidental.hu e-mail: [e-mail]
EN
HEXACAST
Middle Frequency
Centrifugal Casting Machine
Instructions for Use
SILVERCAST

INSTRUCTIONS FOR USE
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Table of contents
1. Safety instructions .............................................................................4
1.1 Intended use ..............................................................................4
1.2 Explanation of symbols ..............................................................4
1.3 Guarantee and liability...............................................................5
1.4 Obligations of the authorized user ............................................5
1.5 Obligations of the personnel......................................................5
1.6 General information for the safe use of the equipment ...........6
1.7 High risks ....................................................................................6
1.8 Packaging ...................................................................................7
1.9 Package contents .......................................................................7
1.9.1 For metal framework casting can be ordered optionally: .7
2. Description of the machines ..............................................................8
2.1. Operating panels......................................................................10
2.2 Function ...................................................................................12
2.2 Assembling the machine..........................................................12
3. Installation .......................................................................................14
3.1 Positioning the machine ..........................................................14
3.2 Connecting the water supply of the laboratory.......................14
3.3 Electrical installation in the laboratory....................................15
4. Setting up and operation .................................................................16
4.1 Container centrifugal system...................................................16
4.1.1 Inserting the investment and the crucible.......................16
4.2 Adjustable centrifugal system..................................................17

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4.2.1 Inserting the investment and the crucible ...................... 17
4.3 Heating cycle ........................................................................... 18
4.4 Casting procedure.................................................................... 20
4.5 Opening the casting chamber cover and removing the casting
ring 20
4.6 Switching off the casting machine........................................... 21
4.7 Using the STOP button ............................................................ 21
5. Maintenance.................................................................................... 22
5.1 Cleaning the water inflow ....................................................... 22
Cleaning the casting machine.............................................................. 23
5.3 Crucible care............................................................................ 23
5.4 Error indicators........................................................................ 25
5.4.1. After turning on the machine................................................ 25
5.4.2 Base position. ......................................................................... 25
5.4.3. Smelting /inductor at high position/ ..................................... 25
5.4.4. Casting /after pressing the cast button/ ............................... 25
6. Technical data.................................................................................. 27

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1. Safety instructions
1.1 Intended use
Caution: Before switching the machine on, read through
these instructions!
The induction casting machine is intended solely for dental laboratory use, for
melting and centrifugally casting all conventional dental alloys with the
exception of titanium. This machine should only be used for the intended
purpose. The producer refuses any liability for damages originating from any
other use of the machine. Intended use also includes adhering to the
instructions for use as well as servicing and carrying out maintenance work at
regular intervals.
1.2 Explanation of symbols
Symbol
Text
Explanation
Attention!
This symbol, when used alone or in conjunction
with any of the following icons, indicates the
need to consult the operating instructions
provided with the product.
WARNING: A potential risk exists if the operating
instructions are not followed
Hot surface!
This symbol indicates the presence of a hot
surface or component. Touching this surface
could result in bodily injury.
WARNING: To reduce the risk of injury from a
hot component, allow the surface to cool before
touching.

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1.3 Guarantee and liability
The manufacturer provides 2 years guarantee for the appliance with the serial
number indicated on the last page of this document according to the General
Conditions of Sale and Delivery. Guarantee and liability claims for damages to
persons or equipment are invalid if the damage is found to have been resulted
from any of the following cases:
improper installation, operation, assembly or maintenance of the
machine
use of the machine other than for the purpose intended
operation of the machine with faulty safety equipment or improperly
installed or non-functioning safety and protective devices
disregarding the Instructions for Use relating to transport, storage,
assembly, operation and maintenance of the machine
inadequate monitoring of the parts exposed to wear and tear
unauthorized structural alterations to the machine
repair carried out improperly
1.4 Obligations of the authorized user
The authorized user is obliged to make sure that all those who operate the
machine
are familiar with the safety regulations and accident prevention and
have been instructed on how to operate the machine
have signed having read and understood the safety precautions and
instructions for use
have been instructed on the current regulations for the accident
prevention.
1.5 Obligations of the personnel
Before commencing any work, all those who operate the machine are obliged
to adhere to the basic regulations regarding safety at work
to sign having read and understood the safety instructions and
instructions for use.

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1.6 General information for the safe use of the
equipment
Do not modify the machine in any way.
The machine should not be used if it is in any way faulty.
Keep the working area clean. Untidiness at the workplace increases the
risk of accidents.
Do not reach into the machine while it is running. Do not open the
machine until the casting arm is at rest. The casting chamber lid cannot
be opened when the arm is rotating.
For safety reasons, use only accessories and materials recommended
by the instructions. Using materials other than those recommended in
the instructions constitutes an accident risk for the operator and
cannot therefore be regarded as intended use.
Always disconnect the machine from the mains before commencing
any maintenance work.
1.7 High risks
Warning: The machine operates generating middle frequency
electromagnetic waves and should not be operated by anyone having a heart
pacemaker.
Warning: Risk of burns on contact with the crucible or investment.
Always use tongs to remove the hot investment after casting.
Warning: Risk of fire! Do not place any flammable object in the casting
chamber.
Warning: Always use protective goggles when observing the molten
metal.
Warning: Only alloys mentioned under 1.1 should be melted.
Melting and casting light metals, such as aluminum, magnesium and titanium,
can be particularly dangerous.

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1.8 Packaging
The packaging protects the machine during transit, but provides only limited
protection against wet, heat and any mechanical force. The packaging should be
disposed of in the proper manner observing the local environmental
regulations.
1.9 Package contents
For Silvercast casting machine with container cenrtifugal system:
1 pc. Silvercast induction casting machine
1 pc. Instructions for Use with CE Conformity Declaration
1 pc. ¾”end fittings, inner Ø 8 mm
3 pcs. clips
1 set mould container (4 sizes: size 1-4)
1 set mould ring (4 sizes: 4 conical plastic ring with plastic plate).
1 pc. crucible for non-precious alloys
For Hexacast casting machine with adjustable centrifugal system:
1 pc. Hexacast induction casting machine
1 pc. Instructions for Use with CE Conformity Declaration
1 pc. ¾”end fitting, inner Ø 8 mm
3 pcs. clips
1 pc. crucible for non-precious alloys
1.9.1 For metal framework casting can be ordered optionally:
Mould rings: 1 set order no. 10-9440
(incl.: 2 sizes of conical Dentaurum system + 1 pc. plastic base
+ 3 pc. plastic funnel)
Mould containers: 1 set order no. 10-9600
(for container centrifugal system) (incl.: 2 sizes for Dentaurum mould rings)

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2. Description of the machines
Picture (1.)
SILVERCAST
with container
centrifugal
system
4
13, 14
15
3
1
10
2
11
12
5
6
9
7
8
20

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Picture (1.)
HEXACAST
with adjustable
centrifugal
system
4
13
14
16
3
5
6
9
1
7
10
2
11
12
8
17
18
19
20
2

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Machine top and rear views [Picture (1)]:
1) Casting chamber
11) Induction coil
2) Operating panel
12) Crucible holder
3) Casting chamber cover
13) Casting-frame
4) View glass
14) Investment holder (cradle)
5) Power out for circulation unit
15) Investment container
6) Two-pole circuit breaker (2 x 16 A)
16) Thumb-support arm
7) Power cable
17) Retraction-arm
8) Water-in from circulation unit or
water supply
18) Centrifuge-arm fixing knob
9) Water-out for water draining
19) Adjustable counterweight
10) Power switch
20) Service window with socket
2.1. Operating panels
see on [Picture (1) / pos. 2]
Operating elements:
[Picture (2)]
1) Power lamp (green LED)
2) Heating indicator (yellow LED)
3) Ready (green) / Error (red) inducator (bicolor LED)
4) Cover status indicator (red LED)
5) STOP button (red button)
6) Heating power regulation
7) Alloy selection
8) Program START button (green button)
9) CASTING start button (yellow button)

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Picture (2)
1
2
4
3
7
6
5
8
9
1
2
4
3
7
6
5
8
9
SILVERCAST
HEXACAST

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2.2 Function
Compact, easy to operate induction casting machine for melting and casting all
dental alloys with the exception of titanium and titanium alloys.
It is ideal for use in smaller commercial laboratories as well as in private practice
laboratories because it can be operated manually and has a variable heating
control. On the other hand, large laboratories can make good use of it too, as its
cooling system and capacity supports continuous operation.
The machine operates based on the principle of energy transfer used in
transformers and known as induction.
By creating a middle-frequency magnetic field, a secondary current is produced
through induction flows on the surface of the metal to be melted and this
current is transformed into heat which then melts the metal.
The eddying currents created in the molten metal ensure that the metal is
thoroughly mixed.
The subsequent centrifugal casting into an investment also helps to produce a
homogeneous mould.
The main advantages of induction casting machine are:
high melting capacity with low energy consumption
homogeneous melting and casting
minimum material loss
less finishing required
easy operation
compactness
easy maintenance.
2.2 Assembling the machine
The main part of the machine is a medium-frequency generator which is
encased in a sheet-steel housing. The generator meets the requirements of the
electromagnetic tolerance. The middle-frequency generator produces a 110 kHz
electromagnetic field which heats and mixes the molten metal to a very

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homogeneous consistency. The induction coil [Pict. (1) / pos. 11] is water-cooled
and protected against overheating.
The centrifugal arm [Pict. (1) / pos. 13] in the casting chamber
holds the crucible and the investment. The centrifugal arm has a
counterweight to ensure smooth, quiet running.
The induction coil (heating element) in the lower section of the
chamber rises automatically to encircle the crucible when the
program is started. After the heating phase, when the Casting
button is pressed, the induction coil is lowered and the casting
cycle commences.
The melting process can be observed through a protective glass
[Pict. (1) / pos. 4] which is integrated in the cover lid.

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3. Installation
3.1 Positioning the machine
Place the machine on a solid base, for example on a sturdy table, and set level.
The installation place should be clean and as free from dust as possible.
Caution: A minimum gap of 20 cm should be left between the
casting machine and any appliances on either side. This ensures
that the machine is well ventilated. Furnaces or other equipment
emitting heat should not be placed next to the casting machine.
3.2 Connecting the water supply of the laboratory
A fabric-reinforced water inlet pressure hose with ¾” threaded end fitting is
used to supply water from the stopcock to the Water-in connection on the back
of the machine [Pict. (1) / pos. 8].
A hose with an inner diameter of 8 mm is used to drain the water from the hose
nipple Water-out [Pict. (1) / pos. 9] on the back of the machine into a siphon or
directly into the domestic water drainage system. Ensure that there is no back
pressure when the water is being drained.
Caution: Check the water supply pressure if necessary before connecting
the machine. Ensure that the water pressure does not fall below
3 bars and does not exceed 8 bars, even in summer. A water
coolant pump unit should be fitted if the water pressure is too
low. If the water pressure exceeds 8 bars, a pressure reduction
valve should be fitted to the Water in connection of the
machine.

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Caution: If the water supply system is known to build up deposits
or collect dirt, a filter must be fitted to prevent the water sensor
malfunctioning.
3.3 Electrical installation in the laboratory
The casting machine should be connected exclusively into a 230 V earthed
socket which is equipped with a 16 Amp circuit breaker or a 16 Amp slow-blow
fuse.
Warning: All electrical work on the socket or electricity supply
and fuses may only be carried out by a qualified
electrician.
Prior to operating, check whether the nominal voltage corresponds
to the value indicated on the type plate the unit. The unit must be
connected to an earthed contact socket!

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4. Setting up and operation
4.1 Container centrifugal system
4.1.1 Inserting the investment and the crucible
After it has been correctly installed, the machine can be set up for casting.
Before each casting cycle the mould container matching by size with the mould
ring and the crucible should be inserted in its place.
1. First open the stopcock of the water supply.
2. Switch the machine on with the Power switch [Pict. (1) / pos. 10]. An
audible signal is heard when the machine is switched on and all the
indicators light up briefly as a check that the LEDs are functioning
properly. The green POWER indicator [Pict. (2) / pos. 1] lights up.
3. The green READY indicator [Pict. (2) / pos. 3] lights up when the water
is circulating properly.
4. Place the mould container matching by size with the investment into
the cradle [Pict. (1) / pos. 14].
Note: Each ring belongs to
its container. The matching
pairs are numbered. [Pict.
(3)]
5. Place the crucible with the ingots into the crucible holder [Pict. (1) /
pos. 12] in the centrifugal arm with the casting spout pointing towards
the investment.
Picture (3)

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If the heating cycle is not to be carried out immediately, the
machine can be switched off with the Power switch.
4.2 Adjustable centrifugal system
4.2.1 Inserting the investment and the crucible
After it has been correctly installed, the machine can be set up for casting.
Insert the investment and the crucible before each casting cycle.
1. First open the stopcock of the water supply.
2. Switch the machine on with the Power switch [Pict. (1) / pos. 10]. An
audible signal is heard when the machine is switched on and all the
indicators light up briefly as a check that the LEDs are functioning
properly. The green POWER indicator [Pict. (2) / pos. 1] lights up.
3. The green READY indicator [Pict. (2) / pos. 3] lights up when the water
is circulating properly.
4. Pull back the casting frame [Pict. (1) / pos. 13] by pulling the retraction
arm [Pict. (1) / pos. 17] by clamping your thumb around the thumb
support [Pict. (1) / pos. 16], insert the hot investment into the
investment holder [Pict. (1) / pos. 14] using tongs, and release the
retraction arm. In this position the investment is fixed automatically.
Position the investment so, that the flow is at the same height as the
crucible spout.
5. Place the crucible with the ingots into the crucible holder [Pict. (1) /
pos. 12] in the centrifugal arm with the casting spout pointing towards
the investment.
6. The centrifugal arm should now be balanced by loosening the arm
fixing screw [Pict. (1) / pos. 18] and turning the counterweight [Pict. (1)
/ pos. 19] on the spindle. Then tighten the star screw and remove the
investment, placing it back to the preheat furnace.
Caution: The arm fixing screw must securely be tightened. The
centrifugal arm or machine could otherwise be damaged during
casting.

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If the heating cycle is not to be carried out immediately, the machine
can be switched off with the Power switch.
4.3 Heating cycle
The actual casting procedure can be carried out after the investment has been
removed and the wax has been burnt out.
Note: The hot investment can either be placed in the mould
container just before starting the melting procedure or after the
ingots have been preheated in the crucible using the preheating
function. This prevents the investment cooling down too much.
Caution: Danger of burn when touching the crucible or the
investment.
Always use tongs to remove the investment after the casting
cycle.
Note: Use a graphite insert in the crucible when melting precious
metals with the exception of palladium alloys.
Heating procedure:
1. Check the water coolant supply before starting the heating cycle.
2. Switch the machine on at the Power switch [Pict. (1) / pos. 10]. The
green POWER indicator [Pict. (2) / pos. 1] lights up.
3. The green READY indicator [Pict. (2) / pos. 3] lights up when the water
is circulating properly.
Note: Use a graphite insert in the crucible when melting precious
metals with the exception of palladium alloys.

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4. Preset the heat using the HEATING POWER regulator [Pict. (2) / pos. 6].
Note: The HEATING POWER regulator should be set for each type of
alloy and according to the amount of metal required so that during
the 30 second preheat program the metal is still not fully melted.
5. Set the centrifugal force using the ALLOY SELECTION switch [Pict. (2) /
pos. 7]. The setting depends on the type of alloy (precious or non-
precious).
6. Turn the centrifugal arm so, that the crucible is just above the
induction coil. At this position you hear a continuous audible tone.
7. Press the PROGRAM START button [Pict. (2) / pos. 8]. The induction coil
rises automatically to encircle the crucible for melting.
8. Close the chamber cover. The red CLOSED sign [Pict. (2) / pos. 4] lights
up and the yellow HEATING sign [Pict. (2) / pos. 2] shows that the
heating function is automatically activated.
9. The metal begins getting melted after approx. 25 seconds. The melting
procedure should only be observed through the protective glass [Pict.
(1) / pos. 4]. The HEATING POWER regulator [Pict. (2) / pos. 6] is used
to regulate the heat during melting.
10. When the metal is pre-molten, the casting chamber cover can be
opened and the hot investment can be placed in the cradle (depends
on container os adjustable system).
11. Then close the casting chamber cover [Pict. (1) / pos. 3]. The red
CLOSED indicator [Pict. (2) / pos. 4] lights up when the cover is closed
and the heating resumes automatically showed by the yellow HEATING
indicator [Pict. (2) / pos. 2]. Keep the casting chamber cover closed
until the metal is molten and is ready for casting.
Caution: Risk of burns. The heating cycle can produce high
temperatures in the casting chamber.
Note: Press the red STOP button [Pict. (2) / pos. 5] or open the
cover to interrupt the heating cycle (refer to section 4.7)

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4.4 Casting procedure
After the casting chamber cover has been closed, the heating cycle resumes
automatically. The yellow HEATING indicator [Pict. (2) / pos. 2] lights up again.
1. Continue to observe the melting metal through the protective glass.
When the metal is completely molten, press the CASTING button [Pict.
(2) / pos. 9]. Casting will start only if the cover is safely closed.
2. The centrifugal arm is rotated by the force of an electric motor. The
centrifugal force casts the molten metal into the hot investment. The
yellow HEATING indicator [Pict. (2) / pos. 2] goes out.
4.5 Opening the casting chamber cover and
removing the casting ring
1. The centrifugal arm must be at a complete standstill before the green
READY indicator [Pict. (2) / pos. 3] lights up.
2. The casting chamber cover can now be opened and the investment
removed.
Caution: Risk of burns when removing the hot investment. Always
wear protective gloves and use the proper tongs to remove the
investment and the crucible.
Caution: Do not use force to open the casting chamber cover.
A cover-locking mechanism prevents the casting chamber cover
being opened during casting until the centrifugal arm is coming to a complete
stop.