schultheiss VPC pure User manual

VPC pure
Vacuum & Pressure Casting Unit
Translation of the Original Operating Instructions
Schultheiss GmbH │Römerstraße 21 │71296 Heimsheim │Germany
Phone [phone] │[e-mail] │www.schultheiss-gmbh.de
Version: 1 (16.05.2022) │DOC000159
EN

Operating Instructions VPC pure
Schultheiss GmbH │DOC000159
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In General
These operating instructions enable the safe and efficient use of the
Vacuum & Pressure Casting Unit. The operating instructions are part of
the product and must be kept accessible to the personnel in its
immediate vicinity at all times.
Personnel must carefully read and understand these instructions before
starting any work. Compliance with the safety instructions and handling
instructions specified in this manual is the prerequisite for safe working
practices.
In addition, the local health and safety regulations and general safety
regulations apply to the area of application of the machine.
Redistribution and duplication of this document, utilization and
communication of its contents are strictly prohibited unless expressly
permitted. Violations oblige to compensation.
After the editorial deadline of this documentation, the product may
have changed. We expressly reserve the right to make any changes to
the product.
The original operating instructions were created in German.
Our general terms and conditions apply.
©All rights belong to Schultheiss GmbH.
These instructions are valid for the following models:
–VPC pure
Schultheiss Customer Service
Phone:
[phone]
E-Mail:
[e-mail]

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Table of Contents
1Safety............................................................................... 5
1.1 Symbols in this Manual ................................................5
1.2 Intended Use ..............................................................7
1.3 Safety Devices.............................................................7
1.4 Attached Safety Markings.............................................8
1.5 Residual Risks .............................................................9
1.5.1 Danger due to Magnetic Field.................................9
1.5.2 Danger due to Electrical Current .............................9
1.5.3 Danger due to Hot Substances ..............................10
1.5.4 Danger due to Hot Surfaces ..................................10
1.5.5 Danger due to Moving Parts .................................10
1.5.6 Danger due to Compressed Air .............................11
1.5.7 Danger of Material Damage .................................11
1.6 Personnel Requirements.............................................12
1.7 Personal Protective Equipment....................................13
1.8 Environmental Protection ...........................................13
2Overview........................................................................ 14
2.1 Machine Assembly & Operating Elements ...................14
2.2 Nameplate ...............................................................15
3Transport & Storage ......................................................... 16
3.1 Transporting the Machine ..........................................16
3.2 Unpacking the Machine.............................................17
3.3 Storing the Machine ..................................................17
4Installation...................................................................... 18
4.1 Setting Up ................................................................18
4.1.1 Requirements for the Installation Location...............18
4.1.2 Setting Up the Machine ........................................18
4.2 Connecting the Machine............................................19
4.2.1 Connecting the Compressed Air Supply..................19
4.2.2 Connecting the Protective/Pressure Gas Supply.......19
4.2.3 Connecting the Cooling Water Supply ...................20
4.2.4 Connecting the Power Supply ................................21
5Emergency Shutdown ....................................................... 22
6Initial Commissioning....................................................... 23
6.1 Checking the Water System for Leaks..........................23
6.2 Switching On Fuse (-2F1) ..........................................23
6.3 Checking the Direction of Rotation of the Vacuum Pump
...............................................................................24
6.4 Performing Leak Detection .........................................25
6.5 Installing the Melting Crucible ....................................26
7Operation ...................................................................... 28
7.1 Switching On the Machine .........................................28
7.2 Selecting the Operation Mode ...................................28

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7.3 Selecting the Casting Program (Automatic Mode).........29
7.3.1 Adding a New Program OR Changing the Parameters
..........................................................................30
7.4 Performing a Casting Cycle in Automatic Mode ...........31
7.4.1 Overview of a Casting Cycle .................................33
7.4.2 Starting the Casting Cycle .....................................35
7.4.3 Filling Melting Material into the Melting Chamber...35
7.4.4 Inserting the Flask into the Flask Chamber..............36
7.4.5 Removing the Flask out of the Flask Chamber ........37
7.5 Performing a Casting Cycle in Manual Mode ..............39
7.6 Machine Information .................................................40
7.6.1 Sensors ...............................................................40
7.6.2 Diagnose ............................................................41
7.6.3 Machine Info .......................................................41
7.7 General Settings of the Machine.................................42
7.8 Casting with Differential Pressure ................................43
8Decommissioning ............................................................ 44
8.1 Shutting Down the Machine .......................................44
8.2 Shutting Down the Machine for a Long Period of Time (>
1 Month) ..................................................................44
9Maintenance & Repair...................................................... 45
10 Disassembly & Disposal.................................................... 46
10.1 Disassemble the Machine ..........................................46
10.2 Dispose of the Machine .............................................47
11 Technical Details ............................................................. 48
11.1 Operating Data ........................................................48
11.2 Dimensions & Weights...............................................48
11.3 Connections .............................................................48
11.4 Nameplate ...............................................................48

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Schultheiss GmbH │DOC000159
1Safety
1.1 Symbols in this Manual
The safety instructions in this manual are marked with symbols.
The safety instructions are introduced by signal words that express the
extent of the hazard.
DA NGER !
This combination of symbol and signal word indicates
an imminently dangerous situation which may lead to
death or severe injury if not avoided.
WA RN IN G!
This combination of symbol and signal word indicates a
potentially dangerous situation which may lead to death
or severe injury if not avoided.
CA UT ION!
This combination of symbol and signal word indicates a
potentially dangerous situation which may lead to minor
or slight injuries if not avoided.
NO TE !
This combination of symbol and signal word indicates a
potentially dangerous situation which may lead to
material damage if not avoided.
NO TE !
This combination of symbol and signal word indicates a
potentially dangerous situation which, if eye protection
is not worn, may result in eye damage.
NO TE !
This combination of symbol and signal word indicates a
potentially dangerous situation which, if protective
gloves are not worn, may lead to hand injuries.
NO TE!
This combination of symbol and signal word indicates a
potentially dangerous situation which, if foot protection
is not worn, may lead to feet injuries.
ENVIRO NME NTA L PROTEC TION!
This combination of symbol and signal word indicates
potential dangers to the environment.

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Special Safety Instructions
In order to draw attention to particular dangers, the following symbols
are used in safety notices:
Prohibition: No access for persons with pacemakers or
implanted defibrillators
Warning: Dangerous electrical voltage
Warning: Hand injuries
Warning: Hot substances
Warning: Compressed air
Tips & Recommendations
This symbol highlights tips and recommendations, as
well as information for efficient and trouble-free
operation.

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Schultheiss GmbH │DOC000159
1.2 Intended Use
The Vacuum & Pressure Casting Unit VPC pure is designed for casting
jewelry moulds in flange flasks or cylindrical flasks or to grain metal in
the granulating station.
The printing system is designed for temperature-controlled interiors
(→Chapter 11). Proper use requires compliance with all information in
this manual.
Any use going beyond the intended use or otherwise is deemed to be
improper. The operator is exclusively liable for any resulting damage.
Use contrary to the intended use includes, but is not limited to the
following actions:
–Operation within potentially explosive areas
–Operation with explosion-hazardous materials
–Outdoor operation
–Operation in tropical climates
–Operation in wet, damp rooms
–Operation without sufficient instruction
–Operation without mandatory safety equipment
–Operation with non-approved spare parts
–Operation with defective or modified safety devices
–Removing or modifying attached safety markings
–Improper conversions, modifications, repairs, and maintenance
1.3 Safety Devices
WA RN IN G!
Danger with non-functioning or dismantled safety
devices!
Safety devices serve to ensure safety during operation
and are not allowed to be removed, changed, or
bridged. Improperly functioning or removed safety
devices can lead to injuries.
–Safety devices are not allowed to be removed,
changed, or bridged during operation and an
active power supply of the machine.
–The safety devices must be removed only when
the machine has been switched off and is
disconnected from the power supply.
–All safety devices need to be checked for their
functionality each time the machine is turned on.
–If the safety devices are not functioning correctly,
the operation must be stopped immediately.
Defective safety devices need to be repaired or
replaced immediately.
The machine is equipped with the following safety devices:
–Lockable main switch
–Red stop button (Attention! No emergency shutdown function!)
–Security covers in the machine

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1.4 Attached Safety Markings
WA RN IN G!
Danger from illegible signs!
Over time, labels and signs may become dirty or
otherwise unrecognizable, so that dangers cannot be
detected, and necessary operating instructions cannot
be followed. Thereby a risk of injury arises.
–All safety, warning and operating instructions
must always be in a legible state.
–Damaged labels and signs must be renewed.
The following labels and signs are in the work area. They refer to their
immediate environment.
No access for persons with pacemakers
or implanted defibrillators
The machine marked with this symbol can emit an
electromagnetic field. The machine must not be operated
by persons with pacemakers or implanted defibrillators.
Live Components
The areas marked with this symbol can be live. Work in
these areas may only be carried out by qualified
electricians.
Hand Injuries
The lid/cover as well as both sides of the flask chamber
of the machine marked with this symbol consists of
moving parts. Work in these areas should be performed
always in awareness of moving parts. There is a danger
of hand injuries.
Hot Substances
The lid/cover of the machine marked with this symbol can
provide access to hot substances through its open state.
Work in this area should be performed always in
awareness of hot substances. There is a danger of
burning fingers/hands/body parts.
Live Components
The protective covers marked with this
combination of symbol and text protect the
operator from touching live parts during
operation. Work in this area may only be carried
out with a disconnected mains plug.
Live Components
The lid/cover marked with this
combination of symbol and text protects
the operator from touching live parts
during operation. Operating the
machine may only be carried out with
the inductor cover installed.

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1.5 Residual Risks
The machine is manufactured according to the state of the art.
Nevertheless, residual risks remain, which require action. The following
lists the residual risks and the resulting behavior and measures.
1.5.1 Danger due to Magnetic Field
DA NGER!
Risk of injury or death of a person due to electro-
magnetic interferences!
During operation, an electromagnetic field could be
emitted and interfere with medical implanted devices
(pacemakers and implanted defibrillators). There is an
electrical hazard of electromagnetic interferences.
–The machine must not be operated by persons
with pacemakers or implanted defibrillators.
1.5.2 Danger due to Electrical Current
DA NGER !
Danger to life due to electric current!
Incorrect connection, insulation faults, foreign objects
(dust, liquid due to inappropriate installation
environment) or lack of grounding can lead to housing
parts being live. There is an imminent danger of
electrocution in the event of contact with live parts.
–Work on the electrical equipment may only be
carried out by qualified electricians and in
compliance with the relevant safety and VDE
regulations.
–Machines with damage to the power cord,
insulation or lack of earthing must be
disconnected from the mains immediately.
Repairs are to be made immediately.
–Before starting work on active parts of the
electrical equipment, a de-energized state must
be established and ensured for the duration of
the work.
–Fuses must never be bypassed or put out of
operation.
–Connect the mains plug to the nearest and
correctly grounded socket to the machine.
–Only operate the machine with the mains voltage
specified for the machine.
–The mains plug must be freely accessible at all
times as the machine is completely disconnected
from the mains in case of an emergency by
pulling the mains plug. (→Chapter 5)
–Disconnect the machine from the mains during
longer absences and during heavy weather.
–Keep moisture away from live parts. This may
lead to short circuiting.

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1.5.3 Danger due to Hot Substances
WA RN IN G!
Risk of injury and burning due to hot substances!
During heating of the melting material, components
and the melting material inside the melting chamber
become very hot, and the operator may burn fingers/
hands/body parts when touching them. There is a
burning hazard of fingers/hands/body parts.
–Be aware of hot substances due to the intended
use of the machine.
–Never touch the crucible with bare fingers and
hands.
–Never locate your bare fingers and hands in the
area above the crucible during and after the
melting process.
–Never work below the crucible during the melting
process, hot liquid material could drop on your
bare fingers and hands.
–Do not work at the sealing rod while it is hot.
–Wear protective foundry gloves during operation
with the machine and hot substances.
1.5.4 Danger due to Hot Surfaces
WA RN IN G!
Risk of injury due to hot surfaces!
During heating of the melting material, the protective
covers may become hot, and the operator may burn
fingers/hands/body parts when touching them. There is
a burning hazard of fingers/hands/body parts.
–The protective covers will not reach a
temperature above 50°C.
–Nevertheless, be aware of hot surfaces due to
the intended use of the machine.
–Wear protective foundry gloves during operation
with the machine.
1.5.5 Danger due to Moving Parts
CA UT ION!
Risk of injury due to moving parts!
During automatic locking of the flask chamber, the flask
chamber will be lifted up towards the melting chamber
for vacuum processes. There is a crushing hazard of
fingers between both chambers during the closing
movement.
–Never insert fingers above the flask chamber
AND under the melting chamber, when pressing
the «Start»button.

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1.5.6 Danger due to Compressed Air
CA UT ION!
Risk of injury due to compressed air!
The machine requires compressed air for operation.
The working pressure of the machine is at 3 bar.
There is a risk of injury due to improper handling of
compressed air.
–Work at the compressed air system may only be
carried out by qualified personnel.
1.5.7 Danger of Material Damage
NO TE !
Material damage due to overheating!
The machine's electrical and mechanical parts are
designed for use only up to a limited ambient
temperature. Attention must therefore be paid to the
appropriate warning notices before putting the machine
into operation, as well as during operation. Deviating
environmental conditions may result in property
damage to the machine.
–Never cover the cooling slots of the machine.
–Maintain a service access to the back of the
machine.
–Maintain adequate space around the machine,
so that the heat generated can dissipate
unhindered. (See the requirements for installation
location, →Chapter 4.1.1)
–Maintain the specified ambient temperature.
(→Chapter 11.1)
–Never install the machine in a closed cabinet.
NO TE!
Material damage due to environmental conditions!
The machine's electrical and mechanical parts are
designed for use only up to a limited ambient
temperature. Attention must therefore be paid to the
appropriate warning notices before putting the machine
into operation, as well as during operation. Deviating
environmental conditions may result in property
damage to the machine.
–Protect the machine from moisture, dripping
water and splashing water.
–Do not operate the machine in damp rooms.
–Do not operate the machine in tropical climates.
–Do not expose the machine to direct sunlight.
–Do not expose the machine to open flames.
–Do not place objects filled with liquids (such as
drinks) in the immediate vicinity of the machine.

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1.6 Personnel Requirements
WA RN IN G!
Risk of injury in case of inadequate qualification of
personnel!
If unqualified personnel carry out work on the machine,
dangers arise which can cause injuries and material
damage.
–All activities must be carried out by qualified
personnel only.
Operator
The operator is the person who operates the machine for commercial
or economic purposes or loans it to a third party for operation and
bears legal product responsibility during the operation for the
protection of the user, the personnel or third parties.
The operator has been trained by the manufacturer in handling the
machine and the necessary accessories and can recognize possible
dangers independently and avoid hazards.
Operator Obligations
The operator is obliged to
–read these operating instructions fully before using the system for
the first time.
–to ensure that all persons working with the machine have read
and fully understood the contents of these operating instructions.
–provide these operating instructions for the personnel at a fixed
location near the machine.
–regularly inform all persons who work with the machine about
the current general accident protection guidelines. The operator
must ensure that precautionary safety measures at work are
respected.
–inspect first aid facilities and fire protection regularly and to keep
them up to date.
–provide the prescribed safety equipment to all persons working
with the machine.
–check all safety devices and safety equipment regularly for their
functionality.
Qualified Electricians
Due to their professional training, knowledge, and experience as well
as knowledge of the relevant standards and regulations, electricians
are able to carry out work on electrical systems and to recognize and
avoid possible dangers independently. The qualified electrician has
been specially trained in the working environment in which he or she is
active.
Impaired Persons & Trainees
Only persons who can be expected to perform their work reliably are
eligible as qualified personnel. People whose response capacity has
been affected, e.g., through drugs, alcohol, or medication, may not
work on the machine.
Personnel who are being trained, instructed, taught, or undergoing
general apprenticeships should only be allowed to work on the
machine under the constant supervision of the operator.

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1.7 Personal Protective Equipment
Personal protective equipment helps protect people from negative
impacts on their safety and health.
Personnel must wear personal protective equipment while working on
and with the machine, as referred to in the individual sections of this
manual.
The personal protective equipment must be provided by the operator
and must be checked for function before starting work on the machine.
The following describes the personal protective equipment.
Protective Goggles
We recommend wearing protective goggles during all
operation steps of the machine to prevent the eyes from
splashing liquid materials or other harmful effects on
the eyes.
Foundry Gloves
We recommend wearing foundry gloves during all
operation steps of the machine to prevent fingers and
hands from hot substances and high temperatures.
Feet Protection
We recommend wearing foot protection during all
operation steps of the machine to prevent the feet from
injury from falling objects, e.g., flask.
Other
We recommend tying up long open hair and wearing it under a hair
protector. Wear tight fitting clothing to prevent long clothing from
getting caught.
1.8 Environmental Protection
E NV IR ON ME NT AL PR OT E CT IO N !
Danger to the environment through incorrect disposal
of materials!
Incorrect disposal of consumables, electronic waste,
electronic components, lubricants, and other additives
can be hazardous to the environment.
–Please dispose of consumables, machine parts
and auxiliary materials in accordance with their
intended use through your local recycling depot
or approved specialist companies.

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2Overview
2.1 Machine Assembly & Operating Elements
Figure 1: Machine overview, front & rear side
1
Main switch
12
Lid/Cover
2
Nameplate
13
Power connection
3
Touch display
14
USB port
4
Stop & Start buttons
15
Ethernet connection
5
Protective covers
16
Vacuum pump power connect.
6
Machine feet
17
Water input connection
7
Flask chamber
18
Water outlet connection
8
Drip tray
19
Vacuum pump tube connect.
9
Melting chamber
20
Pressure gas connection
10
Lid/Cover opening knob
21
Compressed air connection
11
Melting chamber window

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2.2 Nameplate
The nameplate is located on the right side of the machine next to the
main switch. It shows the most important technical data and the serial
number of the machine.
Figure 2: Nameplate VPC pure (example)

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3Transport & Storage
3.1 Transporting the Machine
CA UT ION!
Risk of injury due to falling loads!
If the machine falls over, there is a risk that body parts
can be crushed.
–When transporting the machine, wear suitable
protective clothing.
–Always transport the machine slowly and carefully
and with foresight.
–Use suitable lifting and transport equipment
which comply with the weight of the machine.
–Always follow the procedure specified for
transporting and unpacking the machine.
–Before starting the transport check that the
transport route is clear of obstacles.
NO TE !
Material damage caused by improper transport!
Improper transport may cause the machine to fall over.
This can cause material damage.
–The machine may only be transported by trained
qualified personnel.
–Before commencing transport, attach suitable
securing devices to the lifting and transport
equipment to secure the transport box against
falling over.
–Never transport the machine in the horizontal!
–In the event of subsequent transport of the
machine, it must be ensured before the start of
transport that no auxiliary materials are present
in the machine interior.
–In the event of subsequent transport of the
machine, use the original transport box to ensure
best securing of the machine.
The machine is shipped upright on a pallet in a secure transport box.
Check the transport box and the attached shock indicator
(ShockWatch®) for visible damage immediately on receipt. Damage
must be recorded in written and image form and then immediately
reported to the transport company and Schultheiss.
Before commencing transport, secure the transport box against falling
over with suitable securing devices on the lifting and transport
equipment, which are designed for the transport box weight including
that of the machine (approx. 200 kg). Transport the transport box to
the destination.

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3.2 Unpacking the Machine
Recommendation: Use a team of two to unpack the machine.
Please proceed as follows to unpack the machine:
1. Ensure there is enough free space around the transport box.
2. Unwrap the machine.
3. Open the box and remove any protective covers/foams and
tensioning belts/lashes from the machine.
4. Check if there are shipping damages or loose components such
as screws.
5. Now set the machine up. →Chapter 4.1
When crossing ground sills, roll each castor of the
machine individually over the sill.
Store all parts of the transport box safely for future
transport of the machine. No warranty can be accepted
for returns made without the original packaging and
additional costs may be incurred as a result.
3.3 Storing the Machine
When not used for a prolonged period, store the machine
–in a dry, dust-free and frost protected (temperature-controlled)
environment.
–on a horizontal and stable base.
–with the flask chamber and lid/cover closed.
–best secured in the original transport box using lashing straps to
protect against outside impact and tipping over.
Also make sure that no consumables are left remaining in the machine
and that coarse impurities have been removed.

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4Installation
4.1 Setting Up
4.1.1 Requirements for the Installation Location
Please observe the requirements for the installation site listed below in
order to provide the best conditions for correctly operating the
machine:
–Separate room away from other work being performed.
–Climate-controlled environment with an adequate supply of
fresh air/air exchange.
–Flat and solid surface for setting up the machine with adequate
space on all sides (approx. 80 cm space at the back of the
machine, approx. 20 cm on the left and right side of the
machine, approx. 100 cm above the machine).
–Compressed air supply available.
–Water supply available.
–Electrical power supply available. →Chapter 11.3
4.1.2 Setting Up the Machine
WA RN IN G!
Risk of injury due to improper setting up of the machine!
When setting up the machine, the machine may fall
over due to non-compliance with the requirements for
the installation site. There is a crushing hazard of body
parts.
–Observe the defined requirements for the
installation site of the machine.
(→Chapter 4.1.1)
–Setting up the machine may be performed by
qualified personnel only.
–In case of doubt, please contact the Customer
Service.
For setting up the machine please proceed as follows:
1. Prerequisite: The machine has already been fully unpacked.
→Chapter 3.2
2. Push the unpacked machine on the castors to the desired
location and set the machine down.
3. To ensure proper operation, the machine needs to be aligned in
a horizontal position for operation. Uneven floors can be
levelled out using the two feet on the front side of the machine.
4. Adjust the two feet of the machine in height by screwing the feet
up or down.
5. Take a spirit level to check that the machine is evenly aligned.
6. Connect the machine to the necessary supplies. →Chapter 4.2

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4.2 Connecting the Machine
4.2.1 Connecting the Compressed Air Supply
CA UT ION!
Risk of injury due to compressed air!
The machine requires compressed air for operation.
There is a risk of injury due to improper handling of
compressed air.
–Work at the compressed air system may only be
carried out by qualified personnel.
The compressed air supply connection is located on the bottom rear
side of the machine. The compressed air supply has to have a pressure
of 6-7 bar, 90-105 psi.
Please proceed as follows to establish the compressed air supply:
1. Prerequisite: The machine has already been completely set up.
→Chapter 4.1.2
2. If the supply tube is newly installed, it is recommended to clean
the new tubing by streaming out a lot of air before the
connection is made to the machine.
3. Connect the compressed air tube of the external compressed air
supply to the compressed air supply connection «AIR PRESSURE»
of the machine. Be careful not to trip over tubes lying around.
4.2.2 Connecting the Protective/Pressure Gas Supply
The protection gas supply connection is located on the bottom rear
side of the machine. The supply bottle must be equipped with fittings
comprising a pressure regulator (0-10 bar, 150 psi) and two pressure
gauges.
The supply has to have a pressure regulator of 4-6 bar, 60-90 psi.
The gas pressure is monitored by means of a pressure switch.
The protection gas must be absolutely dry and of the following
composition:
99,99%
99,99%
95%
nitrogen OR
argon OR
nitrogen with 5% hydrogen (ready mix)
Please proceed as follows to establish the protective/pressure gas
supply:
1. Prerequisite: The machine has been connected with a
compressed air supply. →Chapter 4.2.1
2. If the supply tube is newly installed, it is recommended to clean
the new tubing by streaming out a lot of gas before the
connection is made to the machine.
3. Connect the protective/pressure gas tube of the external
protective/pressure gas supply to the protective/pressure gas
supply connection «GAS PRESSURE»of the machine.
Be careful not to trip over tubes lying around.

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4.2.3 Connecting the Cooling Water Supply
NO TE!
Cooling water must be free of suspended matter. If it is
possible that the cooling water is polluted, it is generally
advisable to install a large-surface water filter in the
water supply line (the inductor tubes have a small
diameter through which the cooling water must flow).
NO TE!
The cleaning operation described in step 2 (see below)
must be affected before the water supply line is opened
to the machine.
The cooling water connections are located on the bottom rear side of
the machine.
The water inlet has to have a pressure of min. 4 bars (60 psi) and max.
6 bars (90 psi). The water outlet must be installed without pressure at
the outlet (max. 0,4 bar, 6 psi). The water pressure at the inlet and
outlet is monitored by means of pressure switches.
Please proceed as follows to establish the cooling water supply:
1. Prerequisite: The machine has been connected with a
protective/pressure gas supply. →Chapter 4.2.2
2. If the supply tubes are newly installed, it is recommended to
clean the new tubing by streaming out a lot of water before the
connection is made to the machine.
3. Connect the cooling water tubes of the external cooling water
supply to the «WATER INPUT»and «WATER OUTLET»
connections of the machine. Be careful not to trip over tubes
lying around.