schultheiss VPC040 Power User manual

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
page 1 of 35
Operating
Instructions
for
VPC040 Power
Vacuum and Pressure
Casting Unit
December 2015
Software Version V53 (V72)

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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Index
Chapter 1 Security instructions Page 03
Chapter 2 Directed use Page 04
Chapter 3 Security prescriptions Page 05
Chapter 4 Installation Page 09
Chapter 5 Installation of the graphite melting crucible Page 12
Chapter 6 Operator Interface and Control Page 16
Chapter 7 Sensor Test / *SENSORS* Page 20
Chapter 8 Automatic casting / VPC040 Power graphite Page 23
Chapter 13 Switch off the unit after the casting cycle Page 31
Chapter 14 Error check-list and corrections Page 32
Chapter 15 Customer service Page 35

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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1. Security instructions
Pay attention to the advice given in the operating instruction
 To ensure a secure and trouble-free performance of the machine, please pay
attention to the basic security regulations for the operation of machines.
 These operating instructions contain the most important prescriptions for a safe
operation of the machine.
 All persons operating this machine must pay attention to the operating instructions,
above all the security instructions.
Responsibility of the operating company
The operating company is obliged to only let persons work at the machine who
 have been trained to operate the machine,
 have been informed about the instructions for safe operation and prevention of
accidents,
 have read and understood these operating instructions and confirmed this by their
signature.
The operating company must examine in regular intervals if their staff pays attention
to the security instructions and regulations.
Responsibility of the staff
Persons, who are instructed to work with the machine are obliged before operating the
unit to
 pay attention to the instructions and regulations for a safe operation of machines in
general
 and especially to pay attention to the instructions, above all the security instructions
and warnings given in this manual.
Dangers in operating machines
The casting machine VPC 040 has been designed and constructed according to the
current standard of technique and the approved regulations for security.
The machine is to use only for
 directed use and
 in impeccable security technical state.
Improper use of the machine leads to danger for the operating or other persons and to
damages on the machine, the work pieces or other real values.
Disturbances, which have a negative effect on the security of the machine must be
corrected at once. Do not work with the machine until the error has been corrected.

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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2. Directed use
The vacuum and pressure casting unit VPC is only designed to cast jewellery and
dental forms in flange flasks or cylindrical flasks.
It is improper to use the machine for other or further purposes. Company Schultheiss
GmbH cannot be held responsible for damages caused by improper use.
For directed use please:
 take into consideration all instructions of this manual
 and carry out regular control and maintenance work.
Warranty and liability
Our „General conditions for sale and delivery“ apply. These conditions have been
placed at the operator’s disposal with the conclusion of the purchase contract at the
latest.
Company Schultheiss cannot maintain warranty services or be held responsible for
personal injuries or material damage when they are due to one or several of the
following causes:
 improper use of the machine
 improper mounting, set-up, operation or maintenance of the machine
 operation of the machine with defective and/or not functioning security and
protective devices
 disregard of the operating instructions
 unauthorised structural changes of the machine
 insufficient control of wearing parts
 catastrophes caused by alien elements or acts of God

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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3. Security prescriptions
Definition of the symbols (operating manual)
The following symbols have been used in this operating manual:
Danger
This sign symbolises dangers for life and
health of persons.
If you do not pay attention to instructions
marked with this sign serious injuries will be
the result.
Attention
This symbol stands for situations that could
be dangerous.
If you do not pay attention to the
instructions marked with this sign smaller
injuries or damage of real values could be
the result.
Advice
This symbol stands for advice and useful
information for the operator.
This advice facilitates the operation of the
machine.
Definition of the symbols (machine)
You will find the following signs on the machine:
Voltage
This sign stands for machine parts which
present a danger through electrical voltage.
Only trained experts may work at these
parts or adjust them.

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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Organisational measures
The protective equipment for the staff must be provided by the operating
company.
All security devices must be examined before starting to work with the
machine.
Security devices
Prior to each working procedure with the machine install the following security devices
and check their proper functioning:
 the main switch, to ensure that no unauthorised person can operate the machine or to
prevent that the machine is started by accident,
 the stop key to switch off the heating element and to stop the automatic cycle.
(Attention: no emergency shut-down function!)
 security and thermal protection covers in the machine.
Removal of security devices
The security devices may be removed only when:
 the machine has been switched off and
 has been protected against unauthorised starting.
Informal security measures
Keep the operating manual at the operational area of the machine. In addition, the
general and local regulations for accident prevention and environmental care must be
provided and observed.
Keep all signs at the machine in readable condition.
Working at the machine
Only trained staff may work at the machine.
Clarify who is responsible for
 operating
 switching on and preparing the machine
 maintenance and repair of the machine
Trainees may only work at the machine under supervision of a trained person.
Security measures during normal operation
Do only work at the machine when all security devices are functioning properly.
Examine the machine at least once per day for apparent damages and check if the
security devices are functioning properly.

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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Danger through electrical energy
 Works at the electrical equipment and power supply of the machine
may only be carried out by an electrician.
 Keep the control cabinet always closed! Only authorised experts may
work in the control cabinet.
 Exchange loose connections and damaged lines immediately. Do not work with the
machine before the defective parts have been exchanged.
Works at live parts may only be effected if absolutely necessary.
Danger through protective gas
 Working pressure of the machine is 4 to 6 bar.
 Works at the protective gas net of the unit may only be carried out by qualified
personnel.
Structural changes at the machine
The machine may not be extended or modified without authorisation of the
manufacturer. An authorisation of company Schultheiss GmbH in writing is necessary
for all modifications at the unit.
Machine parts which are not in impeccable condition must be exchanged immediately.
Use only original spare parts of company Schultheiss GmbH. The manufacturer cannot
maintain warranty if other replacements, spare parts or wearing parts are used.
Cleaning the machine and waste disposal
Used material must be disposed of properly.
Copyright
Company Schultheiss GmbH has the copyright on this operating manual.
This operating manual is meant only for the operating company and its staff.
The operating manual contains instructions and information which may not be issued or
copied neither completely nor partially.

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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WARNINGS TO BE PAID ATTENTION TO:
 Before filling in the metal to melt, please check if the sealing rod is
adjusted to correct height and if the crucible bottom is sealed. Turn the
sealing rod to get dirt out of the sealing area.
 Fill metal into the crucible only when the vacuum chamber is under the casting system
and when the metal collecting basin has been installed at the vacuum chamber (security
system).
 Melt only if the vacuum chamber is under the casting system with the melting crucible
outlet.
 Never work below the crucible during the melting procedure, hot liquid metal could drop
onto your hands and fingers and you might get burned.
 In hot status of the crucible refill only dry metal and metal corresponding to the melt and
system temperature. Hot metal could drop out and you might get burned.
 Make sure to wear safety goggle, safety gloves and safety clothes when filling in the
metal. Hot metal could drop out and you might get burned.
 Do not work at the sealing rod while it is hot. You may burn your fingers.
 Do not change the crucible while it is hot. You may burn your fingers.
 A regular maintenance of the machine must be provided. This includes:
- electricity supply check and lines check
- water supply pressure, flow and quality check at and through the machine
- checking of mechanical, electrical, pneumatic as well as power components of the
machine.
 Adjust the casting parameters according to the metal in use and the desired
parts. Consult casting experts and/or the metal material supplier (metal
datasheet) for assistance in setting casting parameters.
 Use a casting program only when all parameters have been set. Missing parameters lead
to faulty logic operation of the casting programs and thus cause problems during the
casting cycle.
 Do not change casting parameters during the automatic operation of a program as this
may cause problems during the casting cycle.

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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4.0 Installation
4.1 Unpacking and set-up:
- Unwrap and verify completeness of the unit and the accessories.
- Position unit at the place of installation and adjust horizontally
with a bubble level.
- Ensure that the unit stands firmly. Put sheets underneath if necessary.
- Check the control cabinet and take out any packaging material
(only if machine is disconnected from power supply).
- Ensure tightness of all electrical connections and screws inside and outside
the control cabinet, as these may have loosened during transport
(only if machine is disconnected from power supply).
- Check for transport damages or loose component parts or screws.
Find connections of the casting unit at the rear side of the unit.
See connecting diagram VPC 040 in the machine documentation.
4.2 Connection of the protection gas supply:
The protection gas supply connection is located on the rear side of the unit.
The supply bottle must be equipped with fittings comprising a pressure
regulator (0 – 10 bar) and two pressure gauges.
The supply has to have a pressure regulator of 4 to 6 bar (recommended 5.5
bar), 60 - 90 psi. No flow gas regulator is allowed.
Protection gas must be absolutely dry and of the following composition: 99,99 %
nitrogen or 99,99 % argon.
If the supply tube and hose is newly installed, it is recommended to clean the
new tubing by streaming out a lot of gas before the connection to the unit is made.
A connection of air supply is not necessary!

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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4.3 Connection of the cooling water supply:
The cooling water connections are located on the rear side of the unit.
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.
The water pressure at the inlet is monitored by means of a pressure switch.
Cooling water must be free of suspended matter. If cooling water may be
polluted, it is recommended to install a large-surface water filter in the supply line.
Otherwise the water flow through the machine –particularly the heating inductor
tubes– may block after a certain time. This will lead to damage of the machine
through pipe burst.
If the supply tubes and hoses are newly installed, it is required to clean the
new tubing by streaming out a lot of water before the connection is made to
the unit.
This cleaning operation must be effected before the water supply line is
connected and opened to the unit.
The cooling water supply line may now be opened to test the water system for
leaks. Water must be discharged without pressure. If there is pressure at the outlet
line, the water inlet pressure must also be increased according to the outlet
pressure to attain a difference in pressure of min. 3 bars.
ATTENTION: – WATER VS. ROOM TEMPERATURE:
COOLING WATER TEMPERATURE MAY NOT FALL MORE THAN 7°C
UNDER ROOM TEMPERATURE (EG. 18° C ROOM VS. 20 TO 25 °C
WATER; E.G. 30°C ROOM VS. 32 TO 37 °C WATER). OTHERWISE,
CONDENSATION OF WATERS MAY CAUSE MACHINE DAMAGE.
MAXIMUM WATER TEMPERATURE AT INLET MAY NOT EXCEED 30 °C
TO AVOID UNIT OVER HEATING.
ATTENTION: - WATER OUTAGE:
IF WATER OR POWER SUPPLY FAILS WHEN CRUCIBLE AND METAL
INSIDE HAVE MORE THAN 100 °C, IMMEDIATE SECURITY WATER BY
TAP
OR BY GRAVITY SUPPLY MUST BE PROVIDED, OTHERWISE THE
CRUCIBLE MUST BE TAKEN OUT FROM THE HEATING COIL BY MEANS OF
TONGS.
ATTENTION: - WATER SUPPLY MAINTENANCE NOTE:
WATER INLET AND OUTLET PRESSURE AS WELL AS WATER FLOW
THROUGH
THE MACHINE MUST BE CONTROLLED REGULARLY. OTHERWISE
DAMAGE OF
THE MACHINE THROUGH PIPE BURST MAY ARISE.
4.4 Connection of the mains voltage:

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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Connect power cable to the mains supply.
ATTENTION – MAINS SUPPLY:
CHECK SUPPLY VOLTAGE OF 230 V AC, +/- 5 %, 50 CYCLES.
FUSING ACCORDING TO UNIT TECHNICAL DATA.
MAKE SURE THAT GROUND CONNECTION
(POTENTIAL EARTH) IS INSTALLED.
4.5 Installation of the vacuum pump:
Connect the vacuum pump to the unit with the vacuum hose. Tighten the hose
clamp carefully. Clean the vacuum connection carefully before installing.
Make sure before connection that hose and connections are absolutely free of any
dirt before connecting.
Switch ON the system at the main switch at the right side of the unit. The display
on the control panel lights up.

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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5.0 Installation of the melting crucible
See mounting drawing in the machine documentation.
5.1 Prepare the side crucible isolation by cutting a rectangular sheet of thermal isolation
(height equivalent to the crucible, length equivalent to one time -ceramic crucible- or
two times -graphite crucible- the circuit length).
Attention:
Use standard temperature isolation mate for the graphite crucible and ultra
high temperature isolation mate for the ceramic crucible.
5.2. Prepare the bottom crucible isolation by cutting a roundish sheet of the thermal
isolation with hole (diameter equivalent to crucible, hole diameter approx. 8 mm /
position according to crucible outlet hole).
5.3 Insert the crucible in the ceramic container.
5.4 Open the sealing rod support screw and remove support.

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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5.5 Place the ceramic crucible support into the melting chamber.
5.6 Place ready crucible with container into the crucible support.
5.7 Insert sealing rod support again and fasten the screw again.
5.8 Adjust the opening of the crucible to align with the center of the sealing rod support.
Rotate and shift the crucible, so that the casting opening is directly under the center of
the opening of the sealing rod support.
Attention:
Verify the opening height of the sealing rod.
The sealing rod must be adjusted with the thread in the rod clamp that
< that it opens 6 to 7 mm
< that the security movement to close the rod in the crucible is 3 to 4 mm
< total sealing rod movement by the cylinder is 10 mm
This adjustment compensates wear of crucible
5.9 Turn the sealing rod into the collet chuck and fasten the screw carefully. The position
of the rod is correct when the end of the sealing rod is on one level with the end of the
collet chuck.
5.10 Introduce the sealing rod into the support. Re-adjust the position of the crucible if
necessary to align the opening of the crucible with the center of the sealing rod
support. Then turn the sealing rod within the support by 90° to fix it.

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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Opening / closing of the sealing rod – fine adjustment of center position:
The rod can be lifted and closed by the function rod in automatic casting (refer to
chapter
5.11 To lift the rod the flask chamber must be closed. When the flask chamber is opened,
the sealing rod closes automatically / remains closed as a security measure.
Verify the centred position of the sealing rod to the crucible by several times opening
and closing the sealing rod. If necessary rotate and shift the crucible until a perfect fit
can be observed.
Attention:
The sealing rod must fit vertically into the casting hole of the melting
crucible. When opening and closing no side movement of the sealing rod
shall be observed. If it does not fit exactly, the rod might break.
Attention:
If necessary rotate and shift the crucible until a perfect fit can be observed.
5.12 Insert the thermocouple into the sealing rod. Make sure the horizontal arm of the
thermocouple clicks into place without pressure at the fixing device of the sealing rod
support.
When installing a new thermocouple plug verify the polarity of the thermocouple
connections:

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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To select type of thermo couple:
< pass with cursor to job code position.
< for K- type of thermo couple enter 125 - following by enter
Temperature range up to 1.100 °C
In display visible thermocouple - k -
< for S- type of thermo couple enter 127- following by enter
Temperature range up to 1.400 °C
In display visible thermocouple - s -
Thermocouple
(+) right connection
(
-
) left connection
Job code
NiCr
-
Ni (type k
)
Green
White
125
PtRh
-
Pt
(type s
)
Orange
White
127

Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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6. Operator Interface and Control VPC040 Power
The operator interface consists of four edit and navigation keys, two control keys and a clear
text display. The function of the keys is described below:
- ‘M’ – key: The “Main key” shows the screen of automatic casting
- ‘E’ – key: The “Edit / Enter key” allows editing and confirming of a parameter
- ‘↑’ & ‘↓’ keys: The “Arrow keys” have a dual function: Up / down navigation through
parameters and screens as well as increasing / decreasing of parameter
values
-‘START’: Starting of the automatic casting cycle and confirming of machine
status
to enter next program step
-‘STOP’: Stop of automatic casting, stop generator, reset failure status
The clear text display has several standard screens. Navigation between screens is effected
via ‘↑’ & ‘↓’ and ‘M’ keys:
‘M‘-key
‘↓’ - key
for 1 sec.
a
utomatic
program
basic
a
utomatic
program
extended
s
ensor
s
‘E’ -
key
on sensors
*AUTOM* 0.00b 1440C
no#→ 1 0.00b 0.0W
0:ready
temperature : 920C
diff-pressure :-0.4b
main-pressure :-1.6b
main-pr.start : 2.0s
start cast autom :1i
flask in fr.start:1i
vibrate start : 0.0s
degassing time: 0s
mixing time : 10s
power max : 100%
rod man.:0i sensors
*SENSORS*
water pressure :1i
chamber closed :1i
thermocouple
–
s
-
:1i
generator 0 10 :1i
Schultheiss 0 :1i
service code : 32145
job code : 0

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Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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Schultheiss GmbH, Römerstr. 21, 71296 Heimsheim
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7. Sensor Test / *SENSORS*
7.1 Switch on the unit with the main switch.
7.2 Press ‘M’ - key to call automatic program. Then keep ‘↓’ – key pressed until the
cursor reaches the ‘sensors’ line. Then press ‘E’ – key to enter sensors.
*SENSORS*
water pressure :1i
chamber closed :1i
thermocouple
–
s
-
:1i
generator 0 10 :1i
Schultheiss 0 :1i
service code : 32145
job code : 0