Whip Mix Xcavator User manual

Xcavator™
User Manual
Whip Mix Corporation •361 Farmington Ave. •P.O. Box 17183 •Louisville, KY 40217-0183 USA
502-637-1451 •800-626-5651 •Fax [phone] •www.whipmix.com
Patent Pending

Xcavator Operating Instructions
2
Intended Purpose
The Whip Mix Xcavator is designed to automatically remove
95% of the volume of investment mold material surrounding
pressed ceramic restorations where manual divestment would
typically be done. When used as directed, the unit will
significantly shorten the total process time required to go from
press oven removal to pattern retrieval. The unit can be run
Grounding
The high velocity flow of glass beads across plastic or
metal surfaces will charge the beads and the surfaces they
flow over. Great pains have been taken to ground every
component in the Xcavator to insure equalization of static
electrical charges. The power cord and the outlet the unit
is plugged into must have 3 prongs to insure the presence
of the earth ground which is vital to the prevention of static
electrical charge buildup. If, for any reason, you receive a
static electrical shock from any part of the equipment, you
should verify the integrity of the grounded outlet the unit is
plugged into, or call an electrician. Operating the unit
ungrounded can result in painful shocks to the operator
and damage to the electronics of the unit itself.
Never cut the ground stud off the power cord or plug
the unit into a 2 lead extension cord or outlet.
Dry Air Supply
All compressed air condenses moisture in the air lines as
a result of the physics of gas compression. This moisture
can accumulate in low areas of the air piping even if there
is a master air dryer at the compressor.
It is recommended that a cartridge type dryer be placed
just before the air regulator of the unit. If moist air enters
the unit it will collect in the reservoir and cause clumping
of beads and disrupt the critical air/bead ratio needed
for consistent divestment. It can also plug up either the
reservoir output orifice or the bead/air injector inside
the injector block and cause inconsistent divestment.
Dry Bead Supply
The strainer supplied with the Xcavator serves two purposes;
(1) it eliminates clumped beads and foreign debris which
could clog the bead transport system, (2) it validates/
invalidates the dryness of the beads. If the beads will not
pass through the strainer without tapping or shaking the
strainer, then they are too moist to be transported reliably.
A five watt heater is supplied with the Xcavator to be
placed fully submerged in the bead storage container. It
will raise the temperature of the beads to about 5°above
the room temperature. This gentle warming will drive off
any moisture the beads might accumulate and insure they
will transport reliably.
Treat Pressurized Components With Care
Never strike the bead jar or pull on the connecting air
tubing while the system is pressurized. This can result in
cracking the plastic jar or wind up spraying glass beads or
plastic debris around the area and pose a safety hazard.
Particulate Exposure
Never open the cabinet door while a divestment cycle is
in progress. The exhaust system will pull the dust cloud
towards the rear of the cabinet, but air conditioning/heating
convection currents in the room could cause a portion
of the dust cloud to escape into the room and pose a
possible health risk.
Handling of Hot Investment Molds
Always use laboratory tongs to handle hot investment molds
and cautiously test the temperature of divested molds before
you attempt to remove divested molds from the cabinet.
Exhaust Flow Volume
The built-in vacuum sensor will prohibit divesting unless
the vacuum flow is sufficient to remove the airborne dust
rapidly. If you are having dust cloud removal issues check
your vacuum unit or central vacuum flow to ensure removal
of the fine dust.
Divesting Media Composition
and Particle Sizes
Use only 50–100 micron glass beads with the Xcavator
for the following reasons:
1. Other material types may be harder than glass
beads and damage the porcelain work product.
2. Other material sizes may alter the depth of cut,
and/or the cut channel width.
unattended and will alert the operator when an investment mold
is divested to allow efficient processing and labor usage.
The unit employs state of the art robotic precision to
ensure consistent material removal time after time.
The Xcavator is easy to operate, ergonomically friendly
and compact enough to earn its place on a work surface
in the casting room.
Important Topics for Safe, Reliable Operation
IMPORTANT NOTE: THE XCAVATOR PRODUCT HAS BEEN
EXHAUSTIVELY TESTED WITH WHIP MIX BRAND 50 MICRON GLASS
BEAD MEDIA. FOR BEST AND MOST RELIABLE DIVESTING RESULTS
WE STRONGLY RECOMMEND YOU USE WHIP MIX BRAND BEADS.
WHIP MIX BEADS FLOW MORE RELIABLY, AND ARE LESS PRONE
TO CLUMPING DURING HIGH HUMIDITY CONDITIONS.
THE USE OF ALUMINUM OXIDE (ALOX), BEADS IS NOT RECOMMENDED
FOR USE WITH THE XCAVATOR. ALOX BEADS WILL POTENTIALLY
CAUSE DAMAGE TO YOUR PORCELAIN BECAUSE THEY ARE HARDER
THAN THE PORCELAIN. ALOX WILL ALSO CAUSE PREMATURE
WEARING OUT OF THE QUARTZ NOZZLE.

Xcavator Operating Instructions
3
Familiarization
Control Panel
Access Door
1. Ready indicator
2. 100 Gram cycle start key (cool mold)
3. 200 Gram cycle start key (cool mold)
4. 100 Gram time delay before start indicator (hot mold)
5. 200 Gram time delay before start indicator (hot mold)
6. Abort cycle key
7. Exhaust flow Indicator
8. Depth of cut selector switch
Setup
Air Supply
1. Connect your compressed air supply to the air regulator
inlet hole shown in the photograph (Figures 1A and 1B).
The inlet hole is a standard 1/8" National Pipe Thread (NPT).
Air Regulator
Setpoint Adjust
2. With air supply connected, pull knob upward, and
rotate it until gauge needle points to 35 psi (Figure 2).
NOTE: THIS MAY NEED TO BE RE-ADJUSTED SLIGHTLY
ONCE BEAD FLOW IS ESTABLISHED.
Push knob back downward after pressure is set.
Daily Moisture Bowl Check
3. Pressing upwards on the black plastic ring at the bottom
of the air regulator opens up a check valve and allows
accumulated moisture to drain from the clear plastic
accumulator bowl (Figure 3). It is very important to keep
drained so that moisture does not pass through to the
bead reservoir. Moist beads will adhere to each other
and prevent transfer to the nozzle.
1
2 6
3
7
4
8
5
Figure 2 Figure 3
Figure 1A Figure 1B

Xcavator Operating Instructions
4
Checking Reservoir Gasket
1. Please note the gasket in the lid of the reservoir.
It is important to keep this gasket and the mating
rim of the reservoir wiped free of beads to insure a
good air pressure seal (Figure 9). The threads in the
lid should also be wiped with a DRY cloth or brush
to remove beads accumulating in the threads.
CAUTION: NEVER USE A WET CLOTH AS THE MOISTURE WILL
GET INTO THE RESERVOIR AND CAUSE TRANSFER PROBLEMS.
Chuck Assemblies
1. There is a dedicated chuck assembly for each nominal
mold size (100 & 200 gram molds) (Figure 6). The chucks
are easily exchanged as work load dictates.
Chuck Assembly Setup
2. Before using the divester make sure the three thumbscrews
are pre-adjusted for the type of ring-former system you
use (Figure 7). If you use tapered ring-formers place
a tapered investment mold in the chuck and adjust the
thumbscrews inward until they contact the investment.
Then withdraw them one full turn to allow enough
clearance for the hot mold to slip into the chuck without
interference which might cause you to lose your grip
on the ring with the tongs.
If you use both tapered and untapered rings of each size
you will want to purchase additional chuck assemblies
so that you don’t have to constantly re-adjust the thumb
screws. (See spare parts list in back of manual.)
Chuck Assembly Installation
3. Select one of the two furnished chuck assemblies
(100 gram or 200 gram) and place it over the two guide
pins on the mounting plate inside the cabinet (Figure 8).
Setup (continued)
Exhaust Port
4. Connect your central vacuum system or
dedicated vacuum unit to the rear of the
cabinet as shown (Figure 4).
CAUTION: NEVER OPERATE THE XCAVATOR UNIT WITHOUT
SUCTION INSIDE THE CABINET TO PREVENT HUMAN EXPOSURE
TO FINE PARTICULATE MATTER WHICH CAN BE HAZARDOUS TO
YOUR HEALTH.
Power
5. Connect the furnished power cord to the unit and
then to any grounded AC outlet capable of furnishing
15 amps (standard branch breaker size) (Figure 5).
NOTE: POSITION THE UNIT LEAVING ENOUGH SPACE AROUND
THE LEFT HAND SIDE OF THE CHASSIS SO YOU CAN EASILY
REACH THE MAIN ON/OFF SWITCH.
Figure 6
Figure 9
Figure 7 Figure 8
Figure 4 Figure 5
100 gram
200 gram

Xcavator Operating Instructions
5
Filling Jar
IMPORTANT NOTE:
THE XCAVATOR PRODUCT HAS BEEN EXHAUSTIVELY TESTED
WITH WHIP MIX BRAND 50 MICRON GLASS BEAD MEDIA. FOR
BEST AND MOST RELIABLE DIVESTING RESULTS WE STRONGLY
RECOMMEND YOU USE WHIP MIX BRAND BEADS. WHIP MIX
BEADS FLOW MORE RELIABLY, AND ARE LESS PRONE TO
CLUMPING DURING HIGH HUMIDITY CONDITIONS.
THE USE OF ALUMINUM OXIDE (ALOX), BEADS IS NOT
RECOMMENDED FOR USE WITH THE XCAVATOR. ALOX BEADS
WILL POTENTIALLY CAUSE DAMAGE TO YOUR PORCELAIN
BECAUSE THEY ARE HARDER THAN THE PORCELAIN. ALOX
WILL ALSO CAUSE PREMATURE WEARING OUT OF THE
QUARTZ NOZZLE.
1. Remove the lid of the reservoir by rotating it by hand
counter-clockwise. Place the strainer over the rim of
the reservoir and pour the new beads into the strainer
slowly, allowing time for the beads to pass through
(Figure 10). Always use the strainer when filling the jar
to eliminate clusters of beads, which will cause the
unit to malfunction. Enclosed with your Xcavator
unit is a 5 Watt heater to help eliminate moisture
in your bucket of beads. Plug in the 5 Watt heater
and submerge it below the surface of the Xcavator
bead storage bucket to insure that beads will flow
through the strainer and transport reliably to the
nozzle. Fill the jar with 50–100 micron glass beads up
to the maximum fill line on the jar, then replace the jar lid
by screwing it clockwise, then snugging it firmly closed
by hand (Figures 11 and 12).
IMPORTANT: NEVER OVERFILL THE JAR AS THE
BEADS REQUIRE AT LEAST A HALF INCH OF
HEAD SPACE TO ALLOW ROOM FOR AERATING
THE BEADS SO THAT THEY WILL TRANSFER.
CAUTION: IF THE LID CANNOT BE REMOVED BY HAND AFTER
THE UNIT HAS BEEN PRESSURIZED DURING A DIVESTMENT
CYCLE, MAKE SURE THE AIR FLOW NOISE HAS STOPPED AND
allow 30 seconds to allow any residual air pressure
inside the jar to bleed off THROUGH THE NOZZLE. IF YOU
CANNOT FEEL OR HEAR ANY AIR AT THE NOZZLE AND
THE LID STILL WILL NOT RESPOND TO HAND LOOSENING,
CONSULT THE TROUBLESHOOTING SECTION AT THE
REAR OF THIS MANUAL.
IMPORTANT NOTE:
IF THE BEAD MEDIA DOES NOT FLOW FREELY THROUGH
THE STRAINER, THIS IS AN INDICATION OF EXCESSIVE
MOISTURE CONTENT. MOIST BEADS WILL ADHERE TO
EACH OTHER AND NOT FREELY SEPARATE FROM EACH
OTHER AND FALL THROUGH THE STRAINER. THEY WILL
CAUSE INTERMITTENT OR EVEN COMPLETE STOPPAGE
OF TRANSPORT FLOW TO THE JET NOZZLE. THE 5 WATT
HEATER PLACED IN THE BEAD BUCKET WILL HELP
PREVENT THIS MOISTURE ACCUMULATION.
Figure 10
Figure 11
Figure 13
Figure 12
Figure 14

Xcavator Operating Instructions
6
Theory Of Operation
The Xcavator is designed to remove 95 percent of
investment material from a 100 gram or 200 gram
investment mold unattended. It will shorten the
overall press to pattern recovery time significantly.
Instead of removing a hot mold from your pressing furnace
and waiting up to 50– 60 minutes for it to cool to a safe
bare hand handling temperature then spending another
Controlling the Depth of Cut
There are four factors which affect the depth of cut
in a given mold:
1. Air Pressure
2. Spindle Rotation Speed
(as set by the Depth of Cut Knob)
3. Density of Investment Material AND
Concentration of Special Liquid.
4. Bead Media Size and Hardness
As a rule of thumb, the air pressure should be set to the
lowest psi value that will yield satisfactory cuts throughout
the range of investment brands and concentrations by
adjusting ONLY the 16 position spindle speed selector
knob. Whip Mix has determined that 35 psig is the
pressure setting which will cover the entire spectrum
of currently available brands and concentrations. The
hardest and highest density investment should be run on a
Depth of Cut setting towards the higher numbered positions
while less dense investments should be run on the lower
numbered settings.
An Important Note
Regarding Air Pressure
Even though the incoming air pressure is perhaps
higher than you would normally select for manual
divestment, the direct comparison is not physically
valid for the following reason; when manually divesting
the nozzle is within less than a centimeter of the glass
pattern. The Xcavator jet nozzle NEVER comes within
2–3 centimeters of the glass pattern and is in
CONSTANT MOTION, making it impossible to dwell over
any given spot on the glass pattern for more than a few
seconds. The increased distance effectively drops the
pressure level of the air propelling the beads so that by
the time they reach the glass pattern the kinetic energy
the beads transfer to the glass is actually less than with
a manual divester.
You should use only one type and size of bead media. In
practice, the only one of these interactive factors remaining
variable should be the Depth of Cut Selector knob.
How Does it Work?
The Xcavator uses a robotic grade precision stepper motor
to digitally turn the investment mold in an ultra-precise rate
of rotation. This rotation is computer controlled to spin
slowly at the outside periphery of the mold and slowly
accelerate as the swing arm approaches the center of the
mold rotation. This precision is the key to controlling the
depth of cut and the uniformity of material removal
across the horizontal material removal plane.
The nozzle swing arm is also controlled by a robotic
grade precision stepper motor to digitally position
the nozzle along each concentric cutting track with
minimal overlap and high repeatability.
5–15 minutes to hand divest, you can remove the mold
from the press furnace, press the corresponding delay cycle
button and the Xcavator will announce when the mold is 95
percent divested with a beeping sound, and the green
Ready light will be lit. The divested mold will now be cool
enough to remove from the Xcavator by hand, and touchup
the remaining 5 percent by hand in as little as 30 seconds.

Xcavator Operating Instructions
7
We recommend you pour up some empty test molds for each
brand of investment you use at the minimum and maximum
liquid concentrations and burn them out, then perform test
divestments and record the spindle speed selector switch
settings to bracket the lowest concentration, least dense mold
(lower numbered speed settings) and the highest density,
highest concentration mold. When you are comfortable that
you can span the entire range of mold densities, you can fill
in the intervening concentration values.
Again, for the maximum protection of your work product, and
the most consistent results, we recommend you keep the air
pressure constant and utilize the Depth of Cut knob to alter
the spindle speed/cycle time to yield the desired depth of
cut. We recommend that you calibrate your depth of cut to
land in a horizontal plane midway between the bottom of
the central glass button, and the top of the glass button
where the sprue(s) join.
Typical settings for Whip Mix Formula 1 Investment:
[In order from the hardest to the softest]
Air Pressure – 35 psi on the regulator gauge.
Bead Media - 50 micron to 100 micron pure glass beads
Investment Type: Whip Mix Formula 1
Liquid Concentration Depth of Cut Setting
100% Switch Position # 5
90% Switch Position # 5
80% Switch Position # 4
70% Switch Position # 4
60% Switch Position # 3
50% Switch Position # 3
40% Switch Position # 2
30% Switch Position # 2
Fill in the data corresponding to the Investment type you use.
NOTE: DATA MUST BE DERIVED FROM ACTUAL PRESSED RINGS AS THE HARDNESS OF THE RINGS INCREASES AFTER THE PRESSING HEAT
CYCLE. TESTING BLANK MOLDS WHICH HAVE BEEN THROUGH THE BURNOUT CYCLE, BUT NOT THE PRESSING HEAT CYCLE WILL GIVE
MISLEADING RESULTS DUE TO THE HARDENING EFFECT OF THE PRESSING HEAT CYCLE.
Investment Type: Investment Type:
Liquid Concentration Depth of Cut Setting @ 35 PSI Liquid Concentration Depth of Cut Setting @ 35 PSI
100% Switch Position # 100% Switch Position #
90% Switch Position # 90% Switch Position #
80% Switch Position # 80% Switch Position #
70% Switch Position # 70% Switch Position #
60% Switch Position # 60% Switch Position #
50% Switch Position # 50% Switch Position #
40% Switch Position # 40% Switch Position #
30% Switch Position # 30% Switch Position #
Investment Type: Investment Type:
Liquid Concentration Depth of Cut Setting @ 35 PSI Liquid Concentration Depth of Cut Setting @ 35 PSI
100% Switch Position # 100% Switch Position #
90% Switch Position # 90% Switch Position #
80% Switch Position # 80% Switch Position #
70% Switch Position # 70% Switch Position #
60% Switch Position # 60% Switch Position #
50% Switch Position # 50% Switch Position #
40% Switch Position # 40% Switch Position #
30% Switch Position # 30% Switch Position #
Before You Commission for Every Day Use
calibrate each brand of inVestMent oVer the ranGe of concentrations you are usinG.

Xcavator Operating Instructions
8
Step By Step Directions For Use
Step 1 Know your material brand and mix
concentration percentage.
Step 2 Make sure there is at least 3 inches
of bead media showing inside the reservoir to
ensure completion of the current mold divestment.
Step 3 Select the mold chuck size which corresponds
to the ring size (100 gram or 200 gram) (Figure 1).
Step 4 Open the door on the Xcavator by swinging
the handle towards you (Figure 2).
Step 5 Insert the chuck onto the mounting plate (Figure 3).
Step 6 Remove the freshly pressed hot mold
from the pressing furnace.
Pick up the still hot mold with tongs and place
it on the open door of the Xcavator momentarily
(with the press plunger facing up) (Figure 4) then
reverse the forceps and re-grip the mold as close
to the door as possible and flip the mold inverted
so that the press plunger is now facing downward.
Step 7 Place the mold on the three threaded screws
inside the chuck assembly so that the mold
is centered between the three posts. Release
the tongs and withdraw them (Figure 5).
Step 8 Close the door by swinging the handle up
and away from you. The Ready/Idle LED will
be on*, signifying the unit is ready to begin
divestment (Figures 6 and 7).
*As long as the unit senses flow
in the dust exhaust system.
CAUTION: DO NOT DEFEAT THIS SAFETY FEATURE, NOR
OPERATE THE UNIT WITH THE DOOR OPEN. THE DUST
GIVEN OFF BY THE AIRBORNE INVESTMENT PARTICLES
CAN BE HAZARDOUS TO YOUR HEALTH.
Figure 1
Figure 2
Figure 5
Figure 6
Figure 3
Figure 4
Figure 7
100 gram
200 gram

Xcavator Operating Instructions
9
Step 9 Position the Depth of Cut Selector knob to the
pre-determined position for the type of investment
and the concentration of the mix for the specific
mold you just put in the Xcavator (Figure 8).
Step 10 Press the Delay button corresponding to the
mold size you just put in the Xcavator. You can
go about other duties until the Xcavator beeps
and the Ready LED lights (Figure 9).
NOTE: IF THE MOLD HAS COOLED NATURALLY FOR
MORE THAN 10 MINUTES YOU CAN BYPASS THE TIME
DELAY FUNCTION BY PRESSING THE “ACTIVE” BUTTON
FOR THE GIVEN RING MASS AND THE DIVESTING CYCLE
WILL START IMMEDIATELY.
CAUTION: DO NOT OPEN THE CABINET DOOR UNTIL
THE READY LIGHT TURNS GREEN AND THE BEEPER
BEEPS. OPENING THE CABINET PREMATURELY
(BEFORE THE BEEPER) CAN ALLOW HAZARDOUS
DUST PARTICLES TO ESCAPE INTO THE ROOM.
Step 11 Open the door and remove the 95% divested mold
by hand, as it will now be cool enough to handle
safely with your bare hand (Figures 10).
Step 12 Use your manual divester briefly, if necessary, to
remove any material “shadowed” by the sprue
arms or inside the hollows of the copings.
Step By Step Directions For Use (continued)
Figure 8
Figure 9
Figure 10

Xcavator Operating Instructions
10
Maintenance
Maintenance Schedule
Suggested Frequency: Weekly
General Cleaning
The inside of the plastic shield may become statically
charged and coat over with dust from time to time. Use
a clean damp cloth or paper towel to wipe it clean.
The cabinet exterior may be cleaned with a damp cloth.
Excess bead/investment debris inside the unit may be swept
into the slot opening inside the cabinet using the brush provided
with the Xcavator. When the drawer below becomes full it can
be removed by pulling it towards you [support underneath
with your other hand] and fully withdraw from the cabinet
for transport to a recycling unit or disposal container.
This plastic bowl should be checked weekly to see if
moisture has accumulated. If it has moisture, you can drain
it by grasping the black plastic ring underneath the clear
bowl and pushing it upward. This will open a check valve
allowing the incoming air pressure to blow the bowl empty.
NOTE: YOU WILL HEAR THE WHOOSHING NOISE OF
THE AIR ESCAPING WHILE YOU HAVE THE BLACK
PLASTIC RING RAISED
Simply release the black plastic ring when the bowl is
empty and a spring will snap it back into place, closing
the relief valve. The whooshing noise should cease. If it
does not, simply push up and release the ring until the
noise disappears.
Jar Lid Gasket Cleaning
Over time, bead fragments and dust can worm their way up
into the retention groove of the Jar Lid and cause air to escape
from the jar, which is one of the two primary reasons for loss
of cutting depth (The other reason is the O-Ring displayed in
the pictorial on page 11). This simple procedure can be quickly
performed to restore the proper cutting depth.
Unscrew the Jar Lid and use a dry cloth to clean the dust
and/or any beads adhering to the square Gasket in the lid as
shown in the picture above. If the gasket is not seated flat in
the groove, pry it loose and remove it. Once removed, clean
all surfaces with the dry cloth and also clean the groove.
NEVER USE WATER OR ANY OTHER LIQUID TO CLEAN THE GASKET
AS IT WILL PROMOTE BEAD CLUMPING. REPLACE THE SQUARE
GASKET IN THE GROOVE. SCREW THE LID ONTO THE JAR UNTIL
TIGHT, THEN REMOVE IT AND INSPECT THE GASKET POSITIONING.
IF THE GASKET IS NOT SITTING FLAT IN THE GROOVE REPEAT THE
PROCESS UNTIL IT IS FLAT. IF THERE ARE STILL WAVES OR BULGES
IN THE GASKET, REPLACE IT WITH A NEW GASKET.
Use a DRY cloth or paper towel to clean the threads of the cap.