Indutherm ROMANOFF VC480V Technical Documentation Manual Download

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[email protected] | romanoff.com

revision

date

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reason

responsible

06.02.17

all

Edition 2017

DV, KS, RK

12.10.17

all

last corrections

This manual has been prepared in good faith by us. Nevertheless, should you find any
mistakes or ambiguities, please let us know. Furthermore, we are grateful for comments
and suggestions.

state: 16.10.2017

The manual is property of:

INDUTHERM
Erwärmungsanlagen GmbH
Brettener Straße 32
D-75045 Walzbachtal
Germany

Tel.: + 49 7203 9218-0
Fax: + 49 7203 9218-70
E-Mail: [email protected]

Unauthorized duplication, even partial, is not permitted.

Walzbachtal, 2017-10-16.

Summary of Contents for ROMANOFF VC480V

Page 1: ...Pressure Casting Machine VC480V Keep for future use 9 Deforest street Amityville NY 11701 USA Romanoff com Romanoff order service for consumables www romanoff com Romanoff technical service Tel 1 631...

Page 2: ...should you find any mistakes or ambiguities please let us know Furthermore we are grateful for comments and suggestions Instruction manual 2017 10 16 state 16 10 2017 The manual is property of INDUTHE...

Page 3: ...arkings on the unit 2 4 2 4 Safety marking 2 5 2 5 Safety advices 2 6 2 6 Residual risks 2 10 2 7 Behaviour in an emergency 2 10 3 Technicaldata 3 1 4 Descriptionofthesystem 4 1 4 1 Components of the...

Page 4: ...Flask structure 7 15 7 10 Granulating 7 16 7 11 Error diagnosis 7 18 7 12 Troubleshooting 7 18 7 13 Diagram casting flasks without flange 7 19 7 14 Diagram casting flasks with flange 7 19 7 15 Servic...

Page 5: ...ill be taken by IN DUTHERM Erw rmungsanlagenGmbH INDUTHERM Erw rmungsanlagenGmbHdon t take liability for dam ages caused by faulty protection of power supply and or wrong con necting the supplies prot...

Page 6: ...by authorized personnel or by service technicians from Indutherm 1 4 EC conformity Declaration of European Community conformity is attached to this manual 1 5 Observation of the product The management...

Page 7: ...ains observing of servicing and mainte nance regulations Set up operation and maintenance is only allowed to be carried out by trained qualified personal that has read and understood all docu ments Th...

Page 8: ...f the system The employees have to know the storage place Every person working at the system has to read and apply the in struction manual especially the safety advices The personnel have to read and...

Page 9: ...ate safety advices in the manual 2 3 2 Protective gear Protective gear PPE includes heat resistant clothes heat resistant closed shoes heat resistant protective gauntlets protecting artery and face gu...

Page 10: ...e dealing with and undisturbed running of the machine is the knowledge of safety instructions and industrial safety regulations On the front of the machine casing the following safety markings are att...

Page 11: ...ubstantial property damage willresult if proper precautions are not taken Warning Death serious injury or substantial property damage can result if proper precautions are not taken Careful Minor perso...

Page 12: ...o life because of strong electromagnetical fields induction For persons with pacemaker it is not allowed to approach or to be near to the machine Danger Danger to life are caused also by the fact that...

Page 13: ...g voltage Work on the electrical equipment is only allowed for au thorized qualified staff Access to the electrical distribution box is only allowed for authorized qualified staff with tool Work on th...

Page 14: ...he pressure is maintained in the lock cylinder Press after a protective gas compressed air failure no pneumatic units e g cylinder Warning Risk of burns burns because of squirting liquid metal burns a...

Page 15: ...rd of the machine With too small dimensioned or forks adjusted too narrowly there is danger for the system to fall from the means of transportation Wear appropriate personal protective equipment PPE M...

Page 16: ...n Health risk for persons with cardiac pacemaker who ap proach the running system Instruct people Burn injury on hot surfaces or hot molten metal Teach people Wear personal pro tective equipment Dange...

Page 17: ...water supply 2 x 8 mm fittings with 1 4 thread 2 5 5 bar min 130 l h max 6 dH water output Pressureless cooling water input temperature 15 25 C 59 77 F ambient temperature 10 35 C 50 95 F relative hu...

Page 18: ...rmer oscillating circuit capacities pneumatic magnet valves pressure regulator for pressure of the sealing rod cylinder and pressure regulator for protective gas The front plate contains front panel f...

Page 19: ...n 3 vacuum chamber With water cooling inlet and outlet 4 flask lift Enables lifting of tank 5 lift for vacuum chamber Enables lifting of vacuum chamber 6 front panel Control the process of the system...

Page 20: ...ual attached to internal modem 4 Power supply Power supply of the vacuum pressure casting machine 5 Vacuum pump Socket for plug from vacuum pump 6 Protective gas Protective gas supply input 7 Compress...

Page 21: ...connector for wall measurement if you work with centre measurement additional option 3 filling cone Top insulation and help for filling crucible 4 thermocouple wall Thermocouple for the crucible wall...

Page 22: ...ll measurement Dual measurement Figure 5 option dual measurement With a software level higher than 8000 0082 the slave temperature is displayed in brackets from a value above 100 C 515 C 0550 8 0 1000...

Page 23: ...designation function 1 protective gas entry Here you can supply additional protective gas 2 water outlet Usual water outlet 3 O Ring For sealing of the barrel without a gap 4 Inside barrel with lever...

Page 24: ...danger of system tip over from the mean of transportation Please wear appropriate personal protective equipment PPE Let do transportation only by trained personnel There is no guarantee for damages b...

Page 25: ...he operating voltage of the system If the voltages do not match the system can be damaged 6 2 Mountingprocess Place the system in a clean dry place horizontally on The ground must be firm and level To...

Page 26: ...e by 2 hoses with in side diameter of 8 mm Water pressure must be 2 5 bar at minimum and don t exceed 5 bar Water outlet has to be pressureless Input water temperature should be between 15 C 59 F and...

Page 27: ...0 operating hours but at least twice a year You need special vacuum pump oil item number 15000910 The oil filter and the exhaust filter should be replaced at every second oil change For detailed infor...

Page 28: ...0500060 For the use an internal cable at the generator must be switched with the actual attached modem cable Here the machine can be connected to a PC Use the data manage ment software provides by Ind...

Page 29: ...parts is only visible when the temperatures are over 500 C Danger Risk of burns The surface of the bell can be very hot depending on the working temperature Danger Danger of crushing shearing by swive...

Page 30: ...before putting back into operation again 7 2 Changing casting parts 7 2 1 Removal Open the bell lid Take out thermocouple Lift sealing rod with button sealing rod and remove it Remove old crucible an...

Page 31: ...bar Flask Actual pressure in the vacuum chamber 1 00 to 0 00 bar 0 0 kW Actual heating power in kW 28 Program Actual program InduTest Program name InduTest Display in the lower area Temp Lowering set...

Page 32: ...elting process 0010 s Melting time 5 to 600 s Set time for holding set temperature Flask Fl Casting mould Flask Flask Fl Flask HSC Ingot Gran flask without flange two chamber system with differential...

Page 33: ...0 to 20 0 s Set value for the exact timing at which an over pressure is applied in the crucible chamber towards the end of the pouring step 1 00 bar Casting pressure 1 00 to 1 50 Set value of overpre...

Page 34: ...less 0 to 600 s Set value for time during which the chamber re mains closed without pressure Automat Opening mode vacuum chamber Manual Swivelling out of the vacuum chamber has to be confirmed from th...

Page 35: ...mixing Automat Automat Automat Automat Automat Label Bronze YG 585 YG 750 Aluminium Brass VC480V Material Silber 925 In got Silber 925 heavy Silber 925 middle Silber 925 light Granu late Test Crucibl...

Page 36: ...00002 Selected parameter 000 Value of parameter is 2 which means here thermocouple type N is activated V With pressing arrow down you get to previous parameter no lower then 000 With pressing arrow up...

Page 37: ...nfo page amongst other with important information on the cooling water flow generator temperature ma chine state and signal strength of inbuilt modem Figure 17 Service Info Page2 After pressing Return...

Page 38: ...mber lifting and sinking is performed automati cally Sealing Rod With pressing this button the sealing rod opens or close which let flow liquid material in the flask or granulation tank when it is req...

Page 39: ...rogram 28 one test program from IN DUTHERM for system check withoutheating power A suggestion for a general casting process 1 Open cooling water compressed air and protective gas supply 2 Switch on va...

Page 40: ...ter to adjust Temperature ca 100 C over melting temperature of the alloy Consid er the recommendation of the alloy manufacturer Melting pressure 0 00 Melting time 030 Casting pressure 0 60 Casting pre...

Page 41: ...loy is fully liquid 8 Wait for the automatic opening of the vacuum chamber Swivel out vacuum chamber and take out flask A new casting cycle can start beginning with step 3 Recommendation INDUTHERM Bef...

Page 42: ...ask was slaked too early too late 6 Contamination in the alloy for example bad copper 7 Material was not pre alloyed granulated 8 Investment for flask was bad old 9 Eventually not enough protective ga...

Page 43: ...f com 7 15 7 9 Flask structure Figure 19 sectional view of flask Figure 20 flask without flange and holes Note The principle of the machine is based on the high gas flow through the machine Please use...

Page 44: ...r area Options Before you start please adjust your parameter You can choose par example pre set pro gram 20 Temperature rightadjustment depends from the alloy about 100 200 C over melting point Washin...

Page 45: ...the display like Swivel in grain tank If the flask chamber is opening then please swivel it completely out Swivel grain tank completely under crucible chamber Press blinking button Automatic Start aga...

Page 46: ...switched on E010 Compressed air supply not switched on E011 Protective gas supply not switched on E013 Thermocouple not put in or faulty 0FbE Generator overheated too hot E021 Another error Exxx Tempe...

Page 47: ...6 bars pressure the flask will move down and the vacuum will be lost 6 Flask has cracks 7 Flask isn t selected in Program Set up 7 14 Diagram casting flasks with flange Figure 26 Flasks with flange va...

Page 48: ...the electrical equipment may only be carried out when the system has been disconnected from the power supply pull the plug The capacitors may still be charged even after turning off the system The ca...

Page 49: ...e spilled Clean the floor with dirt immediately Discard the cleaning cloths in the collecting means made available Caution Health hazard due to inhalation of fibre particles Store the crucible shield...

Page 50: ...y the extent of sealing rod graphite ball crucible and the crucible bottom insulation Remove thermocouple crucible and insulating materials Clean inductor housing carefully with a vacuum cleaner Befor...

Page 51: ...rent con nections Retighten all screws of the water cooling compressed air and protective gas supply Renew oil separator filter of vacuum pump Figure 29 Oil separator filter of vacuum pump Every 4 yea...

Page 52: ...ncorrect repairs can lead to health problems or damage to the equipment Directive 2009 104 EG of the European Parliament and of the Council of 16 September 2009 concerning mini mum safety and health p...

Page 53: ...ted by the Environmental Protection Act and its regulations Deliver spent lubricants from at the hazardous waste collection point Spilled lubricants immediately sprinkle with binder and disposed of af...

Page 54: ...age 2 7 9 Figure 18 Front panel below display 7 10 Figure 19 sectional view of flask 7 15 Figure 20 flask without flange and holes 7 15 Figure 21 granulating crucible 7 16 Figure 22 Program parameter...

Page 55: ...014 35 EUProtectiontargets as per MRL Annex I Chap 1 5 1 EN 60204 1 2006 A1 2009 Security of machines Electrical equipment of machines Part 1 General requirements EN 61010 1 2010 inextracts Safety req...

Page 56: ...and at other specified positions in an essentially free field over a reflecting plane with negligible environmental corrections Directive 2014 30 EUonElectromagnetic Compatibility EN 61000 6 2 2005 E...

Page 57: ...4 10 3 Test result chart 6 5 4 3 2 1 Material Quantity Type of cast pieces Casting problem Crucible temperature Casting mode standard vacuum over pressure Flask size casting mould Flask temperature In...

Page 58: ...Annexe sales romanoff com romanoff com 10 5 10 4 Connection diagrams 10 4 1 Connection diagram machine with 3x 400V Figure 30 connection diagram power part 3x400V...

Page 59: ...Annexe sales romanoff com romanoff com 10 6 Figure 31 connection diagram control...

Page 60: ...Annexe sales romanoff com romanoff com 10 7 Figure 32 connection diagram temperature sensor digital I O...

Page 61: ...Annexe sales romanoff com romanoff com 10 8 10 4 2 Connection diagram machine with 3x 230V Figure 33 connection diagram power part 3x230V...

Page 62: ...Annexe sales romanoff com romanoff com 10 9 10 5 Water cooling circuit Figure 34 water cooling circuit...

Page 63: ...th wall measurement Attention The numbers like C008are placeholder for the posi tion in the machine The article number to order this piece is 8 digits and listed in your machine specific order list G1...

Page 64: ...very index 00 At request we can send you the actual consumables list in PDF format Is there a consumable part or replacement piece replaced by an advanced or better one changes the index number in the...

Page 65: ...Annexe sales romanoff com romanoff com 10 12 Replace this sheet with G17999_00...

Page 66: ...webshop you can get prac tical help for troubleshooting Figure 36 contact formwebshop Until you can enjoy the ad vantages of the Webshop you have to apply for an access Therefore please fill in the fo...

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