ROMANOFF Yasui 77-014 Operation Manual Download

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OPERATIONS MANUAL

RBF37+

ROTATING BURNOUT FURNACE

Summary of Contents for Yasui 77-014

Page 1: ...OPERATIONS MANUAL RBF37 ROTATING BURNOUT FURNACE ...

Page 2: ...5 EXHAUST SYSTEM 20 3 6 DRAIN ORIFICE 21 3 7 SETTING AUTO DOOR 22 3 7 1 RELEASING DOOR LOCK 22 3 7 2 CONNECTING FOOT PEDAL 22 3 7 3 CHECKING REGULATOR PRESSURE 23 3 8 USING AUTO DOOR 24 4 MAINTENANCE 26 4 1 CLEANING FILTER FOR COOLING FAN 26 4 2 CLEANING OF FURNACE AND ROTATING UNIT 26 4 3 CHECKING CRACK OF ADIABATIC MATERIAL 27 4 4 CHECKING DEFORMATION OF TURNTABLE 27 4 5 REPLACING THERMOCOUPLE 2...

Page 3: ...7 2 3 ADD and DELETE STEP s 38 7 2 4 ROT AB and COMMENT 39 7 3 MANUAL OPERATION 40 7 3 1 POWER ON AT BREAKER SWITCH 40 7 3 2 SWITCH MODE 40 7 3 3 START HEATING 40 7 3 4 TAKE FLASK OUT FOR CASTING 41 7 3 5 STOP OPERATION 41 7 3 6 POWER OFF 42 7 4 EMERGENCY STOP BUTTON 42 8 DESCRIPTION of EACH WINDOW 43 8 1 FLASK INFO window 43 8 1 1 Tap FLASK INFO tab 43 8 1 2 Details 43 8 1 3 MANUAL AUTOMATIC 44 8...

Page 4: ...9 8 3 5 TEMP 49 8 3 6 KEEP TIME 49 8 3 7 ROT 49 8 3 8 AB 49 8 4 CONFIG 50 8 5 LOG OFF 50 9 CONFIGMENU 52 9 1 MACHINE 54 9 2 COPY 54 9 3 SECURITY 56 9 4 DATE TIME 56 9 5 DISPLAY 57 9 6 PAYMENT PASSWORD 58 9 6 1 WHAT IS MONTHLY PAYMENT 59 9 7 MAINTENANCE 59 10 WHENIRREGULARITYHAPPENED 61 10 1 ERROR MESSAGES 61 10 2 ERROR CODE LIST 62 10 3 BLACKOUT 67 10 4 OVER HEAT PROTECTION DEVICE 69 10 4 1 ON AND...

Page 5: ...installed 4 When incomplete combustion gas of wax is generated do not open the door If you open the door at this time inside of the furnace may be combusted and flame may spread toward front through the gap between the door and the furnace body 5 Before connecting tubes for auto door be sure to set the insert pin to the handle of door to release the door lock Removal of the insert pin after the au...

Page 6: ...as short circuit may be caused CAUTION 1 Periodically check and clean the rotation driving parts Remove wax on the bearing system 2 Do not try to cool inside of the furnace forcibly and very rapidly using a fan Particularly if forced cooling is done when the machine is heated to high temperature the door frame material may be cracked or deformed 3 When burning out a large number of flasks in one b...

Page 7: ...es due to machine downtime Damages to the instrument and or human bodies resulting from contacting with high temperature parts and their consequential or indirect damages are not compensated by the manufacturer Damages resulting from delay of reaction at emergency and mistaken operation are not compensated by the manufacturer Damages from electrical noise over voltage or wiring error are not compe...

Page 8: ...oard for afterburner Afterburner Cover for drive unit box Door Weep hole Dew protection pan for main body Eave Cover of power control box Control panel Overheat protection key switch Overheat protection device EMERGENCY STOP button Power lamp Breaker switch Filter cover for cooling fan Handle Level adjuster Foot pedal for auto door ...

Page 9: ...77 014 Yasui Rotating Burnout Furnace 37 9 9 2 2 DIMENTIONS START STOP 860 265 1125 1073 747 1739 2176 129 308 ...

Page 10: ...urnout Furnace 37 10 10 2 3 OPERATION PANEL MAIN DISPLAY START BUTTON STOP BUTTON BREAKER SWITCH TURN TABLE ROTATION button OVER HEAT PROTECTION KEY SWITCH USB SLOT POWER LAMP OVER HEAT PROTECTION DEVICE EMERGENCY STOP BUTTON ...

Page 11: ...y side allow enough spacing Do not use the machine in a closed room Provide adequate ventilation of air for the machine 1 When doorways are not wide enough the power control box can be separated from the furnace body temporarily Contact the distributor at your place 2 Mount the machine on a sturdy place endurable to weight Weight of the machine may be more than 600 Kg when flasks are contained 3 A...

Page 12: ...ew or the like in the main body of the furnace If you happen to drop it be sure to pick it up otherwise it might cause short circuit 4 Do not move the position of the thermocouple 1 Place the sheath heating element deliberately into the hole of afterburner unit 2 Place the afterburner bobbin deliberately CAUTION Take care not to drop the sheath heating element and bobbin because the parts of the m...

Page 13: ... Rotating Burnout Furnace 37 13 3 Place the honeycomb cover in position passing the cables through its holes as the below figures 4 Connect the cable for sheath heating element to the terminal block for afterburner ...

Page 14: ...rnace 37 14 5 Repeat the above 1 to 4 for other two afterburner sheath heating elements 6 Insert the tip of thermocouple tube into the hole for thermocouple as the below figures 7 Fix 2 patrs with included saddles like this IMPORTANT ...

Page 15: ... Burnout Furnace 37 15 8 Place the afterburner to the top of the RBF37 main body Connect the cables for the afterburner heater from the built in power control box of RBF37 main body as the figures below and in the next page ...

Page 16: ...asui Rotating Burnout Furnace 37 16 16 9 Fix the afterburner body with the fixation plates and bolts On the right side fix the cables for afterburner with the retainer to the fixation plate for afterburner body ...

Page 17: ...thread holes Screw in the short foot bolts at the front screw thread holes IMPORTANT By screwing the long foot bolts into the rear threaded holes the dew protection pan for main body can be inclined its front will be lower than its rear Generated water drops will naturally flow toward the weep hole So be sure to use the longer bolt at the rear and the shorter bolts at the front ...

Page 18: ...ion pan for main body as figure the weep hole should be positioned at the front left corner so that water droplets generated during burnout will not enter inside the RBF37 main body 13 Be sure to assemble the adiabatic and dew protection board for afterburner as the figure ...

Page 19: ...rrupter Connect to the round fault circuit interrupter on the power switch board in your factory If the grounding wire is not earthed correctly the ground fault circuit interrupter may not work normally Connect the grounding wire correctly 4 Wiring should be made by a qualified electrician 1 Loosen the fixation screws of the cover for power control box and remove the cover 2 Connect the power supp...

Page 20: ...by a qualified technician 2 Use noncombustible material 3 Install high power fan suitable for exhaust of fumes 4 Dew drops should not fall directly onto the machine body 5 Make the exhaust system earthquake resistant 6 Check the exit of the exhaust device periodically to see that it is not obstructed by birds nest or by other causes and that the exhaust fan works normally ...

Page 21: ...37 21 21 3 6 DRAIN ORIFICE The drain orifice is used for limiting the amount of air which flows inside the furnace Remove and clean the drain orifice periodically IMPORTANT Always place a container below the drain orifice for collecting wax ...

Page 22: ...ain to the auto door to replace air supply source because the door may unexpectedly and very rapidly open or close because of same reason as above 2 4 Do not bend or kink the air supply tube 3 7 1 RELEASING DOOR LOCK When the auto door is used pull the lever of door handle and insert the pin as shown in the figure so that the door will be set to unlocked position 3 7 2 CONNECTING FOOT PEDAL Connec...

Page 23: ...overheat of internal controller circuit Check that the gauge of auto door regulator indicates the below specified pressure Working pressure Standard RBF37 0 4 to 0 5 MPa If the gauge does not show the above pressure set with the knob of the regulator for auto door to the above pressure Note that maximum allowable working pressure is 0 8 MPa Depending on the conditions of felt and refractory materi...

Page 24: ...d do not open the door with hand manually When air is supplied next time the door may close unexpectedly and rapidly which may cause injury 2 When air is supplied do not open or close the door forcibly with hand because the door may unexpectedly and rapidly move by rebounding power which may cause injury Further the internal cylinder mechanism of the machine may be affected resulting malfunction 3...

Page 25: ...ain the door closes Safety use of the door During night or heating at daytime set the auto door to off as follows 1 Close the door with the foot pedal 2 Shut the air supply 3 Remove the insert pin of the door handle 4 Move the door back and forth a little to check that the door is securely closed and held by the latch NOTE For more safety fix the handle with the lock bolt By this the door will not...

Page 26: ...filter Dusts accumulation or clogging of filter may cause trouble of the machine flow of cooling air is shut off cooling does not work temperature of internal electric circuit rises malfunction 1 Move the filter cover downward to remove 2 The filter can be removed together with the filter cover 3 Clean the filter 4 Assemble the filter and the filter cover again so that each hook of the filter cove...

Page 27: ...e afterburner 4 3 CHECKING CRACK OF ADIABATIC MATERIAL Cracks in the door frame should be repaired with adhesive P 48 at its early stage 4 4 CHECKING DEFORMATION OF TURNTABLE If the turntable is deformed by deterioration the flask may tilt resulting an accident such as short circuit or damage of the heater etc If deformation has become so large that the flask may tilt replacement of the turntable ...

Page 28: ...be sure to pick it up otherwise it might cause short circuit 3 Take care not to reverse polarity and at wiring 4 5 1 REPLACING THERMOCOUPLE FOR AFTERBURNER Remove the terminal block cover of afterburner and then replace the thermocouple 4 5 2 REPLACING THERMOCOUPLE FOR MAIN BODY Remove the cover of power control box and then replace the thermocouple 5 3 REPLACING THERMOCOUPLE FOR OVERHEAT PROTECTI...

Page 29: ...ndition Thermo sensor display accuracy within 10 deg C for 0 to 1000 deg C Turntable position display 1 to 48 Step numbers 8 steps MAX Memory numbers 20 memories MAX Power failure detecting time over 5 minutes shorter time than this will be handled as short break Max height of acceptable flask 230 H mm Furnace capacity for flask 37 flasks 100 mm diameter 45 flasks 89 mm diameter Dimensions includi...

Page 30: ...pan time is expiration date of this password Unless final password is input new update password input is necessary monthly to use the machine on and after this day Without the new password operation becomes impossible Example of initial installation password 2 Monthly update password In case this machine is used by monthly use conditions input of this kind of password is necessary on or after the ...

Page 31: ...xample of monthly update password 3 Final password When this password is input and is verified by the machine normally the machine can be operated without time limit IMPORTANT Once this final password has been verified by the machine the machine cannot be reset to the monthly update password mode 6 2 ISSUE OF PASSWORD To issue next password in the case of use by monthly update password mode the fo...

Page 32: ...ATIC OPERATION AUTOMATIC OPERATION can be processed as follows Turn breaker ON choose Memory No Put flasks into furnace Check Finish time Push start button 7 1 1 POWER ON AT BREAKER SWITCH Please wait for the display shown 7 1 2 CHOOSE RECIPE Tap MEMORY button to open SERCH window to choose recipe ...

Page 33: ...out The estimated time of process end if start now will be indicated here You can find the table position at PP present position window here Please take note the position each time you put flask one by one so that you can easily take out required flask without opening door each time Tap one of recipes at this window and tap OK button Back ground color changes ...

Page 34: ... You can check how much time passed from temperature reach down to casting point here at this window 7 1 6 TAKE FLASK OUT FOR CASTING 1 Enter the number of position you want to stop here at SET POSITION window Tap this button to activate key board 09 AUG 23 08 00 00 00 27 1 1 230 370 520 600 750 3 6 9 15 12 0 09 AUG 23 08 00 00 00 27 1 1 230 370 520 600 750 3 6 9 15 12 0 START STOP Keyboard appear...

Page 35: ...ion suspended Do not forget to push rotation button for 2 seconds after taking flask out of furnace to keep rotation The back ground color will turn blue 7 1 7 STOP OPERATION 230 370 520 600 750 3 6 9 15 12 0 09 AUG 23 08 00 00 00 27 1 1 600 7 1 8 POWER OFF 1 Tap LOG OFF tab Push STOP button after taking the last flask out The back ground color will turn blue START STOP ...

Page 36: ... MEMORIES 7 2 1 EDIT TEMPERATURE 1 Tap MEMORY No button 2 Tap MEMORY No 1 for instance 3 Tap OK button after that 4 Tap LIST button 2 Tap OK button 3 Turn breaker switch OFF when you see the pop up window 520 600 750 09 AUG 23 08 00 00 00 09 AUG 23 08 00 00 00 27 1 1 01 ...

Page 37: ...Yasui Rotating Burnout Furnace 37 37 39 5 If you want to change Temperature at STEP1 230c to 250c Tap the CELL marked as above 6 You will see a keyboard activated 7 Type 2 5 0 and tap OK button to confirm edit ...

Page 38: ...TE STEP s 1 When you want to add one additional step Tap blank cell next to Final cell marked as below You will see STEP5 has been added Please edit STEP5 and Final step and go back to GRAPH window to check the line chart 2 When you want to delete one step from the recipe Tap previous step of Final step to delete the line You cannot delete all of STEPs Minimum recipe consists of 4 steps ...

Page 39: ...BF37 You can refer and program with correct time for ELV time by this This means you will not achieve your request even if you set 30 minutes for ELV TIME at step1 when you load max flasks inside It takes at least 57 minutes to reach 250c and actual keep time will be shorter than you set Step 2 and 3 as well 7 2 4 ROT AB and COMMENT Please check the details for them described later ...

Page 40: ...ERATION 7 3 1 POWER ON AT BREAKER SWITCH 7 3 2 SWITCH MODE Tap FLASK INFO button Tap MANUAL button 8 3 3 START HEATING Push START button to heat The back ground color will turn pink Tap PRESENT TEMP button to edit Please wait for the display shown START STOP ...

Page 41: ...e point you ve entered The present back ground color will turn green This is to prevent leaving rotation suspended Do not forget to push rotation button for 2 seconds after taking flask out of furnace 7 3 5 STOP OPERATION Push stop button when you want to finish heating The background color will turn blue Push START button for 2 seconds START STOP ...

Page 42: ...ox when you want to suspend all of the function The button will be fixed unless you release it by manual Nothing can be operated on this condition IMPORTANT Please confirm safety before reset emergency very carefully 2 Tap OK button 3 Turn breaker switch OFF when you see the pop up window Turn button clockwise to release lock Pop up window when button pushed ...

Page 43: ...ION of EACH WINDOW 8 1 FLASK INFO window 8 1 1 Tap FLASK INFO tab to open 8 1 2 Details Choice of MODE Memory No edit button Button for setting position of turn table Shows positioon of turn table Present value showing and setting change TIME AFTER TARGET ...

Page 44: ... when MANUAL mode is chosen 8 1 4 Change memory number 1 Tap memory No button 8 1 5 SET POSITION You can stop rotation at your request Tap this button to activate keyboard enter any position number you like from1 to 48 Tap OK button to confirm Rotation will stop at the position you ve set 2 choose memory from the list Tap OK button 01 Turn table is divided into 48 areas ...

Page 45: ...p up window if you tap this button at AUTOMATIC mode This means 1 Temperature setting for MANUAL heating 2 Temperature edit for AUTOMATIC mode at only final step No need to cancel burnout cycle anymore New switching function for another casting temperature 8 1 8 TIME AFTER TARGET This informs you how long it passed from the point when temperature reaches final level You will know ideal time for fi...

Page 46: ...N heater and After burner 8 2 6 PRESENT TEMPERATURE 27 1 1 230 370 520 600 750 3 6 9 15 12 0 09 AUG 23 08 00 00 00 27 1 1 Present temperature Heating pilot lamp Turn table position Positioning button Tap this to activate keyboard Finish time indication and edit LIST button Jump to LIST window TIME AFTER TARGET Time passedfromthe point whentemperature reaches finallevel MEMORY No display and edit T...

Page 47: ...ou require 3 The color of characters turns red which means Standing by RBF doesn t start heating and waits for extra time for the target you ve set after you tap START button 4 Tap CLEAR button at 2 if you want to cancel it 8 2 9 TIME AFTER TARGET Already described in previous page 8 2 10 LIST You can open LIST window by tapping this button You can check and edit the recipe detail here in this win...

Page 48: ... turn Memory search window when this button is tapped COMMENT edit button Selected COMMENT is indicated here Can be edited with keyboard by tapping this button After Burner setting You can set after burnerON or OFF Tapped cell and before changes OK button Edit result will be saved and valid by tapping this Rotation select You can set rotation ON or OFF Tapped cell and later changes Yes KEEP TIME s...

Page 49: ...anges to NO and the last cell which is set No can be switched Yes by one tap 8 3 8 AB You can cancel After burner heating from required step Tapped cell and after that changes NO and first cell with No can be switched Yes by one tap RBF37 is shipped with 20 Memories already included with same recipe detail next page Comment Au_and_Ag is registered to Memory number 00 only Other memories have no co...

Page 50: ...77 014 Yasui Rotating Burnout Furnace 37 50 8 4 CONFIG Will be described later 8 5 LOG OFF 1 Tap LOG OFF tab before turning breaker OFF ...

Page 51: ...77 014 Yasui Rotating Burnout Furnace 37 51 2 Tap OK button 3 Turn breaker switch OFF when you see the pop up window ...

Page 52: ...G MENU You have several configuration menus in this menu page How to open CONFIG menu window 1 Tap CONFIG tab to open the window CONFIG window About each icon MACHINE You can check machine information like its serial number and several program versions ...

Page 53: ...can also change password for protection here DATE TIME You can set calendar and clock at your region DISPLAY You can control display setting here PAYMENT PASSWORD You can enter Passwords for Monthly payment here Only for customers who use this system MAINTENANCE You can check each single action power source sensor and others Some optional configurations for maintenance can be done here ...

Page 54: ...ACHINE icon to open VERSION You can check program version information here DATA OUTPUT You can record temperature data into USB flash drive 1 Put USB flash drive to the port 2 Tap SYSTEM USB button 3 Automatically completed You will see a pop up window when finished 9 2 COPY You can easily create new memory by copying existing recipe How to open COPY window 1 Tap CONFIG tab to open CONFIG menu 2 T...

Page 55: ...tton 4 button You can copy all of Memories in USB flash drive to the system Put USB flash drive into the slot and tap this button Multiple copy When you want to copy the data of recipe 1 to memory 2 5 4 copies Enter the value and tap COPY button as follows Single copy When you want to make a copy of recipe 1 to another memory 8 1 copy Enter the value and tap COPY button as follows CLEAR You can ch...

Page 56: ... protect to the blanks Ex 00 00 for single recipe 00 03 for plural recipes protection 2 Tap button 3 Enter password YASUI_RBF 4 You will see a pop up window RECIPE LOCK ID REGISTER You can edit password to protect RECIPEs The default password is YASUI_RBF 1 Tap button 2 Enter new password you like 3 Tap OK button 4 Enter old password In this case YASUI_RBF 5 Tap OK button 9 4 DATE TIME You can set...

Page 57: ...TIME icon to open Tap blank to open keyboard to enter date and time Tap SET button to finish 9 5 DISPLAY You can switch suspension power ON or OFF adjust brightness How to open DISPLAY window 1 Tap CONFIG tab to open CONFIG menu 2 Tap DISPLAY button to open ...

Page 58: ...the brightness of the display Tap button to decrease tap button to increase You can also long tap for continuous adjusting Direct entering value by keyboard can be also done The range is 0 100 9 6 PAYMENT PASSWORD How to open PAYMENT PASSWORD window 1 Tap CONFIG tab to open CONFIG menu 2 Tap PAYMENT PASSWORD button to open 3 PASSWORD You can enter password The rest of months to be paid ...

Page 59: ...payment system is to pay machine payment every month RBF37 stops working if you forget to pay RBF37 accepts anytime for any months not only every month one by one 9 7 MAINTENANCE How to open MAINTENANCE window 1 Tap CONFIG tab to open CONFIG menu 2 Tap PAYMENT PASSWORD button to open ...

Page 60: ...t voltage monitor PEAK Vol Peak voltage input RESET Reset button for peak voltage input THERMO COUPLE K Input voltage through K type thermocouple for afterburner MAIN HEATER SV TEMP You can tap and edit Setting Temperature Value here PV TEMP Monitor of present temperature HEAT Heat button for setting value SR1 SSR1 formain heater ON OFF switch SR2 SSR2 formain heater ON OFF switch AFTERBURNER SV T...

Page 61: ...ppens You cannot operate RBF while message is displayed Example of error message 1 Error code Code of error 2 Error icon 3 kinds of icons will be shown Error warning information 3 Error detail Detail of error 4 Remedy Countermeasures 5 OK Tap OK button to go back to previous page 1 Error code 2 Error icon 3 Error detail 4 Remedy 5 OK button ...

Page 62: ...ce supplied Check SSR solid state relay for main heater at maintenance window by tapping SSR button to check if LED activated or not Replace SSR if not E0200 Afterburner thermocouple disconnection Remove cables from control board and check disconnection or defective on wires Replace if defective E0400 Afterburner trouble Check heater resistance under no power source supplied Check SSR solid state ...

Page 63: ...t switch defective Check DOOR 2 LED shows reaction or not at maintenance window E0900 Blackout Informs blackout record of longer than 5 minutes E1300 Turn table does not rotate Check motor rotating at maintenance window Check photo sensor 2 ON OFF when switch is ON or OFF E1605 Thermocouple disconnection of temperature rise safety device Check if LED on SSR activated or not by turning ON at mainte...

Page 64: ...about errors not mentioned above or not solved by this OTHER MESSAGES Error code Level Description How to recover Cause Remarks E1301 Warn ing Disconnection of microphoto sensor Check wiring on sensor PH1 Check sensor at Maintenance window Sensor of table original position not detected E1400 Error Short circuit error on push key Check push buttons E1500 Error TEMP setting error Target must be in t...

Page 65: ...mmunication error Check communication program on control board and control panel check noise on line E5204 Error Control panel communication error Check noise on line E5205 Error Control panel communication error Check communication program on control board and control panel check noise on line E5300 Error Flash programming error Reboot PCB check control program E5301 Error Flash programming error...

Page 66: ...n as SYSTEM USB flash drive broken Wait for copy finishing and normal reboot takes long time and replace broken drive after that E9055 Warn SYSTEM USB flash drive 1 broken Replace System USB1 E9056 Warn SYSTEM USB flash drive 2 broken Replace System USB2 E9057 Warn ing Data copy to replaced new drive will begin Wait for copy finishing and normal reboot takes long time and replace broken drive afte...

Page 67: ...efore the set start time of Step 1 the machine resumes its running when power supply is restored In this case finish of total burnout cycle will not be delayed See the figure as follows 3 AUTOMATIC BURNOUT MODE blackout before the set time of Step 1 and recovery after the set time of Step 1 In case blackout happened during standing by restored after the set time of Step 1 the machine will be activ...

Page 68: ...hen electric power supply is restored the machine automatically resumes its running from the point where blackout occurred Time standing by STEP 1 STEP 4 STEP 3 STEP 2 Nextstep beggins withoutdelay Black out Nextstep continued withoutdelay Blackoutwithin 5 minutes Starting operation Black out TIME ...

Page 69: ...tion panel of the front panel is turned to ON this overheat protection system becomes effective If it is turned to off the overheat protection system does not work 10 4 2 OPERATING OVERHEAT PROTECTION 1 Check the set temperature limit on the overheat protection device and change the limit value if necessary considering properties of the stones volume of flask etc in accordance with the procedure d...

Page 70: ...77 014 Yasui Rotating Burnout Furnace 37 70 10 4 3 CHANGING SET VALUE OF OVERHEAT PROTECTION DEVICE Overheat protection device 3 Push MODE key 4 Display goes to next page Push MODE key again ...

Page 71: ...u will go back to PV window A message E1605 will be on Operation panel when thermocouple for the device is defective while another message will blink on the display of controller which means Input error signal from thermocouple CAUTION Do not change default setting at PV window Another configuration will be activated which disturbs normal operation The value must be always 0 ...

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ROMANOFF Yasui 77-014, Operation Manual

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