Instruction Manual for Bench Top Casting Unit MC20V
Contents 1. Introduction........................................................................................................ 3 1.1. General description of the MC20V................................................................. 3 1.2. Machine components .................................................................................... 4 1.3. Technical Data .............................................................................................. 5 1.4. General information .......................
1. Introduction 1.1. General description of the MC20V The INDUTHERM mini casting machine MC20V is suitable to cast all kind of metals into moulds or into investment flasks. Except dental alloys and very reactive alloys like Magnesium. The melting charge is heated up by induction. The special advantage of strong inductive heating is that the melting temperature is reached rapidly, because the heat is directly generated in the metal or will transported to the metal by a crucible with graphite insert.
1.2.
1.3. Technical Data MC20V Crucible temperature 15 cm 3 (ceramic crucible) 10 cm³ (with grafite inlay) max. 2000 °C Melting performance 3.5 kW Mains supply 230 V / 16 A, 50 or 60 Hz Cooling water supply 2.5 - 5 bar / min. 1,5 ltr./minute Cooling water recoil Pressureless Cooling water entry temperature 10 - 20 °C Protective Gas Argon oder Nitrogen, 8 bar Vacuum min. 8m³/h, 0,1 mbar abs. Ambient temperature 10 - 35 °C Relative atmospheric humidity 20 - 80 % Weight Crucible volume ca.
1.4. General information Safety information In order to ensure a constant, ideal performance of the machine and to ensure safe working conditions, the user is to observe the following safety measures: The complete electrical wiring is to be performed only by qualified and specially trained personnel. Check the machine and the supply devices regularly on possible damages.
The safety valves placed inside the machine housing may not be removed, closed or altered in any way. As melted metal is processed with this machine (= temperatures up to 2000 °C), the utmost care and attention has to be applied when working with the Machine.
Use as determined/liability This casting machine is designed and manufactured to comply with the latest technical knowledge and according to approved safety regulations. When not putting into operation correctly or not using the machine as determined, however, danger and damages may occur.
2. Putting into operation On delivery, immediately check if the machine is complete and if there are any transportation damages. In the case of damages, please contact at once supplier or forwarding agent. 2.1. Set-up directions The machine should be placed on clean and dry ground. The ground should be even, solid and level. The rear side of the machine must remain freely accessible to ensure sufficient circulation of cooling air.
2.4. Protective Gas The connection of inert gas supply is done by a hose with outside diameter 8 mm. Primary pressure should be 6-8 bars. Regulator on the gas bottle is a pressure regulator (NEVER use a flow regulator !!!) This armature must be purchased at a serious dealer for gas bottles. Ask him! To purchase this armature at Indutherm: difficulty because all countries have different standards in gas bottles.
3. Operation 3.1. Components 4 5 1 6 7 2 3 Abb. 1: 8 front view Position 1 2 3 Description function tilting handle with due to movement to the right the machine will lock cast allows temperature measurements above pyrometer 1300°C inductor housing the melting and casting process takes place here 4 LCD screen see 3.3 5 control buttons see 3.
3.2. Connections on the backside 8 7 Abb.
3.3. Operation elements MC20V screen when starting the machine or "Temp. Edit" On the middle section shown: 100°C == actual temperature 1530°C == set temperature 0.00 bar == actual crucible pressure (-1 to 2 bars) 0.0 kW == actual heating power in kW 3.
MC20V modify program screen On the top level shown: 0013 program == selected program to modify 1530°C Temperature == set temperature inside the crucible 115% Pyrometer correction == allows you to adjust displayed temperature (if necessary) 100% Heating power == allows you to adjust displayed temperature (if necessary) 0000 Washing before heating == washing cycles before heating (starts with vacuum, then backfill to 0.0 bar with protective gas). Number display the cycles that will be done.
On the left side shown: Arrow up Arrow down == active parameter (highlighted with white background) changes to the parameter one level above == active parameter changes to the parameter one level below ( here Pyrometer correction) On the right side shown: + == changes set temperature to 1001 == changes set temperature to 0999 Main page == display moves back MC20V modify system parameter If you start from the start page and you press“ Program setup“ for 5 seconds you get access to the system paramter.
MC20V modify program screen second page If you press now „Service“ button you see the software ID, machine number and generator number. If you press now „Service“ button again you see the water flow and machine stat OPERATING_MANUAL_MC20V.DOC 18.03.
3.4. Operating buttons MC20V buttons left and right side Manual area: Generator Vacuum pump == starts and stops heating ( if not operating in program ) == switches vacuum pump on and off Automatic area: Stop Start == stops active program == starts selected program Special function of "Start" button: If you are operating within a program cycle and melting pressure ist active, you can release and reactivate the melting pressure by pressing the start button. OPERATING_MANUAL_MC20V.DOC 18.03.
3.5. Inside the vacuum chamber 4 3 2 5 1 Abb.
3.7. Test running After setting-up MC20V according to our instruction manual, you should make a final countercheck before you start casting: Please check once more connection: Electrical Supply: Cooling water: Vacuum: Protective Gas: .
3.8. Casting programs MC20V Casting programs MC20V Version _02 since August 2011 Preprograms_MC20V_02 Graphite crucible with thermocouple reading Silver Yellow 935/Cu gold 18k Material Program No. Temperature* °C Pyrometer correction % Heating power % Washing before heating Washing while heating Melting pressure** bar Casting pressure start (in ° or ° seconds) Casting pressure bar Vibration sec Label * ** *** Ceramic crucible with holder and pyrometer reading 950Pt CrCo 950Pd stainl.
Open the casting chamber and remove the flask and the flask holder. 3.10. Important information about direct induction heating Direct induction melting is necessary on metals with high temperature melting points, such as Pt, steel etc. High temperatures do not allow use of graphite crucibles because of quick burning under standard atmosphere. Also direct induction melting is necessary on metals, which reacts unwanted with graphite.
Caution: danger of squirting. 3.11. Temperature Control To use the temperature controller a thermocouple type N article no 13400010 up to 1300°C (parameter -01- must be set to 0002) * or type S article no 13000030 up to 1600°C (parameter -01- must be set to 0001) * Has to be connected to the socket inside the casting chamber. Very important is that you use the thermocouple together with the thermocouple protection cover article no 13200045.
On this main sprue single pieces are fixed in a style of a spiral. This is best for cutting off the casting pieces after casting process. On MC20V this tree is more a bush, pieces are fixed on the button cone directly. Only a short piece of main sprue is required. This main sprue is fixed in the rubber base, the diameter of the rubber base is according to the diameter of the flask.
3.13. To find out the weight of the metal ALL rubber bases must be determined on a scale. Write exact weight on this rubber bases by a felt pen. After mounting the tree, take the total weight. Deduct the rubber base weight from the total weight = net wax weight. To simplify matters we assume the specific weight of wax as 1.
3.14. About casting metal: Because of high costs casters do not like to use every time fresh alloy. For some alloys customers mix „second hand metal“ up to 50%, mainly Au, Ag based alloys. Never use finished jewellery pieces. The alloy composition is not known, solder in casting material will give no good casting result. Never mix two alloys, even if they have the same contents of gold All already cast metal should be very clean, sand blasting and pickling are adequate methods.
Palladium 950 Platinum Palladium should be melted in the same type of crucible like Platinum. Palladium has a strong reaction with oxygen. That´s why we recommend to „wash“ the chamber atmosphere as follows: Set „power“ to zero “P000”. Put in metal, set in flask. Push button start (want to heat, but set point power is zero = no heating possible). After then start again = vacuum comes. After reaching vacuum, another push on start: vacuum will be released by ARGON gas.
Cobalt-chromium, steel alloys Set heating power to P080 (80%). Use the ceramic crucible for steel. Put in crucible, set in flask. Push “Start” twice to start heating and vacuum. If full vacuum is there for at least 30 seconds (see timer) increase heating power to P100 (100%) and cast when metal is ready. One more problem of NiCr, CoCr and steel alloys: some alloys tend to splash in molten condition and under vacuum. In this case it is useful to change setting of parameter P060 = limitation of vacuum.
3.17. Mixing instructions for flasks in Investing process Investment process means, that powder is mixed for a certain time with water in a special ratio into a slurry and filled into a flask. It is generally possible to do it by hand in an open rubber bowl. But during this process you will mix in air which creates bubbles afterwards in the investment and on top of the castings as well.
3.18.
flask size investment powder in grams water in ml mixing time in min:sec Ø 30mm x 55 mm Ø 50mm x 55 mm Ø 65mm x 55 mm Ø 80mm x 55 mm Ø 50mm x 80 mm Ø 65mm x 80 mm Ø 80mm x 80 mm 60 150 270 390 220 370 560 21 52 95 136 77 130 196 3:00 3:00 3:00 3:00 3:00 3:00 3:00 3.19. Burnout cycles of flasks After investment process the flasks have to undergo a firing process. For this purpose the flasks have to be placed in the furnace with the button (opening) down to ensure a complete flow-out of wax.
Temp. 730 Casting temperature 300 2 3 5 6 time in h Firing cycle for MC20V, gypsum bound investment material This „gentle“ firing cycle needs around 7 hours, so from wax to casting it will take only one day. But it is also possible to push this cycle. Here a recommendation of a RAPID firing cycle: OPERATING_MANUAL_MC20V.DOC 18.03.
Temp. 730 Casting temperature 300 0,5 1 1,5 2 3 time in h RAPID firing cycle for flasks MC20 gypsum bonded investment material Caution: In case of a „gentle“ firing cycle all amenities of the investment material are prevented from damage. A rapid firing cycle doesn’t take care on this amenities. Already aged investment powder or thus of lower quality can react because of gruff handling with cracks. In the dental field most people are using „SPEED“ investment material.
3.20. After casting: Most castings in gold- and silver alloys, palladium- and platinum alloys can be quenched immediately after the 240 seconds cooling time in the machine. Except: stone in place castings, they should cool down to room temperature. However, some alloys need to cool for prolonged time, see datasheets of alloy suppliers. Castings in CoCr, NiCr and steel alloys should cool down to room temperature before removal of the flask.
4. Service 4.1. Trouble shooting MC20V does not start: Is the plug plug in? Fuse of the electrical circuit tripped? Otherwise MC20V will show information by an error code system in the display: Exxx There are two graduations: Warnings: will be displayed if something is wrong, but machine will not shut down. Errors: will shut down machine immediately to prevent system against serious damages.
5. Collection of Spoiled Castings Horizontal Flashing or Finning Cause Incorrect powder / water ratio (too much water). Work time of investment not used up. Remedy Using correct amount of water (especially important with vacuum investing machines). Ensuring the work time is used up and slurry temperature is 20 - 22ºC Other Flashing Or Finning Cause Work cycle too long. Investment beginning to set while still under vacuum. Disturbing the flasks too soon Heating too quickly during de-wax.
Bubbles - Complete Spheres Cause Investment too thick. Too little water. Vacuum pump/ tank faulty. Work cycle too long. Investment beginning to set while still under vacuum. Remedy Use correct powder / water ratio. Ensure equipment is regularly serviced and adequate for the task. Ensuring the work cycle is not too long and slurry temperature is 20 - 22ºC. Bubbles-Incomplete Spheres Cause Static electricity on waxes. Grease or dirt on waxes. Remedy Use a wax wash.
Water marking Cause Incorrect powder / water ratio (too much water). Work time of investment not used up. Remedy Using correct amount of water. (Especially important with vacuum investing machines). Ensuring the work time is used up and slurry temperature is 20 - 22ºC. Gas porosity Cause Overheating the metal. Inadequate burn out. Flask overheated during burn out. Impurities in the metal. Remedy Reduce metal casting temperature. Increase the time at 730ºC.
Rough Surfaces Cause Rough waxes. De-wax temperature too hot. Steam de-waxed for too long. De-waxed too quickly. Flasks overheated during burn out. Metal too hot. Remedy Use less release agent on the rubbers. Can be caused by excess talc. Do not exceed 150ºC during de-wax. Steam, de-wax for a maximum of 1 hour. Steam will erode surface of the investment. Leave flask for at least 1 hour to achieve maximum strength before de-waxing Ensure maximum burn out temperature does not exceed 730ºC.
Incomplete castings Cause Metal or flask too cold. Improperly sprued. Incomplete burn out. Remedy Increase casting temperatures. If the metal or mould is too cold, the metal will freeze before completely filling the mould. The sprue system should be designed to allow the metal to enter easily and without restriction. Increase the burn out time at 730ºC. If the flask is not properly burnt out it will be impermeable and not allow gases to escape when the metal enters the mould.
Blisters, Spalling Cause Flask being heated too rapidly during de-wax. Flasks overheated during burn out. Flasks put in furnace too soon after investing Remedy Do not exceed 150ºC during de-wax. Wax will boil and erode investment surface. Ensure maximum burn out temperature does not exceed 730ºC. Leave flasks undisturbed for a minimum of one hour before de-wax. OPERATING_MANUAL_MC20V.DOC 18.03.
6. Connection diagram OPERATING_MANUAL_MC20V.DOC 18.03.
7. Appendix 7.1. CE-declaration OPERATING_MANUAL_MC20V.DOC 18.03.
7.2. Consumables The spare part list for this machine starts on next page. INDUTHERM is now using only machine specific spare parts lists, which contain all the information for your machine. The list is printed on the following pages. The name of the stored list starts with a 1.) G 2.) The next 5 digits are the machine number. 3.) Next is the specification for what application it is used for. (only at multipurpose machines) 4.) The version index. A new machine has the index _00. One example is G10120_ 00.
Bitte anstelle dieser Seite die aktuelle Verbrauchsteileliste und die Bilderliste der Verbrauchsteile einfügen ! / Replace this side with actual spare parts list G xxxxx = Serial number of machine OPERATING_MANUAL_MC20V.DOC 18.03.
7.3. Error and Warning Codes The Error and Warning Codes for this machine start at next page. Attention: On our webside http://www.indutherm.de/errors.html you can find examples how to troubleshoot errors. Here you find PDF files with examples and pictures Attention: Warnings will not shut down machine! You can still operate machine, but inform us please. The software documentation for this DM - generator system has 7 digits and starts with 8000xxx. xxx = is the software index.
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