Heraeus Heracast iQ Bedienungsanleitung

Heracast®iQ

Operating instructions

Casting Machine Heracast®iQ

Dateiname: W14040_66036086_02_BA Heracast iQ_GB_V01_X4

SAP-Nr: Version

66036086 GB-02 HK-Toolbox-Nr:

W14040 Format: Falzmaß:

420 x 280 mm 210 x 280 mm

Projektmanager:

Michael Helken HKG-Version:

V01, 0.AK Datum HKG Freigabe

27.08.2015

HKG-Layout W14040_66036086/02 BA

Heracast_iQ_GB

EURO / Pantone Sonderfarben Druckverfahren: Digitaldruck

C M Y K varnish DieCut var.Data

1 Scope of applicability .................................................................................................................................... 5

1.1 General ............................................................................................................................................................. 5

1.2 Designation and type of machine ......................................................................................................................... 5

1.3 EU Statement of conformity ................................................................................................................................ 5

1.4 Instructions on using the unit safely .................................................................................................................... 6

1.4.1 Explanation of Symbols ...................................................................................................................................... 6

1.5 Warning pacemakers .......................................................................................................................................... 6

1.6 Transport damage .............................................................................................................................................. 6

1.7 Operator‘s obligations ......................................................................................................................................... 6

1.8 Unit book .......................................................................................................................................................... 7

1.9 Safety information ............................................................................................................................................. 7

2 Useinaccordancewithspecications ............................................................................................................. 8

2.1 Working rules .................................................................................................................................................... 9

3 Description (of the unit) ................................................................................................................................. 9

3.1 Features ........................................................................................................................................................... 9

4 Scope of delivery / original equipment ............................................................................................................. 9

4.1 Scope of delivery ............................................................................................................................................... 9

4.2 Original equipment .......................................................................................................................................... 10

5 Structure and function ................................................................................................................................ 10

5.1 Control and display elements ............................................................................................................................ 10

5.1.1 Description “Total view Heracast iQ” ................................................................................................................. 10

5.1.2 Description “Interface” .................................................................................................................................... 11

5.1.3 Description “Supply connections” ..................................................................................................................... 11

5.1.4 Description “Front panel with control keys and display” ....................................................................................... 12

5.1.5 Description “Partial view open chamber” ........................................................................................................... 13

6 Location and installation .............................................................................................................................. 13

6.1 Transport ........................................................................................................................................................ 13

6.2 Unpacking ...................................................................................................................................................... 13

6.3 Set-up ............................................................................................................................................................ 14

6.4 Mains connection ............................................................................................................................................ 14

6.5 Compressed air supply ..................................................................................................................................... 15

6.6 Filling the cooling system ................................................................................................................................. 15

6.7 Room ventilation ............................................................................................................................................. 15

7 Operations .................................................................................................................................................. 16

7.1 Putting into operation ...................................................................................................................................... 16

7.2 Putting out of operation .................................................................................................................................... 16

7.3 Errors and causes ............................................................................................................................................ 17

8 Working with the Heracast iQ ....................................................................................................................... 19

8.1 Setup main menu – casting (diagram) ................................................................................................................ 19

8.2 Description main menu – casting (diagram) ........................................................................................................ 19

8.3 Setup menu (diagram) ...................................................................................................................................... 20

8.3.1 Description Table 1. “Setup” ............................................................................................................................ 20

8.4 Service menu (diagram) .................................................................................................................................... 21

8.5 Description Service menu (diagram) .................................................................................................................. 21

8.5.1 Description Table 2. “Service” .......................................................................................................................... 22

9 Melting and casting ..................................................................................................................................... 23

9.1 General ........................................................................................................................................................... 23

9.2 Heraeus spruing system .................................................................................................................................... 23

9.3 Suitable investment materials ........................................................................................................................... 23

9.4 Premelting ...................................................................................................................................................... 23

Table of Contents

9.5 Casting ........................................................................................................................................................... 24

9.5.1 Graphite insert ................................................................................................................................................ 24

9.5.2 Ceramic crucible ............................................................................................................................................. 24

10 Alloys ......................................................................................................................................................... 25

10.1 Gold casting and high gold content ceramic bonding alloys

Universal and silver-palladium alloys ................................................................................................................. 25

10.2 Reduced precious metal ceramic bonding and palladium-based alloys .................................................................. 25

10.3 CoCrMo and non-precious metal alloys ............................................................................................................... 25

10.4 Titanium and aluminium-containing alloys .......................................................................................................... 26

10.5 Description of alloy database ............................................................................................................................ 26

10.5.1 Enter new alloys .............................................................................................................................................. 27

10.5.2 Casting of alloys .............................................................................................................................................. 29

10.5.3 Deleting datasets ............................................................................................................................................. 29

11 Spruing system ........................................................................................................................................... 30

11.1 Melt characteristics of Heraenium CE and Heraenium EH .................................................................................... 30

11.1.1 Preparations .................................................................................................................................................... 30

11.1.2 Premelting (phase 1, 2, 3) ................................................................................................................................ 30

11.1.3 Insert the casting mould ................................................................................................................................... 30

11.1.4 Main melt ....................................................................................................................................................... 30

11.2 Melt characteristics of Heraenium alloys ............................................................................................................ 31

12 Maintenance ............................................................................................................................................... 32

12.1 Maintenance and care ...................................................................................................................................... 32

12.1.1 – daily ............................................................................................................................................................ 32

12.1.2 – weekly (or after 100 castings) ........................................................................................................................ 32

12.1.3 – annually (or after 3.000 castings) ................................................................................................................... 32

12.1.4 – after 30.000 casting or after 3 years ............................................................................................................... 33

12.2 Tests .............................................................................................................................................................. 33

12.3 Maintenance ................................................................................................................................................... 33

12.4 Disposal .......................................................................................................................................................... 33

12.4.1 Disposal of old equipment according to WEEE .................................................................................................... 33

13 Repair / Maintenance work ........................................................................................................................... 34

13.1 Exchanging the pump oil .................................................................................................................................. 34

13.2 Exchangingthepumplter............................................................................................................................... 35

13.3 Exchangingthelterinthevalvebox................................................................................................................. 35

14 Exchanging the cooling water ....................................................................................................................... 35

15 Technical data ............................................................................................................................................ 36

15.1 Rating plate .................................................................................................................................................... 36

16 Circuit diagrams .......................................................................................................................................... 37

16.1 Compressed air ................................................................................................................................................ 37

16.2 Water circulation ............................................................................................................................................. 37

16.3 Terminal assignment ........................................................................................................................................ 38

17 Alloys ......................................................................................................................................................... 39

18 Control information Heracast iQ .................................................................................................................... 40

19 Service ....................................................................................................................................................... 41

19.1 Service agents / Contact in the countries ............................................................................................................ 41

20 Document history ........................................................................................................................................ 42

Table of Contents

Operating instructions

Casting Machine Heracast®iQ

1 Scope of applicability

1.1 General

Combilabor®is a registered trademark of Heraeus Kulzer GmbH.

Author 42415SCH

These working instructions apply to:

Order No. Type Features Date

66004331 Heracast iQ integrated water cooling and vacuum pump 2015-08 / 66036086/02

1.2 Designation and type of machine

Designation of the machine: Type of machine: Serial number.:

Induction casting machine Heracast iQ Heracast iQ from 2093

1.3 EU Statement of conformity

Herewith we, Heraeus Kulzer GmbH,

Grüner Weg 11, 63450 Hanau (Germany),

conrmthatthefollowingunitduetoits

intended use and the version marketed by us

corresponds to the relevant basic safety and

health requirements of the EC guideline.

This statement will become invalid in case

ofanymodicationoftheunitthatisnot

co-ordinated with us.

1.4 Instructions on using the unit safely

1.4.1 Explanation of Symbols

Symbol Accompanying word(s) Explanation

CAUTION! Safety-relevant chapters and sections in these working instructions

have been marked with this symbol.

NOTE! Information within the working instructions

on the optimum use of the unit.

HOT SURFACE! Hot surface risk of getting burned.

HIGH FREQUENCY! Caution high frequency.

Not to be used by persons with pacemakers.

WARNING! Warning:

Caution High frequency.

CHANGE! Important:

Changes have been made to this paragraph.

Please read carefully.

CERTIFICATE Registrationcerticateaccordingtotheministryofhealth

of the Russian federation.

1.5 Warning pacemakers

WARNING!

Not to be used by persons with pacemakers Read working instructions prior to use! We cannot accept any

guarantee claims or assume liability if the machine is used for other purposes as stated or for damage

resulting from non-compliance with these working instructions!

1.6 Transport damage

Please check the unit for transport damage and, if necessary, report the damage to the forwarder within 24 hours after receiving

the unit. Under no circumstances, work with a damaged machine.

1.7 Operator‘s obligations

Inadditiontocomplyingwiththestatutoryregulationsspeciedbythemanufacturer,theoperatormustensurethestatutory

obligations are observed and implemented in the workplace, i.e. he must train his personnel and comply with industrial safety

legislation and any other regulations or laws in force.

Operating instructions

Casting Machine Heracast®iQ

For working on and with the machine, the operator must draw up written instructions in understandable form and give these

to his employees in their own language. These instructions must be based on the operating manual and written in light of the

work to be performed.

1.8 Unit book

Werecommendyoukeepaunitbook.Alltestsaswellasallessentialworks(e.g.repairwork,modications)mustbe

documented in this book.

1.9 Safety information

With these laboratory units the safety concerning the protection of persons, the environment and the material to be processed

mainly depends on the behaviour of the persons operating the unit.

Prior to operation read the working instructions carefully, adhere to the information provided in order to avoid errors and

damage, in particular damage to the health.

In addition to the information in these working instructions, relevant national laws and guidelines must be observed for setting

up and operating this unit (technical connection requirements of the electrical supply companies, etc.).

HOT SURFACE!

The metal surface around the casting chamber heats up during continuous operation.

Do not touch this surface.

When casting and in particular when handling melted metal face guards, gloves and aprons must be worn.

Cleaning must always be carried out when the unit is cool.

NOTE!

Due to the waste gases released during working, adequate ventilation must be provided.

WARNING!

This symbol warns of the dangers of electric voltage. In the case of non-compliance the result of an electrical

shock with all known effects can be death. When inspecting the housing cover this safety symbol is visible

on the free surface on the operating unit. Please observe the safety instructions when carrying out servicing.

Works at the electrical equipment of the unit must only be performed by the authorised Heraeus service and

in the safe condition (voltage cleared).

CAUTION!

Power cable and plug must be checked for damage prior to operation.

If any damage exists, the unit must not be connected to the mains.

A damaged mains connecting cable may only be replaced by a mains connecting cable of the same type by the

authorised Heraeus service.

Works at the electrical equipment of the unit may only be performed by adequately trained service companies and in the safe

condition (voltage cleared).

Only permissible original spare parts must be used. The use of different parts holds unknown risks and must be avoided

at any rate.

Proper function and safety of the unit are only guaranteed if the required tests, maintenance and repair work have been

performed by Heraeus Kulzer service agents or by personnel adequately trained by the manufacturer.

Heraeus Kulzer GmbH will not accept any liability for damage to the unit resulting from inexpert repair which has not been

performed by Heraeus Kulzer service agents or if no original spare parts/accessory parts have been used during the exchange of

these parts.

CAUTION!

It is essential that the following safety instructions are adhered to

Fully close the locking lever before the start (push into the end setting). If the closed lever is not closed

overdeadcentrethereisariskthatthelevercouldipopenifpressurised.Thegivesrisetotherisk

of impacts and the danger of hot gases or melted metal splashing out.

When casting and in particular when handling melted metal face guards, gloves and aprons must be worn.

Cleaning must always be carried out when the unit is cool. The unit must always be supervised when in

operation.

Theoretically a control error can accidentally start a rotation.

This can lead to crushing via the locking lever.

Switch off the unit when not in use!

A self test also initiates an automatic rotation cycle.

Do not work in the area of the locking lever when the unit is switched on. Always keep this closed.

Don‘t place any objects under the chamber!

2 Useinaccordancewithspecications

The induction casting machine Heracast iQ is a laboratory unit for casting all precious metal and almost all non-precious and

CoCr alloys for dental applications with a liquidus temperature of 500 °C up to > 1600 °C.

The unit is not suitable or intended for casting pure titanium or beryllium-containing alloys!

CAUTION!

Processing of beryllium-containing alloys is hazardous to health!

Casting of these alloys is performed at the user‘s risk! Heraeus Kulzer GmbH will not accept any liability

for any health damage that may have been caused by casting such alloys!

Casting of titanium- or aluminium-containing alloys is performed in special working steps.

See paragraph 10.4 “Titanium and aluminium-containing alloys”.

Precision castings with alloy quantities of up to 130 g in the graphite crucible and 100 g in the ceramic crucible are possible.

Alloy quantity for CoCrMo and non-precious metal bonding alloys in the ceramic crucible: up to 60 g.

NOTE!

We recommend the exclusive use of original Heraeus Kulzer crucibles which are especially matched with this

type of application. The use of other materials leads to the exclusion of guarantee claims in case of damage to

the unit or the molten material. In view of the various causes for faulty castings, we do not grant any guarantee

for such cases.

 Normally,theunitissuitabletobesetupandoperatedinthefollowingelds:Commercialandindustriallaboratories,

schools, universities, hospitals, etc. The unit has been designed for continuous operation.

The pressure control is technically set to 3.5 bar on the unit and by means of a safety valve set to a pressure of 3.7 bar.

Operating instructions

Casting Machine Heracast®iQ

2.1 Working rules

CAUTION!

Personal protective equipment such as hand, face and body protection must be worn;

jewellery must be taken off prior to working.

CAUTION!

Do not use the unit for the following activities:

The unit must not be used for melting and casting beryllium-containing alloys (hazardous to health!).

Do not use the unit for melting, drying or thermal treatment which may lead to the release of combustible

gases and vapours which burn with air or which may form a hazardous, injurious or explosive mixture.

The unit is not suitable for thermal treatment of hazardous or health-hazardous materials

(e.g.dusts,bres,liquids,solids).

The unit must not be used to heat up food.

3 Description (of the unit)

3.1 Features

Reliable and material-appropriate melting and casting under vacuum.

Temperature control via electronic power control and time.

Long lifetime of ceramic and graphite crucibles.

NOTE!

In order to avoid errors and problems during working we would like to ask you to read these working instructions

carefully and store them at a place ready to hand. Additional information on vacuum pressure casting can be

obtained upon request. Phone No. of Customer Service, see paragraph 19 „Service“

4 Scope of delivery / original equipment

Check that all components are in perfect condition on delivery of the machine.

If you wish to make a complaint, contact your supplier.

4.1 Scope of delivery

1x HeracastiQ,workinginstructions,testcerticate

1 x Filling hose with connector and container

1x Mufeholder

1 x Pressure hose 13 mm, incl. 2 hose clamps and a socket 13 mm

2 x Door signs Caution! High frequency. “Not to be used by persons with pacemakers”

HIGH FREQUENCY!

Attach the supplied adhesive pictorial symbols “Not to be used by persons with pacemakers” to all entrances

to the unit service room.

4.2 Original equipment

1 x Small alloy spoon

1 x Box cont. small melting powder pellets

1 x Spruing aid - plexiglass half-pressing

1 pack 6 pcs ceramic crucibles for CL-IG / IM / I95 / Heracast iQ / EC

1 pack 6 pcs ceramic crucibles NPM-crucibles for CL-IG / IM / I95 / Heracast iQ / EC

1 x Crucible box CL-IG / IM / I95 / Heracast iQ / EC

1 pack 10 pcs graphite inserts for CL-IG / IM / I95 / Heracast iQ / EC

3 x each Casting ring (X3, X6, X9)

1 x each Cone former (X3, X6, X9)

5 Structure and function

5.1 Control and display elements

5.1.1 Description “Total view Heracast iQ”

1Front panel with control elements

2Viewing glass casting chamber

3Front limit switch chamber lock

4Locking lever – casting chamber (with carrying handle) and bow

5Viewing glass for oil level of the pump

6 Holderforspecialtoolmufelift

7Filter cover air supply

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