S e r i e s 6 INDUCTION CASTING MACHINE

Transcription

1 4 S e r i e s 6 INDUCTION CASTING MACHINE P r e c i s e V e r s a t i l e C o n s i s t e n t Priced well below other electronic induction casting machines in its class, the Modular 4 Series 6 will precisely cast non-precious, semi-precious and precious alloys in just 60 seconds! Operation is so effortless, so consistent, training is minimal. The high skill level required for torch casting is eliminated. Complete control is at your fingertips! Semi-Automatic for Excellent, Precise Consistency Standard Integrated Electronic Eye for Absolute Accuracy Solid-State Circuitry Throughout (No Tubes!) Self-Contained Water Cooling System Adjustable Cradle for Varying Flask Sizes Safety Control Cover (Arm Will Not Spin When Cover is Up!) Small, Compact Design Laboratory-Proven SPECIFICATIONS Model No. 2007M 220V/60 Hz, 20 Amp 23 1/2 (60 cm) W 27 (69 cm) D 41 (104 cm) H w/eye 364 Lb (165 Kg) Sh Wt Modular 4 Series 6 specifications may be subject to change without notice as modifications & improvements are made. Owner s Manual

2 Congratulations! You have just purchased a quality piece of CMP Dental Laboratory Equipment. It has been carefully quality-controlled and thoroughly tested at the factory for optimum performance and durability. From the smallest bench unit to the largest floor-standing casting machine, each piece of equipment must adhere to the same standards of quality and efficiency that have made all CMP laboratory equipment an outstanding value. If you have any questions regarding CMP s quality line of dental laboratory equipment and supplies, please call toll-free: or (Fax: ) between the hours of 8:00 AM and 4:30 PM Eastern Time. Or, if you prefer, visit us at our website: we will be happy to assist you. Demand the best! Insist on quality CMP Dental Laboratory Equipment. 2

3 Unpacking Carefully remove the outer packing crate from the Modular 4 Series 6. The packing container is held together with nails or screws on the bottom of the crate. Once the screws on the base are removed, the crate should lift off. Remove styrofoam, shrink-wrap and any other packing material. Thoroughly inspect the casting machine for damage at this time. Important: If any damage is found, it must be reported immediately to a representative of the carrier that delivered the casting machine. The representative should come to your laboratory, inspect for damage, and fill out necessary damage reports. At that time, they will instruct you as to the next step in the damage claim procedure. After, and only after the carrier has been notified, should CMP Industries be notified. If no damage has been found, proceed to remove your Modular 4 Series 6 Casting Machine from its shipping crate base. The crate has two bolts holding the machine on the palate. Remove these bolts and gently slid the casting machine off the base of the crate. Electrical Connection 220 Volt, 20 Amp, Single Phase, 60 Hz The customer is responsible for providing a 220 volt, single phase, 20 amp electric line to the casting machine. The receptacle is shipped with the machine and can be found in the accessory kit (CMP Part No. 2004MP2). The receptacle should be mounted within 6 feet of the lower left rear of the casting machine. Note: A conveniently reached disconnect switch is recommended within 20 feet of the casting machine. An electrical panel circuit breaker is fine as long as it is convenient and within 20 feet of the casting machine. Install a 20 amp, 220 volt receptacle in accordance with appropriate electrical codes. See device box for proper wire connections. The installation of receptical is the responsibility of the laboratory and not the Technical rep. CAUTION: It is important to check that voltage is correct for the Modular 4 Series 6. Modular s plugged into incorrect outlets are the responsibility of the purchaser and all warranties are void. Voltage can vary only ±5% of name plate voltage. Call CMP if voltage varies more than ±5%. Modular Set-Up This is a very important step in the proper installation of your new Modular 4 Series 6 Casting Machine. Even though your unit was fully tested and inspected before leaving CMP Industries, we cannot control the handling of equipment en route to you. For this reason follow the set-up steps carefully and be sure cooling systems are functioning properly before initial operation. Note: The parts lists and schematics located in the back of this manual will help in the proper identification of items (pages 15-19). 1. Remove all packing material from casting wall. 2. Remove black knob located in top center of front panel. See Figure 1 3

4 3. Remove 12 screws that secure front panel. Tilt front panel out from top. Locate panel ground wire at lower left, wiggle gently and pull off from panel. Remove panel. 4. Locate tank cover locks and pull up to loosen. See Figure 2 5. Remove tank cover. Fill tank with distilled water to within 1 inch of top about 9 gallons. Do not use any additives in the water! 6. Install cover on tank. Make sure hoses are well below surface of water. 7. Test water pressure switch: A. Turn power on. See Figure 2 B. Raise coil, close the cover and check for green pilot light on top right front of Modular 4 Series 6. See Figure 1 C. Locate suction hose. The suction hose goes from the tank to the brass pump located above and to the left of the tank. See Figure 2 D. While watching the green light, slowly pull suction hose out of tank cover. When removed, green pilot light should go out. When pushed back below the water surface, the green pilot light should come back on. E. If green pilot light works as described above, the Modular 4 Series 6 cooling system is functioning correctly. F. If green pilot light is not on, check to see that the hose is below water surface. If green light still does not come on, go to trouble shooting section. 8. Replace front panel and black knob. Warnings & Precautions 1. Never remove panels with power on. 2. Nothing flammable should be near the Modular 4 at any time. 3. The electrical line feeding the casting machine must be grounded. 4. Never try melting without metal in crucible. 5. The room housing the Modular 4 Series 6 must be free of the following: A. Moisture B. Sandblasting equipment C. Corrosives D. Flammable liquids E. Dust 6. The panels should be removed periodically and the inside swept and vacuumed. Do not use compressed air, water or cleaning agents. 7. Change water at least every 6 months. Tank and filter must be cleaned when water is changed. See maintenance section. Modular Operation For location of components mentioned in text, refer to schematics in back of this manual (pages 15-19). 1. Connect in electric line that laboratory installed. 2. Turn On/Off switch 90 clockwise or from 0 to 1 to turn Modular 4 on. White See Figure 1 pilot light and the pyrometer should come on. 4

5 3. Select crucible that you will be using and place in crucible carrier. Put metal in crucible. CAUTION: The Modular 4 Series 6 should never be started without metal in the crucible. Starting without metal can cause severe damage to the machine. 4. Balancing the arm is very important. Do this by placing a dry mold, like the one you will be using, on the arm. Next, move the crucible carrier up to within 1/16 to 1/8 of the mold. Locate 2 Phillip set screws on the collar of the left Inox Bar. See Figure 3 Position the collar so it will stop the crucible carrier as described above. Use the set screws to lock collar on Inox Bar. Loosen black plastic nut located in the center of the arm. See Figure 3 The arm is mounted on a pivot and, by moving the counter weight in and out, the arm can be balanced. Move weight by rotating. Make sure crucible carrier is against stop. Lock black plastic nut after balancing, making sure that notch in bottom of arm center is on drive pin or pivot. 5. Loosen black lever on right side of arm 90. See Figure 3 Use lever to rotate mold cradle so hole in crucible spout lines up with center of sprue hole. Clamp by tightening black lever. Be careful that black lever can not hit cover. If lever hits cover, pull lever out and reposition. 6. Raise the coil. Grasp black handle See Figure 1 with your right hand. Use your right thumb to push chrome locking lever to the left. With your left hand, grasp black knob on crucible holding plate assembly. Align reference pin over hole in reference pin block. See Figure 3 Now raise coil with your right hand and release the locking lever with your thumb. Coil should be up and locked. 7. Rotate the melt switch fully counter clockwise past click. See Figure 1 8. Close cover. Green melt light should come on. See Figure 1 9. Rotate the melt switch clockwise See Figure 1 to desired melt speed. Remember, fast melts are not always the best. 10. After metal starts to glow, get mold from oven. Open cover (stops melt), place mold in cradle, being sure crucible spout and sprue hole are aligned. 11. Close cover and melt will restart. 12. When metal is molten and ready to cast, grasp black knob with your right hand and silver locking lever with your left. Pull the locking lever to the left and place coil down firmly. If allowed to just drop, spin will not always occur. 13. Cover will be locked down during spin for the operator s protection. It will release about 5 seconds after spin stops. 14. To stop spinning, rotate melt switch fully counter clockwise past click. See Figure Open cover and raise the coil. Grasp black handle with your right hand. Use your right thumb to push the chrome locking lever to the left. With your left hand, grasp black knob on crucible holding plate assembly. Align reference 5

6 pin over hole in reference pin block. Now raise the coil with your right hand and release locking lever with your thumb. Coil should be up and locked. 16. Remove mold from cradle. 17. Remove oxide shell from crucible. 18. Repeat procedure for rest of castings. 19. The Modular 4 Series 6 can do about 15 castings in a row with normal ambient conditions (air temperature at 70 F 21 C). As air temperature rises, the number of consecutive melts will decrease. Melting Multiple Pieces 1. Turn On/Off switch to On position. 2. Raise coil around crucible. 3. Load crucible. Be careful not to allow metal to form a solid bridge between inside walls of crucibles or expansion will crack and break crucibles. 4. Close cover. 5. Rotate melt switch clockwise to desired setting for alloy being melted. See Figure 4 6. When metal has melted and formed a single mass (pooled together, flat across top), open cover to stop heating. Note: It may be necessary to use a quartz probe to assist formation of the pool. 7. Place mold on arm. Adjust cradle so spout of crucible lines up with sprue hole in mold. 8. Close cover and resume heating. 9. When metal is almost ready, place your left hand on silver lever and your right hand on black knob. 10. When metal is at right temperature, push silver lever to left and push black handle down firmly. 11. When black handle reaches bottom, the arm will spin. For proper length of spin, please contact alloy manufacturer. An average time to try is 15 seconds. 12. To stop spin, rotate melt switch fully counter clockwise. Wait 5 seconds for cover lock to release and open cover. 13. Rotate arm until crucible is over coil. With your left hand, push the crucible carrier back to center crucible over coil. Place the fingers of your right hand under the black handle and lift while pushing the silver lever to the left with your thumb. Be careful and make sure reference pin goes into hole in reference pin block. When finally up, release silver lever to lock coil up. 14. Remove mold from arm. 15. Remove oxide shell from crucible. 16. You are now ready for your next casting. Temperature Controller Temperature is monitored by an infra red Pyrometer that looks down into the crucible. See Figure 1 Readings go up as temperature rises. Care must be taken to not obstruct the view of sensor. 6

7 Carbon-lined (graphite) crucibles get hot and transfer heat to the alloy. The Pyrometer reads the temperature of these crucibles. When alloy is ready to cast, the crucible and alloy should be the same color. After controller reaches temperature, it needs to cycle a few times for the alloy to reach the same temperature and color. The more consistent the operation, the more consistent the temperature control will be. Examples: A. Same weight (as close as is convenient). B. Melt first to a pool. Then stop, get mold and start again. Melt will be one mass heating the same. C. Probing may be required to help metal form a pool. D. Use the same type of crucible. Color, depth, shape, etc. will all affect consistency. E. Minimum load of 10 dwt when using a ceramic crucible. F. Melt speed. Keep consistent for type of alloy. Faster melting can be harder to control. G. Keep procedure the same. H. Carbon-lined (graphite) crucibles must be used with covers. This means temperature control must be with covers on. I. Non-precious alloys should not be cycled more than 3 times. This is because they form oxides which will fool the sensor. J. Precious alloy should cycle at least once or until crucible and alloy are the same color. The function button should never be pushed. If pushed by accident, wait a few minutes until set point numbers appear. If this does not happen, call CMP. The Potentiometer is located on the top right front corner of the Modular 4 Series 6 See Figure 1 to help better understand pyrometer layout). Top yellow/green umbers show heat rise of the alloy. When first turned on, it should read about 600. As metal gets hot, the numbers will increase. Bottom red numbers indicate chosen set point or casting point. Manual button. Push manual button and hold. The bottom red numbers should change to small double zeros. If zeros do not appear, hold manual button and up arrow until double zeros appear. turn main power switch off and on to restore set point. When in manual mode, temperature will continue to rise after set point is reached. When in normal mode, temperatures will cycle on and off after temperature is reached. Use up arrow to raise set point. Use down arrow to lower set point. Note: Cycling will start before numbers reach set point. Machine heats faster than numbers can change. DO NOT TOUCH FUNCTION BUTTON! If accidently pushed, wait a few seconds and display should return to normal. If display does not return, call CMP. Note: Changes in pyrometer settings should be in 25 division minimums. Changes made in less than 25 divisions will have no effect on castings. 7

8 Setting Temperature Control 1. Set maximum temperature. See Figure 1 2. Load crucible with a typical charge of your alloy. Melt alloy as normal. Watch alloy and, when alloy is ready to cast, read temperature in top display (yellow/green numbers). Repeat this 3 or 4 times. Record these readings. Use the highest number as your set point. 3. Push up or down arrows to adjust set point. 4. Try a couple of castings to check results. Remember, a change of 25 divisions is needed to have an affect. 5. Once set, the Modular 4 will always cycle at that set point. 6. To override cycle, eye must be in manual mode as declaired on page 7 Note: It is not good to cycle non-precious alloys too often. They tend to build oxide rapidly which will cause inaccurate temperature readings. Non-Precious Alloys Melted in Ceramic or Green/Tan Wash Lined Crucibles 1. Leave pyrometer in the normal casting mode. Melt will cycle on and off when set point is reached (semi-automatic mode). 2. Load crucible with a typical charge of alloy. 3. Semi-Automatic Melt Mode: A. Choose set point for proper correspondence of your alloy. Selecting a set point may be a trial and error process. B. Once the set point is reached, cast alloy by dropping coil firmly to initiate spin. 4. Manual Melt Mode: A. Watch alloy melt. Alloy will turn orange and slump. As the alloy continues to melt and become brighter, the center or tip of the ingots or mass will still have a darker hue. This is known as shadow. B. Observe shadow disappearance, wait approximately 4 to 5 seconds (one thousand one, one thousand two, one thousand three, etc.) and cast alloy by dropping the coil firmly to initiate spin. 5. Align crucible over the coil, raise and lock. 6. Remove casting ring. Precious Alloys Melted in Carbon-Lined (Graphite) Crucibles 1. Leave pyrometer in normal casting mode. Melt will cycle on and off when set point is reached. 2. Load crucible with a typical charge of alloy. Put cover on crucible with cut out to the rear. 3. Heat until alloy balls. 8

9 4. Reduce power to 60%. 5. Watch alloy and, when surface clears, read top numbers. 6. Continue melting. When surface starts to roll, read top numbers. Stop melt. 7. Casting point will be between these two readings. 8. Use the high reading as the starting point. Set Temperature. 9. Start melt. When temperature set point is reached, the Modular 4 Series 6 should be allowed to cycle at least 3 times to assure uniform temperature. Alloy and liner should be the same color. 10. Cast alloy by dropping coil firmly. 11. Align crucible over coil. Raise and lock coil. 12. Remove casting ring. 13. Deflask and check casting. You can now raise or lower temperature to fine tune the process. High-Palladium Alloys Melted in Ceramic Crucibles Note: High palladium alloys melt very quickly. Use a reduced speed. 1. Set to maximum temperature reading. 2. Load crucible with a typical charge of alloy. Melt the way you normally would with non-precious alloys. 3. Watch alloy. First it will slump, then it will come together and ball. At this point, it may or may not clear. Shortly after this, it will smoke. You should read temperature immediately. 4. You should cast just before the smoke occurs. 5. Push up or down arrows to set the set point as determined in step Try a casting at this setting. 7. Change temperature up or down to zero. Changes must be made in 25 point divisions to be effective. Modular 4 Series 6 Crucible Selection CMP Industries feels our crucibles are the finest available. We have a selection that should cover all your casting needs. Below are some things to consider when selecting a crucible and tips on proper crucible handling. 1. Who knows most about the alloy you are using? The manufacturer of that alloy. We can suggest a crucible but the alloy s manufacturer should have the final input. 2. Cracking crucibles is usually the result of improper loading. A solid metal bridge from one inside wall of the crucible to the other is usually the cause. The metal heats, expands and pushes out the walls. 3. Most high-palladium and chromecobalt alloys wet the walls of the crucible and stick. Because of this, it may not be wise to use an expensive lined crucible. 9

10 4. Do not allow the crucibles to become contaminated. It can drastically reduce their life and may contaminate the metal. 5. When hot, the crucibles are more brittle. Great care should always be taken when probing alloy, moving the crucible and removing the oxide shell. 6. Front wall pull-out is usually caused by the crucible hitting too hard. To best eliminate this, try reducing carrier travel or decelerate carrier before stopping. 7. DO NOT use any flux in Modular 4 Series 6 crucibles! 8. Remove prior oxide shell before beginning a new melt. Recommended CMP Crucible Types: Modular 4 Crucible #4115 Modular 4 Series 6 Crucible w/tan or Grey Lining: The best crucible for chrome-cobalt alloy. The tan lining resists metal adhesion and attack by most alloys. Very good for nickel-chrome and high-palladium alloys. Can be used with high-fusing porcelain gold. Carbon-Lined Crucible: Good for low-fusing golds (melt under 2000 F/1093 C). Modular 4 Crucible #4114 Modular 4 Series 6 Unlined Crucible: Good for chrome-cobalt and high-palladium alloys. Will also work with nickel-chrome. Can be used with high-fusing golds. Carbon-Lined Crucible #4116 Ticonium Ti-Crucible #65046 Ti-Crucible w/green Lining: The best crucible for melting nickel-chrome alloys. Can be used with Ticonium and other nickel-chrome, non-precious alloys. Also may be used for high-palladium alloys. 10

11 Modular 4 Series 6 Casting Machine Troubleshooting Guide 2. Cover up. 2. Close cover. PROBLEM: NO AMBER POWER LIGHT 1. Tripped circuit breaker or blown fuse. 1. Reset or replace. 2. On/Off switch off or bad. 2. Replace. 3. F4 fuse blown. 3. Replace. 4. LED burnt out. 4. Replace. PROBLEM: NO GREEN MELTING LIGHT 1. No amber pilot light. 3. Coil down. 3. Raise coil. 5. F4 fuse blown. 5. Replace fuse. 6. Top melt switch (SC1). Jumper(10) to (27) to check. 6. Adjust or replace. 7. Water pressure switch. Jumper (26) to (28) to check. 7. Check water level; check flow of water; clean filter on pump; check F3 pump fuse; check pump motor; check switch setting. 8. LED burnt out. 1. See above. 8. Replace. Continued on Next Page 11

12 9. Pressure switch. 9. Adjust or replace. 10. Water pump. 10. Check fuse F3; clean filter; replace filter; replace pump; check water output (2.5 liter/minute. 11. SCHEDA board. 3. Bad SCHEDA board. 3. Replace board. 4. Not enough power to the generator board. 4. Check power at terminal 031 and 032, 220 volt. 5. Mosfet bad. Resistor burnt, 33 ohm. 11. Replace. 5. Replace. 12. Thermal regulator. Jumper (10) to (11), see if light comes on. 12. Replace. 6. Pyrometer set below at rest reading. 6. Raise the set point to a number above the at rest reading. PROBLEM: MODULAR 4 SERIES 6 SEEMS NORMAL BUT WILL NOT MELT 1. F3 fuse blown. 1. Replace fuse. 2. F4 fuse blown. 2. Replace fuse (No amber, green or orange LED). PROBLEM: ARM TRIES TO SPIN WHEN POWER IS TURNED ON (Remove arm before starting) 1. Bottom drop switch is stuck or arched closed. 1. Replace. 2. K1 relay arched closed. 2. Replace. 12

13 PROBLEM: ARM FAILS TO SPIN 1. Sequence. 1. Coil up; cover closed; power on; power level switch to Coil fails to drop. 2. Check drop mechanisms. 3. F3 fuse blown. 3. Replace fuse. 4. Cover lock switch. Jumper (7) to (9). (Arm must be removed first) 4. Make sure cover is closed and switch is activating. 5. Cover interlock. 5. Bring lock screw to horizontal position or replace 6. Bottom drop switch. Jumper (7) to (9). (Arm must be removed first) 6. Adjust or replace. 7. Check for 220 volt at spin motor. 7. Power present, replace motor. PROBLEM: WATER PRESSURE (No melt light; orange LED) 1. Water low. 1. Add water. 2. Water not circulating. 2. Add water; check and make sure hoses are completely in the water; clean filters (located under the pump head). 3. Motor fuse. 3. Check pump fuse F3. 4. Motor. 4. Replace motor. 5. Pump. 5. Replace pump. 13

14 6. Pressure switch. 6. Adjust or replace. 7. Green LED on and orange LED off. 7. Water too hot. Must wait for the machine and water to cool. PROBLEM: INCREASED MELT TIME 1. Low line voltage. 1. Check line voltage, must be 208 volt minimum. Outside boost transformer may be necessary. PROBLEM: THERMAL REGULATOR DOES NOT FUNCTION 1. Machine will not melt on the semi automatic setting. 1. Temperature or set point too low. Must be over 1650 F (900 C) 14

15 Figure 1 Modular 4 Series 6 Front View ITEM DESCRIPTION PART NUMBER N/S Electrical Plug 220 Volt, 20A 2004MP1 N/S Electrical Receptacle 220 Volt, 20A 2004MP2 1 Black Knob (Coil Lifting) 2004MP3 2 Melt Switch/Potentiometer 2004MP4 3 Pyrometer 2004MP56 4 Cover Handle N/A 5 Panel Screw 2004MP8 6 On/Off Switch 2004MP9 7 Blue Glass Knob 2004MP10 8 Green LED Right Side (Melt) 2004MP13 9 Orange LED Right Side (Thermostat) 2004MP11 15

16 Figure 2 Modular 4 Series 6 Internal Front View ITEM DESCRIPTION PART NUMBER 1 On/Off Switch Inquire 2 Cover Lock 2004MP19 3 Spring, Silver Lever Return 2004MP21 4 Rilsan Tubing 2004MP22 5 Switch, Water Pressure 2004MP23 6 Pump 2004MP24 7 Pump Filter 2004MP25 8 Water Tank w/cover N/A 9 Pyrometer 2004MP5 10 Water Pump Motor 2004MP30 11 Capacitor 2004NP73B 16

17 Figure 3 Modular 4 Series 6 Casting Arm Assembly ITEM DESCRIPTION PART NUMBER 1 Insulating Bushing, Right Inox Bar 2004MP32 2 Support, Crucible Holding Plate Right 2004MPA2 3 Inox Bar Right (Requires #2 Above) 2004MP34 4 Lid Holding Group Adjustable Stop Collar 2004MP36 6 Flask Holder Assembly 2004MP38 7 Inox Bar Left 2004MP39 8 Spring, Arm 2004MP41 9 Crucible Holding Plate 2004MPA1 10 Knob, Adjusting Flask Holder Assembly 2004MP44 11 Knob, Secure Arm (Not Shown, See Page 18 #19) 2004MP46 12 Melt Coil 2004MPA6 13 Vertical Holding Plate 2004MP52 14 Ref Pin Block 2004MP47 15 Ref Pin 2004MPA47 16 Support Crucible Holding Plate, Left 2004MPA3 17 Coil Holding Tube, Right 2004MPA8 18 Coil Holding Tube, Left 2004MPA7 17

18 Figure 4 Modular 4 Series 6 Top & Internal Views ITEM DESCRIPTION PART NUMBER 1 Ceramic Plate 2004MP48 2 Melting Coil 2004MP53 3 Orange LED 2004MP11 4 Melt Switch & Potentiometer 2004MP4 5 Pyrometer 2004MP5 6 Green LED 2004MP13 7 Knob, Secure Arm 2004MP46 8 Crucible Holding Plate 2004MP42 9 Flask Cradle Assembly 2004MP38 10 Micro Switch, Cover 2004MP18 18

19 Figure 5 Modular 4 Series 6 Internal Side View ITEM DESCRIPTION PART NUMBER 1 K1 Spin Relay 2004MP56 2 K2 Melt Relay 2004MP57 3 Main Control Board (SCHEDA) 2004MP58 4 Motor Starting Group 2004MP59 5 Spin Motor 2004MP60 6 Belt, Spin Motor 2004MP62 7 Generator Board 2004MPA9 8 Thermostat 2004MP68 19

20 413 North Pearl Street P.O. Box 350 Albany, New York Call: Fax: Rev 3/2017 Form 2007MA Form 2004M/OM