Heracast EC Operating instructions Heracast EC
Contents
1. Welcome Safety test Main menu Heraeus HERACAST EC HERHCHST EC U SETUP ln INFO SHaa ma ma na8 HU 2 The vacuum pump evacuates the chamber Then the induction coil and the casting ring are turned automatically and pressurization is started Prior to turning back the induction coil and the casting ring to the basic position the chamber is deaerated automatically In case of a defect or an error a respective message is displayed Once the test run has been successfully completed the machine is ready for operation CAUTION N If an error cannot be eliminated please contact the responsible service agent The addresses can be found on the paragraph 15 Service of these instructions Unauthorized opening of the machine include unknown risks and are not permissible 2 Putting out of operation Remove crucible and casting ring from the chamber Z E B Letthe unit cool down for approx 3 minutes before switching it off B Switch off the unit unplug the unit if it is not to be operated for longer periods E Remove contamination from the crucible fielding plate and the chamber 7 3 Errors and causes If a malfunction occurs during test run or when operating the unit the malfunction is shown on the display There are various warnings W and error messages E Warnings are indicated on the display by an ATTENTION icon see paragraph 8 1 1 Icons in the status display the process is continued If an error occurs t2. M The rear side of the unit must be at least 100 mm away from the wall to avoid blocking the air outlet ra of the built in fan M There must be no combustible materials e g newspapers and similar present near the casting machine and in particular near the casting chamber and under the unit MW To transport the unit do not lift the unit at the chamber Risk of damaging the unit Ba Risk of damage and injury in case of non compliance NOTE R gt This unit may emit high frequency energy and cause interference with radio communication Should this unit cause interference with radio or television reception it is recommended for users to eliminate interference with one or several of the following measures M Adjusting or changing the position of the antenna s B Enlarging the distance to the receiver M Connecting the unit to a circuit separated from the circuit of the receiver 6 4 Mains connection Mains 200 230 V AC 1 P N PE 50 60 Hz connect to mains in accordance with VDE specifications and local power supply specifications with flexible mains connecting cable with hot appliance plug and safety plug to a correctly installed socket with safety contacts protection class 1 Mains fuse Separate safety fuse 16 A inert or safety cut out fuse C 16 A Mains connection The unit should not be connected via a connection fault current circuit breaker If the use of a fault current circuit breaker is specified by the local el
3. e f message is still displayed after 10 min cooling OSC Temp gt 70 C gt 70 C 1 sec Short circuit at NTC sensor outlet Cooling OSC Temp lt 5 C lt 5 C 1 sec e Oscillator temperature outlet too low e Broken wire at NTC Sensor outlet Cooling WTR Temp 60 C gt 60 C 1 sec e Cooling liquid temperature inlet too high Allow to cool down e f message is still displayed after 10 min cooling Short circuit at NTC sensor inlet e Broken wire at NTC Sensor inlet EJ Induction Energy control After 300 kW s e induction automatic cut off This is not an error but a protective measure EK PWR Supply 1 0 reading error l sec e Received no acknowledgement from switching power supply EM Vacuum Vac not reached 500 mbar 2b sec e Check pressure air supply 100 mbar AER e Check vacuum pump EN Leakage Vacuum pressure During Self test Pressure rise in the vacuum gt 30 mbar or pressure drop when pressure gt 300 mbar e Check chamber sealing for air leakage Pressure too low 4 sec e Check pressure air supply EQ Pressure Release time gt 6 sec 6 sec e Check air release filter at valve block ER Pressure too high 4 sec e Check valve block pressure sensor Check POTI Short circuit e Position sensor defective POTI movement ED EE 4 sec e Check chamber sealing valve block for air leakage Pressure LO m TI m Movement E Movement No change at Upot 1 sec e
4. 12 ANS OO pP 12 DAC KG er e AAA bete e a cabe d te ei en N Nid clans toler Nee en ee 12 SEUD Rec cp EET MER 13 TEE c mS 13 compressed all Supl ARI 13 Vacuum abore OF AI odds 14 Filline tme Coone SVSIOITI center tes ita wets eben de ehre eet e e rct ui tu YA ld LE dns M cuc M gende 14 ROOM Venta O Zenit ee ae tl E cuo oo Asie S Arc c EM c Natal ay 14 DErALIOMS e DEP 14 PONE TED UOI 0 e NEE 14 EECH operatio eege chus O EI Ari 15 EO EE eet ee afia AA md aam hase dial ndi ee E AER 15 Manual unlocking of casting chamber EE 17 Working with Heracast EC arrainen ien A A E A A A A waeeaesiaes 18 Controls tor OpF rallne ae a dd aca ce 18 Corsa Ihe Stratus cis ay ee Men EI D sei 18 casta MEDU EE 19 e Die Men EE 19 Kate gd UE EE 20 Steiere EE 20 Melline and Casting wu ee ee ee 20 Ee cM TRU o CET ed 20 Sultable INVESIMEDE materials bedeelegen 20 Een ET d ee O mou AA MEE uU Dll ed er 20 WA INE ka ae Ne ed cct duin t dct edu MM Lic uc AAA 21 UA Aa AA IA 21 Cr Ee EE 21 10 10 1 10 2 10 3 10 4 11 11 1 11 2 11 3 11 4 11 5 12 12 1 12 2 12 3 12 4 13 14 15 15 1 16 AA Ja Lu eed dE A SAANA WAWA sen Rn Erw A BAKA EKA Ne d EA SIAME IS SARE ME HOP RE 21 Gold casting and high gold content ceramic bonding alloys Universal and silver Ballad umalloys EE 21 Reduced precious metal ceramic bonding and palladium based alloys sees 22 CoCr partial denture and non precious metal alloys x esa imer
5. The Netherlands Heraeus Kulzer Benelux B V Fustweg 5 2031 CJ Haarlem Tel Phone 31 235 43 42 50 Fax 31 235 43 42 55 Nordamerika North America Heraeus Kulzer LLC 300 Heraeus Way South Bend IN 46614 2517 Tel Phone 1 57 42 99 54 10 Fax 1 57 42 99 66 31 sterreich Schweiz Austria Switzerland Heraeus Kulzer Austria GmbH Nordbahnstra e 36 Stg 2 4 4 5 A 1020 Wien Tel Phone 43 0 14 08 09 41 Fax 43 0 14 08 09 41 70 0 Singapur Singapore Heraeus Dental Heraeus Materials Singap Pte Ltd 4407 01 TechPlace Il 569881 Singapore Tel Phone 65 65 71 75 69 Fax 465 65 71 75 77 Skandinavien Scandinavia Heraeus Kulzer Nordic AB Hammarbacken 4B 19149 SOLLENTUNA Tel Phone 46 8 58 57 77 55 Fax 46 86 23 14 13 Spanien Spain Heraeus S A C Forjadores 16 Prado del Espino 28660 Boadilla Madrid Tel Phone 34 913 58 03 75 Fax 34 913 58 03 68 Ungarn Hungary Heraeus Kulzer Hungary Kft Stefania ut 101 103 1143 Budapest Tel Phone 36 17 88 42 22 Fax 36 17 88 42 33 16 Document history 2010 03 First release 2011 04 Editorial modifications technical data Complete Service agents and update contacts in the countries 2013 10 Text editing Adding paragraph 7 4 Subject to modifications Dated 2013 10 Heraeus Kulzer GmbH Gr ner Weg 11 63450 Hanau Germany Telefon 49 61 81 35 58 94 Telefax 49 61 81 35 59 93
6. This statement will become invalid in case HersigierfManufacturer Heraeus Kulzer GmbH BEEN P Brine Vy 11 of any modification of the unit that is not 81450 Hanau Germany coordinated with us Hiermit wind bast tigi dass das Geral IL im har confirmed Mal Thes und Heracast EC Induldives Vakuum Druckgufigersit Induction vacuurm preesurne Cashing machne den grundiegenden Anforderungen complies with the essential requirernents of der Maschinenerichtlinie MaschRL 20064 EG ihe Maschineny Directa 200614 EG der Fachtsrme ber elekromagnebsche Yertragiichicon EA 2004104 EG ihe Directa concerning electramagnelic compatibiliy EME 2004 1 0B EC der Miederspannungsrichtline 2006 05 EG the tow tension Directive 2006 8S EG m deren Anderungsrichilinien anmsprich including their amendmarnis Angewandte Harmen Standards applied DIN EN 61326 1 2006 10 anmsonchbecompbes wit EN 81328 2006 undand IEC 81328 1 2005 DIN EN 61010 1 2001 antsnechbicompbes with EM 6101041 2001 abend EC 61010 1 20011 DIN EN 61010 2 010 2003 ir htm with EN 81010 2 010 12003 und anmd EC 61010 24010 2003 Hanau 55 rwr _ it i Ort und Datum Fr Dr Hecker 1 Sehmid Pince and Date Cinca Herem amp Hegaacongs Allan Tace bar ac K rning aaa EC deen Varronz Geile ton 1 2 Instructions on using the unit safely Explanation of Symbols Symbol Accompanying word s Explanation CAUTION Safety relevant paragraphs and sections in t
7. alloy from flowing out of crucible The following measures working steps are suitable to reduce the formation of oxide and to support the flowing properties of the metal NW Increase the preheating temperature of the ring by 50 C B Minimum quantity of alloy 15 20 g M Use ceramic crucible type C Order No 66001901 Programming Ceramic NPM reduce the given vacuum from 250mbar to 50mbar reduce residual air eliminate oxide behaviour B No premelt MW The ring is placed and fixed in the holder immediately before starting the main melt and casting processes NW Melting powder pellet can be added M Melt until the casting shadow has disappeared and the melt is moving most strongly This moment varies with all alloys concerned and must be determined previously M As soon as this moment is reached casting is started by pressing CAST 11 Maintenance Proper function and operational reliability of the unit are only ensured if the required tests maintenance and service work are performed by Heraeus Kulzer service agents or personnel instructed by Heraeus Kulzer Heraeus Kulzer GmbH will not accept any liability for damage in particular personal injury resulting from improper maintenance or repair work which has not been performed by Heraeus service agents or adequately trained personnel or if no original spare parts or accessory parts have been used during the exchange of parts We recommend to conclude a maintenanc
8. approx 100 mbar approx 100 mbar approx 100 mbar approx 250 mbar Place ceramic crucible with Place ceramic crucible with Place ceramic crucible in coil Place ceramic crucible in coil graphite insert in the coil graphite insert in the coil Adjust ring size and height Adjust ring size and height Adjust ring size and height Adjust ring size and height Add metal in small pieces into Add metal in small pieces into Add metal in small pieces into Ensure horizontal parallel the crucible the crucible the crucible placing of metal cylinders Recommendation For clear analysis of the melting process when premelting add a melting powder pellet small Close chamber Close chamber Close chamber Close chamber Premelt press START Premelt press START Premelt press START Premelt press START power 100 Yo power 100 Yo power 100 6 power 100 6 Observe melt interrupt premelt Observe melt interrupt premelt Observe melt after splitting Observe melt depending on with STOP button after the with STOP button after the up of the oxide layer interrupt alloy type interrupt premelt with alloy has completely melted alloy has completely melted premelt with STOP button STOP button Open casting chamber and add Open casting chamber Open casting chamber Open casting chamber melting powder pellet Recommendation For clear ana no melting pellet lysis of the melting process after premelting add a melting powder pellet small Place
9. ei 22 Titanium and al minium containing alloys arena bes eis 22 Mamtenance sita ee 23 M intenanc amp and care AA arcadas 23 cua ee ee ee De UU CMM ee ee 23 Weekly tor alter 00 Castas sra add lidad 23 EE gt 0002351108 tee 23 after 10 000 casting or after 3 years antenne le ee ee ee 23 NEE 23 VAESTU Sin Io e AA AA estepas laa AA EE 24 A e o se need raed aed dace t a ed ee can ees 24 Disposalor old equipment according E 24 Technical data ua nalen ee 24 Operating Conditions a ole e se MR 25 Egeter 25 Gireult lagrams MISA AI ea 25 Carcuit diaerams eer EE e EE 26 Recommendations 10r casuung ii ee ee 26 COMEFOU IRON ea Co ME REED 28 SENICE as TE 29 Service agents Contact inte countries eer eege een ee ehe esse 29 Document MISION mar len Veen 30 Operating instructions Heracast EC 1 Scope of applicability 1 1 General Combilabor is a registered trademark of Heraeus Kulzer GmbH Author f48618 These working instructions apply to Order No Type Features Date 1 2 Description and type of machine Induction vacuum pressure casting machine Heracast EC 2010 01 0001 ff 1 3 EU Statement of conformity Heraeus Herewith we Heraeus Kulzer GmbH Gr ner Weg 11 63450 Hanau Germany confirm that the following unit due to its Konformit tserkl rung intended use and the version marketed by us Declaration of Conformity corresponds to the relevant basic safety and health requirements of the EC guideline
10. for Pd based alloys or gold Pd alloys B NPM crucible for NPM or CoCr frameworks Push the turning knob to confirm the selection In the Enter Vacuum menu you can accept the default value or specify a different HERACAST EC value by turning the turning knob The currently specified vacuum value is also indicated in the graphic vacuum indicator Vac Push the BACK button to return to the previous menu Ba E 1 515 mbar p Push the turning knob to confirm the specified vacuum value The Casting menu displays the entire casting process In the upper left corner the current vacuum value mbar or pressure value bar is displayed with the pressuriza tion time in seconds a timer mm ss is displayed on the right The timer starts automatically with induction and can be reset to 00 00 by pressing the turning knob In the lower part of the Casting menu the currently specified power value is displayed as percentage in large numbers You can change the default value anytime by turning the turning knob to the left or to the right Now close the chamber and start the melting process by pushing the key under the START menu item The chamber will automatically be locked and the specified target vacuum will be built up Induction starts automatically from a vacuum value of 450 mbar upwards Any power adjustments during melting must always be performed manually Push the STOP key when premelt is completed Push the CAST key to
11. ring in chamber and lock Place ring in chamber and lock Place ring in chamber and lock Place ring in chamber and lock in place close chamber in place close chamber in place close chamber in place close chamber Observe main melt and readjust Observe main melt see para Observe main melt Observe main melt power if required see para graph 13 Recommendations for start timer after oxide layer start timer after the shadow graph 13 Recommendations for casting and at the end of the has split up see paragraph 13 see paragraph 13 Recommen casting time turn inductor manually Recommendations for casting dations for casting At the end of the time CAST key At the end of the time At the end of the time turn inductor manually turn inductor manually turn inductor manually CAST key CAST key CAST key After approx 60 sec the After approx 60 sec the After approx 60 sec the After approx 60 sec the induction coil and casting ring is induction coil and casting ring is induction coil and casting ring is induction coil and casting ring is turned back open chamber and turned back open chamber and turned back open chamber and turned back open chamber and remove casting ring remove casting ring remove casting ring remove casting ring Putting unit out of operation Remove crucible after casting The unit can be switched off after 5 minutes If required turn off compressed air supply cool down 15 Service 15 1 Service ag
12. Heraeus Heracast EC 3 vos e s y es SE Operating instructions Heracast EC HKG Layout 66044668 02 BA Heracast EC GB Dateiname W10095 66044668 02 BA Heracast EC GB V4 X3 SAP Nr Version HK Toolbox Nr Format Falzma 66044668 02 W10095 420 x 280 mm 210 x 280 mm Projektmanager HKG Version Datum HKG Freigabe am Michael Helken V4 3 AK 01 10 2013 07 10 2013 EURO Pantone Sonderfarben Druckverfahren Digitaldruck C M Y K varnish DieCut var Data oan m Table of contents Scope Re e Le EE 5 General tee AA aa dee A ee EE 5 Descupuon HANA eeler IA Ia 5 EU Statemeht Orc oP TOL lbi estat dd eee 5 instructions on usme the unit EE 6 EXP AB omoro MR ele RT E TUN 6 kan Spon damage acaecido tierra Wa TEE 6 Operators ODI CANONS a6 en teca states beer kr uncle dde eed EE eor cert 6 Burg else RE tp ere ee 6 SA emm 6 Use in accordance with specifications EEN nn nn nn nn nn nnnnnnnnunnnnnnnnnnnan REENEN nn nn sese seseseses senes 7 WAKINA 52 25 teres sonar ee hata e 8 Scope of delivery consumables Set 8 SCOPE OP de INES p 8 Accessories not included in the scope ordeliVeky aan 8 onemalcgtlPmentT SCT li een Sale seen nee een 8 Structure and TUNCHON ii AAA 9 Conrolana display elenen RT OUR 9 IS e KA aa 10 Partial EENEG enee 11 Partial view inlet and power connections een nee lese air ee Berne 12 Location and INSTA ATION anne near euer
13. N The casting chamber surface see symbols on the unit and the surrounding components are heated up as a result of the process To avoid the risk of being burned always wear protective gloves when working 10 1 Gold casting and high gold content ceramic bonding alloys Universal and silver palladium alloys Alloy quantities 5 gto 130g Gold casting alloys Use ceramic crucible with graphite insert Add a melting powder pellet small after premelting Ceramic bonding Use ceramic crucible with graphite insert Recommendation To enable clear analysis of the melting process add a melting powder pellet small after premelting Premelt Until all components are completely melted Press STOP key immediately to end premelt 22 Main melt Manual power regulation Observe delay time when the liquidus temperature is reached again see paragraph 13 Recommendations for casting Then press CAST key to start manual casting Gold casting alloys and Universal alloys with a liquidus temperature of up to 1070 C can be cast with 70 power for main melt From a liquidus temperature of 1080 C or higher it is recommended to use full power during the main melt 10 2 Reduced precious metal ceramic bonding and palladium based alloys Processing Use ceramic crucible Recommendation To enable clear analysis of the casting result add a melting powder pellet small at premelt Alloy quantity 15 gto 100 g Min quantity of 20 g fo
14. Turning motor not activated Check position sensor Check turning motor Basic position 15 digits 3 sec e Basis position not reached Casting position 15 digits 3 sec e Casting position is not reached Rotation to OPEN Limit switch for 3 sec e No rotation of motor locking OPEN e Cable breakage not achieved e Check limit switch for locking position OPEN adjust if required m U V W Movement Movement Locking EX Rotation to LOCK Limit switch for locking LOCK not achieved e No rotation of motor e Cable breakage e Check limit switch for locking position LOCK adjust if required Locking 3 sec 7 4 Manual unlocking of casting chamber In the event of a bad casting result or excessive contamination of the casting chamber the chamber locking mechanism may be jammed or blocked in the worst case Afterwards automatic unlocking of the chamber locking mechanism is no longer possible Manual unlocking will support the automatic process Step 1 Preparation Please switch off the device Remove the sealing cap 1 and insert the steel stick included in the scope of delivery 2 into the guide as shown in the photos on the right Make sure to use a hammer and apply gentle blows to the steel stick to support the automatic chamber locking mechanism Step 2 Manual unlocking Please switch on the device Press the left key while the welcome screen is displayed The mechanical un
15. arts have been used during the exchange of these parts 3 Use in accordance with specifications The induction casting machine Heracast EC is a laboratory unit for casting all precious metal and almost all non precious and CoCr partial denture alloys for dental applications with a liquidus temperature of 500 C up to gt 1600 C The unit is not suitable or intended for casting pure titanium or beryllium containing alloys CAUTION N 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 CoCr partial denture 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 made for this type of application The use of other materials voids guarantee claims in case of damage to the unit or the molten material Due to various possible causes for bad castings results we do not grant any guarantee for such cases 3 1 4 Working rules CAUTION EM Pers
16. aution High frequency Not to be used by persons with pacemakers HIGH FREQUENCY Attach the supplied adhesive symbols Not to be used by persons with pacemakers to all entrances to the unit service room Accessories not included in the scope of delivery Vacuum pump CL P Typ 7 230 Volt 50 60 Hz Order No 66002450 4 3 Original equipment Set 1x Small alloy spoon 1x Box cont small melting powder pellets lx Acrylic sprue canal aid 1 pack 6 pcs ceramic crucibles for CL IG IM 195 Heracast iQ EC 1 pack 6 pcs ceramic crucibles NPM crucibles for CL IG IM 195 Heracast Q EC lx Crucible box CL IG IM 195 Heracast iQ EC 1 pack 10 pcs graphite inserts for CL IG IM 195 Heracast iQ EC 3x each Casting ring X3 X6 X9 1x each Cone former X3 X6 X9 Operating instructions Heracast EC 5 Structure and function 5 1 Control and display elements Viewing glass casting chamber Graphic display with control elements Locking lever casting chamber Filter cover air supply A AA MM Hm 5 2 Partial view open chamber Viewing glass casting chamber Ceramic crucible Shielding plate Adjustable casting ring holder Locking lever casting chamber Collecting plate Screw for adjustable casting ring holder Clamping device for casting ring Interactive buttons Turnable push knob Operating instructions Heracast EC 5 3 Partial view cooling water 15 Side trap door wit
17. cal regulations of the local Electricity Board have to be observed Cut out fuse 16 A or automatic circuit breaker C16 A Operating Instructions Heracast EC 12 1 Operating conditions Use only indoors Temperature range 5 C to 40 C Relative humidity 80 to 31 C 50 at 40 C Installation altitude up to 2000 m above sea level Overvoltage category l Level of contamination 2 Protection class 1 Protection type IP 20 25 Duty cycle ED 80 96 intermittent operation Heraeus Kulzer GmbH NA Gr ner Weg 11 D 63450 Hanau 201 0 01 001 0 2 3 kVA 200 230V 10 50 60 Hz 12 2 Rating plate 66041213 Heracast EC 80 ED 2x T16A250V N made in Germany C 2009 4033 133 003 12 3 Circuit diagrams compressed air Druckluft compressed air air comprim DS H Drucksensor compressive sensor comressif d tecteur Vakuum Druckkessel vacuum pressure boiler vacuum r servoir de pression Sicherheitsventil emergency valve soupape de s ret SV SD NY Schalld mpfer sound absorber absorbant de bruit Vakuumpumpe vacuum pump pome a vide 12 4 Circuit diagrams water circulation Wasserbeh lter water reservoir r servoir d eau Durchflu messer flow meter debimetre Pumpe pump pompe Induktor inductor inducteur Temperaturf hler temperature probe sonde de temperature W rmetauscher heat exchanger l changeur thermique Rec
18. e Assembly Component Group El VAC Sensor check pressure sensor If ambient pressure e Check pressure sensor of 600 or e Cable break 1200 mbar measured W2 W3 C WC C C Allow to cool down C WH C WL E2 Cooling Waterflow too low lt 600ml e Blocked drains at Cooler Oscillator e Defect at Water tube Water pump Flow meter PWR Supply PWR Temp gt 100 C 100 C e Switching power supply too hot 15 m o 1 The following error messages may be displayed Assembly Component delay Group EA TMP Sensor WTR Temp Sensor Short circuit or 2 sec e NTC sensor defect inlet broken wire TMP Sensor OSC Temp Sensor Short circuit or 2 sec e NTC sensor defect outlet broken wire TMP Sensor AIR Temp Sensor Short circuit or 2 sec e Sensor defect broken wire Switches Chamber position NO NC contact 1 sec e Check limit switch for chamber position not antivalent readjust if necessary e Broken wire Possible cause E5 6 E 7 Chamber lock OPEN NO NC contact Switches 1 sec e Check limit switch for chamber lock position OPEN if necessary readjust e Broken wire e Check limit switch for chamber lock position CLOSED if necessary readjust e Broken wire not antivalent m LO Switches Chamber lock CLOSED NO NC contact 1 sec m O m TI Cooling e Oscillator temperature outlet too high not antivalent Allow to cool down
19. e contract with our service agents an offer can be requested there see paragraph 15 Service 11 1 Maintenance and care ra CAUTION 23 N Prior to maintenance and service work the unit must be switched off and unplugged Strict adherence to the dS maintenance intervals is recommended to avoid faulty castings and damage to the unit Use mild soap solution detergent and an absorbent cloth moist but not wet to clean moist but not wet the outer surface control elements und washer of the chamber Maintenance work types daily Mm Check water level NW Check oil level and remove contaminations e g milky consistency M Clean the inside and the outside of the viewing glass using a soft cloth E Remove alloy residues etc from the collecting plate below the inductor the chamber the sliding rails and the washer when the unit is cold extract or clean with compressed air EM In case of moist compressed air empty the water extractor of the optional pressure reducer through the release valve on the bottom of the casting machine weekly or after each 100 castings M Clean the inside of the casting chamber the ring holder fielding plate and the sealing when the unit has cooled down annually or after each 3 000 castings CAUTION N The following work includes interventions into the unit and may only be performed by adequately trained service personnel M Change oil of the vacuum pump Clean oil mist filter
20. ease 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 3 x 1 0 mm HO5RR F black 155 C central plug straight power connector NOTE Due to the waste gases released during working adequate ventilation must be provided WARNING A N This symbol warns of the dangers of electric voltage In the case of non compliance the result of an electrical shock 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 will not accept any liability for damage to the unit resulting from inexpert repair which has not been performed by Heraeus service agents or if no original spare parts accessory p
21. ectricity board type 30 mA should be used 6 5 Compressed air supply 3 NOTE The compressed air must be clean and dry NM Air pressure min 4 bar max 7 bar Higher air pressure even short term can result in damage to the inner valves To avoid this an optional pressure reducer filter combination must be used Order No 66005499 M Incase of moist compressed air this pressure reducer filter combination or water separator filter must also be connected in series The pressure reducer includes accessories for unit mounting or wall mounting B Line cross section inner min 10 mm M Rapid pressurization lt 1 5 sec is essential for the mould filling behaviour Non compliance can result in faulty castings The use of a separate compressed air tank 10 mm in the direct vicinity of the casting machine is recommended for small line cross sections Order No 66008921 NOTE IRs Any guarantee claims shall be excluded in case of malfunctions or damage resulting from inadequate compressed air supply 14 6 6 Vacuum air connection CAUTION AN Prior to operating check whether the nominal voltage corresponds to the value indicated on the type plate of the vacuum pump Attach the hose of the vacuum pump to the connection of the casting machine Connect vacuum pump to the socket rear of the unit The power cord must not touch the casting chamber Follow to the working instructions of the vacuum pump 6 7 Filling the c
22. ents Contact in the countries LAND COUNTRY NAME ADDRESS Australien Australia Heraeus Dental Australia Pty Ltd Rydecorp Unit 6 2 Eden Park Drive Macquarie Park NSW Australia 2113 Tel Phone 61 2 8422 6100 Fax 61 2 9888 1460 Brasilien Brazil Heraeus Kulzer South America Ltda CNPJ 48 708 010 0001 02 Rua Cenno Sbrighi 27 cj 42 America Sul America del Sur South America Sao Paulo SP 05036 010 Tel Phone 55 11 3665 0506 Fax 55 11 3665 0521 China China Shanghai Heraeus Kulzer Dental Trading Co Ltd 1585 Gu Mei Road 200233 Shanghai Tel Phone 86 21 64 95 84 88 Fax 86 2164 95 17 32 Frankreich France Heraeus S A S Parc Silic Bat i 2 Villebon BP 630 12 Avenue du Qu bec 91945 Courtaboeuf C dex Tel Phone 33 169 18 48 85 Fax 33 169 28 78 22 Gro britannien United Kingdom Heraeus Kulzer Ltd Heraeus House Albert Road Northbrook Street RG14 1DL Newbury Berkshire Tel Phone 44 163 53 05 00 Fax 44 163 53 06 06 Italien Italy Heraeus Kulzer S r l Via Console Flaminio 5 7 20134 Milano Tel Phone 39 022 10 09 41 Fax 39 022 10 09 42 83 Japan Japan Heraeus Kulzer Japan Co Ltd 2F TSK Bldg 8 13 Hongo 4 chome Bunkyo ku 113 0033 Tokyo Tel Phone 81 358 03 21 53 Fax 81 358 03 21 50 Mexiko Mexico Heraeus Kulzer Mexico S A de C V Homero 527 301 y 302 Col Pol 11560 Mexico D F Tel Phone 52 55 31 55 49 Fax 52 55 52 55 16 51 Niederlande
23. er still locked Repeat process again HO YES 8 Working with Heracast EC After switching on and successful completion of the Auto Test the user is automatically directed to the main menu In this menu additional options are available 8 1 Controls for operating The Heracast EC is operated using two buttons and a turning knob with noticeable pressure point The functions of the buttons vary depending on the active menu and device status 27 Choices display of the selected item is inverted EN SE TUF 28 Variable menu bar options can be selected using the push button 29 Push button for menu bar 30 Status displays 8 1 1 Icons in the status display ci E Chamber open Indicates that the casting chamber is open Chamber unlocked Indicates that the casting chamber is closed but not yet locked MAINTENANCE icon After 3000 castings Please contact the Heraeus Kulzer Service Chamber locked Indicates that the casting chamber is closed and locked Message Indicates that a warning Or error message occurred MAINTENANCE icon After 10 000 castings Maintenance of safety relevant components Please contact the Heraeus Kulzer Service 8 2 Casting Menu The main menu includes the following options which you can select using the turning knob M Ceramic crucible with graphite insert for gold casting or high gold content HEEHCHST EC ceramic bonding alloy M Ceramic crucible
24. h viewing glass for cooling water level 16 Carrying handle 54 Partial view inlet and power connections 17 Compressed air prefilter for pilot valves for service only 18 Compressed air supply 19 Vacuum connection 20 Interface RS232 for service only 21 Mains connection for vacuum pump 22 Fuses for vacuum pump T 6 3A 23 Type plate 24 Power switch 25 Unit fuse T 16A 26 Mains connection 6 Location and installation 6 1 Transport Carefully transport the unit horizontally to prevent the pump oil from leaking and damaging the unit Packings and units must not be stacked Shocks must be avoided If there is a risk of frost during the transportation of the unit the cooling water must be removed from the unit Please notify the service technicians For dimensions and weight refer to paragraph 12 Technical data 6 2 Unpacking Remove straps If required screw in the carrying handles at the corners of the unit 6 3 Set up Location Table with load bearing capacity of at least 70 kg Table area w x d 650 x 550 mm The casting machine must be placed on a solid skid proof surface laboratory desks racks so that a horizontal safe position is ensured The room temperature should not be more than 40 C Air inlet and outlet openings in the housing of the unit rear and lower surface must not be covered or blocked Minimum distance to the wall 100 mm CAUTION N Following instructions must be strictly followed
25. he process is terminated immediately and the error screen of the information menu is activated The current error is inverted see paragraph 8 5 Error history The following warning messages may be displayed Code Message Condition Time Possible cause Assembly Component delay Group Cooling Waterflow too low lt 800 ml 4 sec e Blocked drains at Cooler Oscillator e Defect at Water tube Water pump Flow meter PWR Supply PWR Temp 75 e Switching power supply too warm Cooling OSC Temp 65 gt 65 sec e Oscillator temperature outlet too high Allow to cool down ge C Cooling OSC Temp 10 C e Oscillator temperature outlet too low C o C W Cooling WTR Temp lt 10 e Cooling liquid temperature inlet too low Cooling AIR Temp gt 50 C e Inside temperature too high WH Cooling AIR Temp lt 10 C e Inside temperature too low Induction Check crucible Deviation of 4 sec e Graphite crucible SET ACTUAL power If weight 7g replace graphite crucible in the graphite e Defect at crucible gt 5 Yo Inductor WM Vacuum Vac not reached 500 mbar 15 sec e Check pressure air supply e Check vacuum pump e Check chamber sealing for air leakage build up time 2 sec e Pressure build up too slow Check compressed air supply Pressure too high e The warning may occur if large casting moulds are used The following error messages may be displayed Code Condition Possible caus
26. hese 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 Caution High frequency DISCONNECT FROM MAINS Danger of electric shock when unit is opened Unplug the unit before opening it CHANGE Important Changes have been made to this paragraph Please read carefully Registration certificate according to the ministry of health of the Russian federation 2 2 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 2 3 Operator s obligations In addition to complying with the statutory regulations specified by the manufacturer the operator must ensure the statutory obligations are observed and implemented at the working place i e he must train his personnel and comply with industrial safety legislation and any other regulations or laws in force For working at 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 2 4 Unit book We recommend you keep a u
27. ins two lines These messages are displayed as follows l Line Process counter and Error code assembly group ERR E HISTORY W Warning message E Error message AH M 2 Line Detailed message description Inactive messages contain a single line only Line Process counter and Error code assembly group BACE ail TOP Push the TOP key to jump to the latest message To exit the error history push the BACK key 9 Melting and casting The technical procedure is described in the following For alloy specific application information see paragraph 10 Alloys 9 1 General NOTE Please request information brochures on casting according to the Heraeus system 9 2 Suitable investment materials NOTE No graphite containing investment materials must be used The graphite content can result in degassing or in damage to the alloy We recommend to use our graphite free phosphate bonded investment materials 9 3 Premelting In order to obtain uniform casting conditions all alloys are premelted The mould is placed into the casting chamber after premelting the alloy Exception Titanium and aluminium containing alloys see paragraph 10 4 Titanium and aluminium containing alloys CAUTION N The alloys must be observed continuously during premelting Generally each melt may only be observed through the blue glass because of the high luminous intensity Risk of getting blinded The premelting process may only be inter
28. lock program is loaded Start manual unlocking by pressing the right START key The vacuum pump is automatically activated and creates a vacuum inside the chamber From a vacuum level of 250 mbar an acoustic signal is heard and the speaker icon is animated As long as the signal is heard you may apply gentle blows to the steel stick to support automatic unlocking of the chamber As soon as the chamber is opened the acoustic signal is stopped and the manual unlocking process is completed Follow the instructions shown on the display switch off the device and clean the casting chamber If the lock cannot be opened during the first cycle 8 seconds the procedure can be repeated as often as desired Please inform your responsible regional Heraeus Kulzer service partner if the chamber locking mechanism does not unlock after repeated attempts NOTE Always attempt to unlock manually without the support of the automatic chamber unlocking mechanism ATTENTION The acoustic signal can be heard for approx 8 seconds The automatic chamber unlocking mechanism should only be supported during this period Failure to follow these instructions may lead to damage to the locking motor IS A Heraeus HERHCHST EC SHAT 61 06 68 HHI 2 Mechanical unlock 2 support the unlocking process only during juzzer sound 3 Vac Ib Ambar ad H Mechanical unlock r a Chamber Switch i and cle MENLI Mechanical unlock Chamb
29. ment according to WEEE Electrical and Electronic Equipment Act ElektroG This Act sets out requirements for electrical and electronic equipment according to the 2002 96 EG directive issued by the European Parliament and the European Council of 2005 05 03 Its main purpose is to prevent waste from electrical and electronic equipment and to promote reuse recycling and other forms of recovery to reduce both the volume of waste for disposal and the inclusion in waste of harmful substances from electrical and electronic equipment dl Consequently corresponding products from Heraeus Kulzer GmbH will be marked with the symbol below s For detailed information on professional disposal of disused old devices contact your dealer or Heraeus Kulzer subsidiary in your country 3 IMPORTANT Marked equipment must not be brought to local waste disposal centers 12 Technical data Mains connection 200 230 V 10 Rated frequency 50 60 Hz Rated power 2 3 kVA Generator power 1 5 kVA Fuse type T 16 A 250 V Vacuum pump socket fuse type T 6 3 A H 250 V Compressed air supply 4 7 bar Nominal pressure 3 3 3 5 bar Pressure control valve 3 7 bar Vacuum 100 mbar with vacuum pump CL P Type 7 Min cross section of compressed air supply Inner 10 mm Dimensions w x h x d 650 x 550 x 450mm Required table are w x d 650 x 550mm Weight 60kg Fuse protection For the connection to the mains the electro technical rules and the techni
30. nit book All tests as well as all essential works e g repair work modifications must be documented in this book 2 5 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 behavior 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 vn HIGH FREQUENCY FINE 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 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 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 Pl
31. of the vacuum pump if required exchange them Check casting chamber lock manual test program Check circulation of cooling water and flow control instrument manual test program If required change cooling water Change filter for vacuum and compressed air in the valve box Check pressure and vacuum hoses Check activatability of the turning mechanism wear and firm seat of the gears manual test program Performance check manual test run with graphite crucible Clean filter mat bottom surface if required exchange them after each 10 000 castings or after 3 years M Check locking bolts if required exchange brass case 11 2 Tests Works at the electrical equipment of the unit must only be performed by the authorised Heraeus service agents or adequately trained personnel and in the safe condition voltage cleared Only approved original spare parts must be used 11 3 Maintenance Permissible parts and accessories Proper function and operational reliability of the unit are only ensured if approved original spare parts are used The use of different parts holds unknown risks and must be absolutely at any rate 11 4 Disposal The unit is designed to be operated for 10 years For the disposal of spare parts or of the unit in Germany please contact Heraeus Kulzer GmbH in Hanau Service department directly For all other countries please contact your appropriate local representation 11 5 Disposal of old equip
32. ommendations for casting Universal A temperature melt Power Note Add a melting powder pellet small after premelting High gold content ceramic bonding alloys Liguidus Crucible Main Delay Time temperature melt Power Herador NH z Graphite insert Recommendation To enable clear analysis of the melting process add a melting powder pellet small after premelting Gold Pd alloys melt Power oxide splits up ee E m E Mw ome 3 WmbwdN ome 3 Wmwou ome 3 5 Recommendation For clear analysis of the melting process when premelting add a melting powder pellet small NPM CoCr partial denture alloys Crucible Main Delay time after the shadow melt Power Heraenium HeraeniumCE 100 EC EC meeen eme xo 8 Until all components are completely melted 14 Control information Putting unit into operation Check compressed air supply Switch on main switch Self test Unit is ready for casting if required open Gold casting and High gold content Pd based alloys and NPM CoCr partial denture Universal alloys ceramic bonding alloys Gold Pd alloys alloys Select menu graphite crucible Menu options Graphite crucible Menu options Ceramic crucible Menu options NPM Check vacuum and change Check vacuum and change Check vacuum and change Check vacuum and change if required recommendation if required recommendation if required recommendation if required recommendation
33. onal protective equipment such as hand face and body protection must be worn jewellery must be taken off prior to working B Normally the unit is suitable to be set up and operated in the following fields Commercial and industrial laboratories schools universities hospitals etc The unit has been designed for continuous operation EM 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 CAUTION Do not use the unit for the following activities B The unit must not be used for melting and casting beryllium containing alloys hazardous to health EM 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 B The unit is not suitable for thermal treatment of hazardous or health hazardous materials e g dusts fibres liquids solids B The unit must not be used to heat up food Scope of delivery consumables set 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 Y N 7 sS b qw WW nu WA N INS p QW gt SUR gt 4 4 2 Scope of delivery 1x Heracast EC Operating instruction test certificate lx Key for casting ring holder 1x Pressure hose 13 mm incl 2 hose clamps and a socket 13 mm 2x Door signs C
34. ooling system For safety reasons the inner cooling system is only prefilled with a small quantity of antifreeze and anticorrosion agent To fill the system completely open the side trap door and fill the container with tap water do not use distilled water If the water level has reached the value MAX stop filling CAUTION Do not fill over the MAX marking Risk of damaging After initial operation the cooling water level must be checked again and the unit must be filled up with pure tap water A WARNING Risk of electric shock when unit is opened Unplug the unit before opening the side flap 6 8 Room ventilation The room in which the unit is operated must have sufficient technical ventilation The unit must not be operated in recesses that cannot be ventilated If several units are to be placed in one room special ventilation measures may be required e g zone ventilation 7 Operations The following pages are to provide basic information and hints which are essential for successful and error free working Please observe the order of the working steps Mostly casting errors cannot be attributed to the casting machine 7 1 Putting into operation When the machine is switched on the request Please open and close the chamber appears as animated icon after welcome display If the chamber was closed it must be opened and then closed again The safety test cycle starts after correctly switching of door limit switches
35. pivot the inductor coil and the casting ring immediately Due to its own weight the melt will flow into the cavities of the casting mould Simultaneously compressed air is admitted to the chamber automatically audible pressure surge and the melt is pressed into the finest areas of the casting mould After the alloy has solidified approx 60 seconds after pivoting the inductor coil and the casting ring pivots back automatically and the chamber unlocks The casting process is completed Open the chamber and carefully take out the casting ring 8 3 Setup Menu The Setup menu includes the following options which you can select using the turning knob M Language German English Japanese M Acoustic signals ON OFF M Service Changed settings must always be saved using the SAVE key ENGLISH Unsaved changes will not be applied To exit the Service menu push the BACK key CE INFO ain SETUP cH BACK E SHUE 84 Info Menu The following information can be viewed in the Info menu M Device serial number S N EM Process counter M MW Total operating hours M Software SW and hardware HW version E Push the ERROR to open the error history ain ERROR To exit the Info menu push the BACK key 8 5 Error History In the error history you can browse through the most recent warning and error messages by turning the turning knob The message currently selected is inverted and conta
36. r reduced precious metal content bonding alloys Premelt Until the oxide layer splits up Press STOP key to end premelt immediately Main melt 100 power Observe delay time once the oxide layer has split up see paragraph 13 Recommendations for casting At the end of the time press CAST key to start manual casting 10 3 CoCr partial denture and non precious metal alloys Processing Use NPM ceramic crucible without melting powder pellet Alloy quantity 10g to 60g Premelt Until the shadow covers only approx 1 4 of the last ingot protruding from the surface of the molten mass Exception Heraenium NF Until all components are completely melted Press STOP key to end premelt immediately Main melt 100 power Observe delay time after the shadow see paragraph 13 Recommendations for casting Then press CAST key to start manual casting NOTE IRs The NPM ceramic crucibles are exclusively suitable for casting NPM alloys and feature a longer lifetime than normal ceramic crucibles If NPM crucibles are used for precious metal alloys the silicon might be damaged 10 4 Titanium and aluminium containing alloys Generally it is possible to cast such alloys in the Heracast EC The alloy components titanium and aluminium exhibit a strong tendency towards oxidation on the surface during the melting process which is intensified through the oxygen supply when inserting the ring The oxide layer may impede or even prevent the
37. rupted when all the alloy has melted The alloy has a spherical shape there are no protruding edges of the molten material Splitting up of the oxide layer is without any relevance during melting in the graphite crucible When melting large quantities more than 50 g small individual portions must be premelted The metal should only be melted so that filling in of the next portion is possible Only in the last premelt all the alloy is melted Exception CoCr partial denture alloys see paragraph 10 3 CoCr partial denture and non precious metal alloys Titanium or aluminium containing alloys see paragraph 10 4 Titanium and aluminium containing alloys NOTE We recommend to do the premelt with 100 power 9 4 Casting After premelting the casting ring is rapidly placed in the casting chamber and locked in place ideally approx 20 40 seconds the chamber is closed and the melting process is started by pressing the key START NOTE R gt The interruption between pre and main melt should not exceed one minute to prevent the melt and the mould from cooling down too much Each crucible should only be used for one alloy to avoid mixing of alloys Use a felt pen to mark the crucibles according to the intended use NOTE Power adjustment during melting must be performed manually Graphite insert NOTE M If graphite inserts lose some of their height or the upper border becomes thin and brittle they must be exchanged minimum weigh
38. t of graphite insert approx 7 g GER Milf a lot of melting powder has accumulated in the graphite insert no melting powder should be added for the next casting M Prior to each casting blow out graphite insert cleanliness 9 4 2 Ceramic crucibles When using ceramic crucibles ceramic bonding and palladium based alloys are heated until the oxide layer splits open When casting CoCr partial denture and NPM alloys melting is continued until the shadow disappears and depending on the alloy casting is performed with or without delay time When casting titanium and aluminium containing alloys the premelt is sometimes omitted completely and premelt and main melt are carried out in a single working step with the ring being placed in see paragraph 10 4 Titanium and aluminium containing alloys M The sprues and the casting buttons must be cut into pieces before melting When filling alloy into the crucible it must be ensured that the alloy is very close to the bottom of the crucible to achieve optimum melting performance 10 Alloys CAUTION N During the melting process it is essential to adhere to carry out the following instructions Under no circumstances must the machine be left unattended The melt must always be observed The viewing glass must be used for each melting process Risk of getting blinded due to the high luminous intensity of the melt No hot melting crucible must remain in the coil after working HOT SURFACE A
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