Attention! - Romanoff - International Supply Corporation
Contents
1. 2 DESCRIPTION M 4 WORKING DIAGRAM AND DESCRIPTION 4 d IA T 6 TECHNICAL CHARACTERISTICS OF MELTING MACHINES F1 D TURBO F3 D F4 D F5 D F9 D F12 D 7 S PL M LO eC M 9 BI 9 eg NIC T 10 a C 10 OSS TOV GI OTL CON RET Em 11 Air mtake ferrule 12 Checking correct adjustment of the gas torch on machines with optical temperature 12 IRV OS TEE UT 12 METAL TEMPERATURE SENSOR 7 7 7 13 T O COU C 13 Dual wavelength Optical 13 TTT TNSTRUC TIONS FOR US 14 15 NU TEST 0 uceeoaers 17 eMAINTENA NCE M E M 18 INSTRUCTIONS FOR PERIODIC MAINTENANCE 18 18 TOG WIT 192. Highvollage jCheckthepowersupplvollage If the machine malfunctions without giving a diagnostic message please contact 1 24 FID Turbo F3D 4 F9D FI2D Rev FI 003 GB 8 2_3_14_16_17 1 1 Selection of voice message language citi th To enter programming switch the MAIN SWITCH to ON while holding down the P key The code of the Lg language parameter appears on the CRUCIBLE TEMPERATURE display while the number of the currently selected language appears on the SELECTED TEMPERATURE display Press key E to enter modification phase the number on the SELECTED TEMPERATURE display will begin to flash Modify the value of the setting using the power adjustment keys and according to the table Italiano English Francais Deutsch Espanol Turkish 5 Press key E or P to leave the parameter modification phase the number on the SELECTED TEMPERATURE display will stop flashing 6 Press key P to exit programming FID Turbo F3D 4 F5D F9D FI2D Rev FI 003 GB 8 2 3 14 16 17 v1 1 25 Entering the TCS700 optical sensor coefficient Every TCS700 optical sensor has a numerical coefficient which determines its accuracy of measurement If an optical sensor is replaced or fited to a melting machine as an upgrade kit this coefficient must be assigned to the OC operating parameter 1 To enter programming switch the MAIN SWITCH to
3. FID Turbo F3D FAD F9D FI2D Rev FI 003 GB 8K2 3 14 16 v1 1 1 Electronic Metal Melting Machines FI DTurbo F2D F4 D F5D F9 D F12 D Operator s manual Serial number Attention Operate the Unit referring to the Technical Booklet having the same serial number of the Machine Program Version MFGC25xx MFG14xx Rev FI 003 GB 8K2 3 14 16 17 v1 1 Date 29 03 2007 FID Turbo F3D FAD F5D F9D FI2D Rev FI 003 GB 8K2_3_14_16_17 v1 1 INSTRUCTIONS ATTENTION READ THESE INSTRUCTIONS CAREFULLY BEFORE WORKING WITH THE DEVICE e Read this booklet carefully before installing or operating the device and before carrying out maintenance operations Keep this booklet in a safe place for future reference e CEIA products may be operated with a high degree of safety provided that all the safety standards following good sense and the manufacturer s advice are observed It is therefore essential that the heads of staff safety make sure that all operators read this manual before being allowed to use the device e At all times during the installation use and maintenance of the device follow the guidelines presented in this booklet CEIA will be held responsible for any damage as a result of the device being used for purposed that are not expressly indicated in this booklet e Whenever there is the risk that the safety standards have been lowered the device must be placed out of service in suc
4. 08 19 Closed circit system 8 19 eS 20 Procedure for checking the aim of the optical 20 Instr ctions Tor replacing GANCTINOCOU DIE c sueco eset Scot le a ot aa A TE aM priu UU Gu VOD Me 21 IGNAC Orr 23 0 23 Fault signalling on SELECTED TEMPERATURE display 23 See conus VOICE Tan SUO BE dsl pesto 24 Entering the 16700 optical Sens r 25 E NU EST dl pee tee nc 26 SPARE PAR c 26 du G 9 ce 26 ACES ORES 26 CONSUMABLE tect 26 DECLARATION OF CONFORMITY eiue ata 27 CEIA S p A reserves the right to make changes at any time and without prior notice to models including programming to accessories and optional features and to prices and conditions of sale 4 FID Turbo F3D FAD 5 F9D FI2D Rev FI 003 GB 8 2 3 14 16 v1 1 DESCRIPTION Working diagram and description The working dia
5. 19248 19248 display card 008005 DP Temperature sensor 19243 19243 19243 19243 19243 19243 19243 19243 19243 19243 19243 19243 connection card 00800S GN 19596 19596 19116 19116 19127 19127 19128 19128 19129 19129 19608 19608 Main switch 19249 19246 19249 19246 19249 19246 19592 19246 19592 19249 19592 19249 20219 20219 7775 7775 19193 19193 9849 9849 9835 9835 19617 19617 9876 9876 9876 9876 9876 9876 14960 14960 14960 14960 14960 14960 4045 4045 4045 4045 4045 4045 4047 4047 4047 4047 4047 4047 Optical pyrometric sensor TCS700 TCS700 TCS700 TCS700 TCS700 5700 TCS700 TCS700 TCS700 TCS700 TCS700 TCS700 19250 19250 19250 19250 19250 19250 19250 19250 19250 19250 19250 19250 Sensor 2176 2176 19889 19889 2177 217 217 217 2177 2177 12078 12078 12079 12079 14448 14438 12080 12080 12081 12081 19619 19619 K type thermocouple 19241 Complete optical pyrometric sensor TCS700 LPD A mu D 220 F9 Dy 220 120 220 400 30086 ws rpm _ a 300 litre stainless steel tank with L 230A 0 37kW 230V pump 300L 230AQ 300 litre zinc coated steel tank 300L 400 500L 400 300L 400AQ 500 litre zinc coated steel tank with 0 37kW 4
6. ON while holding down the P key The code of the Lg language parameter appears on the CRUCIBLE TEMPERATURE display while the number of the currently selected language appears on the SELECTED TEMPERATURE display Press power adjustment keys increase or decrease until you get to the OC command Press key E to enter modification phase the number on the SELECTED TEMPERATURE display will begin to flash Modify the value of the setting using the power adjustment keys and Press key E or P to leave the parameter modification phase the number on_ the SELECTED TEMPERATURE display will stop flashing Press key P to exit programming 26 FID Turbo F3D F4D 5 F9D FI2D Rev FI 003 GB 8 2 3 14 16 v1 1 H Bi V LIST OF PARTS Spare parts FID FID F3 D F3 D F4 D F4 D F5 D F5 D F9 D F D FI2D 2 Turbo Turbo 220 400 220 400 220 400 220 400 220 400 220 400 ee ee ee ee 19505 19505 Generator MFG F3 400 19506 19506 J P Generator MF G F 4 220 Generator J Generator MFG F5 220 f 19509 190 Generator MFG F9 400 P oc 190 1510 Generator MFG F12 400 f TT 19609 19609 1 1 19247 19247 19247 19247 19247 19247 19248 19248 19248 19248
7. cleaning be carried out every six months The cleaning operation is carried out by means of a series of washes of the unit with a solution of water and solvay soda and continues until the tubes are completely clean Water filter The water intakes IN are equipped with a filter net to ensure that any impurities in the water do not get into the cooling system and impede the flow Check regularly that this filter is not blocked Fig IV 2a Detail of the water inlet Fig IV 2b Water inlet fitting components fitting Taking out the filter Closed circuit system MTA cooler The system does not need any maintenance apart from periodic topping up of the liquid N B Use only distilled water for topping up If distilled water is not used the instructions in the section above should be followed 20 FID Turbo F3D 4 F9D FI2D Rev FI 003 GB 8 2_3_14_16_17 1 1 Optical temperature sensor If the thermoregulator does not measure variations in the temperature during melting operations or the reading is erroneous check that the sensor is aimed correctly and that the lens is clean Also check that the gas torch is not directed toward the sensor during use see Installation section Clean the sensor lens periodically The lens can be cleaned with a cotton tipped stick dipped in alcohol It is advisable to carry out this cleaning every six months Procedure for checking the aim of the optical sensor owi
8. in this user s manual e Insert the metal into the crucible taking care not to scratch the sides and calculating the quantity so that during the melting stage it will remain a few centimetres below the rim of the crucible This allows it to be stirred using a graphite rod and thus a constant fineness of product can be obtained e Melting additives For quicker better melting use additives such as boric acid the resulting deposit can easily be removed with a graphite rod when melting is completed e Adjust the melting temperature using the increase decrease buttons the indication on the SELECTED TEMPERATURE display will change e Press button green to start the melting process e During melting the POWER display shows the power delivered by the generator the generator is switched on and off automatically to keep the melting temperature constant When the generator is off the display shows the message 87 When the button is pushed and during the heating phase a short audible signal is emitted at intervals of about 30 to indicated that the melting machine is in operation e Adjust the power to the desired value using the Hs increase and decrease buttons the POWER display indication with flash during adjustment e Metal temperature control Thermocouple When metal is on the point of melting start the temperature control by inserting the thermocouple into the crucible IMPO
9. laid down in this chapter Power supply Connect the machine to earth ground and to the voltage indicated on the plate and in the CONFIGURATION sheet at the end of the manual using the power supply cable The line conductors should have a minimum section equal to those specified in the CONFIGURATION sheet For the standard model with 380 400V power supply the line conductors should have aminimum section of 4 mm a 16A rated socket models F1 D F5 D Or a 32A rated socket models F9 D F12 D For the model with 208 230V power supply the line conductors should have a minimum section of 6 mm and a 50A rated socket N B in this case the power supply cable is not fitted with a plug The conductor key is as follows Function Conductor colour EUROPE USA L1 blue black L2 brown red L3 black orange Earth Ground yellow green green 10 FID Turbo F3D 4 F5D F9D FI2D Rev FI 003 GB 8 2_3_14_16_17 1 1 Feed IN plant with water from from a water system or from zinc coated steel tank see Technical characteristics AN N B It is important to ensure that the temperature of the water entering the machine does not exceed 40 C The water supply must be controlled upstream by a safety cock If a tank is used Fig Il 1 the pump will take water from the bottom of the tank while the water returning to the tank from the machine will be deposited at the top of the tank Connect
10. the message Attention replace crucible If the crucible is too worn the message is given a few seconds after the machine is switched on after this message the machine will continue to operate as long as there is no immediate danger to the apparatus Here it must be noted that in continuing to use a worn out crucible one runs the risk of it breaking during melting which could cause serious injury to the operator or damage to the machine CEIA will not accept any responsibility for improper or negligent use or for use which does not comply with this warning This is continuous check The machine turns itself off and will not accept further instructions until the correct voltage supply resumes Attention interrupted Check the thermocouple and replace if necessary If the spare part is thermocouple not immediately available disconnect the thermocouple cable from connector Ct on the side of the casing Fault signalling on SELECTED TEMPERATURE display Fault code Cause Ati Crucible missing Put the crucible in Internal fault Contact CEIA technical service personnel Insufficient water flow e Check the water supply outlet e Check the H20 IN filter Internal fault Contact CEIA technical service personnel High water temperature Check the temperature of the water entering the machine Check power supply connections Check the thermocouple and replace if necessary Check the power supply voltage r9
11. the water drain H9O OUT Important do not invert load and drain fig 1 2 8 tank R water cock P pump AN The liquid of the cooling unit must be water only without additives anti freeze anti calcium agents salts etc In order to allow proper heat transfer from the water to the environment do not use a tank in insulating material plastic fiberglass etc We recommend fitting the crucible with a gas torch which will prevent the metal oxidation and will lengthen the life of the crucible This accessory is fitted directly onto the melting machine work surface and orientated so that the flame completely envelops the crucible opening fig Il 3 Upstream of the gas torch install a valve to bring the pressure to 200 300 kPa Flame adjustment is made by balancing the intake of air using the Fs locking ring and Ra regulator and the gas flow using the Rg tap FID Turbo F3D FAD F9D FI2D Rev FI 003 GB 8K2 3 14 16 v1 1 11 fig 1 48 Cg gas cannula Rg gas tap Fs fig Il 4b Nozzles included 1 methane or locking ring Tg hose for inflow of gas Ra air town gas nozzle 2 propane gas nozzle adjuster Ug nozzle amp ATTENTION The nozzle Ug of the gas torch must be changed depending on the gas used Gas torch orientation The orientation must enable the flame to envelop the crucible mouth completely If the Melting Machine is fitted with an optical pyrometer the gas torch must be
12. 00 600kPa 200 600kPa flow gt 2 l min gt 2 5 l min gt 2 5 l min gt 2 5 l min Inlet 3 4 screw fitting Outlet hose fitting 012mm Safety features Monitoring of thermocouple operation Monitoring of cooling water temperature and flow Monitoring of all phases of the power supply FID Turbo F3D FAD 5 F9D FI2D Rev FI 003 GB 8K2_3_14_16_17 v1 1 Special features Accessories supplied Options Monitoring of the power supply voltage for both excess and insufficient voltage Very high efficiency fast melting with the minimum energy consumption No generator maintenance required Consistent melting results thanks to microprocessor control Digital selection and control of the power and melting temperature Monitoring of wear on crucible Automatic cut out if crucible is missing Self diagnosis with messages by voice synthesis and display indication e Gas torch useful to avoid metal oxidation during melting Installed on the induction melting machine plate in order to let the flame spread on the crucible e Crucible e Crucible cover e Crucible tongs e Water circuit connection pipes length 4 m TCS700 LPD Optical Temperature Sensor this can replace a thermocouple sensor and has the following advantages e temperature measurement without contact gt inertia so allowing precision and reliability of reading maintenance e no problem of metal contamination durin
13. 00V pump 300 litre stainless steel tank with 0 37kW 400V pump Cooler MTA10 220 240V 1 Cooler MTA20 380 415V 3 e Co z lt c 3 Consumables F1 D Turbo 220 F3 D 220 F4 D 220 F5 D 220 F9 Dy 220 12 220 F1 D Turbo 400 F3 D 400 F4 D 400 F5 D 400 F9 D 400 FI2Dy 400 21463 C1 G1 2316 C3 G1 19230 C4 G1 2314 C5 G1 2315 C9 61 19611 C12 G1 ee O 5 2176 19889 2177 2177 2177 FID Turbo F3D F4D F5D F9D 12 Rev FI 003 GB 8 2 3 14 16 71 DECLARATION OF CONFORMITY CE DECLARATION OF CONFORMITY CE DECLARATION DE CONFORMITE CE KONFORMITATSERKLARUNG DECLARACION DE CONFORMIDAD CE DICHIARAZIONE DI CONFORMIT CE Manufacturer Fabricant Hersteller Fabricante Costruttore CEIA S p A Zona industriale Viciomaggio 54 G 52040 Viciomaggio Arezzo ITALY Declares that the product d clare que ce produit erkl rt dap das Produkt declara que el producto dichiara che il prodotto Product name Nom du produit Produktname Nombre del producto Nome Model S rie Serie Serie Modello F1 D TURBO F5 D D Melting machine Fondeuse a moyenne fr quence Schmelzofen Fundidora electr nica de metales Fonditrice ad induzione F3 D F9 D F4 D F12 all model tous mod les alle Modelle todos los modelos tutti i modelli conforms to the following Product Specificati
14. 1 1 13 Metal temperature sensor Two types of temperature sensor can be installed on the electronic melting machine Thermocouple Fix the two thermocouple supports St to the surface of the unit on the right hand side of the machine using the screws supplied Connect sensor cable C to the Ct connector on the side of the unit and rest the sensor on the supports fig Il 7 Ti thermocouple St thermocouple supports C thermocouple cable Ct sensor cable connector Dual wavelength Optical Sensor Fix the tubular support SoP to the surface of the machine the sensor So will point at the crucible s interior automatically Then connect the sensor cable to connector Ct fig Il 8 So optical sensor C optical sensor cable Ct optical sensor connector DO NOT CHANGE the orientation of sensor cylinder So 14 FID Turbo F3D FAD 5 F9D FI2D Rev FI 003 GB 8K2_3_14_16_17 v1 1 Ill INSTRUCTIONS FOR USE AN CEIA will not accept any responsibility for improper or negligent use or for use which does not comply with the rules laid down in this user s manual AN Before each melting operation e Crucible wear and tear Before each melting operation the condition of the crucible should be checked if there are areas that have suffered damage the crucible should be replaced with a new one e Noxious fumes Additives and some alloys may produce noxious fumes during melting all necessary measures should
15. 1 EEC et 93 68 CEE concernant les interf rences lectromagn tiques Dieses Produkt entspricht den Anforderungen der EMC Norm 89 336 und nachfolgender in den Normen 92 31 0006 und 93 68 EEC angegebener Anderungen El producto indicado cumple los requisitos de la Directiva EMC 69 336 CEE y siguientes modificaciones indicadas en las Directivas 92 3I EEC y 93 68 EEC Il prodotto conforme alle norme della direttiva EMC 89 336 e successive modifiche indicate nelle direttive 92 3 I EEC e 93 68 EEC Person in charge Lab EMC Resp Laboratoire EMC Laborattach EMC Resp Laboratorio EMC Resp Lab EMC Ing E Sorini 28 FID Turbo F3D FAD F5D F9D FI2D Rev FI 003 GB 8K2_3_14_16_17 v1 1
16. ERATURE display indicates the selected melting temperature e When the melting machine is operative the status of the indicators is as follows TTD th model with temperature model without temperature sensor sensor e Place the crucible in position Absence of the crucible is noticed by the machine when the EX button is pressed if this happens the machine switches itself off and gives the message Crucible missing AN Avoid melting when the crucible is very worn as the crucible heats more slowly and the apparatus might not reach its normal operational rating M The melting machine is delivered with the voice messages in the language indicated on the CONFIGURATION sheet at the end of the manual To activate a different language follow the procedure described in the MAINTENANCE section 16 FID Turbo F3D FAD 5 F9D FI2D Rev FI 003 GB 8K2_3_14_16_17 v1 1 e lf the crucible is too worn the message Attention replace crucible is given a few seconds after the machine is switched on after this message the machine will continue to work as long as there is no immediate danger to the apparatus Here it must be noted that in continuing to use a worn out crucible one runs the risk of it breaking during melting which could cause serious injury to the operator or damage to the machine CEIA will not accept any responsibility for improper or negligent use or for use which does not comply with the rules laid down
17. RTANT after insertion of the probe the temperature sensor takes some time to reach thermal equilibrium with the crucible in this situation the pyrometer reading is not completely reliable and the temperature of the crucible will not correspond exactly to that programmed If one wants to be certain of the working temperature of the metal it is necessary to wait till the thermoregulator is stabilized this is indicated by the frequency with which the pyrometer is activated which initially is of the order of every few minutes but when balance is reached is of the order of every few seconds When the immersion thermocouple reaches high temperatures or is subjected to sudden fluctuations in temperature it becomes mechanically weak in this situation handle the thermocouple with care and avoid impacts agaist the melting machine casing or other hard surfaces Optical temperature sensor This is aimed at the crucible sinterior If a cover is necessary remember that it darkens the crucible Due to the lack of inertia the pyrometer will show a valid measurement of the metal s temperature when the cover is taken off AN If the optical sensor malfunctions refer to the notes in the MAINTEANCE section FID Turbo F3D FAD F5D F9D FI2D Rev FI 003 GB 8 2_3_14_16_17 1 1 17 gei e Gas torch If a gas torch is used to avoid oxidation of the metal keep the flame on the crucible for the entire duration of the melting It is advisabl
18. al characteristics of melting machines F1 D Turbo F3 D F4 D F5 D F9 D F12 D Operating Power supply Maximum Maximum Dimensions Machine capacity in voltage absorbed output width x depth x height weight pure gold three phase power power 50 60 Hz F1 D Turbo 220 200 240 V 4 5 kVA 50 kVAR F1 D Turbo 400 360 440V 4 5 kVA 50 kVAR F3 D 220 2 8kg 200 240 V 4 5 kVA 50 kVAR 430x450x905 mm F3 D 400 FI D 220 Fa D 400 F5 D 220 F5 D 400 F9 D 220 575x580x905 mm F9 D 400 12 0 220 12 07400 380 HV Metal melting temperature selectable thanks to a digital thermoregulator and pyrometer with an immersion thermocouple or an optical sensor optional Measurement range K type thermocouple 150 1300 C optical sensor 700 2000 The maximum value should not be considered applicable for continuous use We recommend that operational temperatures should be at least 150 C below these values Water cooling via a tank witha 0 5 Hp pump or via a direct supply at the pressure indicated in the table below F1 D Turbo F3 D F4 D F5 D F9D F12D intermittent working 5096 tank capacity 200 300 300 500 direct supply pressure 200 600kPa 200 600kPa 200 600kPa 200 600kPa gt 2 l min gt 22 5 l min gt 2 5 l min gt 2 5 l min flow continuous working 1300 tank capacity 500 7501 7501 1000 pump power 0 5 Hp 0 5 Hp 0 5 Hp 0 5 Hp direct supply pressure 200 600kPa 200 600kPa 2
19. ch indicates insulated from one of the thermocouple terminals uninterrupted operation To access the terminals see once again by using the multimeter that is to say step 2 of the procedure given below the tube in stainless steel must be insulated from the head in Cr Al In this case the resistance must be above 10 MOhm Should the test results not correspond to the above mentioned values the thermocouple must be replaced To do so follow the procedure given below 1 Unscrew the locking ringlet A which frees the external protective sheath B from the thermocouple Unscrew the joint C 2 Remove the screws E which seal the outside cover D Fig IV 4a 22 Fig IV 4b FID Turbo F3D FAD 5 F9D FI2D Rev FI 003 GB 8 2 3 14 16 17 v1 1 H Remove the fixing screws G for the ceramic terminal support H and loosen the terminal support in such a way that it can be rotated Free connecting cable J by loosening screws F and ring nut K and then remove this cable The correspondence between the conductors and the terminals is shown below green conductor v red terminal r red conductor r yellow terminal g Rotate the square joint L anti clockwise until it can be removed from the support tube Bend the rear of the thermocouple M into a wide curve and carefully remove the square joint L Straighten the sheath M and pull it out of the support tube Insert the new thermocouple M
20. e to use an auxiliary gas torch during the casting phase AN Before removing the crucible during melting stop the machine by pressing the button red Halting processing e After use turn off the MAIN SWITCH Disconnect the mains supply AN Before closing the water cock or disconnecting the pump wait till the crucible has completely cooled or take the crucible out SF To prolong the life of crucibles we recommend that it is removed from the machine when work is finished and allowed to cool slowly with a cover on in order to reduce thermic shock It is a good idea to put in some boric acid in this case as the acid vaporizes during the cooling phase and as it is in a closed container causes convection which helps to distribute it uniformly over the inside of the crucible FID Turbo F3D 4 5 F9D FI2D Rev FI 003 GB 8 2_3_14_16_17 1 1 IV MAINTENANCE AN Any maintenance or repair to the machine must only be carried out after the power supply cable has been disconnected CEIA will not accept any responsibility for improper or negligent use or for use which does not comply with the rules laid down in this user s manual Instructions for periodic maintenance Melting unit Crucible AN It is very important to check the condition of the crucible before every melting operation Here it must be noted that continuing to use worn out crucible one runs the risk of it breaking during
21. g melting caused by damage to the thermocouple sheath Sensor accuracy is not influenced by the metal state or type nor by the presence of smoke Immersion thermocouple Measurement range K type thermocouple 150 1300 C The maximum value should not be considered valid for continuous use We recommend that operational temperatures should be at least 150 C below this value MTA 10 Cooling unit Characterized by its compact dimensions and equipped with digital regulating it allows continuous operation for standard melting temperatures below 1300 maintaining the temperature of the cooling water at the optimum level of 25 Cooling capacity 3 31 kW MTA 20 Cooling unit Characterized by its compact dimensions and equipped with digital regulating it allows continuous operation for standard melting temperatures below 1300 C maintaining the temperature of the cooling water at the optimum level of 25 Cooling capacity 6 94 kW FID Turbo F3D 4 F5D F9D FI2D Rev FI 003 GB 8 2 3 14 16 v1 1 9 Il INSTALLATION In this chapter the procedure for correct installation and maintenance of the machine is explained In the event that further information or clarification is required customers are requested to contact the Technical Department of C E l A It should be noted that is not responsible for any damage that may result from installations that do not follow the guidelines
22. gram of the Electronic Melting Machine is shown in Fig 1 1 The following sections are illustrated 1 Control panel this is located on the front of the device and allows the operator to select the amount of power delivered and the operating temperature 2 Medium frequency generator transforms the power supply voltage into medium frequency energy which drives the coil The amount of energy supplied to the coil can be adjusted 3 Coil transforms the medium frequency energy provided by the medium frequency generator into a variable magnetic field 4 Crucible contains the metal to be melted the crucible is heated by currents induced therein by the magnetic field generated by the coil In order to obtain an efficient transfer of energy the crucible is placed within the coil 400V 3 220V 37 MEDIUM FREQUENCY GENERATOR CONTROL PANEL Temperature Power adjustment Sensor Temperature adjustment Melting On Off Fig l 1 Melting machine block diagram Control of the apparatus is entrusted to a microcomputer which accepts instructions from the operator switching on and off adjustment of the power delivered and selection of melting temperature checks that the machine is working correctly by means of a self diagnostic device and uses voice synthesis to give information about the melting of the metal and any action necessary on the part of the operator The power delivered which depends on the temperature to be reached and
23. h a way that as to render its accidental usage impossible and assistance must be requested The safety standards are to be considered lowered when the device shows visual signs of deterioration the device does not work correctly the device has been stored in less than satisfactory conditions for a long period of time the device has had to undergo severe strain during transportation the device has come into contact with liquid substances The area directly surrounding the working zone must be supplied with adequate anti incendiary devices e All combustible materials must be removed from the working zone and placed at a safe distance e Do not use excessive force during installation use or maintenance of the device e operator must be able to access the controls of the device easily without running personal risks e Before providing the device with electrical power check that the voltage from the power mains corresponds to the voltage shown on the device s electrical specifications plaque Only connect the device to the power mains after having made all the connections needed for its complete installation e electrical plug must only be inserted into a socket containing a grounding contact Any interruption in the protective conductor either inside or outside the device or the detaching of the protective grounding terminal renders the device dangerous Intentional interruption is forbidden e After melting en
24. melting which could cause serious injury to the operator or damage to the machine CEIA will not accept any responsibility for improper or negligent use or for use which does not comply with the rules laid down in this user s manual In the event that the melting device is under powered indication lower than 70 of maximum power it is recommended that the crucible be replaced information given by the machine in the form of a voice synthesized message To prolong the life of crucibles we recommend that they are allowed to cool slowly with a cover on in order to reduce thermal shock It is advisable to put in some boric acid in this case as the acid vaporizes during the cooling phase and as it is in a closed container causes convection which helps to distribute it uniformly over the inside of the crucible The parts that make up the melting unit are illustrated in Fig IV 1 It is recommended that weekly checks are made on the condition and correct positioning of these parts and in particular of the condition of the coil insulation Fig IV 1 Melting unit components Rif Description RP Refractory plate MR Refractory brick CR Graphite crucible with refractory container CP Refractory crucible cover PL Tongs S Heating inductor In order to obtain the best possible results we strongly recommend that only approved crucibles be used with CEIA melting machines FID Turbo F3D F4D 5 F9D FI2D Re
25. ons est conforme aux sp cifications suivantes folgenden Produktspezifikationen entspricht es conforme a las siguientes especificaciones conforme alle seguenti specifiche di prodotto Safety S curit Sicherheit Seguridad Sicurezza EN 60204 1 1997 This product complies with the requirements of the Low Voltage Directive 73 23 EEC and following modifications indicated in the 93 68 EEC Directive Le produit ci dessus r pond aux exigences de la Directive 73 23 CEE et aux modifications suivantes mentionn es dans la Directive 93 68 CEE concernant la basse tensions Dieses Produkt entspricht den Anforderungen an Niederspannungsger te gem der Norm 73 23 EEC und nachfolgender in der Norm 93 68 EEC angegebener Anderungen El producto indicado cumple los requisitos de la Low Voltage Directive 73 23 CEE y siguientes modificaciones indicadas en la Directiva 93 68 Il prodotto conforme alle norme della direttiva 73 23 EEC e successive modifiche indicate nella direttiva 93 68 EEC sulla bassa tensione Arezzo 2000 05 24 EN 55011 Group 2 Class A EN 61000 4 2 EN 61000 4 3 EN 61000 4 6 ENV50204 EN 61000 4 4 This product complies with the requirements of the EMC Directive 89 336 EEC and following modifications indicated in the 92 31 EEC and 93 68 EEC Directives Le produit ci dessus r pond aux exigences de la Directive 69 336 CEE et aux modifications suivantes mentionn es dans les Directives 92 3
26. positioned correctly and the air flow properly adjusted otherwise the pyrometer will measure the flame temperature rather than the metal temperature during melting The figures below show the proper position of the gas torch the flame must be aimed towards the rear rim of the crucible and must create a whirl over the crucible mouth fig 11 5 1 gas torch 2 crucible 3 air adjustment 4 optical sensor 12 FID Turbo F3D F4D 5 F9D FI2D Rev FI 003 GB 8 2_3_14_16_17 1 1 s mp E Air intake ferrule adjustment The locking ring 3 must be adjusted so as to obtain a blue flame as far as the rim of crucible and a yellow red one when over the crucible mouth Checking correct adjustment of the gas torch on machines with optical temperature reader e urn the melting machine on at the main switch place a crucible at room temperature in the melting unit do not start the melting process e Light the gas if the position and the air adjustment are correct the thermoregulator should indicate a temperature below the measurement range display symbol Use of an auxiliary gas torch Do not use an auxiliary gas torch as the pyrometer might read the gas temperature instead of the metal temperature always keep the torch on the same side as the optical sensor fig 11 6 1 gas torch 2 crucible 3 optical sensor FID Turbo F3D FAD F9D FI2D Rev FI 003 GB 8K2 3 14 16 v
27. raulic unit should be cleaned every six months see Maintenance section e Optical temperature sensor During operation the lens of the sensor may become dirty due to dust or smoke it should be cleaned at least once a week The melting machine is equipped with a magnetothermal MAIN SWITCH located on the control panel This switch serves as a protection against malfunctions FID Turbo F3D 4 F5D F9D FI2D Rev FI 003 GB 8 2 3 14 16 17 v1 1 15 Work Cycle i eae asm fures TUM CONT TEMFERATURE EE Pe ee CMUCHX TPT erg tien ewe scc UM 3 BELEE TED TEUFERATYRE c INDUCTION HEATING GENERATOR Gela i mg rr LED power indicator 7 Selected temperature decrease button Measured temperature 8 Selected temperature increase button Indicator of power delivered 9 Melting process Stop button Selected temperature 10 Melting process Start button Power decrease button 11 Main switch Power increase button fig 111 1 detail of the control panel e Supply the correct voltage see values indicated on the plate attached to the rear of the unit and water e urn on the MAIN SWITCH the LINE indicator comes on the POWER display indicates the device s software version 2 figure sequence the SELECTED TEMP
28. ry plate H20 IN water inlet So optic temperature sensor optional 20 OUT water outlet SoP support of the optic temperature sensor S coil Ti immersion thermocouple optional MO container unit TG label 6 FID Turbo F3D FAD 5 F9D FI2D Rev FI 003 GB 8K2_3_14_16_17 v1 1 Model Mod le Modello I F9 D 400V 105 Serial Number Num ro de s rie Matricola Vollage Tension Tensione eer Power Pulssance Polena 3 199900839009 fig l 5 detail of the plaque with the details of an F9 D melting machine Crucibles The machines are supplied with graphite or silicon graphite crucibles selected to provide optimum performance in terms of power delivered and melting quality Their characteristics are set out below In order to obtain the best possible results we strongly recommend that only approved crucibles be used with CEIA melting machines Ei 04 01 19230 graphite 350cc 60_ ze 90 model model 3 4 C9 S1 14764 silicon graphite 800cc for high temperatures C12 G1 19611 recommended for operating temperatures up to 1200 C recommended for operating temperatures up to 1600 C fig 1 6 available crucibles A crucible B refractory container TABLE OF SPECIFIC WEIGHTS OF SOME METALS 835 Ag 10 28 FID Turbo F3D FAD F5D F9D FI2D Rev FI 003 GB 8 2 3 14 16 v1 1 7 800 10 20 Technic
29. sure that the metal that has been worked upon is allowed sufficient time to cool before handling it or bringing it into contact with combustible material e All electrical shocks are potentially fatal Never touch parts charged with mains power Keep clothes and body dry and never work wet environments Whenever one becomes aware that the device or part of it has accidentally become electrically charged immediately stop the soldering operations and do not use the device until the problem has been located and resolved by qualified personnel e Wearers of electronic devices such as pacemakers must consult a doctor before coming into close contact with the device in order to ascertain whether the magnetic fields produced by high currents may influence the functioning of the pacemaker e Always remove the plug by hand when disconnecting the power supply cable never by pulling on the cable e prevent damage by lightening disconnect the power supply cable during thunderstorms e Do not wash the device with water liquid detergents or chemical substances Use a slightly moist non abrasive cloth for cleaning e Never cut off the safety features of the device e Before any maintenance cleaning or movement the device must first be disconnected from all sources of power e Carefully read the Maintenance chapter of this booklet before contacting your service centre In the event of a problem only technicians that are specialized and authorized
30. tch the main switch to the ON position Press the START button Cera 8 1880008664 7 Wait for the temperature read out to exceed 800 C Press the START button for at least 5 seconds the message Or appears on the CRUCIBLE TEMPERATURE display whilst the SELECTED TEMPERATURE display shows a number which updates every second Loosen the sensor locking screw BS and find the position which gives the maximum reading on the SELECTED TEMPERATURE display This figure should generally be 15 Lock the sensor again Press the STOP button to return to normal operation FID Turbo F3D FAD F5D F9D FI2D Rev FI 003 GB 8 2 3 14 16 v1 1 21 Instructions for replacing a thermocouple If the sensor fails the thermoregulator stops the machine in order to save the metal being treated The digital temperature controller will show an error message The thermocouple may stop functioning for one of two reasons 1 The stainless steel protective sheath for the conductors in Cr Al has become worn 2 The working temperature has gone beyond the maximum limit of 1300 C causing fusion of the above mentioned components Correct operation of the thermocouple can be verified by checking the thermocouple terminals after having removed it from the machine The Ohm value displayed by the multimeter a scale Another check is to verify that the external sheath is of Ohm x 10 must be close to zero whi
31. the mass of the metal to be melted can be adjusted digitally by the operator The machine is also equipped with a thermoregulator with a pyrometer via which the temperature the metal must reach during the melting phase can be set The temperature sensor can be a dual wavelength optical reader or an immersion thermocouple for measurement ranges see the Technical Characteristics section In addition to the power supply the machine requires a water supply for the cooling system for the electronic power devices inside connections for which are made on the left side of the machine The cooling water supply is monitored by a flowswitch which prevents the machine from operating in the case of supply failure or low water flow rate The water temperature is controlled by a thermostat which blocks operation of the machine if overheating occurs Figures 1 2 and I 3 illustrate the electronic melting machines described in this manual FID Turbo F3D FAD F9D FI2D Rev FI 003 GB 8K2 3 14 16 v1 1 5 Fig l 2 models F1 D Turbo F3 D and F4 D with Fig 1 3 models F5 D F9 D and F12 D with optical optical temperature sensor optional temperature sensor optional Fig 4a cooling water inlets and Fig 1 40 detail of the melting unit Fig 1 4 detail of the immersion outlets thermocouple CA power supply cable MR refractory brick CG gas torch PC control panel crucible lid PL crucible tongs CR crucible RP refracto
32. therefore be taken to protect the health of the operator e Additives Do not put into the crucible compounds or materials which may produce phenomena harmful to persons or property during operation and use of the melting machine CEIA will not accept any responsibility for improper or negligent use or for use which does not comply with the rules laid down in this user s manual e Crucibles During the first melting operation crucibles must be subjected to a gradual temperature increase to allow evaporation of any moisture which may have been absorbed It is advisable to keep crucibles near a source of heat to avoid the absorption of environmental humidity Check periodically and always after moving the melting machine that the coil is perfectly centred in order to avoid undue wear on the coating of the coil itself due to the friction of the crucible Metal temperature Do not overheat the metal to temperatures significantly above that of melting so as to avoid splashing of incandescent metal and the consequent risk of damage to persons or property CEIA will not accept any responsibility for improper or negligent use or for use which does not comply with the rules laid down in this user s manual e Cooling system The cooling unit must be supplied with water only without additives anti freeze anti calcium agents salts etc e Cooling system If the melting machine cooling system is connected directly to a water mains outlet the hyd
33. to work on CEIA machinery should be contacted e malfunctioning parts must be replaced with parts specifically designed for the device e tis important as much as possible to avoid carrying out maintenance or repairs on the device while it is open and supplied with electrical power if absolutely essential such work must be carried out only by qualified personnel who are well aware of the risks that are involved e capacitors within the device may remain charged even after the device has been disconnected from all sources of power Wait 60 seconds before beginning repair work on the device Symbols The device is marked with this symbol whenever the operator or the maintenance personnel in order to avoid possible damage have to refer to the present manual The same symbol appears in the booklet at points where warnings or particularly important instructions are given instructions that are vital to a safe and correct use of the device The device is marked with this symbol in those areas where a dangerous amount of voltage is present Only specialized maintenance personnel should make adjustments in these areas WARRANTY TERMS The Warranty on all CEIA equipment relates to goods delivered from our factory under our general and specific conditions of sale FID Turbo F3D F4D 5 F9D FI2D Rev FI 003 GB 8 2 3 14 16 v1 1 3 CONTENTS Page 2 SI 2 A eec
34. v FI 003 GB 6K2 3 14 16 v1 1 19 Hydraulic unit A A The liquid supplied to the cooling unit must be water only without additives anti freeze anti calcium agents salts etc For closed circuit systems distilled water should be preferred To avoid periodic cleaning of the cooling system we recommend that a closed circuit system with distilled water be used With the use of non distilled water the tubes of the hydraulic cooling unit are subject to the build up of calcium sediment As a result one or more sections of the tubes may become totally or partially blocked If this occurs a partial block stops the water from flowing smoothly causing overheating the machine control system interrupts the melting and signals a malfunctioning with a vocal message A total block stops the flow of water again the machine control system interrupts the melting and signals a malfunctioning with a vocal message If blocking of the unit occurs a complete check and manual cleaning of each component of the cooling unit should be carried out rubber tubing and power modules It is advisable to disconnect one tube at a time to avoid the risk of mistakes in re assembly It is important that cleaning of the cooling unit be carried out with the machine switched off in order to avoid the danger of injury to the operator After the above operation however it is still advisable to carry out the periodic cleaning It is recommended that cyclical
35. with its ceramic support H into the support tube and reassemble by following the above mentioned procedure in reverse FID Turbo 4 5 F9D FI2D Rev FI 003 GB 8 2 3 14 16 v1 1 23 gei Fault signals Voice messages The melting machine is fitted with an effective system of self diagnosis which notifies the operator when some parts of the apparatus malfunction Messages relating to this self diagnosis are as follows This is continuous check The machine turns itself off and will not temperature too high accept further instructions until the situation changes T 65 Attention insufficient water This is a continuous check The machine turns itself off and will not pressure accept further instructions until the situation changes Check that the water flow corresponds to that shown in the Technical Characteristics section The message is also given when the tubing is obstructed by calcium deposits in this case the water cooling system must be cleaned Attention one phase This is a continuous check and warns the operator that the three phase missing power circuit is unbalanced and will therefore not allow the machine to work properly The machine will not accept instructions until the situation returns to normal Attention crucible missing Absence of the crucible is noticed by the machine when button 15 presed if this happens the machine switches itself off and gives
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