RT650 Manual

OPERATIONS AND
MAINTENANCE MANUAL
FOR
xxxxxxxxxxxxxxxxxxxxxxxx
xxxxx
MODEL RT 650
AC SERVO DRIVE
CONTINUOUS CASTING
MACHINE
Issue 77 - English language version
1st February 2008
IMPORTANT NOTICE
OPERATIONS AND MAINTENANCE MANUAL Issue 77
RT CONTINUOUS CASTING MACHINES 1st February 2008
Any modifications made to these machines or to its operating practices or principals laid down in this
manual, without prior consultation and written approval from Rautomead Limited, renders any declaration
of safety or compliance null and void.
It is important to read this manual before the installation and use of these machines because it contains
essential health and safety information. This process uses molten metal, which is a hazardous material.
Regular reference should be made to this manual to ensure that the correct working practices are followed.
Safety procedures are detailed in Section 8.0 and specific mandatory protective clothing in Section
8.1
Only trained personnel should operate these machines, they should never work alone and all non-essential
personnel should be excluded from the area.
The machine uses nitrogen inert gas.
The machine is built with materials containing ceramic fibres. When handling / disturbing these materials,
during build up or strip down of the machine, the operator must at all times wear the appropriate respiratory
mask and clothing. Refer to section 8.1
The machines are constructed to best practice to reduce electromagnetic radiation by the use of compliant
instruments.
NOTE: The key holder of the machines should be a responsible person.
It must be established at a very early stage as to who is the person responsible for the plant. The control
console key(s), drawings, manuals, etc. should be handed over as commissioning training period draws to
end.
WARNING: Do not activate power pack or control console until all connections, including the fitting
of the heating element assembly, have been made as damage could occur.
WARNING: Rautomead will not accept any responsibility for any parts other than those
made, approved or modified by Rautomead.
Any subsequent usage of non-Rautomead parts is done so entirely at the

customer's own risk.
Any losses, personal injury or equipment damage are the responsibility of

the customer.
The customer must ensure that all operators are fully trained in the
operation of the machines and the use of new parts.
Page 2 of 146
Model Number RT 650
Serial Number xxxxxx
Power rating xxxxxx
Primary Volts xxxxxx
Primary Amps xxx
Secondary Volts xx
Control Volts xx
Net weight of major machine items :

Furnace 2650kg
Electrical controls cabinet 350kg
Withdrawal unit 400kg
Transformer Cabinet , 150kVA 1830kg
Crucible Assembly full of gold 2000kg
Top Thrust Plate 100kg
Page 3 of 146
Table of Contents
Item Description
INTRODUCTION
TABLE OF CONTENTS
PROPRIETARY MANUAL LIST
DRAWING LIST
1.0 INSTALLATION NOTES
1.1 FOUNDATIONS
1.2 NITROGEN
1.3 WATER
1.4 POWER SUPPLY
1.5 AIR SUPPLY
1.6 INSTALLATION
1.7 SAFETY CHECKS
2.0 EXPLANATION OF EQUIPMENT
2.1 FURNACE
2.2 TEMPERATURE CONTROL EQUIPMENT
2.3 CONTROL EQUIPMENT
2.4 ALARMS
2.5 INERT GAS
2.6 GRAPHITE
2.7 SAFETY EQUIPMENT
2.8 STARTER BARS
2.9 CONTINUOUS CASTING - GENERAL NOTES
3.0 CASTING MACHINE FURNACE BUILD
3.1 FURNACE BODY DRY-OUT, RT MACHINES

3.2 FURNACE BUILD - FITTING AND TESTING THE HEATING ELEMENTS
3.3 FURNACE BUILD - FITTING THE CRUCIBLE AND SEALING THE FURNACE
3.4 FURNACE BUILD – CLEANING THE CRUCIBLE BETWEEN CASTS
Page 4 of 146
4.0 CASTING DIE ASSEMBLY
4.1 JACKET COOLED DIE TOOLING - MAINTENANCE OF JACKET COOLERS
4.2 ROD DIE TOOLING - ASSEMBLY OF JACKET COOLER WITH CASTING DIE AND
FEEDER TUBE
4.3 ROD DIE TOOLING - FITTING THE ROD DIE ASSEMBLY INTO THE CASTING
MACHINE
4.4 ROD DIE TOOLING - REMOVING THE ROD DIE ASSEMBLY FROM THE CASTING
MACHINE
4.5 ROD DIE TOOLING - DISMANTLING THE ROD DIE ASSEMBLY
5.0 CASTING PROCEDURES
5.1 CAST AND SHUTDOWN OVERVIEW

5.2 SWITCH ON POWER
5.3 DIE TIGHTENING
5.4 CHARGING THE CASTING MACHINE - SAFETY
5.5 CHARGING PROCEDURE
5.6 DE-SLAGGING THE CASTING MACHINE
5.7 THERMOCOUPLE SETTINGS WITHIN THE CASTING DIE ASSEMBLY
5.8 WITHDRAWAL PARAMETER SETTING, AC DIRECT CONTROL DRIVE
5.9 START CASTING, AC DIRECT CONTROL DRIVE
5.10 STANDARD CHECK PROCEDURE
5.11 DIFFICULTIES DURING START-UP
5.12 RAISING THE CASTING SPEED AFTER START-UP, AC DIRECT CONTROL DRIVE
5.13 CONTINUOUS CHARGING OF METAL INTO THE CASTING MACHINE
5.14 PROCEDURE FOR STAND-BY
5.15 SHUT DOWN AT THE END OF A CASTING CAMPAIGN
5.16 ABORTED CAST PROCEDURE
5.17 PROTECTION OF LIQUID METAL BATHS
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6.0 HAZARDS - PREVENTION AND CONTROL
6.1 TAP-HOLE LEAK

6.2 ROD BREAKAGE , JACKET COOLER TOOLING
6.3 FRONT RUN-OUT
6.4 DISTORTED OR BENT ROD , STRIP & TUBE
6.5 INADEQUATE MOLTEN METAL FEED
6.6 A BRIDGE - WITHIN THE CRUCIBLE
6.7 EXCESSIVE ZINC BURN-OFF DURING BRASS PRODUCTION
6.8 SURFACE DETERIORATION OF THE ROD, STRIP OR TUBE
6.9 ROD SEIZURE WITHIN THE CASTING DIE
6.10 INSIDE RUN-OUT
6.11 DROP IN FURNACE TEMPERATURE
6.12 SOLIDIFIED METAL – WITHIN THE CRUCIBLE
6.13 FURNACE TEMPERATURE LOSS
6.14 ELECTRICAL TROUBLE SHOOTING GUIDE
6.15 GENERAL FAULT FINDING GUIDE
7.0 MAINTENANCE PROCEDURES
7.1 CASTING MACHINE STRIP-DOWN, CRUCIBLE REPLACEMENT

7.2 HEARTH REPLACEMENT
7.3 HEATING ELEMENTS
7.4 CLEANING OUT THE CRUCIBLE
7.5 LINER MAINTENANCE AND REPLACEMENT
7.6 FITTING OF LOW THERMAL MASS, LTM INSULATION
7.7 ELECTRICAL POWER
7.8 WITHDRAWAL UNIT
7.9 COOLER MAINTENANCE
8.0 SAFETY PROCEDURES
8.1 MANDATORY PROTECTIVE CLOTHING

8.2 FEED-STOCK
8.3 WATER FLOW
8.4 WATER TREATMENT
8.5 FIRE EXTINGUISHERS, FIRES, EMERGENCIES
8.6 FUME REMOVAL
8.7 DUMP BOXES
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9.0 APPENDICES
APPENDIX 1 Recommended furnace temperature settings
APPENDIX 2 Vendors List - Graphite
APPENDIX 3 Maintenance Schedule
APPENDIX 4 Temperature Control PID
APPENDIX 5 PLC Programme ; To Copy , Restore or Upgrade
APPENDIX 6 Main Panel Touch Screen
6.1 Start-up Screen

6.2 Clock Screen
6.3 Furnace Temperature and Thyristor Control Screen
6.4 Furnace Setup and Alarms Screen
6.5 Power Monitor Screen
6.6 Furnace , Overtemp , Dies & History Power Screen
6.7 Die Water Temperature Screen
6.8 Die Water History Screen
6.9 Die Temperature Screen
6.10 Services Temperature Screen
6.11 Withdrawal Unit Screen
6.12 Main Alarms Screen
6.13 Pressure / Temperature Trip Alarms Screen
6.14 Alarms History Screen
6.15 Auto Start Screen
APPENDIX 7 Jacket Cooler Setting
Also included are :
Manuals - Proprietary Items (English only)

Health & Safety Data Sheets
Drawing List and Drawings as issued to the customer
The drawings supplied are the property of Rautomead Limited and associated companies.
They must not be transmitted to unauthorised parties, or copied in any way.
The copies supplied must be returned to Rautomead Limited and associated companies upon
first request.
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10.0 DRAWINGS AND PROPRIETARY MANUALS
DRAWINGS LIST
Factory Layout , RT650 x

Factory Layout Service Trenches x
Water Services Schematic RT Machines , 150kVA x
Platform Assembly x
Dump Box , Front & Side x
Furnace External Build LH Taphole x

Furnace External Build , Die Water Inlet & Exhaust System x
Furnace External Build , Rear Services x
Busbar Cable Connection Assembly x
Furnace Internal Build RH Taphole x

Upper Concrete Build , RT Machines x
Steel Former , Upper Concrete Build , RT Machines x
Heating Elements Assembly x

UPPER SUPPORT LINTEL 1 1/2"BSF x
LIVE LINTEL 1 1/2"BSF x
RIGHT OUTER BUSBAR 1 1/2"BSF x
CENTRE BUSBAR 1 1/2"BSF x
LINTEL CONNECTOR BLOCK 1 1/2"BSF x
CONN. BLOCK BUSBAR/LIVE LINTEL x
REAR UPPER DROPPER 1 1/2"BSF x
HORIZ. DROPPER SPACER 1 1/2"BSF x
REAR LOWER DROPPER 1 1/2"BSF x
SIDE HORIZONTAL ELEMENT 1 1/2"BSF x
SIDE VERTICAL ELEMENT 1 1/2"BSF x
SIDE BRIDGE ELEMENT 1 1/2" BSF x
FRONT DROPPER 1 1/2"BSF x
LINTEL DROPPER BLOCK x
NUT GRAPHITE 1 1/2"BSF x
WASHER GRAPHOIL 1 1/2"BSF x
INSULATION SUPPORT LINTEL x
REAR LINTEL SUPPORT PLATE x
FRONT LINTEL SUPPORT PLATE x
THRUST BLOCK x
GRAPHITE STUD 1 1/2"BSF VARIOUS LENGHTS x
LIVE LINTEL EXTENSION x
LEFT OUTER BUSBAR 1 1/2"BSF x
Die Heater Assembly x

Dropper , 235mm lg x
Element , 150mm lg , 2 Clearance Holes x
Page 8 of 146
Dropper , 255mm lg x
Element , 360mm lg , 2 Threaded Holes x
Crucible Liner Assembly , No Baffle x

Crucible Body x
Upper Crucible Liner , Clay Graphite x
Lower Crucible Liner , Clay Graphite , 300mm lg x
Bubbler Assembly x
Adaptor , Nitrogen Bubbler x
Crucible Blanking Plug x
RT Services LH Assembly x
Die Service Fluidics Assembly x
Nitrogen / Air / Water Cabinet Assembly x
Taphole Control Panel x
Withdrawal Unit General Assembly x

Withdrawal Unit Assembly Pneumatic Hold Down x
Withdrawal Unit Body & Shafts Assembly x
Enclosed Pneumatic Control Panel Assembly x
TOOLING ASSEMBLY , Dia 4.000” ROD x

JACKET COOLER TO DIE FITTING ASSEMBLY x
JACKET COOLER & PROBE ASS’Y , Dia 150mm SERIES x
BRAIDED HOSE KIT, 8 PORT COOLER SINGLE SERVICE WING x
DIE BODY , Dia 4.000” ROD x
STARTER & SLAVE BAR ASS’Y, Dia 4.000” ROD x
STARTER BAR, Dia 4.000” ROD , PARENT METAL x
SLAVE BAR , Dia 4.000” ROD x
HOT END CLAMP SCREW TOOL x
FEEDER TUBE x
CLAMP SCREWS 1” BSF X 22mm Lg. x
Electrical Drawing List x

Main Panel Thyristor & Transformer x
Main Panel 220V Distribution x
Main Panel Inverter Power & Control x
Main Panel 24V Distribution x
Fluidics Panel x
Main Panel Furnace Temperature x
Main Panel Relay Output Card x
Page 9 of 146
MANUALS – PROPRIETARY ITEMS
-1
Health & Safety Data Sheets Provided :
1.0 RT INSTALLATION NOTES
Page 10 of 146
1.1 FOUNDATIONS
1.2 NITROGEN
1.3 WATER
1.4 POWER SUPPLY
1.5 AIR SUPPLY
1.6 INSTALLATION
1.7 COMMISSIONING
1.8 SAFETY CHECKS FOR RT MACHINES
Page 11 of 146
1.0 RT INSTALLATION NOTES
1.1 FOUNDATIONS
A standard load bearing factory floor will provide adequate support for a Rautomead and RT
continuous casting machines, transformer cabinet, withdrawal unit, fluidics and electrical cabinet.
The factory layout drawing shown in the Drawing List shows the overall dimensions and
foundations of this machine and the agreed factory layout.
A water system is required as detailed in your original quotation and similar to that illustrated in the
water system drawing shown in the Drawing List. This includes an emergency water system.
1.2 NITROGEN
NITROGEN QUALITY
The specification of nitrogen suitable for continuous casting is 99.999% nitrogen, high purity,
oxygen-free
1. Oxygen Content: less than 5vpm
2. Moisture Content: less than 2vpm
3. Dewpoint better than -70 degrees C
NOTE : Do not use inferior grades of nitrogen as this will accelerate the erosion of the
graphite parts.
NITROGEN SUPPLY 8mm OUTSIDE DIAMETER COPPER PIPE
Nitrogen can be fed to the furnace from a bulk liquid tank or from a cylinder supply. Supply
pressure should be regulated down to 2.0 to 2.75 Bar, (35 to 40 psi). A full bottle is kept on
standby for a quick change over.
Page 12 of 146
1.3 WATER
COOLING WATER SPECIFICATION
Cooling water for casting primary casting die coolers, furnace body water tracing and power
terminals.
It is recommended that a closed circuit re-circulating cooling water system be used, enabling water
treatment to be introduced.
* mechanically pure viz. optically clear, showing no turbidity or deposits

(mesh size 0.38micron)
* chemically neutral
* total hardness max. 80 mg/litre
* electrical conductivity max. 300 micro siemens/cm
Specific Values
total hardness max. 80 mg/litre

at pH value 7.8 max. 80 mg/litre
free carbon dioxide with total hardness:

80 mg/litre max. 8 mg/litre
carbon-dioxide (CO2) must be ‘no trace’

ammonia (NH3) must be ‘no trace’
nitrates (NO2) max. 0.04 mg/litre
iron max. 0.30 mg/litre
manganese max. 0.05 mg/litre
sulphates max. 250.0 mg/litre
chlorides max. 150.0 mg/litre
KMnO4 consumption max. 15.0 mg/litre
Cooling water inflow temperature should be not less than 25C (77F) and not more than 35C
(95F).
A typical water schematic for a these machines is detailed in the Drawing List
There are two water manifold assemblies. One is for the casting dies and the other is for the
machine services. Both the manifold assemblies have separate inlet and exhaust connections.
Page 13 of 146
WATER INLET 35mm OUTSIDE DIAMETER COPPER PIPE
The customers inlet water connection on both the die and services inlet manifolds, is via a 35mm
compression coupling, into which the customer is required to connect, using a 35mm outside
diameter copper pipe.
Mains water or recirculation system can be used.

There must be no interruption to the water supply while the machine is in operation. To ensure this
a second automatic emergency supply must be connected.
Supply pressure should be in the range of 4 – 6 Bar (58 - 78 psi), flowrate 250 litres / minute.
WATER EXHAUST 42mm OUTSIDE DIAMETER COPPER PIPE
The exhaust water connection on both the die and services outlet manifolds is via a 42mm
compression coupling, into which the customer is required to connect, using a 42mm outside
diameter copper pipe.
EMERGENCY WATER SUPPLY
Refer to the supplied the supplied Water Services Schematic for guidance.
NOTE : Emergency water should only be used for safely cooling down the machine in the
event of a primary water system failure. No casting should be attempted when emergency
water is being used as this will cause a molten metal front run out and injure personnel.
The emergency water supply is connected to the supply pipe to the fluidics panel assembly and
separated from the pump supply by a double non-return check valves.
A normally open solenoid valve should be fitted on the exhaust from the fluidics panel assembly
thereby allowing the emergency water to run to drain.
The emergency water supply can be either Regulated City Water or via a 10m elevated Water Tank.
Regulated City Water :

Pressure = 2 to 3 bar
Minimum Flowrate = 150 L/min
Water Tank :
Tank Height = 10m minimum
Capacity = 10800 L
Minimum Flowrate = 30 L/min (7.926 US Gal / min) at 1 bar (14psi) pressure for 6 hours to flow
through the casting machine in the event of a power failure.
Page 14 of 146
1.4 POWER SUPPLY - 150 kVA
The power supply required is 480 volts 60Hz 3 phase plus EARTH and the current rating is 180
amps. An appropriate rated supply cable and fused isolator should be provided for the machine by
the customer.
The customers power supply cable is fed through the base of the electrical control cabinet and
connected to terminals of the main isolator switch. The “Earth” wire should be connected to the
copper earth strip on the cabinet floor.
The 220 volt power supply to the electrical control and fluidics panel if fed from this 480v supply
via a step down transformer which is located within the cabinet. Rautomead supplies all the
necessary inter-link wiring for the installation.
Page 15 of 146
1.5 AIR SUPPLY 8mm OUTSIDE DIAMETER NYLON TUBE
A 6 to 7 bar air supply is required, 0.5 normal cubic metres per minute, to operate the clamping
rolls on the withdrawal unit. If this air supply is not available, this can be supplied from a separate
cylinder of air or nitrogen.
Connect the air supply for the withdrawal unit initially to the tee fitting underneath the nitro / air /
water cabinet. Then connect another 8mm nylon tube to the tee fitting and then run this tube to the
inlet of the regulator and drier for the withdrawal unit.
NOTE : Any machine using a pneumatic driven withdrawal unit should have a completely separate
large diameter (16mm O.D) air supply pipe in order to successfully supply the required volume of
air per minute.
1.6 INSTALLATION
Reference should be made to the photographs (if supplied) and drawings of the machine contained
within the operations manual.
INSTALLATION WORK TO BE DONE BY CUSTOMER
1. Carefully unpack all the crates and boxes and check the contents against the packing list. Advise
Rautomead of any missing or damaged parts as soon as possible. Store all parts safely (inside
original wrappings) in a dry place until required.
2. Use a fork-lift truck to lift the platform, furnace body, transformer cabinet, withdrawal unit,
fluidics cabinet and electrical cabinet into position, as per the factory layout drawing (see
drawing list), using the indicated lift points. If the floor is not perfectly level use shims where
necessary.
NOTE: The control panels can be lifted into position using the eye-bolts attached to the top of
the cabinets.
3. Secure the furnace body, transformer cabinet and electrical cabinet to the floor using rawl-bolts.
If the floor is not perfectly level use shims where necessary.
NOTE: The commissioning engineer may have to adjust the furnace body upon his
arrival.
4. Do not secure the withdrawal unit to the floor until it is accurately aligned with both the furnace
body and the casting die tooling by the commissioning engineer.
5. Install all the interconnecting water and nitrogen pipework. The corresponding connections are
marked at each end. If there are any questions about the pipework installation refer to
Rautomead.
Page 16 of 146
6. Install the SUPPLY and RETURN water pipework with :
 Shut off valves.
 An inlet water filter, preferably of the double canister type, with change over and bypass
valves.
Where possible flush out the pipework before making the final connections in order to
remove / minimise the amount of foreign debris that could damage the machine.
NOTE: Do not turn on the die water flowmeters as this will be done by the
commissioning engineer.
7. Connect the nitrogen or argon gas supply to the machine gas control cabinet, with suitable
isolation or transfer valves, using a 8mm O.D pipe. NOTE : It is the responsibility of the
customer to feed the machine with the appropriate protective gas for the given casting
operation.
8. Mount on a suitably adjacent wall the air pressure regulator and isolator and then connect the
factory air supply to it. Connect the air supply to the machine gas control cabinet, with a shut
off valve, using a 8mm O.D pipe.
9. Connect flexible cables between the furnace busbars and the transformer busbars.
10. Connect all the supplied interconnecting electrical wiring between the furnace body,
withdrawal, transformer cabinet and the electrical connection cabinet. The cables are labelled at
each quick connect end with the numbers corresponding on the connection cabinet. The
numbers are also listed on the electrical drawing.
NOTE : If in doubt leave this until the commissioning engineer is present.
11. Connect the supplied interconnecting earth cable between the transformer cabinet and the
furnace base frame steelwork
12. Connect a power cable to the electrical control cabinet main isolator switch and connect the
"EARTH" wire to the copper earth strip on the cabinet floor
NOTE : Do not turn on the electrical supply to the machine until the commissioning
engineer is present.
Page 17 of 146
1.7 SAFETY CHECKS
1. The furnace body steelwork must not be moved while connected to the mains supply, and
therefore it must be bolted to the floor.
2. Certain materials can give hazardous emissions if involved in a fire, see safety leaflets.
3. While this machine is a very low noise emitter the combination of this machine with others may
take the combined value over the legal thresholds, take necessary precautions.
4. Appropriate lighting levels are essential for safe operation of the machine.
5. Shut off valves for the supply of air and nitrogen are required with down stream dumping.
6. A local wall mounted isolator should be provided for terminating the electrical supply to the
transformer cabinet.
7. During the build up or strip down of the furnace ensure that the operator is wearing the
appropriate protective clothing, respiratory mask and gloves. The respiratory mask should be a
personal protection face-mask, PPF3 or filtering face-piece FFP3S type suitable for protection
against non to high toxicity solid aerosols in concentrations up to 50X Threshold Limit Value,
TLV.
8. Full protective clothing is defined as : Heavy woollen jacket and trouser set, flame retarding in
570 g/m2 ( 1.8 oz/ft 2 ) material, quick release foundry boots or gaiters, helmet and visor and
thick heat resistant leather gloves whenever metal is charged, level or tap hole checked, and
throughout dump procedure. All gloves to be inside sleeves, all pockets to be covered flaps,
jacket to cover trousers at all times and be fastened, trousers to cover boots at all times. When
charging volatile materials such as brass or during maintenance of the inside of the furnace the
operator should wear an approved filtering mask to reduce inhalation of fumes.
9. Any visitor to the machine, should be warned of risk, and dressed in appropriate casting
clothing, and accompanied at all times, he should not be present during, dumping, and only
during charging if considered safe by the engineer. These visitors should wear helmets long
cotton 320 to 450 g/m2 ( 1.0 to 1.4 oz/ft 2 ) material laboratory coats coated to be flame
retarding material, and safety glasses.
10. If fumes will be driven off by the molten metal appropriate extraction equipment and ducting
must be provided, this should take into account the dump box and front containment box areas
as well as the furnace lid.
11. An earth strap must be attached to the transformer cabinet as part of the electrical installation.
12. A suitable access platform for charging the furnace is required, advice is available from RIL.
13. Installation criteria: The machine is approved for working in the following environments 10 to
40C ( 50 to 100F ), up to 95% RH and up to 1900 metre (6270 feet) altitude.
Page 18 of 146
14. The User should do his own risk assessment for the use of the machine in his work environment
and issue appropriate working procedures to his staff, Rautomead can give assistance with this
preparation.
15. Suitable first attack fire fighting equipment should be provided and first attack fire fighting and
basic first aid techniques training should be given to operators.
16. List of possible external risks should be checked for during installation, proximity of water
pipes, fire sprinklers, cables, skylights, flammable surfaces and containers, paperwork stores
etc.
17. The water supply is best filtered to remove possible contamination of pipework resulting in
sudden flow reduction.
18. It is important that the lid is kept in good repair and regularly cleaned and repainted this reduces
gas usage, protects against melt contamination and ensures operator safety during charging.
19. If a machine is involved in a Fire, Flood or other major trauma Rautomead should be asked to
inspect machine prior to re-use.
20. Measurement of temperature is the single most important criteria in this process, water, die,
furnace are all of which are critical, ensure thermocouple calibrations are regularly made.
21. The water supply is essential to the safe running of the machine, it should never be operated
without both a main water supply and an emergency system.
Page 19 of 146
2.1 FURNACE
2.4 ALARMS
2.5 INERT GAS
2.6 GRAPHITE
2.8 STARTER BARS
Page 20 of 146
2.1 FURNACE
The furnace body is a robust welded steel box mounted on steel supports. A drawing of general
arrangement cross-sections is appended to this Manual.
The principal internal components of the furnace are made of high quality graphite on account of
the heat susceptibility, engineering strength at high temperatures and the machinability of this
material. These components include the crucible, elements and die assembly. Certain areas of the
case have water tracing applied, to ensure maximum casting stability during operation. The effect
on heat abstraction and energy removal is negligible, as the water flow, through the traced areas
(front, top, and part of the rear) will be set to a low level during normal operations.
The furnace base is built from refractory brick of appropriate thermal rating. This is covered with a
dry rammable refractory to seal the brick build and form a furnace hearth that will guide any metal
leakage to the tap hole. From the top insulation brick layer of the base system to the top of the
furnace, the remainder of the insulation is of the low thermal mass, LTM, type. The furnace
insulation system has been designed in order that body temperatures are kept to a minimum and
therefore an extremely small amount of energy is lost due to body losses. The top of the furnace
around and above the crucible is insulated with refractory wool.
FURNACE SEALS
The whole furnace body is sealed, so that an inert gas atmosphere (normally nitrogen) under slight
pressure can be maintained. This atmosphere protects the internal graphite components from
oxidation and aids in refining the molten metal. The furnace is fabricated to be gas tight. Access
points are sealed in other ways, as shown below.
The taphole lid is sealed with a circle of refractory blanket 25mm (1") thick. Regular checks for
leakage of molten metal into the tap hole tube must be made during routine operation of the
furnace. This is done with care to avoid any molten metal splashes.
The crucible charging orifice is covered by a circular lid, which locates into a circular orifice
containing a layer of ceramic fibre wool blanket. The lid itself is partly filled with hi temperature
refractory concrete. When the lid is located within the top thrust plate orifice this creates a seal.
During heat up or cool-down the seal is further improved by packing a circumferential layer of
wool between the lid and the top thrust plate circular orifice. The wool should be replaced as
necessary.
The top of the crucible is sealed from the main furnace body by layers of refractory wool, which
also act as thermal barriers. There are two layers between the top castable and the top thrust plate.
These are clamped down by the top thrust plate assembly. The gas seal thus effected ensures that
the inert gas atmosphere surrounding the crucible is maintained. The wool protects the steel thrust
plate from excessive heating and carburisation, which could occur by the contact between steel and
graphite at high temperatures. Replacement of these wool layers is only required at major
overhauls, strip-downs, or crucible exchange.
Page 21 of 146
When supplied the crucible bubbler feed tube should also be sealed using ceramic fibre wool
blanket. The wool should be tightly packed between the bubbler feed tube and the top thrust plate
orifice.
The furnace body to die seal is between the furnace body and the outer part of the die assembly.
The area is packed with refractory wool, which should be renewed each time the die assembly is
changed.
A graphite paper gasket is used to effect a molten metal seal between the crucible seal face and the
inner end of the die assembly. This seal is maintained by the uniform pressure applied by the die
thrust plate, at the front of the casting machine.
The power feed to the furnace is by graphite busbars at the rear of the body. These enter the
furnace through a Sindanyo insulation plate, which is sealed with ceramic fibre rope and heat-
resistant silicone rubber cement. The recesses in the Sindanyo, around the busbars are packed with
ceramic rope and silicone cement as above, to give a seal, which allows some movement and
expansion.
CRUCIBLE LINER
The top of the graphite crucible is normally protected from abrasion and oxidisation by a
replaceable clay graphite liner. Liner replacement is described in Section 7
COOLERS
When the casting machine is in production, molten metal flows from the crucible into the casting
die system, which normally is surrounded by fabricated coolers in which cooling water is
circulated.
All coolers must be pressure tested and examined for flaws before re-use. After a production run,
the used cooler must be cleaned. Refer to the appropriate chapter in Section 4 for supercoolers,
jacket and plate coolers.
TAP HOLE
Behind the tap-hole door is the tap-hole tube, which directs any molten metal leakage from the
furnace hearth to the dry dump box.
Such molten metal leakage can occur at the crucible to die seal, particularly at the start of a casting
run, if the die is incorrectly docked. If the die must be adjusted to correct this problem, adjustment
is carried out by alternate partially tightening and slackening of each of the nuts on the die thrust
plate.
CRUCIBLE REACTION THRUST

This consists of two robust graphite blocks extending from the rear of the crucible to the furnace
body via alumina plates, which prevent direct contact between the steel of the furnace wall and the
graphite thrust blocks. The purpose of the reaction thrusts is to stop the crucible sliding backwards
/ rotating, as the die is tightened up.
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The thyristor cabinet and hence the interconnected transformer cabinet requires a main supply
strictly in accordance with the specific rating plates appended.
Wiring diagrams are appended to this manual. All control instruments on this machine are single
phase 220V.
All internal wiring is completed at the Rautomead factory, leaving only a correctly fused and
protected mains supply as the customer’s responsibility.
All inter-link wiring between the furnace body, transformer cabinet, electrical control panel and
fluidics panel is supplied for the customer to use during the installation.
POWER PACK 3-PHASE 3-WIRE FURNACES
The furnace is powered by a thyristor transformer power pack, which feeds closely controlled
power to the furnace.
Low, safe furnace voltages are used, 15 to 30 volts, according to model. Primary volts are as stated
on the rating plates.
A thyristor of the appropriate voltage and current rating, is fitted to the primary supply of the
transformer.
A 0-10 volt DC signal, from the plc to the thyristor, controls the % power given to the furnace
heating elements.
A maintenance manual is supplied for the relevant thyristor.
The transformer is double-wound, air-cooled and should never be covered over or boxed in when in
operation. The power pack must be installed in an area where air can freely circulate free from
dusts, metal swarf particles and debris etc. Some heat can be expected from this unit as both the
transformer and thyristor warm up in operation.
NOTE: High-speed semiconductor fuses are fitted to the thyristors. It is important that
ordinary fuses are never used, only the correct ones as specified in the manual.
The transformer part of the power pack normally is of delta-star type, double wound, 3 phase
primary with an earthed screen between the windings.
Power output from the transformer is by heavy copper busbar coming through an insulated plate at
the front of the transformer cabinet. The secondary connections must be very clean and it is
important that all high current connections are checked regularly for overheating.
NOTE: The thyristor transformer power pack unit should never be operated without the
graphite heating elements being connected.
The furnace body and transformer cabinets must be correctly earthed.
TEMPERATURE CONTROLLER.
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A touchscreen / plc is used for temperature control of all models with ratings up to 1350C (2462 F).
It is an accurate and advanced technology instrument. The temperature sensor is a Type-R platinum
/ platinum-13% rhodium thermocouple / recrystallised alumina sheath assembly.
The thermocouple assembly is situated at the rear of the furnace, between the busbars.
Exceeding 1350C (2462 F) will damage the low thermal mass insulation modules.
TUNING FOR PRECISE TEMPERATURE CONTROL
In order for the Temperature Controller to function correctly it must be tuned to the response of the
furnace. The unit employs ‘Pid’ control method, which enables precise control of a wide range of
furnace types and power scales. Refer to Appendix IV
OVER-TEMP PROTECTION
The over-temp control monitors the furnace temperature via a second type ‘R’ thermocouple
assembly situated at the rear of the furnace. The over-temperature alarm should be set to about 20 to
30C above the maximum temperature set on the touchscreen. Should a fault develop causing an
uncontrolled temperature rise, the over- temperature protection will cut off power to the heating
elements at the pre-set temperature, preventing damage to the furnace interior through over-heating
and meltdown of insulation.
NOTE: It is critical that all temperature measuring and monitoring instruments are serviced,
checked and re-calibrated on a regular basis, as recommended by the manufacturer.
Instrument calibration drift may cause production or safety problems with the
equipment due to wrong temperatures being indicated.
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POWER MONITORING
Secondary volts and secondary amps are displayed on the touchscreen panel.
The power (kVA) as used by the heating elements can be observed on the touchscreen.
The power pack maximum rating should not be exceeded.
DIE TEMPERATURE MONITORING
The casting die temperatures are monitored using type K thermocouples situated within the casting
die assembly and displayed on the touch screen. The display has a range of 0-1200 deg C. The
temperatures indicate the die temperature when casting using either a jacket cooled or plate cooled
die assembly or a supercooler die assembly. Note this temperature is indicative of temperatures of
the metal. It is used to indicate metal fluidity in the die in-gate and stability during casting. It is not
the actual temperature of the die at casting front or of the metal. Its interpretation must be done with
this in mind.
WITHDRAWAL UNIT CONTROLS ; AC SERVO DRIVE
The withdrawal power unit is controlled electronically which enables the withdrawal to be operated
in a variety of ON-OFF or GO-STOP type of motions. This is to give the required pulsing
withdrawal unit condition necessary for the correct pulling or extraction of the as-cast rod, strip or
tube for a given alloy.
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2.4 ALARMS
The following alarms are monitored and acknowledged via the touchscreen :
Low High Danger Deviation Deviation

Low High
Furnace √ √ √
Overtemp√ √ √ √
Die No1 to No4 √ √ √
Die Water No1 to No8 √ √ √
Clamp 1 & 2 √ √ √
Probe 1 & 2 √ √ √
Tracing √ √ √
Water Inlet √ √ √
Transformer √ √ √
Transformer Trips √
Thyristor Cabinet Temp √
Water Pressure √ typically set at 3.75 Bar (54 psi)

Nitrogen Pressure √ typically set at 1.50 Bar (22 psi)
Air Pressure √ typically set at 4.75 Bar (69 psi)
If any of the above listed alarm conditions occurs then the beacon on the top of main control panel
will light and the siren will sound. To acknowledge the alarm the “Accept Alarm” button should be
pressed. If the fault that caused the alarm remains the indicator will then become green and the siren
will be silenced. The alarm will only clear if remedial action has removed the fault. The beacon will
then cease flashing and the indicator background will revert back to the magenta colour. (If the fault
that caused the alarm has been removed before the “Alarm Accept” button has been pressed the
alarm status will remain although the display box will have changed from red to yellow.)
NOTE :
If any of the highlighted alarms listed above are activated then the power to the furnace heating
elements will automatically be switched off until the alarm condition is rectified at which point the
power to the furnace heating elements will automatically be restored. During the period that the
furnace heating elements are switched off the furnace temperature will decrease.
All the other alarms will activate the beacon and siren but will not switch off the power to the
heating elements.
DETECTING BREAKS IN THE CAST SECTION
The low die temp alarm can be used to detect breakages in cast sections. The setpoint for this alarm
is best set once the casting speed has reached its maximum value.
For rod, strip or tube breakage refer to the appropriate chapter in Section 6.0
2.5 INERT GAS
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Gas flow meters are provided to adjust and monitor the flow of nitrogen or argon to the casting
machine body, the casting die assembly and to the liquid metal crucible bubbler if fitted.
An sensitive pressure gauge measures the internal furnace pressure. The flow through the casting
machine furnace flowmeter should be adjusted to give a small positive reading on the furnace
pressure gauge.
The flow to the die should normally be set at 0.5 to 1 litre per minute or as experience dictates.
Excessive flows to the die should be avoided, as this can cause gas defects on the product surface as
it is cast.
The bubbler (if fitted) flow should be adjusted to give proper degassing and mixing of the melt, but
not so vigorous as to cause splashing at the top of the melt.
Proper attention to the sealing of the furnace body at the various access points will ensure economic
usage of inert gas.
Serious damage can occur due to graphite oxidisation if the inert gas supply is discontinued for any
length of time while the furnace is above 350C ( 662F ). If gas does fail, do not open the tap hole to
maintain gases in the furnace the elements will self protect by forming carbon monoxide for a short
time. If the furnace must be dumped turn off open the tap hole dump the furnace and close the tap
hole quickly to reduce erosion.
If a gas supply failure is anticipated, time must be allowed for the furnace temperature to fall from,
say 1250C ( 2282F ) to below a safe temperature of 350C ( 662F ).
NITROGEN
Nitrogen should be supplied from a bulk liquid or cylinder supply. The line feed pressure should be
regulated to around 35-40 psi (2.0 - 2.75 bar).
The suitable grade is Oxygen Free Nitrogen gas with specification < 5 vpm oxygen , < 2 vpm
moisture and better than -70 deg C dewpoint.
NOTE: Do not feed nitrogen gas bubble through copper alloys containing - Ti, B, Ni, Cr,
Zr, Be or Mg because these elements react with nitrogen at high temperatures
forming nitrides. With these materials, argon must be used.
ARGON
Argon, when used, should be to a similar high quality specification as nitrogen above.
2.6 GRAPHITE
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The Rautomead continuous casting machine incorporates many graphite components. This material
is used on account of its versatility and strength at elevated temperatures. Great care must
nevertheless be taken to avoid oxidation on exposure to air. It is for this reason the continuous
casting machine is fully protected internally by an inert gas atmosphere, which must be maintained
at all times, both to the main body and to the casting die while the machine is under heat, and above
350C ( 662F ).
MECHANICAL DAMAGE
Mechanical damage could occur in all strand back-tapping operations referred to in this Manual.
Excessive hammering will lead to breakage of graphite parts and consequential stoppages of
production. When back-tapping a strand section, firm hand-held cushioning support must be
applied to the strand just in front of the graphite casting die assembly to give a firm steady and to
prevent excessive vibration which could cause serious damage.
STORAGE OF GRAPHITE CASTING INSERTS AND DIES
NOTE: All graphite should be stored in a dry, clean area to ensure that no moisture pick up
occurs. Moisture ingression into casting dies can seriously impair their performance
and lead to premature failure.
Before their use, it should be ascertained that the casting inserts and dies are completely dry.
If damp or wet graphite casting inserts and dies should be intensively dried before using in the
casting machine. The following drying and conditioning periods are recommended:
12 hours at 175C (350F) or 24 hours at 115C (240F)
Moisture in the die, from adverse storage or transport conditions, can lead to difficulties at the start
of casting.
Refer also to the SAFETY PROCEDURES in Section 8 of this manual.
DUMP BOXES
The dump box is used to collect any molten metal, which may leak from the crucible or the
complete charge if the crucible has to be emptied. It is essential that the dump box refractory
material is completely dry and the dry out procedure, refer to Section 8, must be followed before
use.
2.8 STARTER BARS
In essence, the starter bar is a device used to connect the solidifying metal to the withdrawal unit
and a number of styles can be used when casting precious metals.
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a. Steel slave bar tipped with precious metal.

b. Steel slave bar and precious metal starter bar.
c. Mild steel starter bars featuring “key design”, coated with graphite or ceramic paint.
Ideally, the starter bar should have the same chemical composition as the metal being cast but for
economic reasons the precious metal starter bar is made usually shorter than the die and attached by
screws to a steel slave bar. The slave bar can be used with several re-useable starter bars having
different compositions.
Rautomead has used mild steel starter bars which have a ‘key’ machined at the hot end into which
the metal flows, solidifies and joins onto the steel bar. We have used graphite paint and a number
of ceramic paints to coat the hot end in order to stop the cast metal welding to the steel but they are
not always reliable or totally successful.
If a single steel bar is used a short length of the precious metal is left attached to the steel which is
machined to the correct size before use. Separate steel starter bars are therefore required for each
size and alloy.
NOTE: Stainless steel starter bars should not be used because complex metallic carbides
can be formed on the steel which adversely affect the adhesion of the metal to the
starter bar.
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The initial stages of continuous casting involves a gradual increase in casting speed from a typical
starting point of 25 to 50mm per minute ( 1 to 2 inches / minute ) to a production speed that equates
to an output kg / hour ( lbs / hour) slightly less than the integrated melting rate of the casting
machine for a particular alloy.
During this period the casting front within the casting die is advancing towards the die exit until it
reaches a point of thermal equilibrium.
At the desired production rate the machine should cast reliably for several hours providing there are
no thermal or downstream disturbances. However, due to the nature of continuous casting, wear
occurs at the ‘break-off’ point within the casting die.
As wear builds up it will reach the extent where it affects the quality of the as-cast product which is
usually indicated by scoring lines, and pulse cracking. When the wear becomes most significant,
the withdrawal unit loading increases and there is a great risk of breakages occurring. To prevent
this happening, the casting front must be moved to a cleaner section of the casting die, maximising
the casting die life and hence maintaining casting quality and production.
The internal surface of the casting die behind the casting front is protected by molten metal and thus
relatively new. In order to move the front back-up the casting die, less heat must be removed by
reducing the casting speed and or reducing the furnace temperature. It is not normally
recommended that the melt temperatures be altered but in certain circumstances, where there is
sufficient superheat, eg. 338 C ( 640F ) for AuSn alloys, this may be possible in three 30C ( 86F )
reductions.
When the casting speed reaches an uneconomical level, the machine should be shut down and new
supercooler or die tooling assemblies fitted.
While the new supercooler tooling assembly is in operation, the worn casting insert can be
refurbished by precision reaming to remove any scoring, burn marks etc. All the packer inserts
should then be reamed likewise so that their internal diameters are identical to that of the casting
insert.
Strip die halves should be refurbished by a combination of grinding and or milling in order to
restore the original surface finish to the casting orifice. In order to maintain the original as-cast
thickness of the strip during subsequent casts it will be necessary to also machine the sealing
surfaces of the top half of the casting die. Remember that the top half of the casting die has a taper
machined in it over its entire length.
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3.1 FURNACE BODY DRY-OUT - RT MACHINES

3.2 FURNACE BUILD - FITTING THE HEATING ELEMENTS
3.3 FURNACE BUILD - FITTING THE CRUCIBLE AND SEALING THE FURNACE
Page 31 of 146
3.1 FURNACE BODY DRY-OUT
The following procedure is carried out at the Rautomead factory prior to setting up the machine for
its first casting run in order to ensure that any residual moisture from the internal components is
removed thereby minimising erosion damage to any of the graphite parts.
This procedure can also be used when the refractory lining of the furnace body is completely rebuilt
at a future date by the customer.
Moisture comes from refractories drying out and must be eliminated totally before temperatures in
excess of 700C ( 1292F ) are reached.
Above 700C ( 1292F ) temperature the water gas reaction occurs with and erodes graphite
components forming hydrogen and carbon monoxide.
C + H2O > H2 + CO
It is important to vent these gases by periodically opening the taphole.
Carry out an element check first and note the power readings.
It is assumed that the machine has been rebuilt at this stage as per the procedure in Sections 3.3,
with the top thrust plate being fully tightened down.
NOTE: When working on the furnace body ensure that the appropriate protective clothing,
respiratory mask and gloves are worn.
It is assumed that the operator is completely familiar with the operation and
adjustment of the touch screen temperature controller.
1. Protect each crucible sealface by placing two tightly fitting pieces of graphite paper into each
crucible socket, ensuring that they make good contact with the sealface.
2. Then fit similar tight fitting layers of ceramic fibre blanket wool until the crucible sockets are
completely filled. This will minimise the risk of sealface damage due to moisture attack during
the dryout.
3. Then fit a piece of ceramic fibre blanket wool in front of the crucible (resting on top of the die
heater) which covers the crucible socket thereby preventing the packing within the socket from
falling out. Repeat with subsequent sockets as applicable.
4. Seal up the front plate orifice by cutting and then fitting a piece of insulation wool (swiss roll
style), so that it touches the piece of ceramic fibre blanket wool in front of the crucible and then
pack with strips of ceramic fibre wool packed tightly around its circumference. The length of
this “swiss roll “
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piece should come to within 25mm of the front plate flange outermost edge. Finally fit a disc of
ceramic fibre blanket wool so as to pack out the front plate to its outermost flange edge. Repeat
with second orifice if applicable.
5. Fit a further two layers of ceramic fibre blanket, slightly larger than the front plate flange,
followed by a similar size piece of mild steel plate and the die thrust plate with its M24 nut and
disc spring assemblies. Repeat with second orifice if applicable. Tighten all the M24 nuts until
the outermost layers of ceramic fibre blanket are firmly compressed thereby providing a gas
tight seal.
6. Partially close the top thrust plate charging lid allowing a small gap for venting off any trapped
moisture.
7. Refit the side door insulation modules in reverse sequence along with strips of ceramic fibre
blanket packed in between the modules but not above them so as to allow any trapped moisture
to vent off.
8. Repair or replace the ceramic fibre rope side door seal as required.
9. Fit the three layers of ceramic fibre blanket ensuring that a venting gap is maintained at the top
thereby allowing any trapped moisture to vent off. Then loosely fit the side doors but do not fit
the securing bolts.
10. Remove each of the vent grub screws above the side door flanges.
NOTE: These vent grub screws are only refitted, with pipe sealant, once the dry-out
procedure for the furnace body has been completed.
11. Fit a new piece of ceramic fibre blanket behind the taphole door and then close.
12. Disconnect the furnace body pressure gauge pipe, which is situated at the rear of the furnace
body, just above the uppermost water tracing panel.
NOTE: This pipe is refitted once the dryout procedure for the furnace body has been
completed.
13. Turn on nitrogen flow to the furnace body and bubbler [ if fitted ] and set the flowmeters to
approximately 10 l/min and 2 l/min respectively.
14. Visually check using the flow meter that water is flowing steadily through the furnace body
tracing, busbar terminal clamps and busbar probes at the required rate. Repair any leaks as
required.
15. Turn off the furnace body water tracing flowmeter at this stage, using the appropriate valves
within the fluidics panel.
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NOTE: Later on during the dry-out it will be necessary to turn on the water flow to the
furnace body tracing once the internal furnace temperature has reached
700C(1292F).
16. Switch on the primary electrical power to the machine transformer using the factory wall
isolator.
17. Switch on the electrical power to the electrical control panel using isolator at the side of the
panel.
18. On the touch screen set the set point to 300C , ramp to 130C/hour and the power limit to 50%.
After a few seconds delay the heating elements will begin to burst fire as indicated on the
power monitor.
19. Maintain the ‘Target setpoint’ temperature of 300C for 12 hours.
20. Seal up the furnace body side doors:
a. In order to minimise electrical shock risk, reduce the setpoint to ZERO and switch off the
electrical control panel.
b. Remove the side doors and the three layers of ceramic fibre blanket.
c. Seal above all the insulation modules with strips of ceramic fibre wool.
d. Tightly refit the three layers of ceramic fibre blanket.
e. Refit the side doors and tighten all the securing bolts evenly so as to ensure a gas tight seal,
thereby avoiding severe damage to the internal graphite parts due to ingress of air during
machine heat-up.
f. Switch on the electrical control panel and reset the setpoint to 300C.
21. Seal up the top thrust plate charging lid by fully closing it and then packing around its
circumference with ceramic fibre wool to ensure a gas tight seal, thereby avoiding a possible
chimney effect, that will severely damage the internal graphite parts due to ingress of air during
machine heat-up.
22. From now on regular checks should be made for moisture formation as the furnace temperature
is increased.
23. Venting the taphole and the crucible lid, periodically, during the dry out can assist in moisture
removal. Moisture comes from refractories drying out and must be eliminated totally before
temperatures in excess of 650 - 700C are reached. Once the temperature is above 380C the
taphole does not need such frequent venting of gases.
24. On the touch screen set the set point to 650C , ramp to 90C/hour and the power limit to 100%.
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25. Once the setpoint has reached 650C (1202F) fully turn on the furnace body water tracing using
the appropriate valves on the fluidics inlet and outlet manifolds. Check flow rates and repair any
leaks as required.
26. The remaining dry-out procedure is now carried out by setting the final setpoint of 1000C
Setpoint = 1000C
Ramp = 90C / hour
Output limit = 100%
The furnace temperature will now rise at a steady rate of 90C / hour until a temperature of 1000
C is reached 4 hours later.
27. Once the furnace temperature has reached 1000C the furnace power should be switched off as
detailed below:
Setpoint = 0
Ramp = 0
28. Maintain full water flowrates for the furnace body tracing, busbar terminal clamps and busbar
probes during the furnace body cool down and thereafter indefinitely for future casts.
29. Once the furnace temperature has decreased to 350C (662F) then the nitrogen flow to the
furnace body and bubbler [ if fitted ] may be turned OFF.
30. Switch OFF the electrical control panel by means of the isolator.
31. Strip down the furnace body for accelerated cool down and inspecting the internal parts by:
a. Open the top thrust plate charge lid.
b. Fully open the taphole inspection door.
c. Unbolt and then remove the side doors along with all the layers of ceramic fibre blanket and
insulation modules contained therein.
d. Slacken then remove all the M24 nuts and disc spring assemblies from the front plate studs
followed by the die thrust plate and the mild steel backing plate.
e. Remove all the layers of ceramic fibre blanket and pieces of insulation modules contained
therein.
f. Carefully remove from the crucible socket the plug of ceramic fibre blanket wool followed
by the layers of graphite paper contained therein. Carefully remove any debris using a
vacuum, then inspect the crucible sealfaces and repair or remachine as required.
32. Refit each vent grub screw, using pipe sealant, above the side door flanges.
33. Reconnect the furnace body pressure gauge pipe, which is situated at the rear of the furnace
body.
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34. During normal machine operation a small pressure should be shown on the furnace pressure
gauge. If no pressure is detected then there is a leak and all seals should be improved until a
seal is obtained.
3.2 FURNACE BUILD - FITTING AND TESTING THE HEATING ELEMENTS
Examine all heating elements, studs, nuts and graphite paper washers for signs of wear and replace
as necessary. When in doubt, replace defective parts. When possible check the condition of the
heating elements and nut tightness weekly.
First visually check on the condition of all the heating elements. Elements that are severely
corroded or have reduced in cross sectional area (approx 20%) should be replaced, as they will
reduce the performance of the furnace.
To remove an element, remove the graphite nuts and washers retaining it. The graphite washers
should be discarded at this time.
Insert the new element, new graphite washers and tighten the graphite nuts to finger tight. Check
that every graphite nut in the furnace element chain is finger tight.
Once satisfied that all the elements are tight and all replacements have been carried out, the
elements should then be tested.
ELEMENT TEST
a. Switch on all water to the furnace body tracing, the busbar cooling probes and busbar
terminal clamps.
b. Switch on the primary electrical power to the machine using the factory wall isolator.
c. On the temperature controller select manual and then set the output power to 50%
After a few seconds delay the heating elements will begin to fire as indicated on the power monitor
screen.
Watch the furnace heating elements. If there are any hot spots or arcing evident, switch off the
furnace immediately and check on the condition of the offending element or connection. If no
problems are evident continue watching the elements until some start turning a dull red colour.
From the recorded secondary amps and volts, determine and also record the power in kVA. During
test heat, do not allow the elements to reach red heat with the furnace open, otherwise oxidation
damage will occur. At this stage the output power must be set to zero.
3.3 FURNACE BUILD – FITTING THE CRUCIBLE and SEALING THE FURNACE
NOTE : Prior to furnace rebuild ensure that the appropriate protective clothing, respiratory
mask and gloves are worn.
Page 36 of 146
Assuming that the furnace body has been fully cooled down to room temperature and stripped with
all the tooling removed :
 Fit the crucible, and the upper build, as per the furnace internal build drawings and ensure that its
left to right alignment is correct for the subsequent fitting of the heating elements and casting die
assembly.
The following procedure assumes that :
a. The furnace body has been cooled down to room temperature.

b. The casting die assembly has been previously removed as detailed in section 4.
1. Carefully remove the old graphite paper gasket from the crucible die socket along with any
remaining metal residue.
2. Using a vacuum cleaner carefully clean the internals of the crucible assembly by gaining access
through the top sealing lid and the front plate orifice. Care should be taken not to damage or
mark the sealface area of the graphite crucible.
2. Remove any remaining ceramic fibre wool and metal residue from just inside the front plate
orifice.
3. Once thoroughly clean check alignment of the crucible socket centre line to the furnace body
front plate to ensure it has not been disturbed during removal of the casting die assembly.
4. Check that the rear of the crucible assembly is still making contact with the graphite crucible
thrust blocks.
5. Replace the casting die assembly as detailed in the section 4.
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4.0 CASTING DIE ASSEMBLY
4.1 JACKET COOLED DIE TOOLING - MAINTENANCE OF JACKET COOLERS
4.2 ROD DIE TOOLING - ASSEMBLY OF JACKET COOLER WITH CASTING DIE
AND FEEDER TUBE
MACHINE
4.4 ROD DIE TOOLING - REMOVING THE ROD DIE ASSEMBLY FROM THE
CASTING MACHINE
4.5 ROD DIE TOOLING - DISMANTLING THE ROD DIE ASSEMBLY
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4.1 JACKET COOLED DIE TOOLING - MAINTAINCE OF JACKET COOLERS
The following procedure refers to the following jacket cooler-die assembly drawings ;
RD17446-1 , Die Body (Dia 4.000” Rod) & 125mm Series Jacket Cooler
This procedure equally applies to other sizes of this type of rod die assembly. Refer to the
applicable drawing when identifying replacement parts for jacket coolers other than this one.
a) Dismantle the jacket cooler assembly by removing all the brass fittings screwed into it.
b) A scale build up seriously affects the effectiveness of heat abstraction from any cooler system.
A check should also be made with the water treatment supplier to see if a water recirculation
additive can be made which will completely prevent the deposition of scales.
c) If scale is suspected to be within the plate cooler it must be removed by the following method.
Using a 10% by weight water solution of citric or tartaric acid crystals (these organic acids
dissolve readily in cold clean water), add the resulting solution to the jacket cooler waterways
and continue to add until all the scale is removed. Lime scales consist of mainly calcium
carbonate and evolution of carbon dioxide gas will occur from the scale as it breaks down and is
removed by the organic acid solution.
d) When effervescence is complete, the scale will be all removed. Flush out the jacket cooler with
fresh water and dry off.
NOTE : There are no health and safety issues associated with the use of these organic acid
solutions, as there is also no known environmental impact on low quantities of
dilute discharges to mains sewer systems.
e) Reassemble the jacket cooler assembly by refitting all the brass fittings using fresh folded copper
washers and pipe sealant as detailed in the drawing.
f) Pressure test the jacket cooler at 11 Bar (160 psi) for 1 hour with no leaks or pressure drop
permitted prior to assembling onto the casting die assembly.
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4.2 ROD DIE TOOLING - ASSEMBLY OF JACKET COOLER WITH CASTING DIE
AND FEEDER TUBE
The following procedure refers to the jacket cooler-die assembly drawing RD17446-1 [Dia 4.000”
Rod Die Body & 150mm Series Jacket Cooler] and Appendix 7 , Jacket Cooler Setting.
This procedure equally applies to other rod sizes using this design of jacket cooler / casting die.
Refer to the applicable drawing when identifying replacement parts for tooling assemblies other
than this one.
a) Carefully inspect all the parts that are to be assembled and replace, refurbish as required.
b) Machine the taper on the graphite die body, to suit the jacket cooler assembly, as shown on
drawing RD17446-1 and fully detailed in Appendix 7 , Jacket Cooler Setting.
c) Heat up the jacket cooler assembly, and fit onto the die body, as shown on drawing RD17446-1
and fully detailed in Appendix 7 , Jacket Cooler Setting.
Do not exceed the temperature stated as otherwise the pipe sealant could degenerate.
NOTE : The jacket cooler must have been previously pressure tested before assembly onto the
casting die. The pressure test is 11 Bar (160psi) for 1 hour with no leaks or pressure drop permitted.
d) Inspect the seal faces and clamp screw holes of the feeder tube RD17444-1. Repair / replace as
required.
e) Inspect the 4 feeder tube graphite clamp screws, RD2252-2, and replace as required.
f) Fit the 4 graphite clamp screws into the feeder tube. They should be easy to rotate. If not replace
faulty screws as required. Remove all screws prior to assembly.
g) Cut and fit a secure fitting feeder tube internal seal face gasket from 1.0mm thick graphite paper.
h) Place the feeder tube on a bench with the internal sealface uppermost. Avoid damaging the
external hot end sealface by covering the bench with cardboard or a rubber mat.
i) Then carefully lift the die body / jacket cooler assembly and insert it into the feeder tube until it
is resting on top of the internal sealface gasket.
j) Rotate the die body / jacket cooler assembly within the feeder tube so that the four flat contact
surfaces of the die body are perpendicularly aligned with respect to the threaded clamp screw
holes in the feeder tube. Insert each clamp screws into the feeder tube until it just touches the flat
contact surface of the die body.
k) Gradually tighten the clamp screws in an even manner until they are firmly gripping the die
body.
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l) Blow the assembly through with compressed air to remove any loose particles and check for
overall cleanliness. Loose particles can quickly damage the casting die during casting and
therefore are best eliminated.
m) Fit the 8 probe cooler assemblies, as per the assembly drawing RD16503-1, into the jacket cooler
fittings. Orientate the assemblies and the individual fittings as required, to suit braided hose
routing, and then tighten.
n) The assembly of the rod casting die is now completed and ready for insertion into the casting
machine.
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MACHINE
The following procedures refers to the fitting of the completely assembled rod casting die, as per
RD17443-1 & -2 and section 4.2, into the casting machine. Reference to detail numbers is from
drawings RD17443-1 & -2. This procedure equally applies to other sizes of this type of rod die
assembly.
NOTE:
It is assumed that the crucible is centrally located with respect to the furnace body front plate such
that the collar thrust plate, detail 10, when fitted onto the casting die assembly, does not make
contact with any of the M24 studs, detail 11, that pass through it. If not then the crucible has to be
moved left or right to suit.
a) Inspect the seal face of the crucible and carefully clean as required. If the sealface is damaged
then remove the crucible and re-machine the sealface to remove any surface defects. Remove
the minimum amount of material possible. The re-machined crucible sealface must be parallel
to the rear surface, and perpendicular to the base of the crucible body.
b) Carefully cut and the fit a graphite paper gasket to suit the crucible sealface. This requires to be
accurately cut so that it does not fall out.
c) When handling the die assembly take care not to damage the feeder tube hot end sealing face.
With the help of a second person and docking aid/s insert the die assembly into the crucible
socket taking care not to disturb the graphite paper gasket and the die heater element. Ensure
correct orientation i.e. thermocouple hole at bottom.
d) Temporarily support the die assembly by raising both of the die support screws so that they just
touch the jacket cooler thereby locating / supporting it in position.
e) Support the die assembly in the initial position whilst the second person slightly lowers both
the die support screws.
f) Dock the die assembly against the crucible using a rocking action until the ‘dock’ is felt. While
this position is held a second person should adjust the two die support screws so that they just
touch the jacket cooler thereby locating it in position and supporting its weight.
g) Check to see that a minimum clearance of 3mm exists between the feeder tube of the die
assembly and the die heater element.
h) Open the taphole and using a torch check that the crucible sealface gasket has not fallen out of
the crucible die socket during feeder tube insertion. If the gasket has fallen out then remove the
die assembly, replace the gasket if in good condition and then repeat the previous steps again.
i) Locate the thrust collar, detail 9, onto the cold end of the casting die body.
NOTE : Ensure correct orientation of the Thermocouple / Nitrogen Gas feed pipe holes with
respect to the matching holes in the die body.
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j) Place the collar thrust plate, detail 10, over the front plate studs and locate onto the end of the
thrust collar ensuring that clearance is maintained between the front plate studs and their
corresponding holes in the collar thrust plate. If there is not, and as the nuts are tightened, the
dock will be lost and molten metal will escape from the crucible. Adjust the holes of the collar
thrust plate or crucible position if required.
k) Fit the M24 “nut assembly” parts in the following order onto each M24 stud.
Details 14 , 13 , 13 , 14 , & 12
The two details 13 should be fitted “base to base” to allow for thermal expansion / contraction.
Ensure that clearance is maintained between the M24 front plate studs and their corresponding slots in
the collar thrust plate. Then tighten the M24 nuts in a diagonal 1-3, 2-4 diagonal pattern to the correct
torque. If the furnace side doors are removed check that the crucible is uniformly thrust against the
thrust blocks at the rear of the furnace. If the thrust blocks / spacers are not correctly making contact
with the rear of the crucible then slacken off the crucible thrust plate nut assemblies and adjust as
required before retightening.
l) If necessary tighten the top thrust plate nuts to the required torque so as to stabilise the crucible
and provide the nitrogen seal.
m) Pack around the jacket cooler with ceramic fibre wool ramming well into the gap between it
and the front plate in order to form a good nitrogen seal. Ensure the ceramic fibre wool packing
has a gap between it and the feeder tube of 50mm thereby not interfering with the undocking of
the casting die assembly at the end of a casting campaign. If the two support screws where
lowered during wool packing , for better access , ensure that they are now raised so that they
just touch the jacket cooler and locate it in the docked position.
n) Carefully fit and tighten all the water Inlet (12mm) , Link (12mm) and Outlet (16mm) hoses
onto the respective probe cooler fittings. [Link” refers to the use of a short interconnecting
hose.] Connect the quick release end of each hose as required and then turn on the water to
each probe cooler. Check that the correct flowrate is established and that there are no leaks.
Repair any leaks as required.
Now that the jacket cooler is fitted into the machine always leave it connected
to the water supply. Do not turn off the water as forgetting to turn the water on
before heating up the furnace will seriously damage the jacket cooler.
o) Assemble the starter bar and slave bar, as per drawing RD17449-1 Remove all sharp edges
from the starter bar, which could scrape the die and remove any marks with fine emery paper.
Fit the assembly into the withdrawal unit. Mark on the insertion depth (die body casting orifice
+ thrust collar length – 3mm) and note on the data sheet. The -3mm is so a 3mm thermal
expansion gap exists between the end of the starter bar and the feeder tube internal sealface .
Bostik Neverseez is good for the slave bar stud threads to aid disassembly. Using a spirit level,
level the assembly within the withdrawal unit.
p) For small / light weight rod sections the starter bar / slave bar assembly can be moved by hand
towards / within the casting die assembly by raising the withdrawal unit top pinch rolls and
then reclamping after movement. However for large / heavy weight rod sections the starter bar /
slave bar assembly can be moved by using the withdrawal unit motor to reverse the starter bar /
slave bar assembly towards / within the casting die assembly.
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q) For very large rod casting using a roller support close to the die will reduce the amount of
bending due to the starter bar / slave bar assembly being unsupported between withdrawal unit
and the die. NOTE ; Its height may have to be adjusted if any of the withdrawal unit
adjustments listed below are made.
r) Check and make the following adjustments whilst approaching or within the casting die orifice :
[1] The level of the starter bar / slave bar assembly.

Adjust the height of the front & rear withdrawal unit arms to suit.
[2] The side gap (left & right) between starter bar / slave bar assembly and the casting die
orifice / thrust collar orifice . Move the withdrawal unit left or right to suit.
[3] The top and bottom gap between starter bar / slave bar assembly and the casting die orifice /
thrust collar orifice. Evenly adjust the height of the front & rear withdrawal unit arms to
suit. Recheck the level of the starter bar / slave bar assembly.
[4] The squareness (left & right sides) of the starter bar / slave bar assembly with respect to the
die thrust plate. Not exact science this measurement as the thrust plate may not me exactly
flat but worth checking with the 6” Engineers Square.
Rotate the withdrawal unit, on the plinth, clockwise or anticlockwise to suit.
[5] Keep slowly moving the starter bar / slave bar assembly into the casting die orifice until the
insertion depth mark has been reached. This should give a starter bar position 3mm from
the hot end of the casting die orifice. Constantly observe the circumferential gap between
the starter bar / slave bar assembly and the casting die orifice / thrust collar orifice.
Periodically stop and recheck points [1] to [4] above. Finally recheck points [1] to [4]
above once the securing bolts between withdrawal unit and plinth are tightened.
NOTE ; Remember to set to zero all touch screen withdrawal unit “PUSH”
parameters when the insertion depth mark has been reached.
In summary :
Ideally the following should be achieved during and at the completion of the starter bar / slave
bar assembly insertion into the casting die orifice.
The starter bar / slave bar assembly is level.
The circumferential gap between the starter bar / slave bar assembly and the casting die orifice
/ thrust collar orifice is even.
The squareness (left & right sides) of the starter bar / slave bar assembly with respect to the die
thrust plate is acceptable.
s) Seal around the starter bar / slave bar assembly at the front face of the thrust collar with
silicone sealant.
t) Fit the withdrawal unit reaction thrust bar assembly, RD9829-1 , between the furnace body and
the withdrawal unit.
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u) Fit the Thermocouple & Inert Gas Feed Assembly pipe, detail 16, into the bottom hole at the
front of the rod die. The stainless steel tube end circumference should be covered with silicon
sealant before insertion. The thermocouple is then inserted to the required depth, refer to
section 5.7 , and sealed in position with silicone sealant.
v) Fit the Inert Gas Feed Assembly, detail 17, into the top hole at the front of the rod die. The
stainless steel tube end circumference should be covered with silicon sealant before insertion.
w) Turn on the Nitrogen to the T/C Nitro Assembly and the Inert Gas Feed Assembly at the
appropriate flow meter in order to check for flow and leaks. Turn off the gas until machine is to
be heated.
x) Once the fitting of the rod die assembly has reached this stage the casting machine is now
ready for heating up.
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4.4 ROD DIE TOOLING - REMOVING THE ROD DIE ASSEMBLY FROM THE
CASTING MACHINE
Reference to detail numbers is from drawings RD17443-1 & -2. This procedure equally applies to
other sizes of this type of rod die assembly.
The following procedure assumes that the casting machine crucible has successfully been emptied
of molten metal at the end of a casting campaign and that the die assembly has been undocked from
the crucible and the machine has now cooled to room temperature.
a) Shut off all the furnace , die and crucible bubbler nitrogen flowmeters.
b) Remove the withdrawal unit reaction thrust bar from between the furnace body and the
withdrawal unit.
c) Remove the type K thermocouple and Inert Gas Feed Assemblies from the front of the die
body.
d) Remove the plug, from the casting orifice, that has been used to seal up the die at the end of a
casting campaign.
e) Remove all the M24 nut assemblies followed by the collar thrust plate and thrust collar.
f) Remove all the ceramic fibre wool packing from around the jacket cooler.
g) Terminate the water flow to each of the jacket cooler inlet and outlet connections via the
appropriate valves on the die fluidics panel.
h) Disconnect each inlet and outlet jacket cooler water hose at the appropriate quick release
connector on the front wings.
i) With the help of a second person insert the docking aids so that they are underneath the jacket
cooler.
j) Lower both of the die support screws so that they are not making contact with the jacket cooler.
This will let the jacket cooler make contact with the die docking aids.
k) Carefully withdraw the die assembly clear of the furnace body and store in a place of safety.
When handling the die assembly take care not to damage the feeder tube hot end sealing face.
l) Inspect the die assembly for signs of damage and repair / renew any parts as required upon
dismantling.
m) Remove any remaining ceramic fibre wool packing from the front plate.
n) Remove the graphite paper gasket from the crucible sealface along with any remaining loose
pieces of metal. Inspect the crucible sealface for signs of damage and repair as required.
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4.5 DISMANTLING OF THE ROD DIE ASSEMBLY
The following procedure refers to the jacket cooler-die assembly drawing RD17446-1 [Dia 4.000”
Rod Die Body & 150mm Series Jacket Cooler] and Appendix 7 , Jacket Cooler Setting.
This procedure equally applies to other rod sizes using this design of jacket cooler / casting die.
Refer to the applicable drawing when identifying replacement parts for tooling assemblies other
than this one.
a) On a bench with the casting die assembly in its normal horizontal orientation remove all of the
water Inlet (12mm) , Link (12mm) and Outlet (16mm) hoses from their respective probe cooler
fittings. [Link” refers to the use of a short interconnecting hose.]
b) Then using 2 spanners remove all of the six probe cooler assemblies , 4 Off RD 11224-1 and 4
Off RD 11217-1 , that are fitted in an alternating pattern around the jacket cooler fittings. Use 2
spanners to avoid disturbing the remaining fitting that is directly screwed into the jacket cooler.
Carefully drain any remaining water from the jacket cooler whilst avoiding any entering the
casting die orifices.
c) Fully slacken the four graphite clamp screws located within the feeder tube and withdraw the
die body / jacket cooler assembly from the feeder tube followed by the internal sealface gasket.
d) If the jacket cooler has to be removed from the die body then follow the disassembly procedure
in Appendix 7.
e) Inspect the die body , feeder tube and the jacket cooler and then refurbish / repair or replace
parts as required.
f) Pressure test the jacket cooler for one hour at 11 Bar with no leak or pressure drop permitted
prior to assembly for the next cast.
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5.1 CAST AND SHUTDOWN OVERVIEW

5.2 SWITCH ON POWER
5.3 DIE TIGHTENING
5.12 RAISING THE CASTING SPEED AFTER START-UP, AC DIRECT CONTROL DRIVE
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5.1 CAST START UP AND SHUTDOWN OVERVIEW
FOR QUICK REFERENCE ONLY
NOTE: REFER TO LATER SECTIONS FOR MORE DETAILED INSTRUCTIONS
It is assumed that the machine has been rebuilt at this stage as per the procedure detailed in Section
3.0 and the required tooling assembly has been previously assembled as per Sections 4.0 and fitted
into the casting machine.
Prior to switching on the furnace, the following list of checks must be made:
1. Connect and turn on WATER cooling system including the fan cooling and ensure that all the
appropriate water flowmeters have sufficient water flowing through with no leaks in the system.
Furnace Body Tracing

Busbar Terminal Clamps
Busbar Probes
Die tooling
2. Turn on air supply to the withdrawal unit.
3. Remove all sharp edges from the starter bar, which could scrape the die and remove any marks
with fine emery paper. Coat the hot end of the parent metal starter bar with graphite paint (DAG
lubricant). If using starter bars made from mild steel strip then coat them with ceramic paint,
Fibrefrax paper and masking tape
4. Calculate the required insertion depth of the starter bar into the die assembly and then mark this
distance onto the starter bar.
5. Carefully insert the starter bar assembly into the die assembly until it reaches the required depth
whilst maintaining its alignment with respect to the casting die orifice and the withdrawal unit.
Then clamp the starter bar assembly between the pinch rolls. Repeat for multiple strands.
6. Ensure the starter bars are 'sealed' to the die exit orifices with heat resisting silicone rubber
sealant
7. Turn on the NITROGEN and set each of the following nitrogen flowrates on the respective
flowmeter, depending on what casting tooling has been fitted.
Furnace Body to achieve and maintain a slight positive pressure, approximately 10 litres /
minute.
Supercooler Holder nitrogen feed pipes to approximately 1 litres / minute each.
Supercooler Nitrogen Packers to approximately 1 litre / minute each.
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Rod, strip or tube Die Nitrogen to approximately 1 litre / minute each.
Bubbler (if fitted) to 2.0 litre / minute.
8. Check that a positive pressure is registered on the casting machine furnace pressure gauge. If no
pressure reading is evident, check all seals, the top lid seals, the furnace to die tooling seal and
the taphole door seal, and improve as necessary and or increase the flowrate as required.
9. Only once all these checks have been made and found to be correct should the furnace power be
switched on.
10. Switch on the primary electrical power to the machine at the factory wall isolator.
11. On the control panel set the Manual power to 50%. Allow the machine to heat up for 3 minutes.
This is done so that when the temperature control is switched to Auto the power thereafter
given to the heating elements, to maintain a ramped temperature increase, is not initially a full
100%
12. After heating the furnace for 3 minutes, via Manual control, at 50% switch the control over to
Auto. Then set the desired setpoint temperature, degrees Celsius, and the required ramp rate in
degrees Celsius per hour.
NOTE : For RT machines the maximum ramp rate should be 120C / hour.
This must be done because they have a larger / more powerful element set and to
also minimise the risk of heating element problems .
The furnace temperature will now rise at the desired ramp rate until the desired set point
temperature is reached.
13. When the furnace starts to control towards the set point temperature check that the top thrust
plate and all the die assembly thrust plate nuts are at the correct torques.
14. Once the furnace has reached the desired furnace temperature, the machine should be allowed
to stabilise and a final check on all the thrust plates should be carried out before charging the
crucible begins.
15. Before charging any metal into the crucible check ;
 The heating elements amp readings are stable

 All water inlet / outlet temps and flows are normal and no leaks are present.
 Note the die temperatures & insertion depths on the data sheet
 Reduce the die nitrogen flow rates to 0.5 L/min thereby avoiding excessive pressure within
the die / bubbling back up through the die assembly.
16. Add a small quantity of metal to the furnace. When melted carefully check the taphole and if
there are no metal leaks, add more metal.
17. Fill the crucible, adjust the bubbler flow-rate and check the tap-hole.
18. When die assembly temperatures are sufficient and stable then casting can begin :
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Usually after the crucible has been completely filled the die temperatures are noted on the data
sheet. The furnace is then left for approximately 1 hour so that the die temperatures can rise /
stabilise.
One satisfied that suitable die temperature is present withdraw all of the die thermocouples to a
position where you estimate that they will display close to Solidus temperatures whilst casting
at maximum speed. Seal the thermocouples with silicone sealant. Refer to previous data sheets
for approximate insertion depth.
19. Break the silicone seal between the starter bar and the casting die.
20. Set the withdrawal unit sequence, adjust roll pressure to between 2.5 to 7 bar, depending on the
as-cast material and product size, and record start-up parameters on a data sheet.
21. Record start-up parameters on a data sheet. Remember that the data sheet should be a full
record of how the machine was operated such that its information could be reused on similar
casts in the future as well as for training purposes. The insertion depths of the die
thermocouples must be recorded throughout the cast as temperatures without insertion depths
are meaningless.
22. When die assembly temperatures are sufficient and stable, the starter bars should gently tapped
back (small rod only) into the die by approximately 5mm before the starting the withdrawal
unit.
NOTE : This procedure is for small rods only. Due not use this procedure when casting strip
or tube otherwise damage to the casting die / mandrel will occur.
NOTE: The manufacturers specification for type-k thermocouples indicates that they can be
used SHORT TERM at a temperature of 1250C ( 2282F ), but can be used
continuously at 1150C ( 2102F ).
23. When casting starts the die temperature will rise, thereafter gradually increase the casting
speed to achieve optimum output.
24. When casting starts the die temperature will rise and if successful stabilise at a given steady
speed. If the initial rise in temperature is quickly followed by a sudden decrease in temperature
then the start up has been unsuccessful. In this case immediately stop the withdrawal unit and
refer to the break procedure in Section 6.0 of this manual.
If the start of casting has been successful then gradually increase the casting speed to achieve
optimum output. It may be necessary to readjust the die thermocouple positions so that the
displayed temperature is close to the Solidus value. Remember to record any changes to
insertion depth on the data sheet.
25. Check the tap-hole for leaks on a regular basis initially at start up and thereafter every hour.
26. Add more solid metal to the crucible to maintain the molten metal level within the top liner.
Add small charges (approx 20kg) regularly and puddle it below the melt surface. Ensure the
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last charge is fully melted before adding the next. Only if required raise the furnace temp
(approx 30C) to further aid the integrated melting. Reseal the top charging lid if possible.
27. After the last charge has been made to the crucible replace the top lid and seal it with wool.
Reduce the furnace temperature to 100C above the alloy Liquidus temperature.
28. At the end of the cast, during spear-out, raise the die nitrogen flow-rates.
29. When all the metal has speared out seal the die with wool or insert a small piece of cast metal
sealing the gap to the die with silicone sealant.
30. Switch off the heating element power by setting the furnace temperature setpoint to zero.
31. Slacken the nuts and disc spring assemblies and then release the die thrust plate followed by
undocking the casting die assembly.
32. Drain any remaining metal into the dump box via the taphole and reseal the taphole door.
Remember to wear appropriate safety clothing. During the draining of the metal , with the
taphole door open , temporarily have the furnace die nitrogen flowrate increased to
compensate. Try and regulate the flow of metal out of the Taphole so it is steady. If required
remove any blockages in the taphole. Cover the dump box with a layer of ceramic fibre blanket
for safety and also to minimise the radiant heat.
33. Restablish the wool seal around the casting die assembly to restore a positive furnace pressure.
34. Maintain all the nitrogen gas flowrates until the furnace temperature falls below 350C (662F ).
35. Maintain all the water flowrates until the furnace temperature falls to room temperature.
36. Switch off the primary electrical power to the machine using the factory isolator once the
machine has completely cooled down. The control panel should remain live during the cool
down just in case any alarm conditions occur. i.e Low Water Pressure , Hi Water Inlet
Temperature or Low Nitrogen Pressure Alarms.
5.2 SWITCH ON POWER
Proceed as instructed in the previous section of this manual. (Section 5.1 Cast Start up and
Shutdown Overview)
5.3 DIE TIGHTENING
This is a very important aspect of casting machine operation, as incorrect procedure can lead to
molten metal leakage from between :
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The external sealface of the supercooler holder, feeder tube, rod , strip or tube die and the crucible
sealface.
The internal sealface of the feeder tube and the rod, strip or tube die .
The supercooler casting insert (“Headed” type) and the internal sealface of supercooler holder
It is recommended that the casting die assembly nuts are torqued to the following approximate
values during the initial machine rebuild, as the machine is heated up and whilst casting.
A check should be made to ensure that the appropriate disc springs and plain washers are fitted in
the correct order between each type of Thrust Plate and its respective nuts.
Supercooler Holder, Rod , Strip or Tube Die Assembly Thrust Plate M24 Nuts should be tightened
evenly to a torque of approximately 14 Nm Cold or 30 Nm Hot
Supercooler Insert (Headed type) Thrust Plate M16 Nuts should be tightened evenly to a torque of
approximately 10 to 15 Nm
NOTE: Initially tightened nuts can slacken over time due to thermal expansion or
contraction effects within the casting machine assembly. It is therefore wise to
check the torque of all the Die Assembly nuts regularly during the furnace heat-up
and casting campaign using a torque wrench.
Disc springs are used on all casting die assemblies, unless a very high withdrawal force is
anticipated, in which case an additional thrust washer cap should be used.
PROTECTIVE CLOTHING
When dealing with molten metal, remember, it can be very dangerous and all machine operators
MUST at all times wear the following safety gear:
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Full protective clothing is defined as : Heavy woollen jacket and trouser set, flame retarding in 570
g/m2 ( 1.8 oz/ft 2 ) material, quick release foundry boots or gaiters, helmet and visor and thick heat
resistant leather gloves whenever metal is charged, level or tap hole checked, and throughout dump
procedure. All gloves to be inside sleeves, all pockets to be covered flaps, jacket to cover trousers at
all times and be fastened, trousers to cover boots at all times. When charging volatile materials such
as brass or during maintenance of the inside of the furnace the operator should wear an approved
filtering mask to reduce inhalation of fumes.
NOTE: Visitors to the casting machine should be made aware of the importance of safe
working practices and must wear molten metal splash approved helmet and face
visor and other approved specialist foundry protective wear. Nylon and other
synthetic fabric underclothing is NOT recommended, woollen or cotton goods
being best.
FEED-STOCK
It is recommended that feedstock be dry and free from oil and moisture. Mineral oil, in particular,
will tend to flare up and can be a source of danger to the operator. If oil contaminated swarf is to be
fed into the casting machine it should be centrifuged first and added in small quantities together
with larger amounts of solid dry material.
Check that the furnace nitrogen pressure is positive and that the cooling water flowing through the
supercoolers, jacket, plate or probe coolers is steady and sufficient.
Feed a small charge into the crucible, then close and reseal the top thrust plate charging lid.
It is important that this initial charge is small, clean, dry material. In order to quickly melt so as to
obtain a pool or ‘heel’ of molten metal at the bottom of the crucible. Further small charges will be
required to raise the level of the molten ‘heel’ above the baffle plate.
Checking at the taphole for metal leakage at regular intervals. If some molten metal is present at the
taphole then quickly remove it using a suitable hammer, chisel and rake and close the taphole door
as soon as possible to minimise the ingress of air. For prolonged periods with the taphole open
increase the nitrogen flowrate to the furnace body thereby minimising the oxidisation of internal
graphite parts.
Recheck the torque of all the Die Assembly thrust plate nuts.
Having made small additions of scrap at first, increasing size and frequency as the metal level rises.
If necessary puddle the fresh charge into the molten metal using only a graphite tipped or ceramic
stirrer or plunger, never use a steel one, and then close and reseal the top thrust plate charging lid.
If required, remove residues from the top of the melt with a graphite spoon or ladle, when the level
of molten metal approaches the top of the crucible liner.
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If necessary, cover the metal with charcoal, or scrap graphite or other cover, as required. The use of
fluxes is not usually recommended, since they can seriously affect crucible life in some instances.
If a pre-melted feedstock is used make sure the furnace is at the correct temperature and add a small
amount first, checking the taphole before adding the full charge.
When melting scrap brasses for example, de-slagging is carried out to remove extraneous dust and
carbonaceous material and also oxides formed in the melting process. The operation sequence is:
Add a small quantity of denser scrap material (solids) and puddle in meticulously so that fine layer
of slag dust is brought to the surface.
Skim the surface of the charge with a graphite colander type spoon or ladle, taking care to avoid
removing metal. Allow any metal, which is caught up in the ladle to pour back into the crucible
through holes in ladle before the slag is placed in a suitable container.
With brasses, allow a thin slag layer to remain on the surface of the molten metal to inhibit zinc
burn-off and protect the metal from oxidation at the surface.
Sieve accumulated slag to recover any metal pieces and store slag residues for sale and recovery of
metal.
In non-zinc containing alloys, it is often beneficial to use a cover of 12mm ( 0.5" ) charcoal or clean
scrap graphite powder to prevent metal loss from the surface of the melt by oxidation.
Ensure good quality cover materials are used otherwise melt contamination can occur from
impurities therein.
Initially the thermocouple is inserted to the full depth of the hole within the casting die assembly,
during heat-up and melting. This ‘fully home’ position either corresponds to the hot end of the
internal casting orifice or very close to it depending upon the type of casting die assembly being
used.
Just before casting is started the thermocouple should be withdrawn from the “fully home” position
by approximately 50 to 75mm (2” to 3”). This will maximise its operational life particularly if the
temperatures are expected to be greater than 1150C (2102F) or zinc vapours are present.
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Ideally the position of the thermocouple within the casting die assembly should be such that when
casting at maximum speed it should be registering the solidius temperature of the alloy thereby
monitoring the solidification front within the casting orifice. At all times the insertion depth of the
thermocouple, into the casting die assembly, should be known and recorded along with the die
temperature. Otherwise die temperature without thermocouple insertion depth is meaningless.
If the thermocouple is located too far into the casting die assembly when casting alloys containing
zinc, zinc vapour or condensed zinc metal will rapidly attack the metal sheath causing premature
failure of the thermocouple. Also, at temperatures in excess of 1000C (1832F) graphite can attack
metal thermocouple sheaths during prolonged casting campaigns.
NOTE: The temperature at the head of the die assembly should be stabilised before casting
with a full pot of metal. Allow approximately 1 hour for this to occur after the last
crucible charge has been made. This should indicate a temperature of at least 20C
above the liquidus of the melted alloy in order to ensure that liquid metal is present at
the hot end of the internal casting orifice.
NOTE: The manufacturer’s specification for type-k thermocouple indicates that they can be
used SHORT TERM at a temperature of 1250C (2282F), but can be used
continuously at 1150C (2102F).
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AC DIRECT CONTROL DRIVE PARAMETERS
All withdrawal unit parameters are set and displayed on the Withdrawal screen as illustrated in
appendix 6. The parameters available are listed below and should be set according to the alloy and
section size being cast. Refer to previous data sheets for start-up casting parameters that have
worked successfully when casting the required or similar alloy and cross-section.
To energise the withdrawal unit press the Power On button.

To de-energise the withdrawal unit press the Power Off button.
To start the withdrawal unit moving press the Motor START button.
To stop the withdrawal unit moving press the Motor STOP button.
For an Emergency Stop press the Emergency Stop button on either the electrical control panel or
the withdrawal unit.
Inch Pull and Inch Push buttons

To aid moving the heavy starter bar / slave bar assembly during the initial setup of the machine the
Inch Pull and Inch Push buttons can be used along with an appropriate small Motor Speed value.
Never ever use the buttons for casting.
Press the Inch Pull button to continuously move the heavy starter bar / slave bar assembly away
from the casting die. Release the button to stop movement.
Press the Inch Push button to continuously move the heavy starter bar / slave bar assembly towards
from the casting die. Release the button to stop movement.
PARAMETERS THAT EFFECT THE CASTING SPEED
Pulse Time is the time, in seconds, that the withdrawal unit will pull the as cast product.
Normally this value remains unchanged during a casting campaign however :
Increasing the Pulse Time will increase the pulse length (distance the as cast product is pulled by
the withdrawal unit)
Decreasing the Pulse Time will decrease the pulse length (distance the as cast product is pulled by
the withdrawal unit)
Dwell Time is the time, in seconds, that the withdrawal unit will stop pulling the as cast product.
i.e. The as cast product remains stationary in order to increase its length by controlled solidification.
Increasing the Dwell Time will decrease the casting speed (mm/minute)
Decreasing the Dwell Time will increase the casting speed (mm/minute)
Motor Speed is % value of full motor speed and can be set between 0 to 100%
Increasing the % Motor Speed will increase the pulse length (distance the as cast product is pulled
by the withdrawal unit)
Decreasing the % Motor Speed will decrease the pulse length (distance the as cast product is pulled
by the withdrawal unit)
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Run Cycles is the number of conventional withdrawal unit pull - stop cycles that will be performed
before a repetitive interruption is made for the Overdwell Time in seconds. When not in use reset to
ZERO.
Do not use when casting tube as it will lead to a broken die mandrel or a broken tube.
Overdwell Time is the time in seconds for which the withdrawal unit casting cycle is interrupted.
When not in use reset to ZERO.
Do not use when casting tube as it will lead to a broken die mandrel or a broken tube.
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Refer to previous data sheets for start-up casting parameters that have worked successfully when
casting the required or similar alloy or cross-section.
Break the silicone seal on each of the starter bars and before starting each individual rod carefully
tap back with a hammer by a distance of about of 2 to 5mm.
NOTE : This “tapping back” procedure is for small rods only , less than 40mm O.D.
Due not use this “tapping back” procedure when casting strip or tube otherwise
damage to the casting die / mandrel will occur.
Ensure that pinch rolls are gripping firmly only on the required slave bar. Adjust the withdrawal
roll pressure accordingly.
Press the "Motor START" button to start the withdrawal motor and watch for a fairly immediate
temperature rise on the appropriate die temperature indicator as the rod starts to move. If the initial
rise in temperature is quickly followed by a sudden decrease in temperature then the start up has
been unsuccessful. In this case immediately stop the withdrawal unit, by pressing the “Motor
STOP” button and refer to the break procedure in Section 6.2 of this manual.
Check the length of the pulse as the rod , strip or tube exits from the die, measure the linear speed in
mm per minute and note all start-up conditions on a data sheet.
Check that the die temperature indicator shows that a stable temperature condition has been reached
before making further adjustments to casting speed or pulse length.
NOTE : When casting multiple rods, start casting one first. Once casting has been seen to be
satisfactory on the first cast, then the second may be started. Repeat this procedure
for the remaining rods.
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After start-up, this standard check procedure should be carried out at 60 minute intervals or more
frequently as the situation dictates.
Check water flowrate through: Plate Coolers (as fitted)

Jacket Coolers (as fitted)
Supercoolers (as fitted)
Busbar Probes
Check for furnace body nitrogen pressure.
Check the tap-hole for leakage and remove any molten metal present with a suitable hammer, chisel
and rake, or a small electric Kango type chisel, may also be used. Close the taphole door as soon as
possible to minimise the ingress of air.
NOTE: The taphole plug must be removed as soon as possible because if it is not, any
further build up in the taphole area will lead to a total blockage or freeze back
situation. It may be necessary to deliberately remove some of the clay graphite
taphole tube so that a very stubborn plug can be extracted. Having done so remove
the broken pieces of taphole tube and quickly fill the remaining voids with dry
rammable powder or D11 refractory cement in order to help protect the steel taphole
flange from any fresh molten metal. For prolonged periods with the taphole open
increase the nitrogen flowrate to the furnace body thereby minimising the oxidisation
of internal graphite parts.
Check the torque of the following casting die assembly nuts:
Supercooler Holder, Rod , Strip or Tube Die Assembly Thrust Plate M24 Nuts should be tightened
evenly to a torque of approximately 30 Nm Hot
Supercooler Insert (Headed type) Clamp Bar M16 Nuts should be tightened evenly to a torque of
approximately 10 to 15 Nm
Check and record the following electrical readings:
Primary Voltage as supplied to the machine transformer.

Secondary Voltage as supplied from the transformer.
Secondary Current as drawn by the casting machine heating elements.
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If, despite a firm grip of the pinch rolls on the starter bar the rod will not pull :
Ensure that the furnace is set at the correct temperature and the desired die temperature is being
obtained.
If a furnace temperature adjustment has to be made, hold the furnace temperature at this new
temperature setting for 30 minutes before attempt re-start.
Stop any coilers used with the equipment to ensure material is not dragged out of the tooling.
Release the grip of the withdrawal unit and tap back the rod gently into the supercooler or casting
die assembly for a distance of around 10 to 25mm in steps of 2 to 5mm using a mallet.
NOTE : This “tapping back” procedure is for small rods only, less than 40mm O.D.
Due not use this “tapping back” procedure when casting strip or tube otherwise
damage to the casting die / mandrel will occur.
A common reason for difficulty with brass during start up is sticking on account of zinc
condensation in the cooler zones of the die. These deposits are generally loosened by the above
procedure, allowing normal starting to proceed.
A ‘Freeze-back’ caused by too low a liquid metal temperature, can be overcome simply by
increasing the furnace temperature.
NOTE : On no account must the water flowrate through the cooler be reduced as this is
potentially extremely dangerous.
If the rod , strip or tube will still not pull then reference should be made to Section 6.9 of this
manual, which deals with seizure.
5.12 RAISING THE CASTING SPEED AFTER START-UP, AC DIRECT CONTROL

DRIVE
Refer to previous data sheets, that have worked successfully when casting the required or similar
alloy or cross-section for guidance. These will show the most reliable way of progressively
changing the casting parameters and hence increase the casting speed to achieve optimum quality
and output.
Optimum running speed is a function of the alloy being cast and the as-cast product dimension.
It varies somewhat depending on such factors as water inlet and outlet temperature, withdrawal unit
settings and type of feedstock used. A useful technique includes setting the output unit to a modest
speed of say 30mm per minute and gradually adjusting from there, observing strand surface quality
and setting the speed to the point of optimum quality and output.
Check as cast product speed in mm per minute.
Either reduce the withdrawal unit “Dwell Time” (i.e. stop period) or increase the “Motor speed”
(i.e. pulse length).
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Check the new speed and allow the die temperature thermocouple reading to stabilise before
making further adjustments.
NOTE: When using supercoolers the temperature rise normally observed when increasing
the casting speed will be very slow and quite small because the die thermocouple is
remote from the casting area.
The operator should continually pay strict attention to the exiting as-cast product to see whether any
surface defects or breakage has taken place.
Further speed increases are made progressively by gradually reducing the Dwell Time.
The length of the pulse can be widened by increasing the Motor speed.
All adjustments to pulse settings must be made very gradually, because rapid or excessive setting
adjustments can give rise to casting die thermal instabilities, resulting in breaks or premature
deterioration of the casting die.
Refer to Section 5.4 Charging the Casting Machine - Safety, for information regarding suitable
protective clothing and feedstock.
SOLID FEEDSTOCK
Pre-heat and load small quantities of feedstock at a frequency that will maintain a maximum level
of molten metal 80mm from the top of the top crucible liner. This is equivalent to 50mm from the
top of the crucible body. If the crucible assembly features a nitrogen bubbler then the maximum
level of the molten metal from the top of the top crucible liner should be 100mm so as to allow for
surface movement.
Refer to crucible assembly drawing see Drawing List
NOTE: Be careful not to over-fill the crucible.
Ensure that the top thrust plate charging lid is closed and sealed after each loading sequence.
Difficulty in charging is indicative of either the need to increase the furnace temperature or de-slag
and remove residues from the crucible melt surface. As the casting speed is increased the output
rate, kg/hour, increases which means that the charging and melting rate must also increase by the
same amount in order to maintain the optimum molten metal level within the crucible without
affecting the quality of the as-cast product.
In order to increase the melting rate of the casting machine, when adding cold metal charges, the
furnace temperature must be increased correspondingly. The amount by which the furnace
temperature is increased to compensate for a given melting rate increase is dependent on the
following factors:
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a. The required melting rate in kg/hour.
b. The metal or alloy being melted.
c. The type and size of the feedstock.
d. The frequency of the cold metal charges.
e. The experience of the machine operator.
A disposable tip dip thermocouple is useful in monitoring the top of melt temperatures.
Typically the amount by which the furnace temperature is increased is usually done in steps of 30C
(86F) to a maximum total of approximately 90C (194F). Only experience, with the above listed
factors, will determine the final total amount that the furnace temperature has to be gradually
increased from the initial start-up of casting to the desired maximum casting speed and output.
Carry out the Standard Check Procedure regularly.
Manual charging is best carried out by gently `puddling' the feedstock through the top of the melt
with an expendable graphite tipped feeding rod. An expendable and replaceable inert graphite type
tip is recommended for most alloys, although for some materials, an inert ceramic may be required
to avoid contamination problems.
Starting and stopping the withdrawal unit whilst waiting for metal, leads to greatly increased die
wear and increased probability of strand fracture, especially when casting hollow sections.
PRE-MELTED FEEDSTOCK
If charging the furnace from a pre-melter, it is vital that enough metal be available to charge the
furnace as required, to allow casting on a wholly continuous basis.
Liquid metal from a pre-melter must be sufficiently superheated to overcome the temperature drop
during transfer from the pre-melter to the casting machine. Ideally, the pre-melter should be at a
temperature closely matching the temperature of the molten metal in the crucible. The crucible
should not be allowed to drop below 75% of its capacity before more molten metal is added from
the pre-melter.
NOTE: Be careful not to over-fill the crucible.
Carry out the Standard Check Procedure regularly.
Starting and stopping the withdrawal unit whilst waiting for metal, leads to greatly increased die
wear and increased probability of strand fracture, especially when casting hollow sections.
NOTE: It is not recommended to stop and re-start tube casting as mandrel breakage can
occur.
STAND-BY (APPLICABLE TO SOLID STRANDS ONLY)
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This is the condition where the casting machine is standing under heat, while not producing, either
at the commencement of a casting run or having been stopped for mechanical or electrical
maintenance, intermittent shift working or a week-end or holiday break
While this is acceptable practice, it is emphasised that as a continuous high-temperature process,

efficiency of operation will inevitably be impaired by periods on stand-by and a slight increase in
die wear will also be experienced. Most machines would normally be emptied after each casting
campaign.
SHORT TERM STOP - SAY UP TO ONE DAY
Before stopping reduce the furnace temperature and casting speed so that the casting front moves
back towards the hot end of the casting die. Once stable die temperatures prevail stop the
withdrawal unit.
Reduce the furnace temperature of the casting machine to just above the solidus temperature for the
material contained in the crucible.
Seal around the as-cast section with respect to the die orifice with high temperature silicone rubber
to keep air from entering the die assembly and conserve inert gas.
If a tap-hole leak is evident under the above conditions then:
Reduce the furnace temperature a further 50C ( 75F ).
Check the torques on all the tooling assembly nuts.
Clear out the taphole.
If the leak persists and is excessive, the cast should be aborted. Refer to ‘ABORTED CAST
PROCEDURE’ in Section 5 for details.
START-UP AFTER STAND-BY
Adopt the normal furnace temperature raising procedures using the power control screen.
Hold the casting machine at the operating temperature for up to one hour before commencement of
casting.
Carry out Standard Check Procedure regularly.

In order to restart casting after a period of stand-by the following procedure should be used.
For rod, release the grip of the withdrawal unit and tap the rod back gently using a mallet into the
supercooler by a minimum distance of around 15mm, by steps of 5mm max. For small round rods
only, rotate the rod with a Stilson type wrench and attempt re-start only as a last resort.
For strip, only tap-back gently, by steps of 2 to 3mm, because of the tapered casting orifice within
the strip die.
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As previously described, a common reason for difficulty with brass during re-start is sticking on
account of zinc condensation in the cooler zones of the die.
NOTE: On no account must the water flowrate through the supercooler or plate coolers be
reduced, as this is potentially extremely dangerous.
Restart casting, charging and increase the casting speed.
Stop charging the casting machine.
De-slag the melt surface. When casting certain alloys, make appropriate additions to compensate
for any loss of elements e.g. Zn which may occur during production. Ensure that the furnace lid is
resealed.
After the last charge has been made to the crucible replace the top lid and seal it with wool. Reduce
the furnace temperature to 100C above the alloy Liquidus temperature.
Continue to cast normally. When the crucible is empty, the cast rod / strip or tube will taper to a
“spear”. Increase the die nitrogen flow during spear out as required.
When all the metal has speared out quickly seal the die with wool or insert a small piece of cast
metal sealing the gap to the die with silicone sealant.
Transport the spear steadily out of the casting die assembly, ensuring that any secondary spray
water cooling is turned off.
Switch off the heating element power by setting the furnace temperature setpoint to zero.
Slacken the nuts and disc spring assemblies and then release the die thrust plate followed by
undocking the casting die assembly.
Ensure that the following safety gear is worn:
Molten metal splash-approved fibreglass helmet and face visor

Heat resistant gloves
Quick release safety boots with leggings

Molten metal splash approved jacket and trousers
Lower the two die assembly support screws so that they are just clear of the die assembly.
Open the tap hole door and increase the nitrogen flow to the furnace body to approximately 20
Litres/min. As the furnace is now open to the atmosphere, the following operations have to be
carried out as rapidly as possible. Normally the operations can be completed in less than 2 minutes:
Slacken and then unscrew the thrust plate nuts back by 2mm. Pull back the corresponding plain
washers and disc springs.
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This will ultimately allow the die to be withdrawn so that it is completely clear of the crucible
socket thereby eliminating the risk of solidified metal preventing the full removal of the die when
the furnace body has cooled down to room temperature.
Using heat resistant gloves grip the die thrust plate with both hands and gently pull the die tooling
assembly away from the crucible sealface by an initial amount of approximately 2mm. This will
allow any remaining metal within the crucible to drain in a steady stream out of the taphole and into
the dump mould.
NOTE: Due to the fact that some casting die assemblies are very heavy they are sometimes
left docked against the crucible during cool down to room temperature. However if
after spearing out there remains sufficient metal between the casting die assembly
and the crucible then separation could be difficult and result in damaged graphite
parts.
Maintain at all times the seal that is provided by the pieces of ceramic fibre wool between the die
and the front plate orifice to prevent ingress of air.
Once the flow of molten metal from the taphole has almost stopped then the tooling assembly
should be pulled further away in increments of 5mm until it is completely removed from the
crucible socket.
When the flow of molten metal has finally stopped, clear the taphole of any metal and close the
taphole door.
Repack around the die and if necessary use additional ceramic fibre wool in order to re-establish a
positive furnace pressure.
For supercooler tooling, fully slacken all the M16 nuts in front of all the secondary thrust plates.
This is done so that as the supercooler tooling assembly cools down any contraction of individual
parts will not increase the main thrust on the supercoolers or the secondary thrust upon the graphite
packers and casting insert unnecessarily. Also slacken all the barrel nuts on the supercooler holder.
Allow the furnace body to cool down by maintaining full water flowrates to:
Plate Coolers (as fitted)

Busbar Probes
Once the furnace temperature as displayed has decreased to 350C (662F ) then all the nitrogen
flows may be switched OFF.
Maintain all the water flowrates until the furnace temperature falls to room temperature.
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Switch off the primary electrical power to the machine using the factory isolator once the machine
has completely cooled down. The control panel should remain live during the cool down just in
case any alarm conditions occur. i.e. Low Water Pressure , Hi Water Inlet Temperature or Low
Nitrogen Pressure Alarms.
UNDOCKING THE DIE ASSEMBLY WITH MOLTEN METAL STILL IN THE CRUCIBLE.
SAFETY NOTE:
Protective clothing must be worn when carrying out the following procedure. Molten metal is
dangerous and serious injury can result if safe operating practices are not adhered to.
Ensure that the following safety gear is worn:
Molten metal splash-approved fibreglass helmet and face visor

Heat resistant gloves
Quick release safety boots with leggings
Molten metal splash approved jacket and trousers
Stop charging the casting machine and stop the withdrawal unit.
Ensure that the top thrust plate charging lid is closed and resealed.
Ensure that the dump moulds, at both the taphole door and beneath the rod die are still dry.
Replace with new dry moulds if required.
Position fume extraction over the taphole.
Ensure that all the supercoolers have either an as-cast rod or starter bar and slave bar assembly
secured within them and they are sealed against the secondary thrust plate by silicone sealant. A
good seal will prevent unnecessary oxidation of the graphite parts.
Ensure that the rod or strip or tube die has an as-cast product or starter bar / slave bar assembly
secured within it and is sealed at the cold end by silicone sealant. A good seal will prevent
unnecessary oxidation of the graphite parts.
On the temperature controller set the setpoint to zero.
Lower the two-die assembly support screws so that they are clear of the die assembly.
Open the tap hole door and increase the nitrogen flow to the furnace body to approximately 20
Litres/min. As the furnace is now open to the atmosphere, the following operations have to be
carried out as rapidly as possible. Normally the operations can be completed in less than 10
minutes:
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On the withdrawal unit release the top pneumatic pinch rolls.
Slacken and then unscrew the thrust plate nuts back by 5mm. Pull back the corresponding plain
washers and disc springs. This will allow the supercooler holder, rod, strip or tube die assembly to
be partly withdrawn from the crucible socket thereby allowing a controlled flow of metal from the
crucible to take place.
Using heat resistant gloves grip the die assembly with both hands and gently pull it away from the
crucible sealface by an initial amount of approximately 5mm.
NOTE: When dealing with large, heavy casting die assemblies and their as-cast product or
slave bars it might be necessary to give one or two pulses with the withdrawal unit so
that metal begins to flow out of the taphole. Proceed with caution.
This should allow most of the molten metal within the crucible to be dumped safely into the taphole
dump mould via the crucible dump slot, which is situated at the bottom of the crucible socket.
Try to maintain a steady flow of molten metal out of the taphole so as no blockages occur. Adjust
the position of the die assembly as required.
Maintain at all times the seal that is provided by the pieces of ceramic fibre wool between the
supercooler body or the die assembly and the front plate orifice to prevent ingress of air.
Once the flow of molten metal from the taphole has almost stopped then the tooling assembly
should be pulled further away in increments of 5mm until it is completely removed from the
crucible socket.
NOTE: When dealing with large, heavy casting die assemblies and their as-cast product or
slave bars it might be necessary to leave them still partly located into the crucible
socket. However if after only partly undocking there remains sufficient metal
between the casting die assembly and the crucible then separation could be difficult
and result in damaged graphite parts.
When the flow of molten metal has finally stopped, clear the taphole of any metal and close the
taphole door.
Repack around the die assembly and if necessary use additional ceramic fibre wool in order to re-
establish a positive furnace pressure.
For supercooler tooling fully slacken all the M16 nuts in front of all the secondary thrust plates.
This is done so that as the supercooler tooling assembly cools down any contraction of individual
parts will not increase the main thrust on the supercoolers or the secondary thrust upon the graphite
packers and casting insert unnecessarily.
Allow the furnace body to cool down.
Check for and maintain full water flowrates to:

Plate Coolers (as fitted)
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Busbar Probes
Once the furnace temperature as displayed has decreased to 350C (662F) then all the nitrogen flows
may be switched OFF.
Switch off the primary electrical power to the machine using the factory isolator once the machine
has completely cooled down. The control panel should remain live during the cool down just in
case any alarm conditions occur. i.e Low Water Pressure , Hi Water Inlet Temperature or Low
Nitrogen Pressure Alarms.
COVERS
With graphite crucible melting of copper, copper alloys and precious metals, there exists a mildly
reducing environment whereby oxidation and oxygen absorption is not normally a problem.
However, precautions should be taken when melting alloys and particularly ones which contain
readily oxidisable constituents such as Mn, Si, Fe, Al, etc. It is good practice to use a cover over
the metal at all times.
Good quality charcoal, or high quality graphite powder or solid broken scrap pieces are excellent
for this purpose. Old elements, dies and other broken up furnace components can be re-used for
this purpose. Charcoal is also a very useful cover.
Pure copper and silver requires a cover at all times. The exposure of the liquid metal surface to the
outside environment should be as short as possible, as some metals e.g. silver, absorb oxygen very
rapidly from the atmosphere. With alloys containing constituents as listed above, it is sometimes
useful to feed inert gas, nitrogen, or blend of nitrogen and natural propane gas over the top of the
melt to enhance the reduction nature of the process atmosphere. (Mn, Si and Al are very easily
oxidised).
Various proprietary fluxes exist, but care should be taken in the use of these. Follow the
manufacturer's instructions closely.
BUBBLING
A nitrogen line from a flow meter with associated pressure gauge in the control panel can be fed
into the liquid metal bath, just above the bottom of the crucible. It can be used to stir the melt and
this is in fact necessary when making alloys where the density of the component parts differ greatly
(e.g. Ag and Cu, Cu and Au etc.).
The crucible bubbler is made by passing nitrogen gas through a hole in the top of crucible.
Thereafter a passageway, consisting of horizontal and vertical x-drilled holes then direct the
nitrogen into the molten metal within the crucible. Since nitrogen is insoluble in copper, nitrogen
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bubbling will completely displace other gases in solution in the copper, particularly hydrogen, by
the law of partial pressures.
Nitrogen will also displace zinc from brasses and other zinc containing alloys, so bubbling is not
recommended for these alloys.
Do not use nitrogen bubbling for alloys containing >5% nickel, zirconium, silicon or chromium
because for such applications argon is the preferred gas.
METAL PURITY (Contamination)
Most crucibles, as supplied, have impurities entrained within their fabric and in some instances this
is a critical aspect particularly when casting high purity metals such as pure copper and gold. It is
advisable to carry out 'wash' or leach out casting runs and by the analysis of the metal produced at
the end of the run, ascertain whether the crucible system is clear. Sulphur, silicon and vanadium are
the most likely contaminants from new graphite crucibles with 60-100 ppm sulphur picked up by
the metal normally during the first run.
After 2 or 3 runs this will be reduced to a very low and satisfactory level of < 5 ppm. Metal
produced during wash-runs can be reserved for non-critical applications, such as brass manufacture,
etc.
Precious metal crucibles for silver and gold, should be pure copper washed to low impurity level
before use with the precious metal.
Cross contamination between alloys can be minimised by careful cleaning of the crucible between
campaigns but where no contamination, material to material, can be allowed, a dedicated
conditioned crucible should be kept for the express purpose of producing the designated material.
In addition, when this crucible is out of the furnace, it should be completely wrapped in plastic
polythene sheet, to prevent contamination from dusts in the atmosphere. Crucibles should be stored
in a clean, dry, safe area.
Attention to hygiene cannot be over-emphasised in metal melting, as the pick up of metal-ferrous

contaminating dusts from other parts of the manufacturing facility within the metal charges or metal
bath is a real possibility.
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6.1 TAP-HOLE LEAK

6.3 FRONT RUN-OUT
6.8 SURFACE DETERIORATION OF THE ROD, STRIP OR TUBE
6.10 INSIDE RUN-OUT
6.14 ELECTRICAL TROUBLE SHOOTING GUIDE
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6.1 TAP-HOLE LEAK
Regular checking of the tap-hole for metal leakage is an important element in the Standard Check
Procedure. This prevents build-up of metal and ultimate blocking of the tap-hole.
To check the tap hole open it using the pneumatic control lever. If clear immediately close in order
to avoid air entering the furnace thereby reducing the life of the graphite components.
Possible causes of taphole leaks are:
a. Cracked supercooler holder, rod / strip / tube die assembly

b. Cracked crucible
c. Over-filled crucible
d. Inadequate seal between the supercooler holder and the crucible sealface
e. Inadequate seal between the rod / strip / tube die assembly and the crucible sealface
NOTE: When dealing with molten metal, remember, it can be very dangerous, casting
Machine operators MUST at all times wear the following safety gear :
- Molten metal splash approved fibreglass helmet and face visor

- Heat resistant gloves
- Quick release safety boots with leggings
- Molten metal splash approved jacket and trousers
NOTE : The dump mould must be thoroughly dried before attempting to use the machine.
If any metal is seen in the tap hole, open the tap hole door and remove any metal present. If it has
solidified use a suitable hammer, chisel, rake or a small electric Kango type chisel. Close the
taphole door as soon as possible to minimise the ingress of air. For prolonged periods with the
taphole open increase the nitrogen flow rate to the furnace body thereby minimising the oxidisation
of internal graphite parts.
NOTE: The taphole plug must be removed as soon as possible because if it is not any
further build up in the taphole area will lead to a total blockage / freeze back
situation.
It may be necessary to deliberately remove some of the clay graphite taphole tube so that a very
stubborn plug can be extracted. Having done so remove the broken pieces of taphole tube and
quickly fill the remaining voids with dry rammable powder or D11 refractory cement in order to
help protect the steel taphole flange from any fresh molten metal.
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Check the torque of the casting die assembly nuts, refer to manual section 5.3
If the leak persists to the extent that the level of the molten metal within the crucible falls so that it
is just above the bottom of the top liner then all casting and charging should be stopped. Reseal the
top thrust plate charge lid so as to avoid ingress of air.
Because the leak still persists and cannot be controlled, the casting run must be aborted.
Refer to section 5.16
Once the furnace body has been cooled down a full examination should be made of:
a. The crucible and its sealfaces.

b. The supercooler holder and its sealfaces.
c. The rod / strip / tube die assembly and its sealfaces.
d. The integrity of all the molten metal graphite paper gaskets.
e. The stability of the furnace hearth.
f. The stability of the crucible thrust blocks.
Repair / replace any parts as required.
If the tap-hole becomes blocked with molten metal, either on account of inadequate checking by the
operator or by a sudden flush of metal, the plug must be removed by the following procedure using
a suitable hammer, chisel, rake and tongs.
Loosen and try to pull the plug out of the taphole remember that there may be some molten
metal behind it.
If the plug cannot be pulled out of the taphole then tap the plug back up into the tap-hole, if
possible, taking care to avoid damaging the graphite heating elements.
Close the taphole door so as to aid the melting of the plug and to minimise the ingress of air.
Raise the furnace temperature if required by up to 50C ( 90F ) but only having first stopped
charging / casting in order to concentrate on the removal of the plug.
Re-open the taphole and remove any molten metal with the remains of the plug then close the
taphole door. Remember that there may now be a considerable amount of molten metal within the
taphole tube so take care. If a leak has been controlled for some time there will be a build up of
metal in the dump box. This reduces its capacity and should be removed for safety.
If the cast is finished / aborted then the melt surface should be completely covered, for safety
reasons, whilst the metal cools down to room temperature.
NOTE: Increase the nitrogen gas flow to the furnace body at all times when working with
an open tap-hole to avoid oxidation of internal graphite parts while the tap-hole
seal is removed.
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With rod continuous casting tooling the operator should watch for a fairly immediate temperature
decrease, on the die temperature indicator, that will occur just after a rod breakage. Such a
temperature decrease indicates that continuous casting has been interrupted within in the casting
die.
The die thermocouple temperature low alarm can be used to indicate a casting break or seizure if its
setpoint is set close to the stabilised die temperature at a constant casting speed.
The operator should also pay strict attention to the surface quality of the exiting as-cast rod to see
whether there are any early signs of poor surface quality or imminent breakage.
Possible causes of rod breakage’s include :

a) Chilling of feed metal within the crucible and rod die.
b) Incorrect composition, hence wrong furnace temperature setting.
c) Worn / defective casting die orifice.
The condition is more likely to occur when casting small rod, or fragile sections.
Care should be taken to support the rod especially when cutting manually.
It is recommended that the broken rod end should not leave the rod die exit orifice, since this is a
hazardous condition and any delay may lead to a front run-out.
If the rod is broken carry out one of the following rod break procedures immediately.
[A] For re-starting a large diameter (above 40mm) / heavy rod after a break :
1. Stop the withdrawal unit.
2. Carefully reverse the withdrawal unit thereby re-inserting the broken rod end immediately back
into the casting die orifice in order to avoid a front run-out. Reinsert the broken end so it is close
to the broken plug of metal still within the casting die but avoid pushing on it just in case it
damages / breaks the casting die or feeder tube.
3. Until an attempt to either restart casting or abort the cast is made the broken rod should be
secured within the withdrawal unit. Always secure the seized rod against further accidental
movement or front run out.
4. An attempt to restart casting a large diameter (above 40mm) / heavy rod after a break should
only be made using the techniques as discussed / demonstrated by the Rautomead
commissioning engineer or as detailed by the Rautomead customer service department.
5. If a second rod continues to cast at acceptable quality / output using a different withdrawal unit
then the cast may either:
Continue to its conclusion, with further regular metal charges into the crucible.
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OR
Continued with no further metal charges into the crucible so as to drain the crucible of molten
metal thereby enabling the casting machine to be shut down for investigation and rectification
of the casting problem that lead to the rod breakage.
6. Refer to Aborted Cast Procedure, in section 5.16 , for aborting the cast / undocking the casting
die assembly with molten metal still in the crucible.
7. The broken rod or starter bar / slave bar assembly should then be sealed up using heat resistant
silicone sealant at the cold end of the die body.
8. Investigate / rectify the cause of the rod breakage.
[B] For re-starting a small diameter (less than 40mm) / light rod after a break :
2. Put on heat resistant gloves.
3. Ensure that the top withdrawal unit rolls, corresponding to the broken rod, are in the raised
position.
4. If a broken rod end does emerge from the casting die either :
a) Re-insert the broken rod end immediately.
OR ALTERNATIVELY WHEN THIS IS NOT POSSIBLE
b) Insert a polished, prepared and marked starter bar / slave bar assembly immediately.
This is not as quick as using the broken as-cast rod. The “marking” of the starter bar refers to
using an indelible marker pen to mark the length of the rod die assembly (rod die body +
thrust collar) onto a prepared starter bar / slave bar assembly. This should have been prepared
earlier prior to the rod breakage.
5. Re-insert the broken rod or the starter bar / slave bar assembly into the rod die body pushing it
gently in as far as possible.
6. Note the position where the broken rod or starter bar meets the ‘break’ as this indicates the
remaining distance that the broken rod or starter bar has to tapped back. The maximum distance
that the broken strip or starter bar requires to be tapped back is equal to the “datum” distance
(hot
end of die to hot end of jacket cooler) achieved when assembling the jacket cooler to the die body.
Refer to the appropriate tooling assembly drawing.
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7. Until an attempt to restart the broken rod is made the broken rod or newly inserted starter bar /
slave bar assembly should be secured within the withdrawal unit. Always secure the broken rod
or starter bar / slave bar assembly against further accidental movement or front run out.
8. Increase the furnace temperature by 50C and allow it to stabilise for 10 minutes.
9. Gently tap back the broken surface back at a rate of about 5mm per minute. Remember to
support the broken rod or starter bar immediately in front of the strip die. Repeat until the broken
rod or starter bar is fully into the die body. The maximum distance that the broken rod or starter
bar may require to be tapped back is equal to the “datum” distance (hot end of die body to hot
end of jacket cooler) achieved when assembling the plate coolers onto the die body.
At this position the broken rod or starter bar will be easier to move as the plug of metal within
the casting die will have either melted or be pushed out of the casting die orifice. If a starter bar /
slave bar assembly is being used then the mark will coincide with the cold end of the thrust
collar.
10. If tapping / pushing back is difficult then it may be due to the following reasons :
a) Low die temperature.
b) Worn casting die orifice.
c) Damaged casting die orifice.
11. It may be necessary to further raise the furnace temperature to melt / tap back the broken
section. The furnace temperature should then be increased by 50C ( 90F ).
12. Restart rod casting using start up parameters, see section 5, once the mark on the broken rod or
starter bar / slave bar assembly coincides with the cold end of the thrust collar. If casting is
successfully restarted lower the furnace temperature to the normal setpoint.
13. If difficulty in start-up is experienced, raise the furnace temperature, allow a period for
stabilisation and repeat the start-up procedure.
14. If the rod won't move or continues to break despite all careful efforts then the die orifice should
be fully plugged with the broken strip or starter bar / slave bar assembly which in turn should
be secured within the withdrawal unit. Always secure the broken strip or starter bar / slave bar
assembly against further accidental movement or front run out.
OR
of the casting problem that lead to the rod breakage.
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17. The broken rod or starter bar / slave bar assembly should then be sealed up using heat resistant
18. Investigate / rectify the cause of the rod breakage’s.
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6.3 FRONT RUN-OUT
A front run-out should be a very rare occurrence and usually takes place shortly after start-up or
after a rod, strip or tube break as a direct result of the adoption of incorrect procedures. For example
failure of the water-cooling or incorrect settings of the withdrawal. Meticulous observation of
standard operating procedures, including correct setting of die temperature thermocouple depth is of
utmost importance. Should a front run-out take place, procedure for recovery is as follows:
Allow molten metal to empty into a suitable dry refractory cement dump box mould under the die
tooling assembly. Switch off all electrical power to the casting machine heating elements and
withdrawal unit.
NOTE: The machine is so designed that there is no combustible material in the area
directly beneath the casting die assembly.
It is possible that some water pipe erosion may occur due to the molten metal flow, and once the
area around the front of the machine is cooled sufficiently, the mass of metal in the run-out mould /
tray should be covered with 2/3 layers of ceramic fibre blanket wool. This will allow easier access
to the die orifice area to deal with any spurious water leaks, slight metal spills, etc.
NOTE: It is very important that no water enters the furnace, otherwise serious damage can
result.
If possible and safe to do so follow the Aborted Cast Procedure, in section 5, for undocking the
casting die assembly as there may be molten metal within the crucible.
If possible and safe to do so seal up all the casting orifices of the casting die assembly and then
increase the die nitrogen flowrate. Also seal up the charging lid and taphole. If necessary increase
the furnace body nitrogen flowrate until a positive furnace pressure is achieved.
The furnace should now be cooled down, inspected and assessed for re-furbishment of damaged
pipes, fittings, etc.
Only remove the solidified metal from the dump mould once it has cooled down to room
temperature. Cut up the metal from the dump mould. Only clean and dry suitably sized pieces
should be re-melted in the crucible. Before re-using cut pieces for re-feeding to furnace, ensure that
all traces of refractory cement, debris etc is chipped out or removed.
The usual cause is misalignment or maladjustment of the withdrawal unit and may be easily
corrected by re-setting the pinch rolls to achieve the positional correctness in the y-axis and
horizontal adjustments may be made on the withdrawal assembly to achieve the correct x-axis
running position.
If a "Vee" type roll is being used then a check should also be made to ensure that the as cast product
is correctly centralised within the vee roll.
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If a flat develops on the top surface of the rod(s) during casting while the crucible is substantially
full, this probably indicates :
1. Too high a die inert gas flow rate or pressure. Reduce flow rate to 1.0 l/min at 2 Bar.
2. Excessive cold metal charges being added to the crucible thereby chilling / restricting the flow
of molten metal into the casting die assembly.
a. Increase furnace temperature by up to 50C ( 90F ).
b. Reduce casting speed.
c. Re-check or reduce the weight of the cold metal charges and recalculate the frequency of
charge additions to the crucible as dictated by the casting speed / output.
3. A partial blockage of the crucible outlet orifices.
Continue casting at a reduced speed until the crucible is emptied.
NOTE: Only increase the casting speed once the surface quality has improved.
Adjust the frequency of cold metal charges and furnace temperature to suit.
When feeding solid metal charges, for integrated melting and casting, a metal bridge can sometimes
develop across the top of the melt. Evidence of bridging is a solid disc of metal formed on top of
the molten metal surface, which cannot be removed by normal stirring or puddling techniques.
Possible causes:
a. Overloading the crucible with excessive cold metal charges.

b. Too low a furnace temperature and hence crucible temperature.
c. Excessive slag accumulation on the surface or on the liner.
The procedure for removal is as follows:
NOTE: When dealing with molten metal, remember, it can be very dangerous, casting
Machine operators MUST at all times wear the following safety gear:
- Molten metal splash approved fibreglass helmet and face visor

- Heat resistant gloves
- Quick release safety boots with leggings
- Molten metal splash approved jacket and trousers
1. Place layers of ceramic fibre wool blanket on top of the bridge inside the top of the crucible so
as to allow the temperature to build up. This should cause the bridge to melt out.
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2. Increase the furnace temperature by 50C ( 90F ).
3. Reduce the casting speed or stop casting.
4. If the bridge persists very carefully chisel a small hole through a centre layer of solid metal -
taking care that chisel does not pass right through to underlying metal bath.
5. Pass small diameter rod of same composition through hole. This will melt and raise the level of
the molten metal to the underside of the bridge. This technique, together with the ceramic wool
placed on top, as above, should ensure a rapid melt out.
6. Avoid excessive banging or vibration, otherwise damage may be caused to the internal parts of
the casting machine.
7. Slowly increase the casting speed or restart casting and adjust the following to suit:
a. Furnace Temperature
b. Cold metal charge weights.
c. Frequency of cold metal charge additions.
Possible solutions:
a. Lower the temperature of the molten metal and feed increased quantities of cold solid material.
b. Correct metal composition by increasing the zinc additions. Rods affected by zinc burn-off
should be quarantined, pending results of careful chemical analysis.
c. Burn-off tends to be greater when manufacturing 65/35 and 70/30 brasses and nickel brasses.
This is due to the higher furnace temperatures, usually greater than 1150C ( 2102F ), used for
these materials.
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6.8 SURFACE DETERIORATION OF THE ROD , STRIP OR TUBE
Evidence of surface deterioration appears either as opening up of the pulse marks, or as a shelled
appearance on the surface of the as cast product.
Possible causes:
a. Worn casting orifice within the casting die.

b. Worn casting bore in the rod casting insert. (supercooler tooling)
c. Cooling gradient too slack within the rod die, or supercooler assembly.
d. Incorrect withdrawal sequence
The correction procedure is as follows:
Worn Die
Surface deterioration during a well-established casting run.
1. Alter the position of freezing front in the casting die by adjusting the casting speed (generally
slowing speed down).
Slack Cooling
1. Stop adding metal to crucible.

2. Reduce the casting speed.
3. Continue casting until the crucible is fully drained of molten metal and undock the casting die.
4. Once the furnace body has completely cooled down, remove the die tooling assembly and
investigate / rectify the cause of the slack cooling.
Withdrawal Sequence
1. Analyse dies and sequence after current cast campaign

2. Run trials with alternative withdrawal sequences
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The die thermocouple temperature low alarm can be used to indicate a casting seizure or break if its
setpoint is set close to the stabilised die temperature at a constant casting speed.
Possible causes :
a) Too low a die / ingate metal temperature.
b) Lack of nitrogen protection within casting die body orifice.
c) Worn casting die body orifice.
d) Damaged casting die body orifice.
If the rod is seized carry out the following procedure immediately.
[A] For re-starting a large diameter (above 40mm) / heavy rod after a seizure :
2. Until an attempt to either restart casting or abort the cast is made the seized rod should be secured
within the withdrawal unit. Always secure the seized rod against further accidental movement or
front run out.
3. An attempt to restart casting a large diameter (above 40mm) / heavy rod after a seizure should
only be made using the techniques as discussed / demonstrated by the Rautomead commissioning
engineer or as detailed by the Rautomead customer service department.
OR
of the casting problem that lead to the rod seizure
6. The seized rod or starter bar / slave bar assembly should then be sealed up using heat resistant
7. Investigate / rectify the cause of the rod seizure.
[B] For re-starting a small diameter (less than 40mm) / light rod after a seizure :
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Endeavour to loosen the rod in the casting die by :
2. Until an attempt to restart the seized rod is made the seized rod should be secured within the
withdrawal unit. Always secure the seized rod against further accidental movement or front run
out.
3. Increase the furnace temperature by 50C ( 90F ) and allow it to stabilise for 10 minutes.
4. Put on heat resistant gloves.
5. Ensure that the top withdrawal unit rolls, corresponding to the seized rod, are in the raised
position.
6. Gently tap back the rod, at a rate of 5mm per minute until the rod is freely moving backwards
within the casting die. Remember to support the rod immediately in front of the casting die.
7. If tapping / pushing back is difficult then it normally follows that casting will be difficult, due to :
a) Low die temperature.

b) Worn casting die body orifice.
c) Damaged casting die body orifice.
8. The furnace temperature should then be increased by 50C ( 90F ) and the process repeated.
9. Restart rod casting using start up parameters once the rod freely taps back.
10. If the rod remains seized despite all careful efforts to free it, then it should be secured within the
withdrawal unit. Always secure the seized rod against further accidental movement or front run
out.
OR
of the casting problem that lead to the rod seizure
13. The seized rod or starter bar / slave bar assembly should then be sealed up using heat resistant
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14. Investigate / rectify the cause of the rod seizure.
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6.10 INSIDE RUN-OUT
Possible causes of this are:
a. Over-filled crucible.
b. Cracked or broken crucible.
c. Cracked or broken supercooler holder.
d. Cracked or broken rod , strip or tube die.
e. Cracked or broken feeder tube.
f. Die tooling assembly not correctly docked onto crucible sealface.
Should an inside run-out take place, all the metal should drain out of the taphole and into the DRY
graphite or refractory concrete dump mould.
Refer to section 6.1 for details of how to check the taphole and keep it clear.
Should the furnace body temperature continually drop due to an electrical fault then the following
procedure should be used.
1. Determine what the fault is and whether or not it can be fixed quickly.
2. If the furnace temperature has fallen and thereby affected the as cast product then quickly
slowdown the casting speed. If the product quality and furnace temperature stabilises casting can
continue. If they do not stop casting and seal the die tooling assembly orifice.
3. If the fault can be fixed quickly, restoring power to the heating elements, then the furnace
temperature should be increased up to the normal start-up temperature. If casting has continued
allow some time for the temperature to return to the normal operating range before restoring the
metal level and increasing the casting speed. Note with some alloys it may not be possible to
slowdown and restart the rods due to their metallurgy. If casting was stopped allow the furnace
temperature to stabilise before restarting the cast.
4. If the electrical fault cannot be fixed quickly there is a risk that the remaining liquid metal
within the crucible will solidify, then the “Aborted Cast Procedure” in section 5 should be
followed.
NOTE: This assumes that the furnace temperature is still 50 or more degrees Celsius ( 90
Fahrenheit) above the metal / alloy Liquidius when the die tooling assembly is
undocked from the crucible sealface. Such a furnace temperature is required, when
dumping, in order to ensure that the crucible can be fully drained of all metal.
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If the furnace temperature has fall so much that it is not possible to dump the remaining metal
within the crucible then it will eventually solidify within the crucible. If such an event occurs then
the following procedure should be followed.
1. Check all the die assembly thrust nuts for tightness and adjust carefully as required.
NOTE: Depending on the die tooling assembly fitted some thrust nuts may have slackened off
or tightened up during the cool down that led to the solidification of metal within the
crucible. Regularly check all these thrust nuts during the re-heating of the furnace
body.
2. Stop charging and seal charging lid.
3. Increase the furnace temperature by 100C (180F) using a ramp rate of 50C (90F) per hour.
4. Allow the furnace temperature to stabilise at this new temperature for 1 hour. This is done so as
to minimise the risk of the solid metal, within the graphite crucible, expanding at a rate greater
than that of the graphite crucible and hence cracking / breaking it, as this would cause a leak
once the metal is molten.
5. Repeat steps 3 and 4 until the normal start-up temperature has been reached.
NOTE : Once the furnace temperature goes above the alloy Solidius regularly check the
taphole for signs of metal leakage. If metal leakage occurs and cannot be stopped
then the “Aborted Cast Procedure”, section 5.16 should be followed
6. If casting cannot be restarted then the “Aborted Cast Procedure”, section 5.16 should be
followed.
7. Once the furnace temperature has stabilised then casting can be restarted. It may however be
necessary to increase the furnace temperature due to the rapid slowdown / stoppage of the as-
cast product. It must be decided whether to add additional cold metal charges as necessary to
regain a full crucible, or restart casting first in case this fails. If the crucible level is inside the
top liner start casting first if not, fill to liner and start casting. As soon as casting has restarted
begin recharging. Watch the furnace temperature closely until the machine reaches equilibrium.
A major furnace body temperature loss may be the result of an electrical fault. To establish the
cause, proceed as follows:
HEATING ELEMENT FAILURE
By looking at the secondary current and volt readings determine weather the heating elements are
still firing when power is called for.
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If the elements are firing then note all the secondary current and volt readings and calculate the
secondary power (kVA) being drawn by the heating elements. Compare this secondary power
(kVA)
value with that originally obtained during the element test or when the casting machine reached the
normal setpoint temperature, prior to metal charges being made into the crucible.
Note : The secondary current values are normally within +/- 10% of each other.
If the secondary power (kVA) is significantly down compared with the original value then an
element failure has occurred. As well as displaying a lower value, the secondary current will
usually also oscillate erratically, indicating arcing heating elements.
If the secondary current reading is zero then a clean break has occurred somewhere in the heating
element assembly.
NOTE: If an element fails during normal operation, charging should stop and preparations
made to “cast out” or “abort” and thereafter cooled down. When the furnace body
has reached room temperature inspect and replace any heating element components
as required. Reorder parts in order to maintain stock level.
The Rautomead system has been designed to avoid heating element problems and if a
failure does occur, the reasons should be thoroughly investigated and rectification
taken.
The main reasons for element failures are:
1. Mechanical Failure - breaks occur due to over-tightened or over-stressing during assembly of

the heating element chain.
a. Check / correct assembly procedure by operators.

b. Check all other existing connections in the heating element assembly.
2. Erosion Break - weakening of the graphite parts occurs due to erosion by oxygen.
a. Check all seals and nitrogen quality.

b. Check / replace any parts as required. Reorder parts to maintain stock level.
ELECTRICAL FAILURE
Check that low water pressure has not activated the pressure switch on the inlet manifold thereby
preventing the heating elements from firing. The Siren and Flashing Beacon on top of the electrical
control cabinet should indicate this. Increase water pressure to cancel the alarm and restore normal
operation.
Following safe electrical practices have a qualified electrician check the following along with
all the interconnecting fuses. Refer to the appropriate electrical drawing supplied with the
machine.
CHECKING THE THYRISTOR AND DEMAND SIGNALS
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Check that the Thyristor and the PLC are powered up and that the Setpoint Temperature and other
parameters have not been accidentally changed.
If the touchscreen does not indicate a numerical value then there may be a thermocouple break.
This is probably a faulty (open circuit) type R thermocouple or interconnecting compensating cable.
If a
thermocouple has recently been changed check the integrity and polarity of the corresponding type
R control thermocouple along with its interconnecting compensating cable.
It is important that the platinum control thermocouple ceramic sheath integrity is maintained at all
times. If the outer sheath is cracked or broken this can lead to rapid disintegration of the
thermocouple wires due to furnace internal metal vapours such as zinc attacking the platinum. The
normal thermocouple outer sheath is re-crystallised pure alumina tube closed at one end.
It is possible to replace either a thermocouple outer sheath and / or thermocouple whilst the casting
machine at normal operating temperature as long as the electrical power to the heating elements is
switch off in order to gain safe access. Broken thermocouple outer sheaths and broken
thermocouples can be removed quickly. Wear high temperature rated gloves.
However care should be taken to avoid thermal shock breakage’s when either removing working
thermocouples or fitting a new thermocouple outer sheath and / or thermocouple. i.e. Slowly and
carefully remove / insert in stages. Once in the final position ensure that the thermocouple outer
sheath is sealed to the furnace body with high temperature silicone sealant in order to prevent
ingress of air.
NOTE: If the thermocouple wires become damaged or broken it may be possible to recover
the metal value of the platinum wires by sending them to your local precious metals
dealer.
NOTE: The lower threshold signal required by the Thyristor Stack is +0.2V dc.
Check that the input main power to the transformer cabinet is switched on at the factory wall
mounted breaker and is at the correct voltage.
If the thyristor is powered up, receiving a demand signal and does not have any obvious error
signals, turn the power off and check the internal Semiconductor Fuses. Replace as required and
reorder parts in order to maintain stock level. To check the Thyristor Fuses; the RED indicator trip
button, on the fuse, should be “IN”. If button is “OUT”, the fuse should be replaced
Check for any loose / broken internal connections or components.
Check that the output main power from the Thyristor Stack is at the correct voltage when the
elements fire or are required to fire.
MAINS POWER TRANSFORMER
Check that the transformer tappings correspond to the mains primary voltage.
Check that the input main power from the Thyristor Stack is at the correct voltage when the
elements fire or are required to fire.
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Check that the output main power from the Transformer is at the correct voltage when the elements
fire or are required to fire.
FLEXIBLE LEADS
Check that all leads are securely fastened to both the Transformer Connections and the water-
cooled Busbar Terminal Clamps. Also check that the leads are in good condition and the end-
crimped connections are well made.
BUSBAR TERMINAL CLAMP CONNECTIONS
Check that all Busbar Terminal Clamps are securely fastened to all the graphite busbars.
Ensure that no short circuits exist between the terminals and the casting machine body.
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6.14 ELECTRICAL TROUBLE-SHOOTING GUIDE
NOTE : a qualified electrician should check the electrical power circuits.
FAULT: FLUCTUATION CURRENT
If the touch screen shows fluctuating Current, when at a steady 100% power, this indicates a
heating element fault. Examine the heating elements for loose connections and replace parts where
necessary.
FAULT: NO OR VERY LOW CURRENT
If touch screen shows no Current but shows Voltage, this indicates a heating element fault.
Examine the heating elements for breaks and replace where necessary.
FAULT: NO OR VERY LOW POWER (KVA)
If the touch screen shows no Power (KVA) this indicates a Thyristor fault.
1. Check the Thyristor Fuses. The RED trip indicator button on the fuse should be “IN”. If button
is “OUT”, the fuse should be replaced.
2. Check the main supply line voltage to the Thyristor at the Thyristor Fuses.
3. Check that there is a power supply to the Thyristor control circuit.
4. Check water pressure and over-temperature alarms are not active. If they are active then the
Thyristor will be inhibited.
5. Check that the Thyristor thermal overload has not tripped. Check that the cooling fan is
running.
6. If the fault cannot be identified, the problem could be within the Thyristor, contact Rautomead.
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This fault-finding list is only intended as a guide to be used as a reference by the engineer in charge
of the casting machine. For further information please contact Rautomead world headquarters in
Dundee. The conditions listed are in general caused by generally inexperience and most often
occurs when a machine is initially installed. Once operators become fully skilled in the operation
of the casting machine, down time due to operator error will be subsequently reduced.
CONDITION
1. METAL SOLIDIFICATION WITHIN CRUCIBLE
2. CASTING STOPS
3. FRONT RUN OUT
4. BENT ROD , STRIP or TUBE
5. POOR SURFACE QUALITY
6. TAP HOLE LEAK
7. ROD, STRIP or TUBE BREAKAGE
8. HIGH WITHDRAWAL UNIT FORCES REQUIRED
9. POROSITY
10. SUDDEN SUPERCOOLER HOLDER / DIE TEMP INCREASE
11. SUDDEN SUPERCOOLER HOLDER / DIE TEMP DECREASE
12. LOSS OF FURNACE TEMPERATURE
13. LOSS OF FURNACE PRESSURE
14. LOSS OF BUBBLER FLOW
15. EXCESSIVE FUMES
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1. METAL SOLIDIFICATION WITHIN CRUCIBLE
CAUSE:
a. Mains power failure
b. Element failure
c. Furnace body thermocouple faulty
ACTION:
1. Check mains power supply
2. Check fuses
3. Check elements
4. Check furnace body thermocouple calibration
2. CASTING STOPS
CAUSE:
a. Withdrawal unit fault
ACTION:
1. Check air pressure
2. Check plc operation
3. FRONT RUN OUT
CAUSE:
a. Unstable casting front
b. Worn casting insert / die
c. Fractured rod
d. Unsuitable withdrawal unit pulse sequence
e. Casting in excess of the thermal abstraction rate of the supercooler / die assembly
EMERGENCY ACTION:
1. Evacuate all personnel to a safe area immediately.
2. Evacuate the surrounding area of all non essential personnel and treat any injuries immediately
3. Decide whether to summon emergency services
4. Only return to machine once the molten metal stops flowing and that which has been spilled has
solidified.
5. Extinguish any fires with the correct extinguisher
6. Seal up the casting machine / casting die assembly and try to achieve a positive furnace
temperature.
7. Switch off the power to the heating elements.
8. Switch off the mains electrical power.
9. Restrict access to area until a cause is established.
NOTE : Always have immediate casting area free from inflammable items.
Fire extinguishers must be available near to the machine.
Buckets of dry sand can also be used to contain metal flow.
FUTURE ACTION:
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1. Pay attention to the surface quality of the as cast rod on a regular basis and adjust the furnace
temperature or withdrawal unit parameters as required in order to maximise the quality and avoid
breakage’s.
2. Investigate the condition of the casting inserts / die upon disassembly and remachine or replace
as required.
3. Review the withdrawal unit pulse sequence and casting speed that was used prior to the front run
out occurring.
4. On the next cast carefully monitor the quality of the as cast product when approaching the
casting speed at which the front run out occurred.
4. BENT ROD, STRIP or TUBE
CAUSE:
a. X or Y axis misalignment from withdrawal unit mechanism.
b. Excessive cooler blockage due to scale.
ACTION:
1. Realign withdrawal unit mechanism
2. Check water flow in the die cooler.
3. Internally clean the die cooler.
5. POOR SURFACE QUALITY
CAUSE:
a. Worn Casting Insert / Die
b. Inappropriate withdrawal unit pulse sequence
c. Inherent alloy condition
d. Furnace temperature too hot or too cold
ACTION:
1. Remachine or replace the Casting Insert / Die
2. Change the withdrawal unit pulse sequence
3. Post cast treatment may be necessary
4. Increase or decrease the furnace setpoint temperature
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6. TAP HOLE LEAK
CAUSE:
a. Over filled crucible
b. Incorrect Supercooler Holder / Die Assembly docking
c. Worn Supercooler Holder, Die or Crucible seal face
The machine will run with a slight tap hole leak provided it is regularly cleaned out. It is possible
to re-adjust the die during casting by tightening alternate die thrust plate nut / disc spring
assemblies.
ACTION:
1. Allow molten metal to flow into dry dump mould.
2. Keep taphole clear using hammer, chisel and rake.
3. Increase flow of nitrogen to furnace body to compensate for the taphole door being open.
4. If the tap hole leak is continuous then the crucible contents should be dumped.
5. Reduce the metal level within the crucible and monitor the taphole.
6. Review the procedure for Supercooler Holder / Die Assembly docking with all operators.
7. Inspect the sealface of the Supercooler Holder / Die and Crucible and repair or replace as
required.
7. ROD, STRIP or TUBE BREAKAGE
CAUSE:
b. Inappropriate haul off sequence
c. Molten metal temperature too hot or too cold
d. Feedstock contamination
ACTION:
2. Change the haul off sequence
3. Increase or decrease the furnace temperature
4. Purify feedstock
5. For immediate action see section in manual on rod breakage.
8. HIGH WITHDRAWAL UNIT FORCES REQUIRED
CAUSE:
b. Aggressive alloy reaction with graphite casting surface
c. Freeze back of metal within the Casting Insert / Die
ACTION:
2. Cast out crucible contents or abort cast and dump crucible contents.
3. Increase the Furnace Temperature
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9. POROSITY
CAUSE:
a. Contamination of feed stock
b. Absorption of oxygen
ACTION:
1. Use clean / dry feed stock
2. All alloys with oxygen affinity to be well covered with graphite powder or charcoal.
Bubble inert gas through melt.
10. SUDDEN SUPERCOOLER HOLDER / DIE TEMP INCREASE
CAUSE:
a. Water supply failure
b. Failure of die assembly type K thermocouple
ACTION:
1. Check water flowrates to supercoolers / plate coolers
2. Remove old thermocouple and replace with a new one.
11. SUDDEN SUPERCOOLER HOLDER / DIE TEMP DECREASE
CAUSE:
a. Rod breakage
b. Accidental thermocouple movement
ACTION:
1. Follow procedure outlined in manual
2. Check position of thermocouple
12. LOSS OF FURNACE TEMPERATURE
CAUSE:
a. Power failure
b. Element failure
c. Thermocouple inoperative
ACTION:
1. Check main power supply
Check fuses
Check furnace temperature and over-temperature protection settings
2. Check heating element secondary volt and ammeter readings
3. Check the position and integrity of the 2 furnace body type R thermocouples.
13. LOSS OF FURNACE PRESSURE
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CAUSE:
a. Leaking furnace body seals
b. Inert gas interrupted / exhausted
ACTION:
1. Check all furnace body seals
2. Check inert gas supply / switch to emergency supply
14. LOSS OF BUBBLER FLOW
CAUSE:
a. Interruption of inert gas supply
b. Leakage of inert gas
c. Blockage of bubbler hole in crucible
ACTION:
1. Check inert gas supply
2. Check / tighten all pipe work connections
3. Check bubbler hole in crucible
15. EXCESSIVE FUMES
CAUSE:
a. Contaminated feedstock
b. Melt temperature too high
ACTION:
1. De-contaminate feedstock
2. Lower furnace temperature set point
Page 96 of 146
7.1 CASTING MACHINE STRIP-DOWN, CRUCIBLE REMOVAL

7.5 CRUCIBLE LINER MAINTENANCE AND REPLACEMENT
7.8 WITHDRAWAL UNIT
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7.1 CASTING MACHINE STRIP-DOWN, CRUCIBLE REMOVAL
NOTE: Prior to furnace strip-down ensure that the appropriate protective

clothing, respiratory mask and gloves are worn.
It is recommended normal operating practice that the interior of the furnace body be checked at the
end of each casting campaign and the necessary repairs / replacements made where necessary. To
gain complete access to the interior of the furnace body the casting machine is stripped down using
the following procedure once the furnace body has been fully cooled down to room temperature.
Once the furnace body temperature has fallen to below 350 C (662 F) then :
Turn off all nitrogen flowmeters i.e. Furnace, Die and Bubbler
Strip down the furnace body for accelerated cool down by opening the top thrust plate charging lid,
removing any discs of ceramic fibre blanket from the charging orifice of the crucible and fully
opening the taphole inspection door.
Remove the side doors of the casting machine by removing their securing bolts from the flanges,
Taking care to avoid disturbing the ceramic rope seal around the side flanges. Should any damage
occur fit new rope using high temperature silicone sealant.
Remove the layers of refractory wool and low thermal mass insulation modules to expose the
crucible and heating elements.
All removed parts must be stored carefully to avoid damage.
NOTE: LTM insulation blocks can be easily damaged. They should be handled very
carefully.
1. Once the furnace body has cooled down to room temperature the casting die tooling may be
removed. Refer to the appropriate part of section 4.0
2. If fitted remove the bubbler guard, associated pipework and the graphite feed pipe.
3. Remove the furnace body top thrust plate by unscrewing the nuts / disc spring assemblies and
lift clear.
4. Remove all the layers of ceramic fibre blanket along with the crucible top castable. The top
castable is made in four pieces and cemented into position using Silset cement. It may be
necessary to gently chip out the top castable with a mallet and chisel.
5. Remove any side and die heating elements that could possibly interfere with the fitting of the
crucible-lifting harness and slings or be damaged during the removal of the crucible.
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6. Carefully fit the crucible-lifting harness and slings provided onto the crucible assembly taking
care not to disturb the remaining heating element chain and the graphite crucible thrust blocks.
7. Carefully raise the crucible out of the furnace body, taking care not to disturb the heating
element chain and the graphite crucible thrust block.
8. Examine the interior build of the furnace body and if required remove the heating elements, for
better access, so that the necessary maintenance may be carried out.
9. Examine all heating elements, studs, nuts and graphite paper washers for signs of wear and
replace as necessary as per section 3.2. When in doubt, replace defective parts.
10. Examine the tap-hole tube, ceramic furnace hearth and refractories for wear. Repair / replace as
necessary before re-building the casting machine. Repack the LTM module joints with 1400
refractory wool as required.
NOTE: Reference should be made to the relevant furnace build drawings, photographs, to
ensure correct repair / replacement.
If the internal hearth is badly damaged, it should be repaired or replaced. The hearth consists of a
rammable refractory supplied in dry powder form. When the rammable is heated it forms a hard
skin on the exposed surface.
Before repairing the hearth check the condition of the tap-hole tube first, it may have been damaged
when a major blockage is removed or as a result of a persistent molten metal leakage.
Replace if required.
To repair the hearth, chip out the hard top crust as required and add more dry rammable if
necessary. Add enough layers to achieve a depth slightly greater than the depth of refractory
required in the finished base. Ram the rammable with a suitable tool then remove the excess using
a scraper to obtain a smooth contoured surface.
If the complete hearth is replaced then replace the crucible and complete a dry out cycle, as per
section 3.1. The temperature only needs to be raised to 250C (482F), and held for 2 hours, in order
to drive off any remaining water as it is a ‘dry’ refractory that is used.
When possible check the condition of the heating elements and nut tightness weekly.
Refer to the procedure in section 3.2 of this manual.
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Small quantities of slag and lumps of debris may be left in the base of the crucible at the conclusion
of a casting run. These can be removed using an industrial vacuum cleaner as necessary. Take
special care to clean thoroughly the channel leading form the crucible base to the die seal face.
Remove any loose slag or metal from the underside of the liner. Care should be taken not to
damage or mark the sealface area of the graphite crucible.
The above procedure should be standard practice to avoid restriction of metal flow in subsequent
production.
Carefully remove the old (graphite paper) seal face gasket from the crucible die socket along with
any remaining metal residue.
Check that the crucible seal face is clean and free from damage. Heavy chips and marks would be
best dealt with by removal of the crucible from the furnace and correction made by machining.
The crucible requires to be removed if repairs are necessary to the furnace hearth, if the crucible
itself has been damaged and / or requires to be replaced. It will also require removal if the
production programme demands that cross-contamination from material to material is undesirable,
e.g. production high copper alloys and zinc based alloys where cross contamination from volatiles
may be critical.
7.5 LINER MAINTENANCE AND REPLACEMENT
Following extensive casting, particularly with brass alloys, the inside surfaces of the crucible liner
may become fouled with compacted debris, thereby reducing the feed orifice to the crucible. If not
cleared, this can lead to bridging of the metal feed. Care must be taken to avoid damage to the liner
surface or the crucible wall when carrying out this cleaning operation. The crucible liner will, in
time, become progressively eroded and will require to be replaced. If the liner is cracked it must be
repaired between campaigns with Silset cement. Failure to repair cracks will lead to accelerated
erosion of the crucible. If the crack is not easily repaired, change the liner.
This may be conveniently carried out as follows:-
Remove, if fitted, the bubbler guard, associated pipework and the graphite feed pipe.
Remove the furnace body top thrust plate by unscrewing the M24 nuts and lift clear.
Remove all the layers of ceramic fibre blanket along with the top castable. The top castable is made
in four pieces and cemented into position using Silset cement. It may be necessary to gently chip
out the top castable with a mallet and chisel. The liner will now be exposed. It may be necessary to
gently loosen the old liner by tapping it with a mallet and chisel. Care must be taken not to damage
the graphite crucible wall itself. Once removed vacume the crucible.
Cut and fit a piece of fibrefrax paper, featuring a matching hole, onto the top of the crucible body.
Fit the replacement liner, ensuring that the fit is not too tight within the crucible.
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Position the liner in the centre of the orifice. Do not pack or cement the liner sides.
Carry out the other previous operations in reverse order, replacing any of the ceramic fibre blanket
wool or other parts as required.
Use Silset cement to join the four pieces of the top castable back together and also to join onto the
upper lip of the new top liner. This will create an effective molten metal splash seal.
During the initial assembly of the furnace body an annular ring of 1800C concrete is placed above
the top castable in order to shield the top thrust plate. Use Silset cement to patch up this interface
and any cracks within the 1800C concrete.
The front and rear of the furnace chamber has monolithic type blocks or modules fitted. These are
fitted within the steel casing against vertical layers of ceramic fibre wool blanket. The modules
fitted are 1350C (2462F) rated. Wool expansion joints must be fitted between the various parts of
insulation block.
Busbar feeder holes are cut in the rear modules. These should be carefully cut or bored with a
suitable sharp tools in situ, care being taken to ensure no damage ensues.
The side door modules are removable and are fitted into the side orifices of the furnace using strips
of ceramic fibre wool blanket in order to provide a gas tight seal. When carrying out element or
other furnace internal maintenance, they should be removed carefully to avoid damage.
Two or three layers of 25mm 1400C rated ceramic fibre wool blanket are fitted into the side door
flange recess before replacing the side doors.
Above the modules layers of ceramic fibre wool blanket are fitted.
The top plate is then carefully bolted down onto its ceramic fibre rope gasket seal on the furnace
body.
TRANSFORMER
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Remember always isolate the power before opening the unit.
A comprehensive set of installation notes will accompany each machine. No maintenance should
be required on the power items other than cleaning. It is recommended that the power pack unit,
(thyristor-transformer power pack) and the electrical control be vacuum cleaned at regular intervals
to remove dusts, which if allowed to build up, may prove harmful.
The transformer is double-wound, air-cooled and should never be covered over when in operation.
The power pack is installed in an area where air can freely circulate free from dusts, metal swarf
particles and debris etc.
Note : High speed semiconductor fuses are fitted to thyristor stacks. If a fuse blows at any
stage, it must be replaced by one of the correct specified value. Ordinary h.r.c.(high
rupturing capacity) fuses must not be used with thyristor stack - Special h.r.c. semi-
conductor fuses must be used (otherwise serious damage could occur). For fault
investigations, refer to operations maintenance manual and to the appropriate drawings or
notes.
All power pack inter-link wiring will have been carried before shipping. Before wiring up on site
check rating plates on the unit and ensure that the mains supply is correct and matches the power
pack.
Power output from the transformer is by heavy copper busbar coming through an insulated plate at
the side of the enclosure and then by multiple 120 mm2 welding cables to the furnace bus bars. The
number of cables is important and should not be changed. On 175 KVA machine 8 flexible leads
are used per phase. The secondary connections must be very clean and it is important that all high
current connections are checked regularly for overheating.
NOTE : The thyristor transformer power pack unit should never be operated without a
load being connected. The machine must be correctly earthed.
FURNACE LOAD
This is the last part of the power circuitry. All components of the element system are graphite and
they operate at the low secondary voltage ( 12 - 24 volts ) but at high secondary currents, 1500 to
5000 Amps.
Being a pure resistive load, no inrush currents occur. Good connections require to be achieved
throughout the element chains and this is assisted by, using graphite paper washers between each
nut and fastener assembly throughout the element build.
Attention should periodically be made to the pairs of copper clamp, water-cooled terminals at the
rear of the furnace, as well as the condition of the flexible leads from the busbars. Any evidence of
overheating or other faults in this area must be investigated immediately and the appropriate
correction measures taken to clean the contact surfaces and re-tighten. Water cooling flow must be
adequate through the copper terminals and they should be kept clean and free from extraneous
matter.
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The condition of the elements and other graphite members of the element system should be checked
on a regular basis. If excessive element erosion takes place, all the furnace seals should be
thoroughly inspected for leaks and air ingress. Meticulous attention to seals and furnace pressure
should always be maintained, with the furnace continually running at a very small positive pressure.
Only very slow erosion will occur with the graphite components as long as this positive pressure is
maintained and no moisture ingress occurs.
During maintenance procedures it is permissible to test the elements BRIEFLY to a dull red
condition, in air atmosphere. Once tested the power should be disconnected and the elements should
not be used again until the furnace body is under positive inert gas pressure.
Refer to section 3.2 for the element test procedure.
ELECTRICAL MAINTENANCE
No maintenance is normally required once the machine is installed, other than keeping it clean, dry
and positioned away from excessive sources of heat and dusts.
7.8 WITHDRAWAL UNIT
The withdrawal unit is the only moving part of the casting machine. The operator should take care
to avoid contact with the moving parts. Various types are supplied according to the task required.
All are of heavy duty, robust construction.
Monthly bearing wear checks should be made and replacement carried out as necessary. Refer to
general arrangement drawing. Gear trains and bearings should be smeared with a small quantity of
high quality grease during the inspection. Remove the gear-case cover at the side of the machine, 4
screws require removal. Check that gear capping screws, key-way grub screws and keys for
tightness of fit during the lubrication period and adjust / repair as necessary. Replace the gear-case
cover before operation of the withdrawal unit.
Shaft coupling key integrity is very important, as the withdrawal unit are powerful and relatively
high torque, slow speed machines. During casting operation select roll pressures on the cast
section, which prevent slip of the strand but keep the pressure as low as possible to reduce rod
marking and withdrawal fatigue to a minimum.
NOTE: It is necessary to ensure that the withdrawal unit power is switched off before
attempting to change the pulley rolls, or carry out any maintenance or adjustments within the
gear case.
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DESCALING OF WATER TRACING, PROBES, SUPERCOOLERS, JACKET COOLERS AND

PLATE COOLERS
A scale build up seriously affects the effectiveness of heat abstraction from any cooler system. If
scale is present in any cooler on inspection, it must be removed by the following method.
Periodically, flush out the water tracing to ensure water flow is maintained.
A check should be made with the local water treatment supplier to see if a water recirculation
additive can be made which will completely prevent the deposition of scales.
Using a 10% by weight water solution of citric or tartaric acid crystals (these organic acids dissolve
readily in cold clean water), add the resulting solution to the cooler waterways and continue to add
until all the scale is removed.
Lime scales consist of mainly calcium carbonate and evolution of carbon dioxide gas will occur
from the scale as it breaks down and is removed by the organic acid solution. When effervescence
is complete, the scale can be removed. Flush out the cooler with fresh water and dry off.
NOTE: There are no health and safety issues associated with the use of these organic acid
solutions, there is also no known restriction on low quantities of dilute discharges to
mains sewer systems, but local requirements should always be checked by Users.
Pressure test each Supercooler , Jacket Cooler , Plate Cooler and Probe Cooler for 1 hour, with no
leaks or pressure drop permitted, prior to re-use. See section 4.1 for further information.
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8.2 FEED-STOCK
8.3 WATER FLOW
8.4 WATER TREATMENT
8.6 FUME REMOVAL
8.7 DUMP BOXES
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NOTE: When dealing with molten metal it is important to note that it can be very
dangerous and safety procedures MUST BE ADHERED TO AT ALL TIMES.
Casting machine operators MUST at all times wear the following safety gear:
Molten metal splash foundry approved fibreglass helmet and goggles or heat protective face visor.
Heat resistant gloves.
Quick release foundry approved safety boots with leggings.
Molten metal splash approved jacket and trousers.
Fire and heat retardant overalls 570 g/m2 ( 1.8 oz/ft 2 ) woollen fabric, in trousers and jacket, are
advised by British Standards for copper production.
NOTE: Visitors to the casting machine should be made aware of the importance of safe
working practices. A local risk assessment must be made by the User and findings
implemented. Nylon and other synthetic fabric clothing including underclothing is
NOT recommended, woollen or cotton goods are safer if there is a molten metal
incident.
In particular visitors to the casting machine must wear appropriate safety clothing and must not go
on to charging platform unless they are provided with safety protective wear and are accompanied
by a competent, trained operator or supervisor. British Standards advise long laboratory type coat
in 320 to 450 g/m2 (1.0 to 1.4 oz/ft 2) fire retardant cotton fabrics, helmet and safety glasses as a
minimum.
During the build up or strip down of the furnace ensure that the operator is wearing the appropriate
protective clothing, respiratory mask and gloves. The respiratory mask should be a personal
protection face-mask, PPF3 or filtering face-piece FFP3S type suitable for protection against non to
high toxicity solid aerosols in concentrations up to 50X Threshold Limit Value, TLV.
8.2 FEED-STOCK
Care must be taken to ensure feedstock is perfectly dry and free from oil or plastic wrapping.
Mineral oil, in particular, will tend to flare up and can be a source of danger to the operator. If oil-
contaminated swarf is to be fed into the casting machine, it should be centrifuged first and added in
small quantities together with larger amounts of solid dry material. Moisture entering a crucible at
temperature can have disastrous consequences.
Operators MUST always wear protective clothing and complete eye protection when charging
metal, puddling crucible or de-slagging. During charging, puddling or de-slagging operations with
alloys with volatile components, suitable fume extraction equipment must be operating.
It is important that the TLV limits (Threshold Limit Value), see Section 8.6, is not exceeded in the
atmosphere during this operation. Scrap metal should be carefully segregated so that care can be
Page 106 of 146

exercised when charging into a molten bath. Scrap tube is particularly troublesome and should be
treated with care. Entrapped air in an open-ended tube will rapidly expand on entering a molten
bath and can ‘blow back’ resulting in molten metal showering out of the caster. Tube should be
crimped or closed on each end prior to charging.
Some alloys require the use of virgin feedstocks for success in casting. Alloys such as CuMg and
CuSn may need preheated cathode where the cathodes are heated to 500C in a nitrogen atmosphere
to remove any moisture or volatiles such as grease and sulphur from the cathode.
8.3 WATER FLOW
A continuous flow of cooling water through the die and terminal coolers is essential for safe
operation.
The water system recommended for this machine is a primary / secondary system using
demineralised water. This runs through the machine’s terminal coolers, body tracing, and die
coolers. Pumped at 4 to 6 bar (58 to 87psi). Pressure should be supplied from a pump unit
consisting of two 7 bar pumps, one pump in use, the other in case of pump failure, to achieve the
required flow through the furnace components :
RMT machine ; 115 litres/minute (30 US gal / minute)
RT machine ; 300 litres/minute (78 US gal / minute)
Because this system is closed, water losses are small and water treatment is minimised.
Demineralised water should be used to fill and top-up the system. The water is passed through a
filter and plate heat exchanger for cooling by a cooled secondary circuit with cooling tower. Water
inlet to the furnace and dies should be 20 to 35C (68 to 95F). The secondary cooler can be a chiller
type or evaporative type, depending on local conditions and requirements.
The water system must include an emergency water supply, which will operate automatically in the
event of power failure. Usually the emergency water supply is fed from a suitable storage tank
located a minimum of 10 metres [ 1 bar pressure ] above the casting machine.
RMT machine ; 6000 litres capacity
RT machine ; 10800 litres capacity
Ideally the User should provide an audible alarm on the pumping system to draw attention to any
loss of the cooling water supply. This stand-by system should be checked prior to every casting
campaign. Water level indicators on any reserve tank are a useful addition.
8.4 WATER TREATMENT (see Section 1.3 for water specification required for this
equipment)
In most areas of the world with relatively soft waterof the required specification is easily available.
Where it is not simple water treatment is relatively straightforward. Dosing the water with an
appropriate amount of general-purpose inhibitor, for example 'Nalfloc A140' or equivalent is
satisfactory. The inhibitor should be compatible with all the materials of the re-circulatory system,
namely brass couplings, copper tube, steel coolers. The water treatment company will recommend
dosing level. Aluminium components are avoided in water systems, as they require special water
treatment additions.
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Many of the inhibitors available can cause the water system to become slightly acid, especially if
they are reacting with the corrosive products on steel surfaces like the water jacket and therefore,
the pH of the water must be checked regularly.
For example, with the Nalfloc A140 inhibition slightly, a pH of 8.5 can be achieved readily by the
appropriate additions of small quantities of soda ash. The addition of inhibitor should be made on a
very regular basis and pH can be simply checked by pH paper. It is also advisable to add, as
required by local legislation, an anti-bacterial agent. Most countries now require separate risk
assessments to be made for this open circuit water cooling equipment.
Water recirculation systems can give rise to relatively high concentrations of dissolved salts, due to
evaporative aspects of the cooling tower, and it is recommended that these should be monitored
regularly.
Where the water is harder and has distinct scale formation tendencies, a more involved treatment of
the water system will be required. Further information on water treatment and condition for the
Rautomead Continuous Casting Machine can be obtained from the closest I.C.I. Nalfloc Division,
Sales and Service Office and they offer a service of testing the water system with a view to making
full recommendations as to the proper treatment required.
All first attack fire fighting equipment should be regularly inspected and tested.
Dry powder fire extinguishers should be at hand at all times.
Carbon dioxide extinguishers should also be on hand to cope with any electrical problems.
Dry sand in buckets is also very useful for damming any molten metal spilt on the floor.
The User is advised to make his own fire assessment.
Metal spills can and do occur. It is important that they are dealt with safely, as injury to personnel
can happen, together with equipment and property damage. In the normal day to day running of a
casting plant, provided all the back up systems and operating procedures are satisfactory and
correct, there is a very low risk molten metal spill if this equipment is used as per the manual and
training given by Rautomead Limited.
Before using the machine a risk assessment should be carried out to ensure should there be an
emergency, people and premises are fully prepare for it.
In an emergency always summon assistance and ensure that you and all other personnel are wearing
complete protective equipment around the casting machine at all times.
Ensure continuity of water supply to the die coolers and furnace power connections.
Switch off the power to the furnace, including withdrawal.
Dry sand should be spread on to the floor, particularly bare concrete. Use the sand to contain any
metal spills on the floor by ensuring that they do not contact water. Make sure that any ancillary
Page 108 of 146

power is off and try to avoid metal contacting power cables. If not in danger personally, try to
prevent molten metal getting under or close to instrument control console or transformer. Damage
in these areas can be costly.
Ventilate the area to minimise inhalation of any toxic fume.

Normally a simple run out would not involve anything like the problems listed above. However,
assume the worst and make every effort immediately to bring the situation under control as quickly
as possible.
8.6 FUME REMOVAL
Some alloys, particularly some of those with volatile constituents, can give rise to toxic hazards,
with respect to the emission of poisonous and harmful substances in the vapour or fine particulate
form. Specific regulations both national and international control the melting of these substances.
These should be studied and a fume removal system applied to deal with any fume. Rautomead can
assist and advise with this aspect. Particular care should be taken when dealing with alloys
containing lead, zinc, cadmium, beryllium and tellurium in that the fumes from these materials are
never ingested or inhaled by operating personnel.
Literature on safety should be freely made available to all operating personnel. Highly
recommended literature is ‘AN EVALUATION OF OCCUPATIONAL HEALTH AND HAZARD
CONTROL TECHNOLOGY FOR THE FOUNDRY INDUSTRY’ published by the U.S.
Department of Health, Education, and Welfare, Public Health Service, Centre for Disease Control
National Institute for Occupational Safety and Health.
Publication no. 79-114 DHEW (NIOSH) Publication available from.
The Superintendent of Documents

US Government Printing Office
Washington, D.C.
20402 U.S.A.
NOTE: European COSHH regulations list Threshold Limit Values for exposure to volatile
metal vapours.
Fume extraction facilities are required in the following positions for volatile alloys :
(a) Top thrust plate ; For charging metal into the crucible.
(b) Taphole door ; For dumping metal into the taphole mould.
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8.7 DUMP BOXES
The dump box supplied is used to collect any molten metal, which may leak from the crucible or the
complete charge if the crucible has to be emptied. The volume of the dump box is usually specified,
as 1.5 times the volume required.
The dump box and front run out box for the RT type of machine is a steel box lined with refractory
concrete. This must be constructed from appropriate grade concrete and then dried by gently
heating it to 600C (1112F), and holding for 2 hours, in an oven or with gas blow torches, refer to
drawings for details. If there is any moisture within these boxes an explosion can occur due to the
rapid atomisation of the water by the molten metal. It is therefore extremely important that these
boxes are thoroughly dry before use to avoid potentially serious injury to operators. The boxes must
be kept dry and operators encouraged to report any fluid spills.
Page 110 of 146

9.0 APPENDICES
APPENDIX 1 RECOMMENDED FURNACE TEMPERATURE SETTINGS
RECOMMENDED FURNACE TEMPERATURE SETTINGS FOR CERTAIN NON-FERROUS

ALLOYS
COPPER DESCRIPTION FURNACE TEMP

ALLOY NO. SETTING
(BASED ON CDA REF.) DEG C
101 - 155 Coppers 1280 - 1330
160 - 191 High Copper Alloy 1250 - 1300
210 - 485 Brasses ( inc. tin brasses ) 1050 - 1130
502 - 548 Bronzes and Leaded Bronzes 1200 - 1300
606 - 642 Aluminium Bronzes 1120 - 1250
647 - 661 Silicon Bronzes 1225 - 1260
667 - 697 Miscellaneous Brass Alloys 1030 - 1130
701 - 725 Copper Nickel Alloys 1300 - 1400
732 - 799 Nickel Silvers 1100 - 1200
- Silver and High Silver Alloys (>80% Ag) 1080 - 1130
- Gold and High Gold Alloys (>14 ct) 1180 - 1280
RAUTOMEAD LIMITED CAN ASSIST, BY ADVISING OPERATIONAL PARAMETERS,

WHERE KNOWN, WITH RESPECT TO ANY MATERIAL.
NOTE: These temperatures are meant for guidance only. They are temperature settings of
the furnace which by experience give the liquid metal sufficient superheat for
trouble-free casting of average, typical sections. Use the higher temperature setting
when machine is in high volume, full scale production, to maintain correct
thermodynamic state. The lower setting is for start-up or lower production rates.
Page 111 of 146

APPENDIX 2 GRAPHITE SUPPLIERS
UNION CARBIDE CORP

SGL
TOYO TANSO CORP
LE CARBONE
RINGSDORFF-WERKE GMBH
Most grades of graphite used in the Rautomead continuous casting furnace will be available
worldwide from the various national outlets of the understated companies. If any difficulty is found
locating any particular grade, Rautomead should be contacted.
General-purpose grades RR1 and RR2 are suitable for heater elements, furnace structural members,
radiation shields, crucibles and feeder tubes.
Fine grained graphite RP1 and RP2 are suitable for casting die or die insert manufacture.
Several grades are suitable for casting dies, with the specific grade to be selected, according to the
degree of difficulty of the metals being cast. These grades are also sometimes used for precious
metals crucibles.
APPROVED GRADES OF GRAPHITE FOR USE ON RAUTOMEAD MACHINES
RAUTOMEAD APPROVED GRADES

DESIGNATION
RR1 UCAR CBY, UCAR CS
RR2 UCAR AGSR
RP1 SGL 4550, UCAR CGW, LEC 2204
RP2 SGL 4500, UCAR ATJ, LEC 2020
NOTE : Use only grade CBY for 25mm, 38mm and 50mm thick heating elements
Page 112 of 146

APPENDIX 3 SUGGESTED MAINTAINCE SCHEDULE
DURING EACH CASTING CAMPAIGN
Water System Check system pressure and flow.

Check filters.
Repair leaks as required.
Nitrogen System Check system pressure and flow.

Check capacity is sufficient.
Organise re-filling or changeover as required.
Air System Check system pressure and flow.

Check supply from compressor is adequate and DRY
Crucible Assembly De-slag the crucible melt regularly and apply fresh melt cover.
Dump Boxes Keep dry.
Access Remove any obstructions, litter especially flammable materials.
AFTER EACH CASTING CAMPAIGN
Water System ; Check system for leaks and sediment.

Check operation of automatic emergency water system.
Check operation of cooling system.
Check secondary water system.
Check water treatments as required.
Nitrogen System ; Check system for leaks.

Check supply is sufficient for next casting campaign.
Organise re-filling or change-over before machine goes back on heat.
Air System ; Check system for leaks.

Check supply from compressor is adequate and DRY
Crucible Assembly ; Clean out crucible internally from top and lower die sockets.
Inspect seal faces and refurbish if required.
Withdrawal Unit ; Check the tightness of all transtorque couplings.

Check the operation of the internal support arms.
Check the operation of the pneumatic clamping cylinders.
Check the operation of the upper rolls.
Page 113 of 146

Furnace Body ; Check and repair or replace the side door ceramic fibre rope seals.
Check and repair or replace the busbar ceramic fibre rope and silicone seals.
Check and repair or replace the ceramic fibre wool below crucible top thrust plate.
Check and repair or replace the ceramic fibre wool used to seal charging
lids.
Check and replace the ceramic fibre wool within the taphole door.
Check and repair or replace the furnace internal build.
Check and repair or replace the bubbler feed pipes.
Check and repair or replace the heating elements.
Casting Die Tooling Assembly ; Pressure test all the die coolers used.
Material Handling Equipment ; Check operation of coilers and coiler control switches.
Check operation of cut off shear or saw.
WEEKLY
Clean anything that has accumulated any unacceptable levels of dirt.
Repaint anything requires repainting.
Grease or oil taphole mechanism pivot points.
MONTHLY
Withdrawal Unit ; Remove gear guards and re-grease gears.

Check or top up gearbox oil levels.
Lightly grease all withdrawal unit bearings.
Electrical Control Cabinet ; Check and vacuum clean if required.
Transformer Cabinet ; Check and vacuum clean if required.
Page 114 of 146

APPENDIX 4 TEMPERATURE CONTROL PID & SERVO SETTINGS
Touch Screen PID Settings at commissioning 2008
Pb =
Ti = s
Td = s
Page 115 of 146

APPENDIX 5 PLC PROGRAMME ; TO COPY , RESTORE or UPGRADE
To Copy , Restore or Upgrade a PLC Programme (Omron CS1 & CJ1 PLC)
DIPSWITCH
MCPWR (Memory Card Power) 7
POWER /WRITE
EJECT
MEMORY
 To Copy existing PLC Programme onto a Memory Card
 Power up the PLC.

 Insert memory card (minimum 32Mb) into PLC. This will cause the MCPWR and BUSY lights to
illuminate. The BUSY light will extinguish after approximately 10 seconds.
 Flip up hinged PLC panel and move DIPSWITCH No7 to ON (left position)
 Push the Power / Write button and hold for 5 seconds so that the MCPWR and BUSY lights both
illuminate. The BUSY light will occasionally flash.
 Wait until both the MCPWR and BUSY lights extinguish. This may take several minutes.
 Eject the memory card.
 Move DIPSWITCH No7 to OFF (right position) and close the hinged PLC panel.
 Copy all the memory card files to PC for safety :
Place memory card in PCI frame and laptop slot , card appears as extra disc.
Read contents of memory card .
There should be a minimum of 6 files all of which should be copied ;
backup.iom , backup.obj , backup.std , backupdm.iom , backupe0.iom (e0 , e1 , e2 etc) ,
backupio.ior
Page 116 of 146

 To Restore the PLC Programme from a Memory Card
 Power off the PLC.

 Insert memory card into PLC.
 Flip up hinged PLC panel and move DIPSWITCH No7 to ON (left position)
 Wait until both the MCPWR and BUSY lights extinguish. This may take several minutes.
 Move DIPSWITCH No7 to OFF (right position) and close the hinged PLC panel.
 Power off the PLC.
 Eject the memory card.
 To Upgraded a PLC Programme
 Delete only the existing backup.obj from the memory card and then copy the new backup.obj onto
the memory card from the Floppy Disc , CD or Email sent to you by Rautomead.
 Load the newly updated software into the PLC using the “To Restore the PLC Programme from a
Memory Card” procedure as detailed above.
 To Download and Read the Memory Card History / Data
 Place memory card in PCI frame and laptop slot , card appears as extra disc.
 On the memory card are back up copies of BANK1 and BACKUP.obj

These should be initially copied over to a secure store file.
These can be used to restore programmes should the need arise.
BANK1 is a folder containing the NS10 touch screen programme
BACKUP.obj is a file containing the PLC programme
 The data is stored on the memory card as a CSV file, with date in the title, and can be displayed /
interpreted using Microsoft Excel.
Also on the memory card is a Headings.xls file which can be pasted onto the data CSV file in order
to get the correct headings.
Page 117 of 146

APPENDIX 6 TOUCHSCREEN DISPLAYS
6.1 Startup Screen
Figure 1
Startup Screen
This is the screen that appears first when the machine is switched on.
It is blank apart from the buttons at the top of the screen and these allow the user to
navigate around the other screens.
Page 118 of 146

6.2 Clock Screen
Figure 2
Clock Screen
The clock can be set using this screen. The current time and date are displayed in the right
column and the user can change these parameters using the input boxes and pop-up
keypad from the left column. The “Set Clock” Button will move the “Set” values in to the
“Current” values.
This screen is accessed from either the Furnace Temperature Control or Auto start
screens
Page 119 of 146

6.3 Furnace Temperature & Thyristor Control Screen
Figure 3
Furnace Temperature and Thyristor Control Screen
From this screen the Thyristor can be turned on and off and the system can be switched
between Automatic and Hand operating modes. Status messages are displayed below the
thyristor ON/OFF buttons.
The “Furnace Temperature”, “Overtemperature” and “Working Setpoint” are displayed in

the display boxes. While in “Automatic” operation mode, “Setpoint” can be inserted by the
user and current “Output Power” is displayed. When in “Hand” mode, “Output Power” can
be inserted by the user.
The “Setup / Alarms” , “Power Monitor” and “History” screens can be selected using the
buttons at the bottom left of the screen.
The “Auto Start” and “Set Clock” screens can be selected using the buttons at the bottom
right of the screen. When Auto Start has been set for a future time then Auto Start ON is
displayed. This message disappears when heating of the furnace begins at the required
time.
Page 120 of 146

6.4 Furnace Setup and Alarms Screen
Figure 4
Furnace Setup and Alarms Screen
This screen allows the user to insert “Setpoint Ramp Rate” and “Output Power Limit”.
The “Proportional”, “Integral” and “Derivative” parameters for PID control of the furnace
temperature can also be entered from this screen.
From this screen the limits to activate furnace temperature and overtemperature danger
alarms can be entered, as can the “deviation from setpoint” alarm limits.
The “Phase Angle” and “Burst Fire” buttons provide a choice as to how the thyristor
controls the power to the heating elements. Normally “Phase Angle” is selected.
If an alarm limit is reached an alarm will be activated and the relevant display box will
become red, the siren will sound and the beacon will flash. To acknowledge the alarm the
“Alarm accept” button should be pressed. If the fault that caused the alarm remains the
display box will then become green and the siren will be silenced. The alarm will only clear
if remedial action has removed the fault. The beacon will then cease flashing and the
Page 121 of 146

6.4 Furnace Setup and Alarms Screen continued
display box background will revert back to the magenta colour. (If the fault that caused the
alarm has been removed before the “Alarm Accept” button has been pressed the alarm
status will remain although the display box will have changed from red to yellow.)
Page 122 of 146

6.5 Power Monitor Screen
Figure 5
Power Monitor Screen
This screen displays both graphically and numerically the Supply Input Voltage, Thyristor
Output Voltage, Primary Input Currents and Calculated Load Power (kVA).
Page 123 of 146

6.6 Furnace , Overtemp , Dies & Power History Screen
Figure 6
Furnace , Overtemp , Dies & Power History Screen
The screen above displays a graph of the furnace, overtemp and dies 1 & 2 temperatures
against time. The axis values can be changed by pressing the values on the axis and
entering new values using the pop-up keypad. Power is also displayed on this graph as a
percentage. The time period that can be displayed on the graph is between 2 and 30
minutes.
Page 124 of 146

6.7 Die Water Temperature Screen
Figure 7
Die Water Temperature Screen
This screen displays the current temperature readings from the die water thermocouples.
“Danger”, “High” and “Low” alarm limits can also be set by the user using the input boxes
and pop-up keypads.
The “Die Temperature” screen can also be selected using the button on the top left of this
screens. The “History” screen can also be selected using the buttons on the bottom left of
this screen.
“Accept Alarm” button should be pressed. If the fault that caused the alarm remains the
Page 125 of 146

6.8 Die Water History Screen
Figure 8
Die Water History Screen
This screen displays a graph of die water outlet temperatures and water inlet temperature
against time. The axis values can be changed by pressing the values on the axis and
entering new values using the pop-up keypad. The time period that can be displayed on
the graph is between 2 and 30 minutes.
Page 126 of 146

6.9 Die Temperature Screen
Figure 9
Die Temperature Screen
This screen displays the current temperature readings from the die thermocouples.
“Danger”, “High” and “Low” alarm limits can also be set by the user using the input boxes
and pop-up keypads.
The “Die Water Temps” screen can also be selected using the button on the top left of this
screen.
The “History” screen can also be selected using the buttons on the bottom left of this
screen.
Page 127 of 146

6.9 Die Temperature Screen continued
Page 128 of 146

6.10 Services Temperature Screen
Figure 10
Services Temperature Screen
This screen displays the current temperature readings from the services water
thermocouples. “Danger”, “High” and “Low” alarm limits can also be set by the user using
the input boxes and pop-up keypads.
Page 129 of 146

6.11 Withdrawal Unit Screen
Figure 11
Withdrawal Unit Screen
This is the withdrawal unit control screen. From here the Power to the AC motor amplifier
can be turned on and off using the “I” and “O” buttons. A status message is displayed
under the Power Off button.
To start the withdrawal unit moving press the Motor START button.
To stop the withdrawal unit moving press the Motor STOP button.
For an Emergency Stop press the Emergency Stop button on either the electrical control
panel or the withdrawal unit.
This screen allows the user to enter parameters for controlling the movement of the
withdrawal unit motor. “Pulse Time”, “Dwell Time” and “Motor Speed” can be entered using
the input box and pop-up keypad.
Page 130 of 146

6.11 Withdrawal Unit Screen continued
An overdwell can also be setup by entering the time of the overdwell and the number of
cycles between the overdwells.
Refer to manual section 5.8 for more information on withdrawal unit parameter settings.
To aid moving the heavy starter bar / slave bar assembly during the initial setup of the
machine the Inch Pull and Inch Push buttons can be used along with an appropriate small
Motor Speed value. Never ever use the buttons for casting. Press the Inch Pull button to
continuously move the heavy starter bar / slave bar assembly away from the casting die.
Release the button to stop movement. Press the Inch Push button to continuously move
the heavy starter bar / slave bar assembly towards from the casting die. Release the
button to stop movement
Page 131 of 146

6.12 Main Alarms Screen
Figure 12
Main Alarms Screen
When an alarm situation occurs, the “ALARMS” indicator at the top right of the screen will
become red. When pressed, the above screen is displayed. The indicators will become red
if the parameter causing the alarm is within that group. The relevant red indicator can then
be pressed which will then display the relevant screen which will indicate the parameter
causing the alarm.
Page 132 of 146

6.13 Pressure / Temperature Trip Alarms Screen
Figure 13
Pressure / Temperature Trip Alarms Screen
This screen can be selected from the main alarms page. If an alarm occurs an alarm will be activated and
the relevant indicator will become red, the text will change to display a message, the siren will sound and the
beacon will flash. To acknowledge the alarm the “Accept Alarm” button should be pressed. If the fault that
caused the alarm remains the indicator will then become green and the siren will be silenced. The alarm will
only clear if remedial action has removed the fault. The beacon will then cease flashing and the indicator
background will revert back to the magenta colour. (If the fault that caused the alarm has been removed
before the “Alarm Accept” button has been pressed the alarm status will remain although the display box will
have changed from red to yellow.)
e.g. “Water Pressure O.K.” will change to red and display “Water Pressure Low” when the water pressure is
below the value set on the water pressure switch.
NOTE : A “Water Pressure Low” alarm will automatically switch off the electrical power to the heating
elements. However once the water pressure has been restored the electrical power to the heating elements
will begin again automatically.
The PLC battery should last for approximately 5 years. When its charge begins to lower a PLC Battery Low
alarm will occur to remind the operator to replace it. Once the battery has been replaced press Battery Reset
to clear the alarm.
Page 133 of 146

6.14 Alarm History Screen
Figure 14
Alarm History Screen
This screen tells the user what alarms have occurred in the “Description” section up
above. It then displays what time the alarm sounded, when it was acknowledged and also
when it switches off (i.e. when the alarm has been cleared).
There are many pages to store the information on and the user can scroll through these by
using the arrow buttons (bottom of the screen) to view the relevant pages so that the user
can have access to all the alarms that have occurred.
Page 134 of 146

6.15 Auto Start Screen
Figure 15
Auto Start Screen
This screen allows the user to enter a start date and time at which the heating up of the
furnace body will begin automatically.
NOTE : The Auto Start facility will only begin to heating up the furnace body automatically
provided any of the following alarms are not present :
Low Water Pressure

Low Nitrogen Pressure
Low Air Pressure
However once the Auto Start facility has begun to heat the furnace body then only a Low
Water Pressure alarm will automatically switch off the electrical power to the heating
elements.
Page 135 of 146

6.15 Auto Start Screen continued
The Start Time date / time and Furnace Setpoint values can be set using the input boxes
and pop-up keypads. The setting of the Furnace Setpoint value on this screen also
changes the Setpoint value on the Furnace Temperature and Thyristor Control Screen ,
ref figure 3 , if it is different.
Once the Start Time date / time and Furnace Setpoint values have been set press the
Auto ON button to begin the countdown to the Auto Start beginning. Once this button has
been pressed then Auto Start ON is displayed on the Furnace Temperature and Thyristor
Control Screen , ref screen 6.3.
This message disappears when heating of the furnace begins at the required time.
Press the Auto OFF button to cancel the Auto Start at any time.
Page 136 of 146

APPENDIX 7 JACKET COOLER SETTING
Jacket Cooler Setting : Graphite Dies
Assembly
The following procedure refers to a typical jacket cooler-die assembly drawing as shown
below ;
This procedure equally applies to other sizes of jacket cooler / casting die. Refer to the
appropriate assembly drawing for a given size of rod or billet.
The following instructions explains how using a lathe, with a taper turning attachment, an
exact copy of the jacket cooler internal taper is made and then machined onto the outer
surface of the casting die body.
NOTE : Ensure that the cooler has passed testing (11 Bar for 1 hour) before assembly
onto the casting die.
Page 137 of 146

Locating and truing the jacket cooler on the lathe
 Locate the jacket cooler on the lathe using a 3 jaw chuck. The hot end of the jacket cooler,
with the larger I.D should be facing outwards.
NOTE ; For some lathes it may be necessary to remove the brass fittings from the jacket
cooler so that the jacket cooler is securely located within the 3 jaw chuck.
 Use a DTI (Dial Test Indicator) and soft (rawhide) hammer to true up the O.D of the jacket
cooler.
Method : By hand rotate the chuck and gently tap the jacket cooler until O.D run out is
minimised.
 Use the DTI and soft hammer to true up the I.D of the jacket cooler.
Method : By hand rotate the chuck and gently tap the jacket cooler until I.D run out is
minimised.
Page 138 of 146

Page 139 of 146

Copying the exact internal taper from the jacket cooler
NOTE : The lathe used to copy the jacket cooler taper and then machine the die body
taper must have a taper turning attachment as shown in the photo below.
 On the taper turning attachment set the scale to 0.5 degrees.
 Mount the DTI on the lathe cross slide and position the stylus within the jacket cooler I.D at
the 3 O’clock position. Set the DTI to register zero.
 Rotate the lathe carriage hand wheel thereby advancing the DTI stylus along the tapered
surface of the jacket cooler I.D towards the chuck.
Ideally if the setting on the taper turning attachment matches the taper angle of the jacket
cooler I.D then the registered movement of the stylus will not deviate from zero as it moves
along the tapered surface.
If however the DTI registers an increase as it moves along the tapered surface then the
angle set on the taper turning attachment should be increased and the taper
measurement rechecked.
Page 140 of 146

If however the DTI registers an decrease as it moves along the tapered surface then the
angle set on the taper turning attachment should be decreased and the taper
measurement rechecked.
Adjust the angle set on the taper turning attachment and recheck the taper measurement
until the deviation from zero is minimized.
 Remove the jacket cooler from the 3 jaw chuck.
 Accurately measure the jacket cooler I.D at the hot end ignoring the internal chamfer.
Record this measurement for future use during the machining of the die body.
Locating and truing the graphite die body on the lathe
 Locate the graphite die body on the lathe using a 3 jaw chuck.
 Use a DTI and soft hammer to true up the O.D of the die body.
Method : By hand rotate the chuck and gently tap the die body until O.D run out is
minimised.
Page 141 of 146

Machining the external taper onto the die body
 Lightly mark on the die body O.D the “Machine Datum” position. In the case of the
illustrated example this distance is 121mm from the hot end of the die.
 Engage the taper turning attachment drive and begin to machine the taper onto the die
body.
 Continue carefully machining the taper until the die body O.D at the “Machine Datum”
equals the jacket cooler hot end I.D.
NOTE : The machined taper should extend along the die body until the start of the
R6 radius.
 With small / light weight jacket coolers the jacket cooler can be carefully positioned onto
the die body to confirm that the “Machine Datum” has been reached.
NOTE : For larger / heavier jacket coolers this should be avoided as this may
disturb the die body within the chuck.
 Remove the die body from the chuck.
Page 142 of 146

Fitting the jacket cooler onto the die body
 Machine up three setting blocks made from graphite or mild steel. In the case of the
illustrated example the height of these blocks is 115mm which is the final setting datum.
 Position the three setting blocks evenly around the die body.
 Carefully lower the jacket cooler onto the die body ensuring its rotational alignment is
correct with respect to any thermocouple / bubbler holes etc. Refer to the assemble
drawing for guidance. The hot end of the jacket cooler should now be approximately
6mm clear of the setting blocks.
 Using a gas torch evenly heat up the jacket cooler until it has expanded enough to slide
down the die body and rest upon the three setting blocks. Allow to cool down before
handling.
Page 143 of 146

 The assembly of the jacket cooled die is now completed and ready for insertion into the
casting machine. Depending on the machine a feeder tube may be required.
Disassembly
The following procedure refers to a typical jacket cooler-die assembly as shown in the
following photographs. This procedure equally applies to other sizes of jacket cooler /
casting die.
 Place the cold end of the jacket cooler-die assembly onto refractory bricks as shown.
NOTE : Use a steel top bench or other suitable worktop for hot objects.
 Using a gas torch evenly heat up the jacket cooler until it has expanded enough to drop off
the die body and rest on the refractory bricks. Allow to cool down before handling.
Last photo on next page.
Page 144 of 146

Page 145 of 146

Rautomead Limited, Copyright 2008.

All rights reserved and all trade marks acknowledged.
Page 146 of 146

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OPERATIONS AND

Issue 77 - English language version

1st February 2008

The machine uses nitrogen inert gas.

NOTE: The key holder of the machines should be a responsible person.

Any subsequent usage of non-Rautomead parts is done so entirely at the

Any losses, personal injury or equipment damage are the responsibility of

Model Number RT 650

Serial Number xxxxxx

Power rating xxxxxx

Primary Volts xxxxxx

Primary Amps xxx

Net weight of major machine items :

Crucible Assembly full of gold 2000kg

Top Thrust Plate 100kg

1.0 INSTALLATION NOTES

2.0 EXPLANATION OF EQUIPMENT

3.0 CASTING MACHINE FURNACE BUILD

3.1 FURNACE BODY DRY-OUT, RT MACHINES

4.0 CASTING DIE ASSEMBLY

4.1 JACKET COOLED DIE TOOLING - MAINTENANCE OF JACKET COOLERS

4.5 ROD DIE TOOLING - DISMANTLING THE ROD DIE ASSEMBLY

5.0 CASTING PROCEDURES

5.1 CAST AND SHUTDOWN OVERVIEW

6.0 HAZARDS - PREVENTION AND CONTROL

6.1 TAP-HOLE LEAK

7.0 MAINTENANCE PROCEDURES

7.1 CASTING MACHINE STRIP-DOWN, CRUCIBLE REPLACEMENT

8.0 SAFETY PROCEDURES

8.1 MANDATORY PROTECTIVE CLOTHING

APPENDIX 1 Recommended furnace temperature settings

APPENDIX 2 Vendors List - Graphite

APPENDIX 3 Maintenance Schedule

APPENDIX 4 Temperature Control PID

APPENDIX 5 PLC Programme ; To Copy , Restore or Upgrade

APPENDIX 6 Main Panel Touch Screen

6.1 Start-up Screen

APPENDIX 7 Jacket Cooler Setting

Also included are :

Manuals - Proprietary Items (English only)

10.0 DRAWINGS AND PROPRIETARY MANUALS

Factory Layout , RT650 x

Furnace External Build LH Taphole x

Furnace Internal Build RH Taphole x

Heating Elements Assembly x

Die Heater Assembly x

Element , 150mm lg , 2 Clearance Holes x

Crucible Liner Assembly , No Baffle x

Taphole Control Panel x

Withdrawal Unit General Assembly x

TOOLING ASSEMBLY , Dia 4.000” ROD x

Electrical Drawing List x

MANUALS – PROPRIETARY ITEMS

Health & Safety Data Sheets Provided :

1.0 RT INSTALLATION NOTES

1.0 RT INSTALLATION NOTES

1. Oxygen Content: less than 5vpm

2. Moisture Content: less than 2vpm

3. Dewpoint better than -70 degrees C

NITROGEN SUPPLY 8mm OUTSIDE DIAMETER COPPER PIPE

COOLING WATER SPECIFICATION

* mechanically pure viz. optically clear, showing no turbidity or deposits

* total hardness max. 80 mg/litre