290-700181 Manual HVPREMIUM EN V131112

HIGHVAC T + 41 21 943 0000
PREMIUM 2C F + 41 21 943 0001

info @fondarex.com
www.fondarex.com
Instruction manual V131112

V000000
200 500 800
1000 2000
Please read this information before

operating this vacuum unit.
CENTRAL
(subject to change)
COPYRIGHT © 2013 FONDAREX SA
290-700181 1
1)
This instruction manual is valid for the following types of Fondarex HIGHVAC PREMIUM vacuum units
HIGHVAC PREMIUM 2C CENTRAL

HIGHVAC PREMIUM 2C 200
2)
Attention
Since this manual also contains information and knowledge in excess of patent coverage, the data,
graphics and illustrations in this document are
reserved exclusively to HIGHVAC PREMIUM users.
The information contained in this document may be changed by Fondarex any time without prior notice.
None of the information contained in this manual may be published or made accessible to third parties.
A written approval from Fondarex is necessary before any copy of this document (or a part of it) is made.
This manual must be carefully studied, understood and complied with before the installation and start up
of the HIGHVAC PREMIUM vacuum unit is performed.
The USB interface is used for process data saving only.
Fondarex cannot be held responsible for damages appearing after connection of the HIGHVAC
PREMIUM vacuum unit to other machines.
290-700181 2
Modification sheet
Version Date of Modification Name Description
___________________________________________________________________________________
- 16.05.2011 CB general
- 03.11.2011 FSr general
- 21.12.2011 FSr additional sheet FILTER VARIATION
- 10.05.2012 FSr general modifications chapter 6 & 7
V250113 17.03.2013 FSr/JE/CBt Additionals settings / Options F3, F4, F8
V170313 17.03.2013 FSr/SAV new drawings & part list adaption
V130508 08.05.2013 FSr/MNo general
V131112 12.11.2013 FSr/SB illustrations, naming, new layout
290-700181 3
Contents
1 Introduction 6
1.1 Brief Description 6
1.2 Glossary 8
2 Preparation / Connection / Operation 10

2.1 Positioning the vacuum unit 10
2.2 Space Requirements 10
2.3 Power Supply / Connections 11
2.4 Interface Machine Signals 12
2.5 Connection from Siemens Control Panel to Vacuum Unit 12
2.6 Connection with Siemens Control Panel 13
2.7 Compressed Air Connection 14
2.8 Connections of Vacuum Valves or Chill Blocks to Vacuum Unit 15
3 Siemens-Bedieneinheit 16
3.1 Description of the function keys 17
3.2 Description of the entry keys 17
3.2.1 Turning ON/OFF the vacuum unit 17
3.2.2 Turning ON/OFF the automated production with vacuum 17
3.2.3 Vacuum test 19
3.2.4 Pollution check 20
3.2.5 Profile control 20
3.3 Using different function keys 21
3.3.1 F1 Production data 21
3.3.2 F2 Pressure parameter 28
3.3.3 F3 Time parameter 31
3.3.5 F5 Saving parameters 38
3.3.6 F6 Operating counter 41
3.3.7 F7 Password and language 42
3.3.8 F8 Maintenance and further preferences 44
4 Interface 49
4.1 Incoming signals from the die-casting machine 49
4.1.1 Vacu start (impulse) 49
4.1.2 Die open (constant) 49
4.1.3 Die closed (impulse) 49
4.1.4 Vacu lockout (constant) 50
4.1.5 Vacupstop SUPERVAC (constant) 50
4.1.6 Setup (constant) 50
4.1.7 Spray (constant) 50
4.1.8 Central Vacuum Error, Central / C-units (constant) 50
4.1.9 Emergency stop external (constant) 50
4.1.10 Switch over (impulse) 50
4.2 Output signals to die-casting machine (all constant) 51
4.2.1 Unit opreational 51
4.2.2 Operation with vacu lockout 51
4.2.3 Operation with vacuum 52
4.2.4 Vacuum in/out of toleracne A/B 52
4.2.5 Profile Control OK 52
4.2.6 Green Control Lamp 52
4.2.7 Red Control Lamp 53
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5 Technical details / Maintenance 54
5.1 Siemens control panel ET200s / IM151-1 / MP277 8“Touch 54
5.1.1 Operating Display 54
5.2. Maintenance information 54
5.3 Vacuum hoses and filters 55
5.3.1 Removal of filter housing 55
5.3.2 Check vacuum hoses 55
5.4 Air filter in front of the pump 55
5.5 Compressed air processing 55
5.5.1 Compressed air unit 55
5.6 Pneumatic system 55
6 Trouble Shooting Guide 56

6.1 System compressed air processing 56
6.2 Excess temperature in the control box 56
6.3 Vacuum in tank insufficient / central system insufficient (P1) 57
6.4 Vacuum in Channels A / B out of tolerance (P2A1/P2A2 P2B1/P2B2) 57
6.5 Pollution (P7A/B) 59
6.6 No Signal Vacustart 60
6.7 No Signal Die open 60
6.8 Incorrect time settings T1 - T2 - T3 60
6.9 Incorrect time settings T4 - T5 60
6.10 Vacuum value display 60
6.11 Emergency Stop internal and external 61
6.12 Profile test failure (P4 A/B) 61
6.13 No storage medium 61
6.14 Storage medium full 61
6.15 Volume tolerance not reached 62
6.16 Leakage tolerance exceeded 62
6.17 Vacuum pump failure 62
7 Accessories 63
7.1 Options 63
7.2 Tool Set 290-600 / 293-600 64
7.3 Type of pump 64
8 Tecnical documentation 65
8.1 HIGHVAC PREMIUM 2C 500 65
8.2 Flow chart 66
8.3 Schema pneumatic 67
8.4 Draws and part lists 68
290-700181 5
1 Introduction
1.1 Brief Description
Thank you for purchasing a HIGHVAC PREMIUM vacuum unit made by Fondarex.
Through precise integration of a Fondarex vacuum unit, quality of die cast parts and production economy
can be greatly increased.
The purpose of the HIGHVAC PREMIUM vacuum unit is to evacuate air and gases out of the die cavity
before and during the injection of molten metal. The system is designed as auxiliary equipment for die-
casting production and can be installed on new or existing die-casting machines.
The HIGHVAC PREMIUM’s system optimizes the operation and eliminates the need for manual
supervision. It also provides and accepts the necessary communication signals for the integration of a
fully automated die-casting production line.
The Fondarex vacuum unit consists of the following components:
• HIGHVAC PREMIUM Vacuum Unit

• Siemens Control Unit MP277 Touch Screen
• SUPERVAC® valve or Chill Block (not mentioned in this manual)
• Hoses and cables
Type Tank Pump Illustration
HIGHVAC PREMIUM 2C Individual Individual

CENTRAL
Pump control:
independant or with
HIGHVAC PREMIUM C
CNTRAL
HIGHVAC PREMIUM 2C 200 200 Litres 25m3/h Busch
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3
HIGHVAC PREMIUM 2C 1000 Litres 100 m /h Busch
1000
3
HIGHVAC PREMIUM 2C 2000 Litres 160 m /h Busch
2000
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1.2 Glossary
Connections
Main Switch
X1 Main Power Supply
X10A Connection To Vacuum Unit
X10B Connection To Siemens Control Panel
X20A Connection between Siemens Control Panel And Vacuum Unit
X30A Connection between Siemens Control Panel And Die-Casting Machine
X420 Connection „Trace Channel“
XFA Connection „Flowmeter A“
XFB Connection „Flowmeter B“
X410 Connection Ethernet RJ 45
Xext Connection External Unit - optional
AS Compressed Air Connection
AS1 System Compressed Air Processing
M Measurement Of Vacuum In The Cavity
S Closing SUPERVAC® Valves, Operation "Without Vacuum"
P Pulse Function for SUPERVAC® -P Valves
VA Vacuum Hose Channel A
VB Vacuum Hose Channel B
Function Keys
F1 Production Data
F2 Pressure Parameter Settings
F3 Time Parameter Settings
F4 System Parameter Settings
F5 Saving Parameter Settings
F6 Operation Counter
F7 Password / Language
F8 Maintenance
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Parameter
T1 Delay Time „VACUSTART“

T2 Duration Of Active Vacuum / Vacuum Measurement
T3 Vacuum Off / Closing Of The Omal-Valve
T4 Delay Of Pollution Control From Signal “DIE OPEN”
T5 Duration Of Pollution Control
T6 Duration Blowing Time Until End Of Spraying
T7 Production Interruption With Automatic Vacuum Lockout
T8 Profile Check Time
T9 External Vacuum Time (Shot Sleeve Evacuation System)
P1 Tank Limit Value

P2A1 Upper Vacuum Limit (minimum) Channel A
P2B1 Upper Vacuum Limit (minimum) Channel B
P2A2 Lower Vacuum Limit (maximum) Channel A
P2B2 Lower Vacuum Limit (maximum) Channel B
P3A Profile Control Minimum Level Channel A
P3B Profile Control Minimum Level Channel B
P4A Profile Control Limit Channel A
P4B Profile Control Limit Channel B
P5A Maximum Compressed Air Profile Control Channel A
P5B Maximum Compressed Air Profile Control Channel B
P6A Minimum Pressure Limit Pollution Control Channel A
P6B Minimum Pressure Limit Pollution Control Channel B
P7A Nominal Pressure Pollution Control Channel A
P7B Nominal Pressure Pollution Control Channel B
P8A Maximum Pressure Limit Pollution Control Channel A
P8B Maximum Pressure Limit Pollution Control Channel B
S1 Number Of Shots Without Vacuum

S2 Number Of Shots With Insufficient Vacuum
S3 Channel Choice
S4 Number OF Shots Before Valve/Chill block Maintenance
S5 Hot Or Cold Chamber Die-Casting Machine (DCM)
S6 Activation Of Air Volume Measurement
S7 Activation Of “S” and “P” Functions
S8 Selection Of Valve Or Chill block
S9 Profile Control ON/OFF
S10 Profile Control Output Signal Selector
S11 Vacuum Measurement During T2
S12 Vacuum Tank Level Monitoring
S13 Saving Log-Data
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2 Preparation / Connection / Operation
Please check your HIGHVAC PREMIUM vacuum unit and components for possible shipping damages.
2.1 Positioning the vacuum unit
The HIGHVAC PREMIUM vacuum unit should be placed as close as possible to the fixed die half of the
die-casting machine.
All connection cables and hoses have to be installed in such a way that they are protected from molten
metal.
Do not create goose necks in vacuum hoses to avoid spray residue building up inside the hoses.
2.2 Space Requirements
HIGHVAC PREMIUM vacuum unit dimensions:
Type Width in mm. Dept in mm. Height in mm.

HIGHVAC PREMIUM 2C CENTRAL 800 300 600
HIGHVAC PREMIUM 2C 200 800 900 1520
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2.3 Power Supply / Connections
Æ E-Plan
The power switch is on the outside of the electrical cabinet. During power connection the switch should
always be set to „0“.
Main Switch
Power Supply (X1)
Attention:
Please verify that the electrical transformer’s wiring complies with your countries power supply.
Countries power supply:
3-Phase 203 V (Europe)

3-Phase 400 V (Europe, Asia)
3-Phase 460 V (USA)
3-Phase 575 V (Canada)
Fondarex recommends using a 3-phase power supply or a secured connection with a 13 Ah circuit
breaker close to the vacuum unit.
Electrical cables and connectors are provided by the customer.
The unit’s power connector (X1) is provided by Fondarex Please connect the main power supply to the
provided connector.
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2.4 Interface Machine Signals
Æ E-Plan
The connection to the die-casting machine is made with a 24-pole connector (X30A).
For a detailed Interface description, please see Chapter 4.
Minimum required signals: START VACUUM and DIE OPEN.
Attention: 24V DC and 0V needed for Siemens inputs!
2.5 Connection from Siemens Control Panel to Vacuum Unit
Æ E-Plan
The standard cable delivered with the vacuum unit should be used to connect the control unit (X20A) to
the vacuum unit (X10A).
Connection X10A
Connection X20A
Optional cable lengths: 5 m, 10m, 15m or 20m.
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2.6 Connection with Siemens Control Panel
5
1
1 X20A Connection between control panel and vacuum unit Æ E-Plan 11, 52, 53
2 X30A Connection between control panel and die-casting machine Æ E-Plan 56, 58, 59
3 X420 Connection Trace Channel Æ E-Plan 41, 61
4 XFA Connection Flowmeter A Æ E-Plan 41, 61
5 XFB Connection Flowmeter B Æ E-Plan 41, 61
6 X410 Connection Ethernet RJ 45 Æ E-Plan 41
7 Xext Connection Extern unit - optional Æ E-Plan 62
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2.7 Compressed Air Connection
It is necessary to supply the HIGHVAC PREMIUM vacuum

unit with minimum 6bar (70PSI) of compressed air.
Attention:
Air pressure cannot fluctuate below 4bar without
triggering an alarm!
The air pressure hose (length 5m) is included in delivery.

Option: other lengths are available for an additional fee.
Please connect the air pressure hose to the “AS” connection of

the vacuum unit.
Connection AS
Adjust the air pressure inside the unit (AS1) to 6bar.
The integrated manometer indicates the adjusted air pressure.
Air Pressure Unit AS1
Integrated manometer
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2.8 Connections of Vacuum Valves or Chill Blocks to Vacuum Unit
Operating Vacuum Valves:
Please connect S, M, P and VA / VB to the vacuum unit.
M Vacuum measurement in the cavity

S For closing SUPERVAC® valves, operating without vacuum or during the warm-up
P Pulse function of SUPERVAC® -P valves
VA / VB Main Vacuum Hose
VB Vacuum connection for Chanel B
P Connection for Channel B

S Connection for Channel B
M Connection for Channel B
VA Vacuum connection for Chanel A
Operating Chill Blocks:
If using Chill blocks, please do not connect S or P!
Please check that all vacuum hoses between the vacuum unit and the vacuum valve have been
positioned correctly with respect to the die and the press. Be sure that these hoses will not be damaged
during operation.
The main vacuum hose should not have any gooseneck bends in order to prevent a siphon effect.
All connections should be tightened and checked.

All unused pneumatic connections on the pneumatic panel must be capped with the plugs provided.
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3 Siemens-Bedieneinheit
Start/Information window
Attention:
• After starting up the vacuum unit, please do not touch the Siemens control panel until the
“start window” is shown after 35 seconds.
• Never activate the control panel with a screw driver or similar tool.
Screen options
- Calibrate touch screen.

- Deactivates the touch screen for cleaning.
- Configuration.
Push on F1 Produktion data to activate the vacuum

unit.
In case of problems please contact Fondarex after sales service!
[email protected]
+41219430000
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3.1 Description of the function keys
Unit OFF
Unit ON,
Pump running,
Production without vacuum
Fully automatic production with vacuum
3.2 Description of the entry keys
3.2.1 Turning ON/OFF the vacuum unit
Vacuum unit switched ON
Vacuum unit switched OFF
3.2.2 Turning ON/OFF the automated production with vacuum
Automated production with vacuum ON
Automated production with vacuum OFF
Note 1:
Manual production with vacuum valve:
Switch on the vacuum only when the valve profile is completely filled with metal.
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Note 2 :
Automated production:
Vacuum activated.
In this situation there are still 3 possibilities for automatic production without vacuum:
• With the internal, automatic VACU-LOCKOUT (F4) of the vacuum unit

• With the signal VACU-LOCKOUT / Warm-up of the die-casting machine
• With the signal SET-UP from the die-casting machine
Vacuum function ON:

The pneumatic function VACUSTOP inside the vacuum valve is inactive.
Exception: VACU-LOCKOUT or SET-UP
Vacuum function OFF:

The vacuum valve is closed. In other words: The pneumatic function VACUSTOP inside the vacuum
valve is active.
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3.2.3 Vacuum test
Vacuum test active
Vacuum test inactive
Vacuum valve test:

During DIE OPEN, it should be possible to listen to the air flow.
This function key enables a vacuum test out of the production cycle.
Please follow these steps:
• Activate the function key Production WITHOUT VACUUM (vacuum pump switched on).
• The die is closed and the injection piston is moved at least 50 mm over the poring hole.
• Press the function key VACU CHECK approximately 2 to10 seconds.
• The vacuum value should be between 40 and 300 mbar.
• If vacuum value is 150mbar or more, over the tank vacuum value (P1). Then the die and/or the
piston and shot sleeve are not air tight.
In order to exclude shot sleeve leaks, fill the chamber and advance the piston until the shot sleeve is full
of metal. Now perform the test again following the above steps.
Attention:
For SUPERVAC®-P-Valve it is necessary to deactivate the S and P vacuum valve functions.
The Vacuum test can not be done with hot chamber die casting machines. The vacuum will fill the cavity
with metal.
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3.2.4 Pollution check
Pollution check active
Pollution check inactive
This function key enables a pollution check out of the production cycle. During die open. Please follow
these steps:
• Activate the function key Production without vacuum (vacuum pump switched on).
• Press shortly the function key Pollution check. The value of the resistance in the evacuation
system (filter, vacuum hose, vacuum valve / Chill block) will be shown (see F2 –T8)
• Channels A then B will be checked during the set time (T5). These values will help to define the
P6 and P7 parameters.
• Afterwards the value is shown on the main screen (F1).
3.2.5 Profile control
Profile control active
Profile control inactive
This function key enables a profile control out of the production cycle during die closed.
Please follow these steps:
• Activate the function key Production without vacuum (vacuum pump switched on). The die is
closed
• Press shortly the function key profile control. The value of the resistance in the chill bock profile
or vacuum valve profile will be shown (see F2 –T8)
• Channels A then B will be controlled during the set time T8. These values will help to define the
P4 and P5 parameters.
• Afterwards the value is shown on the main screen (F1).
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3.3 Using different function keys
3.3.1 F1 Production data
The main screen indicates the values of each cycle. The values are continuously updated with every new
shot.
F1 Main screen:
Information:
• Green: Signals active
• Green/Yellow: Information
• Red: Alarm
Indication:
• Status of the die casting machine
• Vacuum tank value (P1):
limit value Æ blue
measured value Æ green
• Profile control A (P4A) and B (P4B):
limit value Æ blue
• Vacuum measurement A (P2A) and B (P2B): limit
value Æ blue
• Pollution check A (P7A) and B (P7B):
limit value Æ blue
• Display of cycle position (T-function)
of the vacuum unit
• Selection of the F-screens
290-700181 21
F1 Measurement of air volume removed per shot:
Attention:
The activation of the measurement of air volume
removed per shot has to be activated using F4-
parameter S6.
Description of the measurement:

The volume of air which enters into the vacuum
tank during the period T2 will be measured.
The following data needs to be entered:
• Volume of the vacuum tank (l)

• Volume of the vacuum hoses (l) > (1m
vacuum hose DN25 = ca. 0,5l)
• Volume of the die cavity (l)
• Extra air volume, for example filter systems,
etc. (l)
• Volume correction due to temperature
changes
• Automatic measurement of the air pressure
inside the tank before and after the T2
• Leak tolerance (there is more air and gas
volume measured than the calculated total
volume)
• Tolerance up to the minimum calculated air
volume (by entering 25%, minimum 75% of
the calculated air volume must be reached)
• Number of shots out of tolerance, before
alarm
290-700181 22
LeakTest
This test consists in supplying air under pressure into the mold through the suction device.
Once an amount of air is injected and a certain pressure reached, measuring of the actual pressure drop
in the mold. (time / pressure).
Pressure drop must considering account of the state of the mold, the state of plunger, of the various
drawers and the vacuum piping.
In practice, the perfect seal is rarely reached, and the pressure is lower.
Once the test is validated, the resulting measures are recorded (memory) for a further comparative test.
LeakHunter
This utility allows you to check for leaks on installation. Air is injected continuously without exceeding the
4bar and without falling below 2.5 bar to always have a presence sufficient to detect air leakage aurally,
or at best with a device.
Stabilization time
Charging time before end self- before measurement Effective testing time,
test measurement of pressure
drop
Pressure values, min

and max adjustable
Release button,
pressure
Residual pressure
after test, current value
Percentage of air
leakage, value
decorded
Percentage of air Recorded values Residual pressure after

leakage, current test, value recorded
value
290-700181 23
LeakTest et LeakHunter
Before running the test ensure that:
• All connections, hoses, clamps are tight and properly implemented

• Pmax = 4bar
• Vacuum cavity, free of material
• adjust the signal VACUSTART in a more advanced position in the eralier departure filling phase
• F4 S7 on 0
• Molde close
• no signal MOLDE OPEN
• Injection Piston advanced manually in a tight position with the flow chamber (about 40 to 200 mm
passing the fillhole)
• if possible testing for leaks 3with liquid metal flow in the flow chamber (more precise,
temeprature- tightness)
• 2 different tests are possible : 1) Position after about 20mm START VACUUM
2) Flow chambre filling with metal
290-700181 24
Examples of settings for the temperature %:
Setting of the
Temperature of the die Volume of the die cavity Vacuum hose length
temperature %
140 up to 3l 7m 99%
180 3 – 8l 5m 95%
220 8l 3m 90%
F1 LOG-DATA: Display and recording all important vacuum die-casting data
Before any production, please enter how many shots should be registered and where the logged-data
should be stored. For further use of this data, Fondarex recommends that you use either a USB flash
drive or a LAN-connection in order to transfer the data to a computer.
Attention: Make sure that there are no viruses on the USB flash drive!
Recording of data under F4
4 possibilities to record data:
1. Internal saving on Siemens control panel:

1’000 shots
2. On MMI card (depending on free space):
5.000 to 100.000 shots
Attention: This data can not be used for
further purposes!
3. On USB flash drive: 1'000'000 shots /
4GB
4. Ethernet (RJ45) to a PC – at the end of
each cycle the data will be transferred to
the designated folder (see optional
manual)
To read the production data, please follow the

steps below:
• Select new Log-Data

• The production number starts from 0
• The designated time and shot can be
selected
The following data is shown on the screen:
• Statistics of the shots produced with or

without vacuum
• Statistics of the die-casting parts
produced within vacuum tolerance
290-700181 25
F1 Average value
Determining average values of:
• Profile control value (P4A and P4B),

• Vacuum value (P2A und P2B)
• Pollution value (P7A und P7B)
• Selected shots (1 to 500)
Allowing precise adjustments of the following

parameter settings:
• Profile control
• Vacuum measurement
• Pollution check
F1 Vacuum curve channel A
The screen shows the last measured vacuum

curve for channel A.
The measured time can be:
• the set time T2 (red line)

• the switch over (DCM-signal) or
• the signal VACU-START (F4 parameter
S11)
F1 Vacuum curve channel B
The screen shows the last measured vacuum

curve for channel B.

S11)
290-700181 26
F1 Air volume diagram channel A
The screen shows the last removed air volume Airflow A

curve for channel A.
• set time T2 (red line)

• switch over (DCM-signal) or
• signal VACU-START (F4 parameter S11)
The calibration of the sensors can be done under

F8
F1 Air volume diagram channel B
The screen shows the last removed air volume

Airflow B
curve for channel B.

S11)
The calibration of the sensors can be done under

F8
290-700181 27
3.3.2 F2 Pressure parameter
F2 Vacuum value in the tank
If the vacuum value inside the tank goes over the

set limit during production, then the vacuum unit
will indicate an error.
To deactivate the alarm, press reset!
Attention:
If the value in the tank increases, check the air
filter and the oil in the pump.
F2 Vacuum limit in the cavity for channels A and B
When the measured vacuum value is

• between the upper vacuum tolerance limit
P2A1 (minimum producing vacuum value)
• and the lower tolerance limit P2A2
(maximum vacuum value)
the shot is considered within tolerance.
The same is valid for channel B
290-700181 28
F2 Profile check limits
Profile check limits for the chill block/vacuum

valve can be set on screen F4 S9.
P3 Minimal Pressure – if the pressure can

not reach the given value, then the
vacuum unit indicates an error Fault
profile check.
P4 Nominal Pressure – if the measured

pressure is higher than the given value,
the vacuum unit indicates an error Fault
profile check.
P5 Maximal Pressure – if the pressure is

over that value, then the vacuum unit
indicates an error without waiting on
result P4 Fault profile check and shuts
down.
By incrementally increasing the values of P3, P4

with P5 being around 3000 mbar, there is also
the possibility to check if the valve during
production without vacuum is correctly closed.
Attention:
The profile check works only with the optional signal DIE CLOSED.
Die closed Dosage
Signal pollution measurement

before dosage
Compressed air
Pollutionmeasurement
Die closed
Pollutionmeasurement by
Vacuum generated air flow
290-700181 29
F2 Pollution control limits
Pollution control limits in:
• Vacuum hose
• Vacuum filter
• Chill block notch
• Evacuation piston notch
P6 Minimal pressure – if the pressure can

not reach the value, the vacuum unit
indicates an error Fault pollution control.
P7 Nominal pressure – if the pressure is

over the value, the vacuum unit indicates
an error Fault pollution control.
P8 Maximal pressure – if the measured

pressure is higher than the value, the
vacuum unit indicates an error Fault
pollution control and shuts down.
Die open
Compressed air
Result of pollution
Difference air flow measurement

Air flow
Difference pollution
290-700181 30
3.3.3 F3 Time parameter
F3 Time settings DIE CLOSED
T1: Delay starting from the signal VACUSTART

up to T2 (active vacuum)
T2: Active vacuum during the filling phase of

the cavity. Measurements of the vacuum in
the cavity until the end of T2.
The setting for T2 should be from the time
the pour hole is has been passed by the
piston and the end of the filling of the cavity.
T3: Vacuum off: closing of the Omal vacuum

valve inside the vacuum unit. The closing
has to happen once the injection process is
complete.
T8: Profile check duration
T9: External Vac duration (shot sleeve

evacuation system). The External Vac is
delivered as an option.
290-700181 31
F3 Time settings DIE OPEN
T4: Pollution control delay once the signal DIE

OPEN has been received.
T5: Pollution measurement

Blowing trough the vacuum hose and filter.
Pollution measurement should begin with

the spraying. This will help to keep the
spray out of the valve. Compressed air
consumption can be high!
Measurement of channels A and B
The measurement should end before DIE

CLOSING, if not the unit indicates an alarm.
F3 Time settings DIE OPEN
T6: Blowing with the M hose, until the end of

spraying.
T7: Production interruption:

Automatic shut down of the vacuum pump
at:
• No signal T7 DIE OPEN
• „Vacuum start“
Reactivate with:
• Reset
• Signal DIE OPEN
• Start Vacuum
Attention: production start
290-700181 32
Digital Outputs Programmable
This function allows you to control other devices via pnematic channels S and P (dedicated screen) or via
2 digital outputs (dedicated screen). All of thema are programmable sequences with different marks of
cycle.
To use this function, set S8 on 2
Then enter the desired sequences by:
• Sequence On / Off
• Start
• Time
• Duration (if no end input)
• End (if no time entry)
• Reccurence
F3 Time settings, Program Channel 1 & 2
Time and duration
F3 Time settings, Stop Pulse Manu
Beginning and end

Digital stop puls F8
290-700181 33
3.3.4 F4 System parameters
F4- System parameters S1, S2, S3
S1 Number of shots to run in auto vacuum

lockout
S2 Number of consecutive shots with vacuum

out of tolerance before activation of alarm
S3 Valve position choice A or B / A + B

Modification only possible at VACUUM
OFF
F4 System parameters S4, S5, S6
S4 Number of shots before reminder of

vacuum valve maintenance. This
parameter does not shut down the vacuum
unit.
S5 Hot- or cold chamber system die-casting
S6 Activate the volume measurement (F1)
290-700181 34
F4 Activation of S and P
S7 Activation of S and P:
0 Æ signal VACUSTART
1 Æ after signal DIE OPEN
2 Æ after signal DIE OPEN turns off an S is
active after time t3
S8 Valve or chill block
0 Æ Valve
1 Æ Chill
2 Æ active digital output for single piston
valve SPV
S9 Activation of profile control
Attention:
The signal DIE CLOSED has to be given by an
impulse after each shot.
(Æ E-Plan)
F4 Vacuum measurement with T2
S10 Output profile control

0,2s or until DIE OPEN
S11 Vacuum measurement during T2

can be set to:
• 0 = T2 or with signal Switch-over (filling

phase or end of the injection phase)
• 1 = T2 or with signal VACUSTART
Attention:
T2 should be sufficiently long!
S12 Time before exceeded value P1 triggers

alarm
290-700181 35
F4 Data-Log
S13 Data-Log:
0 = Siemens Control Panel

1 = MMI Card
2 = USB flash drive Æ choose F8!
3 = Ethernet (optional)
(Manual included)
F4 System parameters out put signal
The output signals can be inverted by entry „1“.
• Vacuum A (tolerance)
• Vacuum B (tolerance)
• Vacuum status (selected)
• Vacuum blocked (actual value)
• Unit status (failure / working)
• Profile control (tolerance)
Attention:
If only one signal for the vacuum level in or out of
tolerance can be received to the DCM, you have
to select under F8 to lead the B channel to A
(one signal for vacuum tolerance)
(Æ E-Plan)
290-700181 36
F4 Vacuum regulation setting
In order to control the flow of air from the die

during T2, a mechanical system using two pistons
can be adjusted. T2 is divided virtually into three
time periods. The first third (R1) is used most to
reduce vacuum as liquid metal enters the runners.
rd
R1 – First 3 of regulation has great influence.
rd
R2 – Second 3 of regulation is used only
with very slow injection piston speeds.
rd
R3 – Last 3 of regulation
In order to use vacuum regulation properly, T2

must be optimally set.
Regulation settings:
0 - No regulation
1 - Light regulation
2 - Strong regulation
Facilities from Septembre 2012 :
Tr 1 large time reduction from the active vacuum

Tr 2 medium time reduction from the active vacuum
290-700181 37
3.3.5 F5 Saving parameters
F5 Time parameters T
F5 Pressure values P
290-700181 38
F5 System parameters S
F5 Output signal configuration
290-700181 39
F5 How to create a new datasheet:
Only once all parameters have been entered then

press:
Then name the datasheet
Then press
to upload parameters.
Then press:
to save.
A oroduction number is automatically assigned
select a datasheet.
To activate (download to CPU) the datasheet

press
the datasheet is operational..
This button is for deleting a datasheet.
Caution:
In order to save parameters, the unit must be
powered up but not running! See 3.1 unit off!
290-700181 40
3.3.6 F6 Operating counter
F6-Operating data log
Showing:
• Operation hours
• Injection counter
• Remaining time before pump maintenance
• Remaining time before valve maintenance
These can be reset to zero at any time by

pressing the reset button:
• Pump should be reset after oil and filter change

• Valve should be reset after valve maintenance
or a valve change
290-700181 41
3.3.7 F7 Password and language
F7 Password entry
F7 Username und Passwort
Username Password
Operator 101
Wartung 202
290-700181 42
F7 Language selection
Please select your desired language.
F7 Alarms Overview
290-700181 43
3.3.8 F8 Maintenance and further preferences
F8 Input signals
(see also E-Plan: P. 58 and 59)
F8 Output signals
With DIE OPEN these signals can be activated

using the password 202.
(See E-Plan: P. 56)
290-700181 44
F8 Pneumatics and sensors
The pressure sensors readings are shown

directly.
F8 Simulation mode
Simulation screen:
On this screen all signals are simulated.
In simulation mode a vacuum valve and/or chill

block, the power supply, compressed air and the
interface must be connected to the unit.
In this mode the vacuum unit can be tested

without connecting the die casting machine.
290-700181 45
F8 Vacuum values freezing
1) The vacuum value (curve) is frozen at the

end of T2 and until die open. This is to give
us the exact value at end of the injection
phase.
2) The vacuum lockout signal can be inversed.

(See E-Plan: P. 61)
3) Vacuum tolerance signals for both channels

A and B can be redirected to channel A.
(See E-Plan: P. 56)
4) S is active if die is not open and works

without vacuum.
5) Pump no operating
6) Digital Stop an Puls on S et P
Reversal of functions S and P
This function allows you to work with a device

that responds to the same sequence S and P as
embedded in the original Highvac but externally
via digital outputs without having to parameterize
7) If a new production is selected (F5 6/6)

injection counter goes automatically back to r
0
8) On F6 information for cleaning (indication)
For further technical questions, please contact the Fondarex after sales service.
[email protected]
+41219430000
290-700181 46
Alarms Inhibiter
With this functionits possible to cancel some
alarms, when the group is supervised already by
ynother entity (Press, Hypervisor cell, etc…)
Once the alarm is disabled, HIGHVSC works
without stopping the production.
Base alarms such as:
- Emergency STOP
- Pump
- Compressed air
- Temperature panel
are maintained for reason of safety, quality and
integrity of the unit
deactivated alarmes
If the vacuum state is no supervised, the quality

of the produced parts can be insufficient and
undermines the process.
Do not use without supervision!!
Equalisense
This feature allows you to refine and correct all

measurement variation that can have sensors
between them.
The calibration is dome from the sensor the most
accurate as P1 (Tank), with the least active
measuring range. At best, P1 has to be calibrated
using an external vacumeter, to get the perfect
quality.
Once P1 is calibrated, the channel sensor can be
calibrated. The system will balance the chosen
sensor and P1, comparing values, adjusts and
corrects the chosen sensor.
For obvious reasons of quality, calibration is
carried out under vacuum, so all values are made
to compare witrh the higher vacuum arttainable
system.
The tools must be implemented for calibration, it
is simly bypass the channel A with measurement
A, to be conitued with other channels ( B +
MB….)
290-700181 47
Sensor, to calibrate Reference sensor Master
Button for calibration
Reset and abandonment

for correction of the
calibration (return to
measurement native
sensor)
EqualiSense
Before starting the test ensure that.
• - The tools required for this operation are available and implemented
• - Verification of P1 was performed
• - no leakage
• - password WARTUNG
Data logging options
When storing on a USB flash drive, the USB data

log must be turned on.
Use the Ethernet data log when transferring data

via an Ethernet cable (RJ45) directly to a PC file.
Analogue value preferences / Airflow sensor

calibration. (en)
(Optional, see E-Plan: P. 55)
290-700181 48
4 Interface
4.1 Incoming signals from the die-casting machine
The HIGHVAC PREMIUM vacuum unit requires two incoming signals to synchronize with
die-casting machines:
Vacustart (impulse)
Die open (constant)
Six further inputs are available for automation of the casting cycle:
Die closed (impulse)

Vacu lockout (constant)
Vacu stop dircet (constant)
Spray (constant)
Switch over (impulse)
Set up (constant)
Central vacuum error (constant)
Emergency Stopp external (constant)
4.1.1 Vacu start (impulse)
The vacuum cycle starts when the signal VACUSTART is activated. This signal can be delayed by T1 in
the HIGHVAC PREMIUM vacuum unit in order to optimize the start of the vacuum called VACUSTART.
This signal can be obtained by in 2 different ways from the die-casting machine:
• Signal given by die-casting machine in reference to the piston position in mm
• Piston start position given by the die-casting machine. In this situation use the T1 parameter to
delay Vacustart until the piston has passed the pour hole.
Attention:
The VACUSTART signal from the die-casting machine must be active for at least 0.2s and also be active
during manual production or production without vacuum.
4.1.2 Die open (constant)
The signal DIE OPEN brings the vacuum cycle to an end and starts the pollution test. DIE OPEN has to
be active as long as the die remains open. This is valid for all situations, also during manual production or
production without vacuum.
4.1.3 Die closed (impulse)
The DIE CLOSED signal activates T8, to start the profile control of the chill block.
This function also controls vacuum valves. For further information see (F4).
290-700181 49
4.1.4 Vacu lockout (constant)
This signal offers the possibility to interrupt the vacuum function without stopping production. This is valid
for die-casting machines which are equipped with the function slow shot or production start.
When the unit is running with VACU-LOCKOUT, the Supervac® valves are closed to avoid molten metal
penetrating into the valves and vacuum channels.
4.1.5 Vacupstop SUPERVAC (constant)
Under some circumstances and for trials, it is possible to close the SUPERVAC® valve pneumatically.
Using SUPERVAC® standard valves the delay time is 60 to 180 ms from the reception of the signal until
the valve is closed.
4.1.6 Setup (constant)

SETUP
Under normal circumstances, the control unit monitors the signals VACUSTART and DIE OPEN per
machine cycle. While setting up the die-casting machines, one of the mentioned signals very often fails to
appear. This will trigger an error in the HIGHVAC PREMIUM unit. This error can be cancelled with the
signal SET-UP.
4.1.7 Spray (constant)

SRAY
As long as this signal is activated, air will be blown out of the SUPERVAC® valve. This signal should be
connected to the spaying units. The signal is important in order to avoid lubricant from entering the valve.
When the signal SPRAYING is activated, we suggest you set the timer T5 to 2s.
4.1.8 Central Vacuum Error, Central / C-units (constant)

CENTRAL VACUUM ERROR
The input signal will be received to check the status of the central vacuum system. In case of a fault, an
alarm will appear on the screen.
4.1.9 Emergency stop external (constant)
EMERGENCY STOP
The unit is equipped with an emergency Stop input signal. If this signal is not active the power supply is
turned off for the pneumatic valves, the fans and the output module of the controller.
4.1.10 Switch over (impulse)
A short signal at the beginning or at the end of the filling phase that is used to determine the exact
vacuum value at either of these set points. Once the active vacuum time (T2) is over, vacuum
measurement ends.
290-700181 50
4.2 Output signals to die-casting machine (all constant)
These signals are at your disposal as dry contacts however, they are not required for the operation of the
HIGHVAC PREMIUM vacuum unit. The signals can be applied to the die-casting machine or used for
external signalling. The signals can be activated and deactivated in the F4 parameter screen.
The following 6 signals are available as low-voltage outputs (24V):
Unit operational / failure
Operation vacu lockout

Operation vacu-lockout
Operation with vacuum
Operation wih vacuum
Vacuum sufficient
Vacuum suffiient
Vacuum insufficient
Vacuum insufficient
Profile control OK
4.2.1 Unit opreational
The signal UNIT OPERATIONAL is activated with the button
The pump will run, once there is sufficient vacuum in the tank and there are no system failures the signal
is active.
In the case of a system failure, this signal is inactive. On certain units it is possible to connect this signal
from output 14 to output 12. This configuration shows a unit failure if the relay is not working properly (e.g.
power failure of the vacuum unit)
4.2.2 Operation with vacu lockout
VACULOCKOUT
If this signal is activated, the SUPERVAC® valve is automatically closed. It is active during:
• Slow shot
• Vacu-Lockout coming from the die-casting machine
• System failure
• Pollution failure
• Set-up
The signal remains active until the unit operates not longer with VACU-LOCKOUT.
In this mode the input signals DIE OPEN and VACUSTART are not accounted for.
290-700181 51
4.2.3 Operation with vacuum
WITH VACUUM
As soon as OPERATION WITH VACUUM is active and the start-shots are completed the vacuum
operation starts. At this moment the signal OPERATION WITH VACUUM becomes active. This signal
remains active until the unit indicates an error or the button VACUUM OFF is pushed.
4.2.4 Vacuum in/out of toleracne A/B

VACUUM IN / OUT OF TOLERANCE
The signal VACUUM IN TOLERANCE is activated when the vacuum value P2A or P2B is reached during
the given T2 time. This signal remains active until the signal DIE OPEN If the vacuum value is not
reached then the signal VACUUM OUT OF TOLERANCE becomes active.
Beware:
When both channels use the same signal then channel A should be activated under F8 5/6
4.2.5 Profile Control OK
The signal PROFILE CONTROL OK is active when the chill block has passed the air flow test. The signal
can be activated either for 0.2s or until DIE OPEN (S10).
4.2.6 Green Control Lamp
Green Control Lamp ON: The system is operating and the vacuum cycle is active.
Green Control Lamp OFF: The system is switched off (or system failure).
290-700181 52
4.2.7 Red Control Lamp
SYSTEM FAILURE
Red Control Lamp On: A system failure has occurred. Please check the following possibilities to solve
the problems (Explanation 6.1. to 6.17)
No VACUSTART signal
No signal DIE OPEN
Synchronizing failure
Central vacuum error
Wrong time setting T1 / T2 / T3
Wrong time setting T4 / T5
Vacuum tank value out of tolerance
Profile controle out of tolerance
Vacuum value out of tolerance
Emergency stop
Compressed air too low
Vacuum pump error
Temperature of control box too high
Pollution measurement out of tolerance
Red Lamp OFF: The system is switched off or works properly.
For further technical questions, please contact the Fondarex after sales service
[email protected]
+41219430000
290-700181 53
5 Technical details / Maintenance
ATTENTION!
For all maintenance work, the HIGHVAC PREMIUM vacuum unit must be switched off.
5.1 Siemens control panel ET200s / IM151-1 / MP277 8“Touch
5.1.1 Operating Display
All lights should be green during operation.
Please contact the Fondarex-after sales service in case of any problems.
5.2. Maintenance information
To make sure that your vacuum unit always works properly, please follow the maintenance schedule as
shown.:
Notice: Ask for our individual service. The experienced Fondarex service team will help you.
Fondarex
Schedule Unit Action Documentation
Article-No.
Daily Vacuum pump Oil-level Busch 080-032
Vacuum filter, 900-085
Channels A und B / Visual check, to clean with
/
Main air filter (in front compressed air or replace
054-026
of pump)
Weekly or after General check of tidiness
Vacuum hoses
160 hours of and tightness
operation Pressure, gauge glass and
Compressed air unit
filter to control, Festo
AS1
maybe.dump water
Pneumatic hoses and General check of tidiness
cables and tightness
Service incl.
Busch RA
Vacuum pump oil filter, air filter, oil
Every 6 months 25/40/63/100m3h
separator, oil change
or after 1500
hours of
operation HIGHVAC PREMIUM Check power connections
vacuum unit by an expert
290-700181 54
5.3 Vacuum hoses and filters
5.3.1 Removal of filter housing
1. Remove vacuum hose

2. Push and turn the filter cap against clock and take it off
3. Take out filter
4. Clean filter
5. Please check that all sealing surfaces are clean
6. Put all positions back on
7. Check pollution test if ok
5.3.2 Check vacuum hoses
Please check recurring all vacuum hoses whether all screws are tightened an
avoid goose necks when installing the vacuum hose Clean vacuum hoses by using
compressed air to avoid pollution.
5.4 Air filter in front of the pump
Check this filter weekly and clean it with compressed air.
Attention:
The filter can be polluted by wax particles.
The air filter has to be replaced when the vacuum data in the tank of 20mbar will
not be obtained in 130s.
Do not wash the air filter!

In case of pore blockage, the filter has to be replaced!
5.5 Compressed air processing
5.5.1 Compressed air unit
Please check regularly the reservoir of the water separator; it has to be empty. Please make sure that the
manometer shows minimum 6bars and that all pneumatic connections are tightened.
5.6 Pneumatic system
In general, there is no maintenance necessary at the pneumatic system.

See chapter 8, Function of pneumatic schema.
290-700181 55
6 Trouble Shooting Guide
SYSTEM FAILURE
The HIGHVAC PREMIUM vacuum unit is equipped with an internal error diagnosis system that allows
locating failures rapidly. The source of errors is shown on the display.
If the system detects a malfunction, the, the vacuum unit turns off and the red control lamp on the control
panel is activated.
Please find the ascertainable errors as described below:
6.1 System compressed air processing

COMPRESSED AIR, PRESSURE TO LOW
The required compressed air is controlled by the vacuum unit’s program.
Possible causes:
• Wrong setting for overload relay (F1). This relay is placed directly on the motor starting contactor
(K1)
• Insufficient air pressure to the system
• The pressure control valve of the pneumatic control unit is set too low, it should be set to 5bar.
• Too much pressure lost during the blowing function of the unit.
• The compressed air hose may be twisted or kinked.
6.2 Excess temperature in the control box

TEMPERATURE OF CONTROL BOX TO HIGH
Overheating of the control box

The temperature is supervised with a control device (T2) that is fixed on the mounting plate.
Possible causes:
• The ambient temperature is too high.

• Check if the HIGHVAC PREMIUM control box is exposed to extreme thermal radiation, e.g. oven,
etc.
290-700181 56
6.3 Vacuum in tank insufficient / central system insufficient (P1)
VACUUM IN THE TANK OUT OF TOLERANCE
The vacuum in the tank is measured by a sensor (P1). If the vacuum value is, for the time of S11, over
the limit value P1 then a system error is shown Vacuum tank out tolerance.
Possible causes:
• Air filter in front of the pump is polluted!
Attention:
The filter can be polluted by wax particles.
Possible causes:
• Oil of pump insufficient or too old

• Required to change oil of pump
• Leak
6.4 Vacuum in Channels A / B out of tolerance (P2A1/P2A2 P2B1/P2B2)
VACUUM OUT OF TOLERANCE
The vacuum was measured out of the tolerance limit P2a and P2b.
Possible causes:
• Die not tight enough.

• Flash on the die.
• Flash on the valve or chill block.
• Too much lubricant in the die.
• Leak in hose M (measure).
• With P valves the spring is fatigued and the valve closes too early.
• Suction time too short.
• T2 parameter not correctly adjusted.
• Limit values P2A1/P2B1 and P2A2/P2B2 not correctly adjusted.
290-700181 57
check tightness
of die : if flashes clean
flashes, sliders surface PRODUCTION
still bad
reading
service
vacuum
disconnct the the vacuum valve :
reading OK
"P" hose check springs, nozzle
PRODUCTION
(only for P-valves) and servo piston
replace if necessary
no
change
check unthight fasten connections

the M-hose connection or PRODUCTION
if tight replace M-hose
no
change
if vacuum
vacuum built up check main vacuum hose :
cover pore hole
OK is to slow - filter on valve
with plunger
PRODUCTION - filter on VP-Mini "valve check"
and
evt. OMAL-valve
press "valve check"
if defect, exchange
vacuum level
still to low
compare Difference
vacuum level on screen >50mbar exchange "valve check"
and on manometer P-sensor
in cabinet
nothing
can be found
contact the
FONDAREçX
Help-Desk
290-700181 58
6.5 Pollution (P7A/B)
POLLUTION OUT OF TOLERANCE
If the actual value higher than the adjusted limit value of P7, please check valve hose or filter for
pollution. When operating chill blocks, please check the chamber or the filter collar.
A failure appears on the control panel and the vacuum unit switches off.
This information stays on the screen until the failure is resolved and can be erased by pressing RESET.
is blow out
possible to hear ?
yes
level
press "Pollution-Test" OK System
w hen die open clean enough PRODUCTION
level
to high
disconnect
clean main vacuum hose
the vacuum valve on vacuum valve
recheck
the pollution level
level
to high
check
clean
the filter
the filter
in the unit
clean
contact the
FONDAREX
Help-Desk
290-700181 59
6.6 No Signal Vacustart
VACUSTART SIGNAL LOST
The internal supervision system checks at each machine cycle if the control units receive the machine
signal VACUSTART. If the signal is absent 6 consecutive times the unit turns off.
Possible causes:
• Loose electrical connection

• Relay failure of machine signals
Actions:
Check the control unit under F8 to see if the input signal concerned are active.
6.7 No Signal Die open

DIE OPEN SIGNAL LOST
Supervision and possible causes see 6.6. no signal VACUSTART.

Please check input signals.
6.8 Incorrect time settings T1 - T2 - T3

TIMING ERROR T1/T2/T3
The time function parameters T1, T2 and T3 determine the duration of the VACUUM ON function. If the
press signals DIE OPEN before VACUUM ON is finished one or more of the time parameters are wrong.
(too long).
6.9 Incorrect time settings T4 - T5

TIMING ERROR T4/T5
Time function parameters T4 and T5 determine the duration of the POLLUTION TEST function.
If the die closes and the pollution test has not yet ended the time parameters are wrong. (too long).
Attention:
While working with channels A and B, the T5 parameter is activated twice consecutively for
channels A and B.
6.10 Vacuum value display
If in doubt that the correct vacuum value is indicated on the display, compare it with the indicated value
on the manometer. If the difference is higher than 50mbar, it is possible that the P2 sensor is defect.
290-700181 60
6.11 Emergency Stop internal and external
EMERGENCY STOP
The EMERGENCY STOP button on the control box was activated or the external EMERGENCY STOP
signal has been released.
6.12 Profile test failure (P4 A/B)

PROFILE CONTROL OUT OF TOLERANCE
The surface of the chill block has to be cleaned.
The time parameter T8 has to be very short (0,15 – 0,5) depending on the size of the chill block.
Using a vacuum valve:

The evacuation piston is not closed! Check the mould clamping and check the vacuum valve
6.13 No storage medium

NO STORAGE MEDIUM
If the data log is set to USB flash drive and this is missing, then this error is shown.
• Install flash drive and press reset.

• Activate USB flash drive under F4 and F8.
If the data log is set Ethernet and the transmission fails, then this error is shown.
• Activate Ethernet under F4 and F8.

• Check Ethernet connection.
• Check available space on the PC.
Caution: Please be sure that your storage medium is free of viruses!
6.14 Storage medium full

STORAGE MEDIUM FULL
There is no more free space on the storage medium.

Please use a new storage medium or free up space on the old one.
290-700181 61
6.15 Volume tolerance not reached
ASPIRATED VOLUME NOT REACHED
Check evacuation time and piston speed.
6.16 Leakage tolerance exceeded

LEAKAGE TOLERANCE EXCEEDED
Die is not air tight.

Too much die lubricant which created a lot of gas.
6.17 Vacuum pump failure

OVERLOAD VACUUM PUMP
Check oil level top up if needed.

Check the vacuum pump (see Busch operating manual).
290-700181 62
7 Accessories
7.1 Options
290-700181 63
7.2 Tool Set 290-600 / 293-600
Pos. Pcs. Article. Description ABC
1 030-062 Plug L 28 (for nut M36x2)

1 070-518 Fuse FST 0,5A "CSA"
1 070-698 Fuse 25A
1 (2) 080-032 Anderol 555
1 080-905 Set of 4 metalsheets
1 082-001 Hex Key Set 1,5-10
1 082-011 Hex Key Wrench 10x13
1 082-014 Wrench 14-17
1 082-019 Wrench 19-22
1 082-024 Wrench 24
1 082-041 Wrench 41
1 200-187 hose lg 5000 assy
2 900-029 Connecting hose assy (Mini)
7.3 Type of pump
Pos. Pcs. Article. Description ABC
1 054-001000 Vacuum pump 160m3/h B 1

1 054-001100 Spin on oil filter 160-250m3/h A 1
2 054-001120 Exhaust filter 160-250m3/h A 2
1 054-001017 Air filter cadridge 160-250m3/h A 1
1 080-032 Oil for pump 1l A 1
1 054-020 Vacuum pump 100m3/h B 1
2 054-026 Air filter cadridge 100m3/h A 1
1 054-027 Vacuum pump 63m3/h B 1
290-700181 64
8 Tecnical documentation
8.1 HIGHVAC PREMIUM 2C 500
290-700181 65
8.2 Flow chart
290-700181 66
8.3 Schema pneumatic
290-700181 67
8.4 Draws and part lists
Spare list of HIGHVAC PREMIUM 290-000181

Recommended spare parts, always in stock A
Recommended spare parts, if possible in stock B
Spare parts, used less often C
Pos. Pcs Article No Description ABC
1 1 290-000080 HV500/40 PREMUIM C 1

1.1 1 290-000070i Case complet C 1
2 1 290-000060c Control Box complete C 1
4 0 290-000085 Support, OPTION C 1
5 0 290-000103 Wall Fixation, OPTION C 1
6 1 270-067 Connecting cabel and VP cde 3m B 1
7 1 070-280 Electro connector Interface C 1
8 1 071-099 Palmtop pen C 1
9 2 080-090 SZ-Key C 1
12 1 070-001013 Connector C 1
13 1 290-000090 Cable Support MSP+E C 1
290-700181 68
290-700181 69
Part list of HIGHVAC PREMIUM 290-0000070k
1 1 290-000001g Case C 1
2 1 290-000003b Mounting plate C 1
3 9 010-168 Hexagonal nut M8x0.8d C 9
4 4 010-073 Washer M8 C 4
5 13 010-165 Spring washer M8 C 13
6 2 290-000018e Block complete C 2
6.1 1 290-000019e Vacuum regulator C 1
6.2 2 290-000020b Piston alu C 2
6.3 2 010-197 Hexagon socket head cap screw M8x20 C 2
6.4 3 010-348 Washer M8x1 C 3
6.5 1 010-347 Washer M8x0.5 C 1
6.6 2 060-075 Joint O-Ring ø29x1.5 B 2
6.7 2 050-582 Compact cylinder ADN B 2
6.8 8 010-159 Washer M4 A 8
8 8 010-026 Hexagon socket head cap screw M6x100 C 8
9 2 030-212 Push-in QSL-1/4-8 C 2
10 3 030-213 Push-in QSL-1/8-8 C 3
11 12 030-214 Push-in QSL-1/8-6 C 12
12 2 290-000034j Filter complete C 2
12.1 1 290-000035h Filter socket B 1
12.2 1 290-000036i Filter head B 1
12.3 1 900-085 Filter cartridge ø75 A 1
12.3.1 1 900-083 Fixing sleeve B 1
12.3.2 2 900-084 Hood air filter ø74 B 2
12.3.3 1 080-028 ø70 Steel wool 100g A 1
12.4 3 090-019 Positioning pin ø6x12 B 3
12.5 1 030-096 Vacuum hose connector DN25 C 1
12.6 1 060-077 O-Ring ø79x3 A 1
12.7 1 060-079 O-Ring ø74.6x3.53 A 1
13 2 030-414 Straight fitting C 2
14 2 050-585 Valve OMAL VIP G1 1/4" EW/NC NBR C 2
15 2 030-413 Male stud coupling 35L C 2
16 2 030-329 Straight fitting G2" DN50 C 2
17 1 290-000076 Double connection C 1
18 1 030-328 Double connection C 1
19 1 050-583 Air reservoir 5l C 1
20 1 030-257 Blanking plug G3/8" C 1
22 4 010-002 Hexagonal screw M8x18 C 4
23 8 010-251 Washer ø8x25 C 8
24 1 030-410 Fitting straight C 1
25 2 030-262 Push-in L-fitting C 2
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26 1 030-411 Fitting straight C 1
27 1 030-406 Multiple distributor C 1
28 1 290-000022b Support for sensor complete C 1
28.1 1 290-000021 Plate for fixing sensors C 1
28.2 2 050-590 Sensor 0-....4bar C 2
28.3 1 050-591 Sensor 0-....1bar C 1
28.4 2 030-418 Push-in QSLF-1/4-6-B C 2
28.5 1 030-419 Push-in QSLF 1/4-8 C 1
28.6 3 050-592 Connection-Cable DCS-CON2 C 3
29 6 010-320 Hexagon socket countersunk flat head screw 6
30 6 010-176 Finishing washers 90° M6 C 6
31 1 050-603 Filter regulator B 1
32 1 030-407 T-connector C 1
33 1 030-408 Push-in sleeve C 1
34 1 050-529 Manocontact C 1
35 1 040-062 Horse PCN-4-NT C 1
36 1 070-659 Single phase power supply (transformer) C 1
37 4 010-338 washer large C 4
38 4 010-185 washer C 4
40 1 290-000002d electrical plate complete C 1
40.1 1 290-000016 Adapter plate electro C 1
40.1.1 1 290-000007d Plate electic C 1
40.1.2 1 290-000008b Cable Trays C 1
40.1.3 1 290-000009 Cable Trays C 1
40.1.4 1 290-000010 Cable Trays C 1
40.1.5 1 290-000011a Cable Trays C 1
40.1.6 1 290-000012b Rail C 1
40.1.7 1 290-000013b Rail C 1
40.1.8 13 010-237 Blind rivet Pop ø4x12.1 C 13
40.2 3 070-631 Snap-on end bracket C 3
40.3 4 070-979 Feed-through terminal C 4
40.4 1 070-001010 Partition plate C 1
40.5 6 070-991 3-wire terminal block TWIN QTC2.5 C 6
40.6 1 070-992 Monitoring relay C 1
40.7 1 070-626 Circuit Breakers C 1
40.8 1 070-847 solid-state reversing C 1
40.9 25 070-978 Feed-through terminal C 25
40.10 1 070-990 Plug-in bridge 1
41 2 010-101 hexagon socket countersunk C 2
42 1 010-029 Hexagon socket head cap screw C 1
43 1 050-550 Valve terminal MPA C 1
44 6 030-227 Blanking plug C 6
45 2 030-344 Push-in connector QS-10H-6 C 2
46 1 030-291 Push-in fitting QS-8H-6 C 1
47 2 030-461 Screw gasket ring M42-G1-1/4" C 2
48 2 030-091 Push-in Y-connector C 2
49 2 040-026 Hose PUN6X1-SI A 2
50 1 040-036 Hose PUN10X1.5 SI A 1
51 4 030-218 Push-in Y-connector Y QSY-6 C 4
52 1 072-043 Adhesive label yellow VP MULTI C 1
53 1 072-044 Adhesive Labels VP MULTI C 1
54 1 072-045 Adhesive label white VP MULTI C 1
55 1 290-000015a Plate MSP C 1
290-700181 71
56 6 030-418 Push-in QSLF-1/4-6-B C 6
57 2 030-224 Male stud coupling L6 / 1/4" C 2
58 2 030-002 Male stud coupling L8 / 1/4" C 2
59 2 030-053 Male stud coupling S8 / 1/4" C 2
60 2 030-074 Cap nut L8 C 2
61 2 030-073 Cap nut C 2
62 2 030-077 Cap nut C 2
63 2 080-080 ball ø9.252 C 2
64 4 080-081 ball ø12 C 4
65 1 070-742 Cable Gland M25 C 1
66 1 070-779 Lock nut C 1
67 2 010-352 hexagonal screw C 2
68 1 030-409 Push-in fitting QSSF-3/8-10-B C 1
69 1 030-422 Thread nipple 3/8" C 1
70 1 030-423 Air quick coupling 3/8" C 1
71 1 030-421 Compressed air hose 3/8" A 1
73 2 030-425 Hose clamp 15-18mm C 2
74 1 030-424 Hose connection 3/8" - 10mm C 1
75 1 070-001012 Panel connector red B 1
76 8 010-237 Blind rivet Pop ø4x12.1 C 8
77 1 080-079 Protecting sleeves C 1
78 3 900-912 Adhesive label C 3
79 1 070-108 main switch C 1
80 1 070-334 Braided sleeving C 1
81 1 070-478 HDC enclosures C 1
82 1 070-476 Female insert C 1
83 1 290-000110 Identification plate C 1
84 4 010-252 Blind rivet Pop ø2.4x7.5 C 4
88 1 070-151 Terminal ring tongue M8 C 1
89 1 010-161 Washer M8 C 1
90 1 070-817 Adhesive label C 1
91 2 010-123 Ring bolt M8 C 2
93 1 900-941 Adhesive label FONDAREX 55cm blue/orange C 1
94 1 900-938 Adhesive label HIGHVAC PREMIUM 20mm C 1
99 1 040-064 Bride/Collier 60-170mm C 1
100 2 052-050 Air Suction Filter PUN 6 C 2
101 2 052-051 Air Suction Filter PUN 8 C 2
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290-700181 73
Part list of HIGHVAC PREMIUM 290-0000060c
1 1 290-000101c Control Box SI C 1

2 1 290-000104c Mounting plate complet C 1
2.1 1 290-000102c Mounting plate SI C 1
2.2 1 290-000105a Cable Trays C 1
2.3 1 290-000106a Cable Trays C 1
2.4 1 290-000107a Rail C 1
2.5 5 010-181 Cap screw M5x12 C 5
2.6 1 290-000108 Rail 35x15/60 C 1
2.7 1 290-000023a Rail C 1
2.8 3 010-187 hexagon socket head cap screw C 3
2.9 1 070-097 Thermostat 50°C C 1
2.11 2 070-631 Snap-on end bracket C 2
2.12 2 070-267 Relay C 2
2.13 4 070-457 Ground modular terminal block C 4
2.14 16 070-455 Feed-through modular terminal block C 16
2.15 1 071-136 Terminal module C 1
2.16 1 071-134 Modul interface C 1
2.17 7 071-135 El. module universal C 7
2.18 1 071-133 El. module output C 1
2.20 3 071-163 El. module input C 3
2.22 1 071-148 Terminating module C 1
3 4 010-018 cap screw C 4
4 4 010-160 washer C 4
5 4 010-341 Washer C 4
6 2 070-890 Finger guard EMV C 2
7 8 010-134 Hexagonal nut M3 C 8
8 2 070-892 Filter matting 80x80 B 2
9 1 070-737 green light C 1
10 1 070-738 red light C 1
11 1 071-131 Panel MP 277 8" Touch C 1
12 1 070-684 Main switch C 1
13 4 010-074 Washer M6 C 4
14 2 010-164 Spring washer M6 C 2
15 2 070-997 Terminal ring tongue M6 red C 2
16 2 010-167 Hexagonal nut M6 C 2
17 2 070-478 HDC enclosures C 2
18 1 070-477 HEAVYCON male insert C 1
19 24 070-642 Female contact C 24
20 24 070-645 Crimpcontact C 24
290-700181 74
21 18 010-151 raised countersunk head tapping screw C 18
22 1 070-476 Female insert C 1
23 4 070-870 Hinged cover black C 4
24 1 070-001006 Hybrid Panel feed-through RJ45 PLAS C 1
25 1 070-869 Connector female C 1
26 1 070-868 cable connector Ethernet C 1
27 1 070-871 Panel connector C 1
28 1 900-942 Adhesive label FONDAREX VS 67cm blue C 1
29 1 290-000110 Identification plate C 1
30 4 010-252 Blind rivet Pop ø2.4x7.5 C 4
31 1 070-334 Braided sleeving C 1
290-700181 75

290-700181 Manual HVPREMIUM EN V131112

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290-700181 Manual HVPREMIUM EN V131112

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HIGHVAC T + 41 21 943 0000

PREMIUM 2C F + 41 21 943 0001

Instruction manual V131112

200 500 800

Please read this information before

HIGHVAC PREMIUM 2C CENTRAL

2 Preparation / Connection / Operation 10

6 Trouble Shooting Guide 56

The Fondarex vacuum unit consists of the following components:

• HIGHVAC PREMIUM Vacuum Unit

Type Tank Pump Illustration

HIGHVAC PREMIUM 2C Individual Individual

HIGHVAC PREMIUM 2C 200 200 Litres 25m3/h Busch

HIGHVAC PREMIUM 2C 800 800 Litres 63m3/h Busch

T1 Delay Time „VACUSTART“

P1 Tank Limit Value

S1 Number Of Shots Without Vacuum

2.1 Positioning the vacuum unit

2.2 Space Requirements

HIGHVAC PREMIUM vacuum unit dimensions:

Type Width in mm. Dept in mm. Height in mm.

Power Supply (X1)

Countries power supply:

3-Phase 203 V (Europe)

Electrical cables and connectors are provided by the customer.

For a detailed Interface description, please see Chapter 4.

Minimum required signals: START VACUUM and DIE OPEN.

Attention: 24V DC and 0V needed for Siemens inputs!

2.5 Connection from Siemens Control Panel to Vacuum Unit

Optional cable lengths: 5 m, 10m, 15m or 20m.

It is necessary to supply the HIGHVAC PREMIUM vacuum

The air pressure hose (length 5m) is included in delivery.

Please connect the air pressure hose to the “AS” connection of

Adjust the air pressure inside the unit (AS1) to 6bar.

The integrated manometer indicates the adjusted air pressure.

Air Pressure Unit AS1

Operating Vacuum Valves:

Please connect S, M, P and VA / VB to the vacuum unit.

M Vacuum measurement in the cavity

VB Vacuum connection for Chanel B

P Connection for Channel B

Operating Chill Blocks:

If using Chill blocks, please do not connect S or P!

All connections should be tightened and checked.

- Calibrate touch screen.

Push on F1 Produktion data to activate the vacuum

In case of problems please contact Fondarex after sales service!

Fully automatic production with vacuum

3.2 Description of the entry keys

3.2.1 Turning ON/OFF the vacuum unit

Vacuum unit switched ON

Vacuum unit switched OFF

3.2.2 Turning ON/OFF the automated production with vacuum

Automated production with vacuum ON

Automated production with vacuum OFF

• With the internal, automatic VACU-LOCKOUT (F4) of the vacuum unit

Vacuum function ON:

Exception: VACU-LOCKOUT or SET-UP

Vacuum function OFF: