REITEL INDURET COMPACT Operating Instructions Manual

1

REITEL Feinwerktechnik GmbH

Senfdamm 20

D - 49152 Bad Essen

Tel.: +49(0)5472 / 9432-0

Fax: +49(0)5472 / 9432-40

Operating Instructions

INDURET COMPACT

With the purchase of the INDURET-COMPACT you have made your decision for a REITEL-

quality product.

After having unpacked the device, please check carefully whether transportation damages of

any kind have occurred. If that is the case, the carrier or manufacturer must be notified within

3 days. The company will not be responsible for any damages found after that.

2

CONTENTS

1

ACCESSORIES ............................................................................................................................................... 4

1.1

B

ASIC

A

CCESSORIES

................................................................................................................................. 4

1.2

S

PECIAL

A

CCESSORIES

.............................................................................................................................. 4

2

GENERAL NOTES ......................................................................................................................................... 5

2.1

G

ENERAL

S

AFETY

I

NSTRUCTIONS

............................................................................................................. 5

2.2

S

PECIAL

I

NSTRUCTIONS FOR THIS DEVICE

................................................................................................. 5

3

INSTALLATION ............................................................................................................................................ 7

3.1

P

ROTECTIVE GAS CONNECTION

................................................................................................................. 7

3.2

C

OMPRESSED AIR CONNECTION

................................................................................................................. 9

3.3

W

ATER CONNECTION

................................................................................................................................ 9

3.4

C

ONNECTION FOR POWER SUPPLY

........................................................................................................... 10

4

PREOPERATIONAL ACTIVITIES ........................................................................................................... 11

4.1

G

ENERAL

N

OTES

..................................................................................................................................... 11

4.2

C

LEAN WORKING AREA FOR PRECISE CASTING

........................................................................................ 11

4.3

I

NVESTMENT

(

MANUFACTURER

’

S RECOMMENDATION

) ........................................................................... 12

4.4

T

HE DISPLAY PANEL OF YOUR

INDURET-

COMPACT .......................................................................... 12

4.5

P

ROGRAMMING MEMORY CELLS

.............................................................................................................. 13

4.6

P

OSSIBLE OPERATOR

’

S INTERVENTION INTO CASTING PROCESS

.............................................................. 13

5

CASTING PROCESS ................................................................................................................................... 14

5.1

S

TART HERE

… ........................................................................................................................................ 14

5.2

C

ASTING WITHOUT METAL PREMELTING

................................................................................................. 18

5.3

C

ASTING WITH PREMELTING

.................................................................................................................... 20

5.4

C

ASTING WITHOUT TEMPERATURE MEASUREMENT WITHOUT PREMELTING

............................................. 22

5.5

C

ASTING WITHOUT TEMPERATURE MEASUREMENT WITH PRECASTING

.................................................... 23

5.6

P

OST

-

CASTING

......................................................................................................................................... 25

6

TROUBLESHOOTING ................................................................................................................................ 25

7

MAINTENANCE .......................................................................................................................................... 25

8

WARRANTY ................................................................................................................................................. 27

9

RULES FOR DISPOSAL OF COMMERCIAL ELECTRICAL EQUIPMENT .................................... 28

10

TECHNICAL SPECIFICATIONS .............................................................................................................. 29

11

KEY ................................................................................................................................................................ 30

11.1

S

PARE

P

ARTS

L

IST

.................................................................................................................................. 32

12

APPENDIX .................................................................................................................................................... 34

3

[A

PPENDIX

A1]

M

UFFLE

O

VERVIEW

C

HART

........................................................................................................ 34

[A

PPENDIX

A2]

INDURET

M

ETAL CHART FOR TEMPERATURE ADJUSTMENT

..................................................... 35

4

1 Accessories

1.1 Basic Accessories

• Casting Machine INDURET - COMPACT

• 1 ceramic crucible (for non-precious metal)

• 1 graphite crucible (for noble metal)

• 1 graphite crucible holder

• 1 ceramic pestle

• 1 graphite pestle

• 1 thermocouple

• 1 hose package

• User video

1.2 Special Accessories

• Order-No. 21601 Pressure minimizer Argon

• Order-No. 23801 Melting crucibles, graphite for noble metal

• Order-No. 23801P Graphite crucible Plus for noble metal

• Order-No. 23802 Pestle graphite

• Order-No. 23803 Ceramic melting crucibles for non precious metal

• Order-No. 23804 Pestle S ceramic

• Order-No. 23805 Graphite crucible holder

• Order-No. 23806 Crucible holder

• Order-No. 23807 Re-circulation cooling unit

• Order-No. 23809 Maintenance unit

• Order-No. 23811 Starting kit, including: 21601, 23801, 23802, 23803, 23812, 23805,

23809, 23812, 23815, 23816, 23818, 23819, 23823

• Order-No. 23812 Longlife pestle

• Order-No. 23814 Thermocouple

• Order-No. 23815 Centering and insulation rings

• Order-No. 23816 Drill for crucibles

• Order-No. 23818 Alloy tray

• Order-No. 23828 Dispenser tube

• Order-No. 23819 Positioning pliers

• Order-No. 23822 PC- Interface

5

• Order-No. 23826 Muffle pliers

• Order-No. 26805 Pressure compensation container

(Part numbers and contents are subject to change. Placing an order pls. ask for the corresponding part numbers)

2 General Notes

2.1 General Safety Instructions

• Operating instructions must be read and followed by all personnel who use this device

• Furthermore, personnel should follow all local safety rules.

• To avoid injury, appropriate protective clothing, noise absorption, protective eyewear and

other tools have to be used.

• If the machine is defective or working improperly it must be taken out of service. Call your

dealer immediately then.

• This device has been designated to be used only for its intended purpose. All other

applications must be prohibited for safety reasons.

• In case of danger turn off the machine and call your dealer or manufacturer for help.

• This device should not be left running while unattended.

• Turn all power sources off after having finished work.

• Repairs may be carried out only by experts. Persons doing repairs take over responsibility

for proper work and adherence to accident-prevention regulations (UVV).

• Use original spare parts only.

• Modifications may only be made after consultation with, and by permission of the

manufacturer. In case of modifications without permission all warranty and liability claims

will expire.

• The machine should be operated in a clean, air-conditioned room with a temperature of 18

to 35° C.

• Danger of fire: Respect the fire regulations. Leave enough space around.

• Don’t use mobiles near the machine since they may lead to disturbances.

• Don’t place anything on top of the machine.

• REITEL GmbH assumes no liability for damages to surfaces caused by equipment

supports/feet.

2.2 Special Instructions for this device

• Never store explosive, highly inflammable or burnable material in the working area.

6

• The hot crucibles, pestles and muffles may only be deposited on a heat-resistant and fire-

proof base, like crucible support.

• Make sure to use the device only for melting metals and alloys in the crucibles meant for

this purpose.

• Don’t melt any material, generating toxic gas.

• The generator (function „melting material“) may only be switched on if the melting material

is already in the device.

• When the heating is on, don’t touch the inductor chamber with your hands or other things.

• Use pliers when inserting or taking out the muffle, mould or handling the thermoelement

because of danger of being burnt.

• Only open the casting chambers when there’s no excess pressure or under pressure.

• Be careful regarding handling gas bottles. Secure against falling down, don’t heat, handle

with care.

• The heating process incl. casting process may only last max. 3 minutes.

Alloys with a longer melting time are inadmissible.

• The rest time between a casting and starting a new heating process has to be at least 6

minutes. There may be no hot crucible in the device during this time. The muffle chamber

as well as inductor chamber have to be open for cooling reasons during this time.

• Entering the casting temperature for non-precious metals generally corresponds to

recommendation of the metal-suppliers. These recommendations are without engagement.

• Tip: several (approx. 5 castings) should be performed visually, possibly with different

temperatures, and in case of a good casting result the casting temperature should be

adopted results-oriented as a set value for a casting program.

• Regarding temperature measurement small metal quantities below 15 g are not

precise due to a lack of quantity and are difficult to cast. If false castings are

produced, often default imbedding or a wrong temperature assessment of the

metal melting is the reason.

• When processing non-precious metals and palladium-containing alloy in the

ceramics crucible, temperature measurement is only possible with the „Longlife -

pestle“.

Generally noble metal (NM) is molten in the graphite crucible, if applicable in the ceramics

crucible with the graphite seal pestle.

• When melting thin and few split noble metal pls. pay attention that they don’t

position vertically as there’s no coupling possible and the metal consequently

won’t melt. Therefore push together split metal, put old sprue onto the new

material or weld split metal together or spot-weld.

7

• Pls. pay attention to the maximum percentage part of old material and crush

sufficiently! The parts have to be positioned on the crucible’s base, otherwise

there will be no or only partly metal melting.

3 Installation

• In order to minimize casting time, the INDURET-COMPACT should be installed very near to

the preheating furnace.

• Don’t install the device in a dusty room, e.g. near a sandblaster.

• The INDURET-COMPACT is a benchtop unit. Ensure a stable placement on the benchtop

and leave enough space around the machine.

• Pls. check connectivity with type plate indications.

• In case of differences of power requirements in your location, we recommend the usage of

the following devices:

Connecting Medium

Remedial action

Order

-

No.

Compressed air Maintenance unit 23809

Compressed air Pressure equalization tank 26806

Cooling water Refrigeration by circulation 23807

3.1 Protective gas connection

Left side of the machine (25)

Connecting

medium

Input port device

max. distance

Laboratory installation

Protective gas

Argon 4.6

Quick coupling NG 7,

hose with 8 mm flow

opening

2m

bottle:

pressure minimizer 5-6

bar (not l/min)

NG: quick-action coupling, possibly adjustment to your plug connection

(pls. ask your plumber or specialised dealer)

The gas cylinder is connected via a pressure minimizer.

Warning: This machine must not be operated by persons who wear a pacemaker.

8

Caution: handling gas bottles. Secure against tilting, don’t throw, don’t heat and pls.

control metal press pressure at the device’s gauge (3 bar at delivery).

Alternatively air can be used instead of argon. Pls. follow the manufacturer’s instructions

regarding connection of the pressure unit to the bottle.

9

3.2 Compressed air connection

Left side of the device (26)

Connecting

medium

Coupling device

Max. distance

Installation in laboratory

air 10 mm quick connect

coupling

10 m to the

compressor

Quick connect coupling

NG 7, 5-6 bar

NG: quick connect coupling, possibly adjustment to your coupling system

(Pls. turn to plumber or specialized dealer)

The casting result is mainly effected by speed of building up air pressure.

Reference speed range fom –0,8 bar to 3.0 bar in 1-2 sec.

Therefore:

a) Ensure a short distance to the compressor

b) Flow opening of all connections and hoses: minimum 8 mm

c) Minimum air pressure: 6 bar (admissible pressure drop of the device: max. 0,5 bar)

d) Minimum tank volume 80 l or free compressor performance / permanent

compressed air supply 50 l/min.

e) Don’t bend the supply hoses

f) Keep compressed air supply free from water, dust and oil (normally a water

separator is installed, that has to be looked after regularly (see chapter “Maintenance”)

3.3 Water connection

Left side of the device (28)

Connecting

medium

Anschlussart Gerät

max. distance

Installation in laboratory

Water inlet

3

/

4

″ - screwing with a

clamping nut

3m

3

/

4

″- screwing with a

clamping nut

Water outlet Flow opening

6-8 mm, fasten with

clamp

2m free outflow

Connect water inlet with provided hose to the feeder (31).

Water inlet pressure has to be at least 3 bar. Lead water outflow hose (32) in an outlet basin

or via the domestic drain.

10

Alternatively the water recirculation cooling can be installed, available from Reitel.

3.4 Connection for power supply

Left side of the device (24)

Connection for

power supply

Power requirements

device

max. distance

Laboratory installation

Power connection Pre-installed 2,5 m

230V / 16A

50 / 60 Hz socket

Plug the IEC power connector in the device’s plug and connect to the supply network

230V 50 / 60 Hz. Check voltage.

Protection: blowout fuse 16 A slow action line relay K16A or C16A,

minimum tension 215V / max. 240V.

Attention: When using the water cooling unit pls. control the water inlet temperature! Max.

30

0

C, temperature of draining water max. 35

0

C

Using the water cooling unit, outflowing water has to be redirected to the storing basin.The

hose end has to be kept under water. Pls. pay attention to choosing the right taps.

WARNING: Do

not connect any further devices to the 16A fuse.

11

4 Preoperational activities

4.1 General Notes

The condition for obtaining good casting results is correct sprueing, embedding and

adherence to the correct casting time.

The REITEL Induret - COMPACT enables precise castings of complex tasks with nearly all

alloys available in the market.

We don’t have any proven findings of the following alloys regarding their suitability or we don’t

recommend the alloy. In case of casting problems, we’ll be glad to do testing for you, charging

you for arising cost.

1. Nickeliferours alloys containing more than 67 % nickel (Ni).

These alloys were developed for flame casting and therefore, often they are unsuitable for

induction heated casting.

2. Ferric alloys containing more than 30 % of iron (FE).

It is hard to stipulate the time of casting due to the iron parts which burn very quickly.

3. Aluminiferous (Al) alloys containing copper (Cu) parts – since aluminium already melts

at low temperature there will be much slag deposits

4. Beryllium-containing (Be) alloys

When melting these alloys set free toxic steam! In case such alloys are used Messrs.

REITEL assume no liability for health affections of any kind or for damages to the machine.

5. Generally we don’t recommend any alloys not certified and of low quality.

6. For Titanium containing precious metal alloys, tests with argon are respectively necessary.

7. Among others pure titanium and high-grade titanium-containing alloys cannot be casted.

4.2 Clean working area for precise casting

• Clean inductor (5) – and muffle chamber (7), if necessary suck

• Pliers must be ready to use

• Check if ceramics crucible has a round outflow hole with 8 mm

diameter, if necessary pls. clean or wipe or use crucible cutter to

countersink

• Inspect lock pestle in the seal cone regarding roundness and

purity, if necessary blow away, wipe or remove rest of slag!

• Pls. clean graphite crucibles and pestles from loose particles by wiping them.

12

Further notes see chapter 7 „Maintenance“.

4.3 Investment (manufacturer’s recommendation)

• The diameters of the channels to the supplier should be 4,5 – 5 mm, the short sprueings to

the object should be 2,5 –3 mm.

• Muffle surface and floor space must be rough and at the same time be grinded according

to corresponding muffle size (we recommend to use a Velcro disc at the trimmer. Diamond

discs tend to be easily damaged by the muffle ring and some investment compounds).

• Caution: Don’t use any wax softening agents

• Wall thickness:

non-precious metal/precious metal crowns and dental bridges

Minimum 0,3 – 0,5 mm

model casting Minimum 0,5 mm

generally for precious metals Minimum 0,3 mm possible

4.4 The display panel of your INDURET- COMPACT

A) Key Function:

01 – Key P Entry confirmation and changing the temperature when programming

02 - Key down Reduce values or select

03 – Key up Increase values or select

04 – key U (This key is without any function if your controller only has one

memory cell)

In order to obtain further dental sprueing information pls. read the delivered instructions.

„The right way“.

13

Option: If the key is pressed 2 seconds long, further memory cells can

be chosen.

11 – Display PV Actual value display (from 70°C)

12 – Display SV Desired value display = set value (casting temperature)

4.5 Programming memory cells

Target

Performance

Choose memory cell

(optional)

⋅ Press U -key several times 2 sec. long until the required

selection appears

Select casting

temperature ⋅ Press P-key, change value with arrow key

Store modified values ⋅ Press P-key

Calling every single

programs’ memory cells ⋅ Press U key resp. 2 sec. for scaling, until set value

(°C) is shown.

4.6 Possible operator’s intervention into casting process

Target

Action

Interrupt melting

procedure

⋅ Turn heat control to the left to „0“

Reduce

meltingperformance ⋅ Turn heat control to the left to „5“ or press Argon key

Entry of the casting temperature for non-precious metal is generally corresponding to the

specifications of the alloy suppliers. The specifications are subject to correction and have to

prove while practising.

14

Benchmark: When using a longlife sealing bar the set value has to be entered

according to alloy-depending correction chart (appendix A2)

a) below 25g (non-precious metal) supplier’s casting temperature indication minus 150

to 200 degree

b) over 25g (non-precious metal) supplier’s casting temperature indication minus

120 degree

5 Casting Process

5.1 Start here…

Step

Description

1. Heat-up muffle in the preheating

furnace ⋅ Due to the down time when melting heat the muffle

up to the upper admissible limit

(pls. adhere to manufacturer’s information).

⋅ A wrong temperature or a too short preheating time

lead to false castings.

2. Turn-

on water cooling

⋅ min. 3 - 4 bar pressure (recirculating cooling optionally

possible)

3. control compressed air ⋅ set compressor-pressure minimizer to 5-6 bar

(Vacuum only possible with compressed air

connection)

4. Turn on Argon bottle

⋅ set pressure to 5-6 bar output pressure

5. Turn on the main power switch

(10)

⋅ Switch shines green

⋅ LED „GREEN“ (12) – is blinking at the beginning

(7x, generator runs up) and then it shines permanently

6. Select memory cell or

enter casting temperature

⋅ Press U –key 2 sec. long until the required program

appears

⋅ Press P -key, change value with arrow keys

7. Select metal pressing medium ⋅ dependent on Argon outflowing rate or air pressure.

15

with switch (31)

a) with air

b) with Argon

We recommend argon for better surface quality and

slighter burn-off of the graphite crucibles.

8. Open chambers ⋅ open inductor chamber (5) + muffle chamber (7) by

swivelling to the left

9. Insert crucible in inductor

chamber (5)

⋅ pls. pay attention to correct crucible combination:

a) coated ceramic crucible and

„longlife - pestle“ (non-precious metal a.o.)

with 8 mm bottom hole

b) Graphite crucible / Graphite crucible plus in the

ceramics crucible holder and graphite crucible

(precious metal)

with 6 mm bottom hole

⋅ Positioning: Insert crucible and lock, pay attention to

marking

The locking pestle, the thermo-

couple as well as the crucible

are sensitive to fracture.

Therefore they have to be

handled with care, e.g. when

they’re hot pls. work with long

nose pliers and use crucible

and pestle support for deposit.

Rupture sensitivity of the

pestles is even increased by

humidity, oil etc. Therefore they

have to be stored dry and are

to be taken off the package just

before using them.

16

11. Insert temperature sensor ⋅ Put temperature sensor into the locking

pestle

12. Adjust muffle height

(Muffle chamber (7) )

⋅ 1-9er muffle: 2x10mm + 2x6 mm insulating plates

⋅ Model casting muffle: 1x10mm insulating plate

upper edge of muffle chamber and muffle must be

brought to the same level

(The muffle chamber is prepared for the standard

muffle sizes 1-9 (height 55 mm) and model casting

(Height 75 mm)

⋅ Attention: The muffle should be placed as near as

10. Clamp lock pestles into holding

clip ⋅ Swivel holding clip over the bottom hole and

clamp pestle in backward direction in holding clip (leg

distance of the clip approx. 4mm)

⋅ check correct position of the pestle’s peak in the

crucible’s hole, if necessary slightly repress pestles (For

this purpose the muffle chamber (7) has to be opened.

There may be no chink of light between bottom hole of

the crucible and pestle visible with the lamp in the

machine’s bottom.)

Temperature

sensor

The thermo element has to reach

down to the bottom of the pestle

opening, otherwise the measured

temperature is incorrect.

Holding clip

17

possible to the inductor in order to shorten the flow

way.

13. Insert isolating and centering tool

dependent on the muffle size

⋅ see muffle chart appendix A1

14. Put metal into the crucible

⋅ At least 15 g metal has to be laid out on the crucible’s

bottom, so that the induction field develops an optimal

structure.

Caution: Never turn on the heating without availability

of alloy!

Caution: The temperature measuring element is suited for a maximum

temperature of 1600°C! This value may not be exceeded, otherwise the

temperature element tends to be destroyed.

18

5.2 Casting without metal premelting

1-14. perform preparational jobs ⋅ see chap. 5.1 „Start here…“

15. Take muffle off the preheating

furnace and insert in the middle

of the muffle chamber

(7)

⋅ Support plate has to be clean

(Insert Insulating- and centering tool before, chap. 5.1)

16. Close muffle chamber (7) ⋅ Muffle may not shift, close chamber as far as it will go

17. Tighten chambers

⋅ Swivel locking lever upwards (vertical)

and press on in direction to the machine.

18. Melting ⋅ Turn multiple-contact switch to „1“, turn rotary switch

from „0“ to "max=10" - LED yellow and green are "ON"

and vacuum starts automatically

⋅ Argon rinsing: 450°C before casting performance is

automatically reduced and Argon is added.

So a more precise temperature measurement

is granted and the casting result is positively influenced

(Oxide reduction, more silent melting. Evacuation stops

until it is reactivated in the following chapter.

⋅ Additionally it’s possible to obtain the same performance

reduction and Argon rising at any time by pressing the

Argon key.

19

19. Reactivating the heating process ⋅ 180 degree before reaching the casting temperature or

after 15 sec. 100% performance is returned and

the metal gets liquid. Vacuum is again drawn.

⋅ Pls. don’t press any longer the Argon-key, so that the

vacuum is completely charged at the time of casting.

⋅ When casting vacuum must be fully charged!

20. Temperature control and

Casting ⋅ When the acoustic signal is perceptible or the

metal surface is ripped or the optical judgment is

corresponding to the judgement based on measurement

(with temperature sensor)

set step switch to step 2.

⋅

⋅⋅

⋅ Reaching the set temperature (acoustic signal) the

heating is automatically switched off,

therefore casting has to be performed immediately.

⋅ If you wish to continue heating, pls. press the key

„P“ and increase temperature with the arrow key

(3) and confirm with „P“.

21. Metal forming pressure

(automatically)

⋅ The lock pestle releases the bottom hole for casting.

After 0,5 sec. pressurization is activated

(Argon or compressed air). Vacuum stops automatically.

⋅ Red LED (18) is blinking.

22. Ventilating chambers ⋅ Set power switch to 0.

⋅ After 20 sec. set step switch to 0.

23. Opening chambers ⋅ Pull the locking lever in direction to oneself and wait until

the gage is declining to 0 bar. Unlock the chambers by

swivelling the lever to the left.

Now they can be swivelled open.

24. User pliers to take out muffle.

20

5.3 Casting with premelting

Is recommended if muffle cooling is leading to insufficiently outflown castings.

1-14. preparational jobs ⋅ see chapter 5.1 „Start here…“

15. Close chambers

⋅

Don’t swivel lock lever upwards (vertically)

and don’t press in direction to the device.

16. Preheating metal ⋅ Turn step switch to „1“, turn rotary switch from „0“ to

"max=10" – LED’s yellow and green are "ON".

Watch procedure through sight glass.

17. Take muffle off the preheating

furnace and place it in the center of

the muffle chamber

⋅ When the red lamp shines (2) swivel open muffle

chamber (7) (heat output is reduced)

⋅ Take muffle off the preheating furnace and place it in the

center of the muffle chamber (7).

⋅ Support plate must be clean

(Insert insulating and centering tool before, chap. 5.1)

18. Close muffle chamber (7) ⋅ Muffle may not shift, close chamber as far as it will go

⋅ swivel locking lever upwards (vertical)

and press on in direction to the machine.

19. Continue melting ⋅ Watch this process until the set temperature is reached

and take care of timely casting.

⋅ Additionally it’s possible at any time to reduce

performance with the Argon key and Argon rinsing,

however only up to max. 150° C before reaching casting

temperature

⋅ When casting a full vacuum must be reached!

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REITEL INDURET COMPACT Operating Instructions Manual

REITEL INDURET COMPACT Operating Instructions Manual

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