REITEL RETOCAST I User manual

Operating Instructions
LABORATORY EQUIPMENT IN
STAINLAESS STEEL
RETOCAST I
REITEL Feinwerktechnik GmbH
Senfdamm 20 | 49152 Bad Essen
Phone: [phone] | Fax: [phone]
www.reitel.com | [email protected]

II
Dear Customer!
The compact benchtop centrifugal induction casting machine RETOCAST I is suitable for
casting precious and non-precious metal alloys under vacuum as well as model casting. The
high performance induction heating melting generator ensures high precision melting of
alloys and fast working. The sophisticated centrifugal arm with three different speeds
ensures rapid adjustment to different mould sizes.
Any other use or usage beyond this scope is considered unintended use. The manufacturer
shall not be responsible for any damages that may result thereby.
Prior to installation of the device operating instructions and especially the safety instructions
must be read and followed by all personnel who use this device.
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.
These operating instructions must be read and followed by all personnel who use this device.
To ensure quick access we recommend to keep it at a safe place near the device. In case of
loss it can be ordered from the manufacturer.

III
INDEX
TECHNICAL DESCRIPTION......................................................................................... 4
BASIC EQUIPMENT....................................................................................................... 4
SPECIAL ACCESSORIES................................................................................................ 4
DEVICE DESCRIPTION.................................................................................................. 5
TECHNICAL DATA......................................................................................................... 8
SAFETY NOTES........................................................................................................... 9
GENERAL SAFETY NOTES ............................................................................................ 9
SPECIFIC SAFETY NOTES............................................................................................10
INSTALLATION ...........................................................................................................11
INSTALLATION.............................................................................................................11
COMPRESSED AIR CONNECTION ..................................................................................11
WATER CONNECTION..................................................................................................11
OPERATION................................................................................................................12
CASTING WITH PREMELTING ........................................................................................13
CASTING WITHOUT PREMELTING ..................................................................................13
TROUBLESHOOTING .................................................................................................14
MAINTENANCE...........................................................................................................14
WARRANTY.................................................................................................................15
DISPOSAL REGULATIONS ........................................................................................18
SPARE PARTS LIST ...................................................................................................18
EC CONFORMITY DECLARATION.............................................................................19

4
Technical Description
Basic Equipment
•RETOCAST I casting machine
•1 ceramic crucible (non-precious metal)
•1 graphite crucible (noble metal)
•1 hose package
•1 manual opener
Special Accessories
•Order-No.: 23807000 Water cooling unit
•Order-No.: 23806000 Crucible holder
•Order-No.: 28001000 Ceramic crucible for non-precious metals (5 pcs./pack.)
•Order-No.: 28002000 Graphite insert for noble metal (5 pcs./pack.)

5
Device Description
1 Timer
2 Switch (torque)
3 Power control
4 Incutions button
5 LED „Power“ (Device is ready to use)
6 LED Generator „On“
7 LED „malfunction“
8 LED (centrifugal arm in correct position)
9 „Start“-switch
10 Locating pin incl. plate
11 Counterweight
12 Adjusting lever
13 Mould’s back insulation
14 Mould support
15 Crucible holder
16 Induction coil
17 Lid
18 Emergency stop switch
19 Power switch
20 Device socket for water cooling unit (option)
21 Automatic fuse 20 A
22 Induction coil flap
23 Automatic fuse 0,8 A for lid opener
24 Sight glass
25 Compressed air connection
26 Water inlet
27 Water reflux
28 Power connection
29 Green control lamp

6
Control unit/panel
Interior of the unit
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
A
B
22

7
Interior with induction coil
Device view
Rear side of the device
17
18
19
20
21
16
22
23
24
25
26
27
28
29

8
Technical Data
Line voltage
230 V/50-60 Hz
Current consumption
3.200 W
Height/width/depth
530(930)/740/510 mm
Weight
60 kg
Speed
500 rpm
Mould size
1-9 and model casting
Amount of metal for casting: max. quantity
Minimum quantity
Noble metal 110 g; non-precious metal 55 g
Non-precious metal 15 g
Material
Noble metal/non-precious metal/model
casting
Sound level
≤70 dB(A)
Housing
Stainless steel
Order-No.:
18000000
Made in Germany (Subject to modifications)

9
Safety Notes
General Safety Notes
•All equipment undergoes final inspection and testing before leaving our factory. However,
if equipment is damaged during shipping or through any other circumstances, it must not
be used in service. Please check the device regularly for damages. Damaged parts
should be replaced immediately.
•All power/air/water/gas sources should be rated for the demands of the device as listed in
the technical data sheets. Maximum ratings must not be exceeded. All VDE (Verein
Deutscher Elektro-Ingenieure) standards should be followed. Equipment should be
grounded according to standards.
•Adherence to valid regulations regarding necessary checks (e.g. according to Accident
Prevention & Insurance or electrical equipment) is exclusively taken over by the
buyer/user of this product.
•This device has been designated to be used only for its intended purpose. All other
applications must be prohibited for safety reasons as otherwise the manufacturer’s
warranty expires.
•The device should be set-up in a clean, well-ventilated room, if necessary under a hood.
•Supporting surfaces should be straight, flat and adequately stable.
•Don’t place anything on top of the machine.
•To avoid injury, appropriate protection should be worn (e.g. gloves, safety glasses, safety
shoes, hearing protection etc.)
•If the machine is defective or working improperly it must be taken out of service. In case
of further use of the machine the owner will be held responsible for any consequential
damage.
•To prevent accidents from water, fire or explosion, all power/air/water/gas sources should
be turned off after working hours and during breaks, and secured against unauthorized
access.
•When carrying out maintenance works or repairs or when opening the device always turn
off the main power switch and unplug the whole unit.
•Repairs should be carried out only by the manufacturer or by qualified and certified
personnel appointed according to chapter 7 –warranty.
•In case of leaking water out of housing or tank shut down device and call service.

10
Specific Safety Notes
•The RETOCAST I is a benchtop unit. When installing make sure the machine is
horizontal and has a stable base. Please make sure that the machine won’t fall off the
support in case of wrong counterweight adjustment, leading to an unbalance in machine.
•Carefully close the metal lid to prevent contusion.
•Don’t store any explosives, highly inflammable or burnable material in the working area.
•Always wear welding goggles and protective gloves during metal fusion. Parts positioned
close to the crucible and liquid metal in the crucible are hot and are subject to approriate
safety measure to avoid causing burns. Installiertes Schutzglas verwenden.
•Use appropriate pliers to insert or to take out the mould and the crucible. Danger of
burns.
•Only use the device for melting metals and alloys in appropriate crucibles (only use
original products from manufacturer).
•Never operate the machine without metal, with too much or too little alloy (minimum
quantity 15 g non-precious metal; depending on the alloy) to prevent damage to the
generator. Don’t us old metal (danger of crucible cracks). We don’t assume liability for
consequential damage.
•Only use metals approved for casting from their manufacturers, don’t use any alloys
containing ingredients like Beryllium etc.; ensure sufficient ventilation, danger of
intoxication.
•Use and processing of endangering material / hazardous to human health, carefully
observe the safety instructions and safety data sheets.
•Prior to casting the crucible is subject to an optical control to exclude damage or wear of
material.
•The generator may only be turned on if the melting material is already in the machine.
•When the heating is on, don’t touch the inductor chamber with your hands or other tools.
Attention:
The machine must not be used by people with electronic implants e.g. pacemakers.
In case of danger press the red emergency button (18) immediately. The casting
procedure can be interrupted prematurely by activating the emergency stop switch. The lid
(17) opens automatically after 30 sec.
After each casting the time to cool down the machine must be at least 10minutes. During
cooling time, please open the lid and remove all muffle or heat exposing objects from the
machine.

11
•Never open lid before the centrifugal arm has totally stopped. Risk of injury when
reaching into the running machine.
Installation
The equipment delivered is ready for immediate use. The sealed plug can be connected
directly to the mains supply 230 V/16 A. For installation please refer to chapter 2.
Installation
In order to minimize mould cooling during insertion, the RETOCAST I has to be set up very
near to the preheating furnace. Please ensure dust-free surroundings (don’t install the
machine e.g. near to the sandblaster).
Compressed air connection
Please arrange for at least 4 bar compressed air. Take care that the hoses are no longer
than 2 m max. Usually a hose with a light width of 9 mm is used as well as a quick couping
system, type NG7.
Water connection
1. Connect water to the tap by the supplied hose. Water supply pressure at least 3 bar.
2. Put water drain hose into the sink or the waste drainage. (Use clamp to secure hose).
Alternatively the REITEL water cooling unit can be ordered and installed.
Note:
Prior to connection to the power supply check whether the specifications on the rating
plate correspond to the supply network: Fuse protection: slow blow fuse 16 A or circuit
breaker K16 A or C16 A, minimum tension 210 V/max. 240 V. Don’t connect any other
loads to the 16 A fuse.
Note:
Take care to prevent compressed air contamination and water in compressed air!
Note:
Water temperature may not exceed 35 °C. When working with the water cooling unit, put
the end of the outlet hose in the storage tank. It’s important that the hose’s end is always
under water.

12
Operation
1. Turn the potentiometer (3) to „0“. Turn the regulator completely to the left until it snaps in.
2. Switch on the unit with the power switch (19). The switch shines and the device is ready
to use.
3. Open the lid. If the lid has locked, press the emergency stop switch (18). After approx. 30
sec. the lid opens automatically.
4. Manually rotate the centrifugal arm until it has reached a position above the induction coil
flap (22). The correct position is reached as soon as a resistance is noticeable and the
LED (8) shines. The moving end of the centrifugal arm is bent.
5. Adjust the centrifugal arm with the counterweight (11) in accordance with the mould size.
Lift locking pin with plate (10) and allow it to lock again after adjustment. For standard
mould sizes markings are provided.
6. Adjust mould support in accordance with mould size. Use the lever (12) to adjust mould
height (12). Pay attention to an aligning position of the mould’s funnel and the crucible
opening.
7. Activate the induction button (4). The induction coil moves upwards into position.
8. When casting noble metal, put the graphite insert in the crucible support (15).
9. Alloy is filled in the crucible by using an alloy tray (minimum quantity non-precious
metal15 g and maximum quantity noble metal110 g/non-precious metal 55 g).
Note:
Prior to switching on the unit make sure that the emergency switch has been released.
When the emergency stop switch is activated, casting procedure will not start!
The timer button „Start/Stop“ shouldn’t be activated after starting the casting procedure, to
prevent premature interruption of the heating process.
Casting procedure starts as soon as the lid (17) is closed and the green control lamp (29)
is off.

13
10. Set startup delay time with switch (2) for torque:
−„0“ = very gentle (for plaster-bonded investment);
−„I“ = gentle (for noble metal);
−„II“ = quick (for non-precious metal).
11. Set timer (1) to required centrifugation time:
−Key A: minutes
−Key B: seconds
−Key A+B: reset
Casting with premelting
1. For casting with pre-melting put the cover (17) on, without closing it. The contact is
closed and the heating process in the induction coil chamber is free.
2. Fully turn on potentiometer (3). The metal starts to melt. Watch melting process through
sight glas (24).
3. Open the lid (17), as soon as the alloy pellets have a red-hot color. (The alloy must not
be entirely melted.) Put the muffle on the muffle support (14) and close the lid (17). The
green control lamp (29) goes off. When inserting the mould, pay attention to an aligning
position of the mould’s funnel and the crucible opening.
4. As soon as the alloy is sufficiently melted, press the „Start“ switch (9) to start casting.The
induction coil goes down and casting procedure starts.
5. The casting process stops automatically after the centrifugation time has run out. After
approx. 30 seconds, the lid (17) opens automatically.
Casting without premelting
1. For casting without premelting put the mould on the mould support (14) and close the lid
(17). The green control lamp (29) goes off. When inserting the mould pay attention to an
aligning position of the mould’s funnel and the crucible opening.
2. Fully turn on the potentiometer (3). The alloy starts to melt. Watch melting process
through sight glass (24).
3. As soon as the alloy is sufficiently melted, press the „Start“ switch (9) to start casting. The
induction coil goes down and casting procedure starts.
4. Upon expiry of centrifugation time centrifugation process is finished. After approx. 30
seconds, the lid (17) opens automatically.

14
Troubleshooting
Device doesn’t start.
a. Check fuse of the building.
b. Check the device’s fuse.
Centrifugation doesn’t start, green control
lamp (29) shines.
Carefully close lid (17).
Lid (17) doesn’t open.
Press emergency stop switch (18) or open
lid with the manual opener (Note: never
open the lid during centrifugation process).
Machine vibration and runout.
Wrong counterweight adjustment leads to
unbalance and strong vibrations →Press
emergency stop switch (18). After 30
seconds the lid opens. Readjust
counterweight.
Induction coil (16) doesn’t lift up.
a. Set potentiometer (3) to "0".
b. Check centrifugal arm position (LED).
Centrifugation time has not been set.
Press emergency switch (18), after 30 sec.
the lid opens, set centrifugation time, repeat
casting procedure.
LED „malfuntion“ (7) shines.
Contact service.
Maintenance
•Regularly check the device. Pay attention to visible damages to housing, power cord or
compressed air hoses.
•Regularly clean or hoover the centrifugal arm. Dirt particles may disturb the coil cover.
•The following components are subject to permanent control:
−perfect mould’s back insulation (13) (clean and non-defective);
−the crucible support (15) should be without cracks;
−the centrifugal arm should be easily movable;
−the induction coil flap (22) is in alignment with the induction coil.
•Reglularly clean the housing with a damp cloth or with REITEL stainless steel care spray.
Note:
Clean and protect your device regularly with the REITEL stainless steel care spray
(order-no.: 90405000) to remove lime, plaster and dust as well as other
contaminants from the surface of equipment and to prevent corrosion. The spray
creates a water repellent protective film which helps keep the equipment clean.

15
Warranty
We, REITEL Feinwerktechnik GmbH, offer a 1 year’s warranty beginning from the proven
date of purchase. This warranty covers all defects traceable to materials, design or
workmanship. The following warranty regulations are applicable:
Within the warranty period Reitel Feinwerktechnik GmbH or an authorized distributor agrees
at its sole option, to perform repair or replace this product at no charge covering all defects
traceable to materials, design or workmanship. Warranty only applies to appropriate use and
regular maintenance of this product according to the operating instructions. Claims under
warranty are restricted to complementary performance. Additional claims, especially claims
for indemnifications, are not covered by this warranty.
1.
Warranty claims have to be addressed to the distributor the product was purchased from or
directly to our service department.
Contact:
REITEL Feinwerktechnik GmbH
Senfdamm 20
49152 Bad Essen
Germany
Phone: [phone] (Service Department)
Phone: [phone] (Reception)
Fax-No: [phone]
2.
In case of warranty claim application the sales receipt or your purchase invoice showing the
date of purchase of the product and the serial number must be furnished. Securely pack and
ship the device, freight charges prepaid, at your own risk to us, along with a report describing
the defect. We reserve the right to decline warranty if this information has been removed or
modified after purchase of the product or if they are not included in case of warranty claims.
3.
Warranty repairs have to performed by REITEL Feinwerktechnik GmbH or by authorised
distributors. Repairs performed by non-authorised companies will void the claim for refund
since damages to the product resulting hereof are not covered by warranty.
4.

16
If the unit sent in for repair or replacement is still under the original warranty then warranty is
to the end of the original 1 year warranty.
5.
If the unit is destined to be operated in another country than originally intended and
manfactured for, modifications to the product might be necessary to comply to special
technical and /or safety standards of that specific country. Such modifications are no defects
traceable to materials, design or workmanship. and are therefore expressly excluded from
warranty claims.
Modification costs or damages arising from operation of the product under deviating
conditions are not covered by warranty.
6.
Exclusions from warranty:
−Service and maintenance work as well as repair and replacement of consumables
according to our consumables‘ list
−Transportation cost of the machine or installation and dismounting expenses incurred
−Damages due to use of the product other than for its intended purpose
−Damages due to faulty installation or insufficient maintenance of the product (e.g.
decalcification)
−Damages due to natural disaster e.g. lightning, water, fire, act of nature beyond
control, war, inadequate line voltage, insufficient ventilation, no decalcification,
insufficient care and cleaning or non-adherence to operation and maintenance
instructions according to the accompanying operation guide.
−Damage due to use of the product other than in accordance with the instructions
provided by REITEL Feinwerktechnik GmH;
−The warranty does not cover the cost of removal and replacement of parts and
accessories, unless supplied as original equipment by REITEL Feinwerktechnik
GmbH
−All kind of damages occurred not directly at the device as well as consequential
damages (e.g. damages to furniture due to a lack of water, downtime of the machine,
material, lost working hours, wages and other consequential damages).
This warranty shall be rendered null and void if:
−the product has been subject to any modification, repair or replacement other than as
authorised by REITEL Feinwerktechnik GmbH
−the product is continued to be operated despite a functional defect

17
7.
The warranty is device specific and may be claimed, within the warranty period, by any
person who has legally acquired the device.
8.
Consumables are excluded from warranty. Spare parts are subject to a warranty coverage of
6 months against all defects traceable to materials, design or workmanship according to
these warranty regulations.
9.
Legal default claims on the part of the purchaser remain unaffected by this warranty.
10.
We reserve the right to charge a fee if repair of the device is rejected and the device is
destined to be sent back unrepaired.
11.
Please note:
Upon repair or replacement of this unit, personal data and settings might get lost or
damaged. We don’t accept liability for all kind of data loss. The customer is advised to
backup essential programs and data before sending for service.
12.
This warranty shall be interpreted in accordance with German law to the exclusion of UN
sales law. Place of jurisdiction is our business location.
13.
If any provisions of this warranty are judged to be illegal or unenforceable, the continuation in
full force and effect of the remaining provisions will not be prejudiced. The provisions of this
warranty judged to be illegal or unenforceable shall be construed so as to give effect to the
intent manifested by the provision held invalid, illegal or unenforceable and to give effect to
section 13 hereof.
14.
Should you need to borrow a device while your device is being repaired, please contact
Messrs. REITEL or your distributor. These loans are a service for which availability cannot
necessarily be guaranteed. After the warranty period, a free may be charged for loan
equipment as well as for shipping and packaging.

18
Disposal Regulations
According to valid laws our devices are disposed of properly according to B2B–
regulations for proper disposal. Pls. contact your local dealer for information on
local disposal guideline
Spare Parts List
Best.-Nr.
Ref.:
Retocast I 76
Ersatzteilliste / Spare parts list 03/2019
Stck/Qty
ME
Unit
E6216400
Dichtungssatz für Sichtscheibe / Sealing set for inspection
glass
1
St./pc.
E6219910
Drucktaster m.Kontaktelement rot / Push button with red
contact element
1
St./pc.
E6031200
Feder für Verriegelungsbolzen / Spring for locking bolt
1
St./pc.
E7807400
Feder, Zug- / Tension spring
1
St./pc.
E7402700
Hauptschalter mit Überstromschutz / Main switch with overload
protection
1
St./pc.
E6047300
Keilriemen 950 / Cog belt 950
1
St./pc.
E6272400
Magnetspule für Deckelöffnen / Solenoid for lid opening
1
St./pc.
28003000
Muffelrückenisolierung / Rear muffle isolation
1
St./pc.
E6042100
Schalter I-O-II / Switch I-O-II
1
St./pc.
E6216520
Schauglas, Sicherheits / Safety inspection glass
1
St./pc.
E7616100
Riegelblock Verschluss an Wanne, Gegenstück zu E72890
Bolt lock chamber side (counter piece to E72890)
1
St./pc.
E6097400
Türöffner Stößel mit Kugelknopf zur manuellen Auslösung
Door opener lifter with ball knob for manual opening
1
St./pc.
E7208000
Türaufwerfer Bgr., kpl. verschraubt
1
St./pc.
E7289000
Verriegelungseinheit im Deckel, komplett vormontiert
Lid lock unit, completely pre-installed
1
St./pc.

19
EC Conformity Declaration

We manufacture in compliance with Quality Management ISO 9001:2015 incorporating
established standards.
REITEL Feinwerktechnik GmbH
Senfdamm 20 | 49152 Bad Essen
Phone: [phone] | Fax: [phone]
www.reitel.com | [email protected]
062019