ELECTRONIC INDUCTION CENTRIFUGAL

CASTING MACHINE
MOD. SMARTCAST

OPERATING AND MAINTENANCE MANUAL

EDITION 04-2011

This manual is an integrating part of the casting machine, as prescribed by EEC directive
392/89 EN 292/1-2 , and must not be alienated from the machine all through its life.
1
 CONTENTS

Preface 3

Declaration of Conformity 4

Warnings and precautions 5

Induction heating principle 6

Electronic induction centrifugal casting machine mod. SMARTCAST 7

Installation instructions 8

Control panel 9

Operating instructions 10

Crucibles 12

Technical information on melting process 13

Melting and casting process 14

Maintenance 17

Standard outfit 18

Wiring diagram 19

Wiring diagram components 20

Demolition and disposal of the unit 21

The warranty 22

Exploded Drawing Table A 23

Exploded Drawing Table B 25

Exploded Drawing Table C 27

Exploded Drawing Table D 29

Revisions 32

SMARTCAST 2
 PREFACE
The manufacturer of this electronic induction centrifugal casting machine congratulates you on your choice which
will fully satisfy your most demanding casting needs.
Since you are the real user of our machine please do not hesitate to let us have your comments, suggestions on the
function of the machine you bought or to ask for any information.

HAVE A GOOD WORK !

GALLONI Company, established in 1948, was the first in the world to produce electronic induction casting
machines for dental purpose.
It employs a professional staff and covers an area of 7000 square meters in S.Colombano al Lambro - near Milan.
Galloni Company has always given its specialist dedication to the following three main purposes:
- Technological research
- Quality
- Customer’s satisfaction
Thanks to its wide technological research it received official awards in 1983, 1990 and 1999 and has developed
high tech vacuum casting machines in order to obtain an excellent physical mechanical quality of all metals and
precious alloys.
Dental technicians have nowadays available a wide range of alloys for dental prosthesis which require special
melting and flask-casting techniques. GALLONI using expertise and experience gained over many years, has
produced a new line of electronic induction centrifugal casting machines incorporating the most advanced
technology. As far as the quality is concerned it is rewarded by 20000 customers including many specialized
schools and universities that are using its machines with full satisfaction in 45 Countries.
The export rate has reached levels of 80% and its products are backed up by after sale service organizations made
up worldwide by technically prepared agents.

This manual gives you the information you need to obtain the best use of your new electronic induction
centrifugal casting machine.
The more you understand about your casting machine before using it, the greater will be your satisfaction when
you find out its simplicity of use, its operation speed and its performance quality.

SMARTCAST 3
 DECLARATION OF CONFORMITY

THE COMPANY

ASEG GALLONI SPA

20078 SAN COLOMBANO AL LAMBRO (MI)
VIA CARAVAGGIO 16

DECLARES UNDER ITS OWN RESPONSIBILITY THAT THE PRODUCT

ELECTRONIC INDUCTION CASTING MACHINE

MOD. SMARTCAST
SERIAL NO. _________

IS IN CONFORMITY WITH:
- MACHINE DIRECTIVE 2006/42/CE
- ELECTROMAGNETIC COMPATIBILITY DIRECTIVE (EMC) 2004/108/CE
- LOW TENSION DIRECTIVE 2006/95/CE

SAN COLOMBANO, THE_______________

___________________________

SMARTCAST 4
 WARNINGS AND PRECAUTIONS

DANGER
IT IS FORBIDDEN TO REMOVE THE PANELS FROM THE MACHINE IF IT
HAS NOT BEEN PREVIOUSLY UNPLUGGED.

DANGER
INFLAMMABLE LIQUIDS AND GASES MUST BE PLACED DISTANT FROM
THE MACHINE DURING ITS USE

WARNING
DURING THE MELTING AND CASTING PROCESS THE OPERATOR MUST
WEAR PROTECTIVE GLOVES AND GOGGLES AS PRESCRIBED BY THE
SAFETY REGULATIONS.

ATTENTION
THE ELECTRIC SYSTEM OF THE ROOM WHERE THE ELECTRONIC
CASTING MACHINE SMARTCAST IS INSTALLED MUST HAVE AN
ELECTRICAL GROUNDING IN COMPLIANCE WITH THE REGULATIONS IN
FORCE.

ATTENTION
THE ROOM WHERE THE MACHINE IS INSTALLED MUST BE FREE FROM
SPRINKLINGS OF WATER, SAND BLASTING UNITS, ACID VAPOURS AND
DUST.

ATTENTION
UNPLUG THE MACHINE FOR ITS PERIODIC CLEANING AND USE A
VACUUM CLEANER OR DRY CLOTH: DO NOT USE COMPRESSED AIR,
WATER OR LIQUID CLEANSING AGENTS.

ATTENTION
THE “PACE-MAKER” CARRIER MIGHT BE AFFECTED

SMARTCAST 5
 THE INDUCTION HEATING PRINCIPLE

The induction heating principle consists in placing a metal within the influence of an oscillating magnetic field at
a determined frequency, such as the one generated by an induction coil. In the electronic induction centrifugal
casting machine mod. SMARTCAST the frequency is 80 KHz.

All metals have induced within them “eddy currents” and the metal electrical resistance to these currents provokes
a temperature rise and eventual melting.

The “eddy currents” form a molecular movement in the melting metal (see pictures 1 and 2) and give a thermic
homogeneity to the melting mass.

The induction heating results to be the best thermic energy source for melting and offers the following
advantages:

– unaltered metallurgical characteristics: elasticity, homogeneity and ductility

– clean working conditions
– higher purity of molten metal
– great productivity
– high melting temperatures without jeopardizing the machine components

PICTURE 1 PICTURE 2

SMARTCAST 6
ELECTRONIC INDUCTION CENTRIFUGAL CASTING MACHINE
SMARTCAST

Centrifugal casting into flask

This electronic induction centrifugal casting machine has been
built using the best technology and has a control lay-out which is
very operator-friendly.
It is designed for melting and casting the following alloys for
dental use:
• precious and non-precious alloys for ceramic and resin
• chrome-cobalt-molybdenum.

To facilitate the molten alloys to smoothly flow out of the

crucible during spinning the SMARTCAST fits a sloping crucible
holding plate which also ensures a complete and smooth flow of
those alloys with a low specific weight.

PICTURE 3

Normally 5 standard flask sizes are used; the smallest flask size of 30 mm diam. must be inserted in the ceramic
container given as standard outfit and both of them must be put in the burn-out furnace. This ceramic container
will maintain a constant temperature of the small flask.

ATTENTION: This machine must be only utilized for the intended purpose in accordance with the
seller’s instructions. Any other use is to be considered improper and consequently dangerous. The
manufacturer cannot be held liable for any damages caused for improper, wrong and unreasonable
uses.

ATTENTION: The use of non-genuine crucibles which do not correspond to the parameters of the
machine final test will considerably shorten the life of the power generator.

TECHNICAL CHARACTERISTICS
Electrical singlephase 230 V - 50/60 Hz 3 kW - see nameplate

Dimensions and Weight Base 510 mm w x 710 mm d x 870 mm h - 95 Kg

Frequency 80 KHz

Melting capacity precious alloys max. 80 gr

chrome-cobalt-molybdenum from 15/20 up to 100 gr
Flasks 30 mm diam. x 45 mm h. - to be used with ceramic
container code A100.001
48-65-80 mm diam. x 55 mm h.
Water cooling 2 litres/m’ - 3 bar

Compressed air 3 bar

SMARTCAST 7
 INSTALLATION INSTRUCTIONS

After having removed the machine from the packing material install it as per following instructions:
1 Check the voltage of the mains. Any variation beyond 10% plus or minus than the voltage indicated by the
nameplate does not allow regular operation of the machine. Connect the line cord to the singlephase 230 V
mains with regular grounding. A possible automatic safety breaker must have a 0.5 A differential.

2 The machine is electrically controlled by an overload safety circuit breaker in compliance with the CE
regulations which cuts off power in case of current overloads due to faults in the machine or to current surges
of the mains.
3

3 On the back of the machine there is the fitting for the compressed air connection. Compressed air supply
should not be lower than 3 bar (range from 3 to 6 bar)

4 Fill the tank with tap (even better demineralized) water up to 3 cm (1”) from the rim and close it with its
cover.
The two hoses must be dipped into the water down to the tank bottom.
As the machine is switched on, the water pump will automatically start the water circulation. Should the water
circulation fail, or be insufficient, the pressure switch will not allow the power output. It is recommended to
periodically check the flow of the circulating water, which must be 2 litres per minute and it is measured at
the machine water outlet by means of the special bottle included in the standard outfit.

A
IMPORTANT NOTICE

To prevent the crucible holding plate A from breaking when it slides

against the flask at the start of the centrifugation, place the ring B in
such a way to stop the travel of the crucible holding place abt 2 mm
from the flask.

The ring B must be positioned in

relation to the length of the
flask. Do not place it too PICTURE 4
distant from the flask B
otherwise the crucible exit
nozzle will not reach the sprue
button of the flask and
the metal might spill during
spinning.

A “universal cradle” for all casting rings is available on request; with

an easy movement of the lever it is possible to adjust the support and
any sprue button of the casting ring will be easily centered with the
crucible exit hole. This unversal cradle is particularly suitable when
using the technique of the free expansion without metal casting rings.

SMARTCAST 8
 CONTROL PANEL

C
D
B A

F
E

PICTURE 5

A MAIN SWITCH: when the white lamp illuminates, the machine is ready to operate

B GREEN PUSHBUTTON: Push it to start operations. When illuminated it shows that the heating power is
available, provided that the water flow is 2 litres per minute, the induction coil is surrounding the crucible
and the machine cover is closed.

C ORANGE LED: when illuminated it indicates that the generator does not supply heating power because
water temperature has exceeded 60 °C or because the generator itself is faulty.

D BLUE PUSHBUTTON : it stops heating power supply and the rotation of the centrifugal arm

E POTENTIOMETER FOR HEATING POWER REGULATION : power output is stepless. After each
casting cycle bring the potentiometer to 1 to have the machine ready for the next cycle.

F SWITCH FOR MELTING COIL MOVEMENT

SMARTCAST 9
 OPERATING INSTRUCTIONS

For a correct use of the electronic induction centrifugal casting machine SMARTCAST proceed as follows:

1 The machine has the built-in water pump for closed circuit water cooling system : the water circulation will
automatically start as the machine is switched
on.
2 Balance the centrifugal arm. Loosen the
handwheel which blocks the centrifugal arm. C
Balance is made with the cold flask on before
putting it in the furnace and the crucible D B
holding carriage positioned against the flask.
Move the counter-weight to reach the balance
using the red signs as reference to each flask
E
size. Block the centrifugal arm tightening the F
hand wheel.
3 Switch on main switch A.
4 Bring the potentiometer E on 1.
5 Remind that the power will be cut off when
the cover of the machine is opened and it
will be restored after the cover is closed.
When using the graphite crucible for precious
alloys the temporary interruption of the
power output is allowed. When using the
ceramic crucible for chrome cobalt
molybdenum or high temperature precious A
alloys this interruption is not allowed and the
flask will be put on the centrifugal arm
before starting the heating power. The very
slight decrease of the flask temperature will
have no negative influence on the casting
result.
6 Never start heating power if the crucible
with the metal has not been placed in the
induction coil lest probable damages in the
power generator. PICTURE 6
7 Put the crucible with the necessary quantity
of metal in the crucible holding plate.
8 With the left hand slide the crucible holding carriage so that when switching to the right the switch F which
raise the melting coil, the reference pin, placed under the crucible holding carriage will enter in the hole of the
coil support.
9 Close the cover and push green pushbuton B checking that it correctly illuminates.
If green pushbutton B is not illuminated it means that :
A - water circulation is missing or insufficient
B - Melting coil has not been raised to surround the crucible
C - The lid cover of the machine has not been closed
The orange led C must be off, If it illuminates it means that the water temperature has reached 60 °C
10 Regulate heating power with the potentiometer E until the melting of the alloy is reached.

SMARTCAST 10
 11 To evaluate the correct moment to start centrifugation, consider the following :
A. Check the melting process carefully. The melt must take place uniformly
throughout the alloy mass.
If the metal in the crucible does not lie together, the pieces lying on the
crucible bottom will melt quickly whereas the isolated pieces on the top
will have difficulty to reach the melt (picture 7). If the operator waits until
the metal on the top melts it might happen that the metal on the crucible
bottom reaches a so high temperature to cause the crucible itself to melt
and break with the consequent loss of melt.
To prevent this risk, it is necessary to touch, with the steel rod supplied
with the outfit, the metal pieces on the top to join them with the pieces on PICTURE 7
the crucible bottom. Regulate the heating power properly. These operations
are made with closed machine cover. The rod will be introduced through the mesh of the machine cover.
B. When using the graphite crucibles it is the graphite which acquires heat from the coil and transfers it to
the metal; consequently it is necessary to regulate power in such a way to have a slow melting process so
that the gradual temperature increase is transfered to the metal and the the colour of the crucible is
similar to the colour of the melting metal.

C. When the molten alloy takes a spherical shape, it has completely adhered to the crucible wall and the
superficial layer of oxyde breaks, it is the correct moment to start centrifugation.
An eventual waiting time of 5 t 15 seconds will depend on alloy quality and quantity and if metal is
partially recovered from previous castings.

12 When the metal is molten and ready to be cast, turn switch F to the left to lower the melting coil.
In this way the spinning of the centrifugal arm and disconnection of heating power will automatically take
place. During spinning the cover will be locked.
ATTENTION: WHILE SPINNING NEVER RAISE THE MELTING COIL.
13 To stop spinning , push blue pusbutton D.
14 Start the heating power potentiometer from 1 to repeat the cycle.

Il it advisable to stop the casting machine and allow the circulating water to cool down after one hour of
continuous work. If the orang led C illuminates, the is necessary to let the machine cool down.

WARNING
DURING THE MELTING AND CASTING PROCESS WITH GRAPHITE AND
SINTER CRUCIBLES, THE CERAMIC LID COVER MUST BE ON THE
CRUCIBLE TO PROTECT THE OPERATOR FROM POSSIBLE SPARKS OF
MOLTEN METAL

SMARTCAST 11
 CRUCIBLES

♦ Galloni’s experience has designed a line of graphite and ceramic crucibles to be used in the electronic
centrifugal casting machine mod. SMARTCAST. Their quality is superior:
– in their compatibility with the alloys available on the market
– in their shape which optimizes the result of the casting pieces.
♦ The crucible is an integral part of the electronic casting machine, therefore it is imperative to use the Galloni
original crucibles to prevent the machine from being jeopardized.
♦ During heating the crucible might release gases or substances which may pollute the alloy: the careful use of
Galloni crucibles ensures the original purity of the alloys.
♦ Warranty fails if non original crucibles are used.
♦ Store crucibles in a dry place.
♦ Crucible production presents different technical difficulties also in connection with the materials which cannot
always be of the same quality and therefore the constant crucible life cannot be guaranteed.
♦ ATTENTION: Do not put the sprue button of the previous casting in the crucible in such a way that the button
edge is wedged against the crucible sides because during heating its expansion will cause the crucible to break.
♦ ATTENTION: When the crucible is hot it becomes brittle. Avoid pressing with the steel rod on the metal
pieces settled in the crucible.

– A100.481 Highly resisting silicon nitride ceramic crucible for chrome-cobalt-molybdenum (100 gr) and for
precious alloys with high palladium contents (80 gr)
– A100.425 Ceramic crucible for chrome-cobalt-molybdenum (100 gr).
– A100.059 Special graphite crucible for precious alloys (80 gr) up to 1450 °C.
– A100.460 Sinter crucible in glass carbon for all alloys containing palladium (80 gr) or normal precious
alloys.

A100.481 A100.425 A100.059 A100.460

ATTENTION
THE ELECTRONIC CASTING MACHINE MUST BE EXCLUSIVELY USED
WITH ORIGINAL ASEG GALLONI CRUCIBLES OTHERWISE THE
OPERATION OF THE MACHINE WILL BE JEOPARDIZED AND WARRANTY
FAILS.

SMARTCAST 12
 TECHNICAL INFORMATION ON MELTING PROCESS

INFORMATION ON INDUCTION MELTING PROCESS

♦ The electromagnetic field (melting heat) heats the graphite crucible, which transfers the heat to the alloy and
melts it.
♦ The electromagnetic field does not heat the ceramic crucible, it is the alloy which acquires the heat by
induction from the coil and melts.
♦ If the quantity of alloy in the ceramic crucible is small, its small mass will acquire a small part of the induction
field which will not be sufficient to reach the melt. It is necessary to follow the indications of the minimum
alloy quantities permitted in the ceramic crucibles given in the next chapters.
♦ The metals and the alloys have different behaviours towards the magnetic field. For example: the same mass of
gold behaves differently from the same mass of alloy for ceramic techniques or chrome-cobalt-molybdenum,
therefore the heating power must be regulated accordingly.
♦ The magnetic field generated by the induction coil, which surrounds the crucible, reaches the highest
efficiency in the area indicated by W, therefore place the metal in this area.
♦ The metal must occupy the area indicated by A and must be put together and close to the crucible sides. If, for
example, some small alloy plates or rods are put in the crucible vertically, these will not build a sufficient mass
to acquire the electromagnetic field (Fig. C).
♦ For heating process it is necessary to follow the instructions given in the next chapters.
♦ When the casting wax model is designed, take care to make the reduced sprue button B and not the large
button D otherwise the latter, if recovered, will not enter in the crucible properly and it will have difficulties to
reach the melt. Furthermore due to its thermal expansion, it may break the crucible.

SMARTCAST 13
 MELTING AND CASTING PROCESS

MELTING AND CASTING OF CHROME -COBALT-MOLYBDENUM WITH HIGHLY

RESISTING SILICON NITRIDE CERAMIC CRUCIBLE REF. A100.481 OR WITH
CERAMIC CRUCIBLE A100.425 - CAP. 100 GR.

Chrome-Cobalt-Molybdenum alloys melt differently from precious alloys. Precious alloys must be heated slowly
and remain in the crucible to heat-soak, whereas Chrome-Cobalt-Molibdenum alloys must be melted quickly to
ensure unchanged properties of the alloys and as soon as the complete fluidity has been reached they must be cast.
We recommend to turn heating power potentiometer on a value between 80-100.
♦ Place the flask and the crucible on the centrifugal arm, without worrying about loss of temperature. Put CCM
in the crucible (min.quantity 15-20 grs, max. quantity 100 grs) taking care to put the metal on the crucible
bottom and against the crucible walls. Start melting process by turning heating power switch to the highest
position. Once the melting process has started do not open the cover otherwise the heating power will be
interrupted. If necessary, collect the metal on the crucible bottom using the steel rod which will be introduced
through the mesh of the machine cover. Operate very quickly to prevent the steel from melting. When CCM
has reached the complete fluidity it is ready to be cast.
♦ Melting must be checked by eye using the blue screen placed under the machine cover. Move the screen by
rotating the black knob on the cover.
♦ After casting, Chrome-Cobalt-Molybdenum alloys leave a thin trace of metal on the side of the crucible which
spontaneously gets detached from the crucible and must be removed by means of small tongs. If the trace of
metal is thick and does not come out of the crucible it indicates that the alloy was not completely molten. Do
not remove it from the crucible to avoid damaging it.
♦ After the first casting, check the crucible for cracks:
– if it shows large cracks do not use it for another melt
– if it shows small cracks it is a normal settling of material which will not bring any technical problem
♦ The crucible is working under extreme conditions. It reaches the temperature of 1500°C in 30/60 seconds, it
then cools down during spinning and is then subjected to the next cycle. The contractions are detrimental to the
crucible.
♦ The crucible life will be longer if castings are made successively one after the other: average life 15-20
castings. If castings are made in interrupted sequences, i.e. with long intervals between one and the following
melting, crucible will cool down continuously and its life will be shorter: average life 8-10 castings.

A100.481 A100.425

SMARTCAST 14
 MELTING AND CASTING PROCESS

MELTING AND CASTING OF PRECIOUS ALLOYS WITH CRUCIBLE COMPOSED OF

AN INTERNAL GRAPHITE LINER A100.059 - CAPACITY 80 gr Au

♦ The crucible is composed of an internal graphite liner of high quality. It is suitable for all precious alloys and
for ceramic alloys with a casting point of max 1450°C, excluding the precious alloys which have over 30%
palladium contents.
♦ For remelting old sprues, buttons, shanks, it is necessary to cut them into small pieces so that they perfectly
adhere to the crucible walls for an efficient heat transfer from crucible to metal. Generally it is recommended
to use 70% of new metal and 30% of old metal. The new metal usually in shape of small plates must be put first
in the crucible and when melting starts the old metal is added.
♦ During melting the graphite crucible produces a reducing atmosphere which will almost completely deoxidize
the precious alloy. Avoid the use of flux of whatever kind. Should the alloy be not completely clean, use pure
boric acid (H3B03) or deoxidizers supplied by the precious alloys manufacturers.
♦ It is always recommended a slow and gradual heating which can be easily reached since the machine has a
stepless heating power regulator: Recommended position from 20 to 40. Remember that when the metal is
close to the melting point , the colour of the metal must be approximatly the same as the graphite liner colour.
♦ All alloys have a “melting interval” expressed in temperature degrees, indicating the start of the melt and the
liquidus point ex. 1150-1200 °C. After the alloy has reached its liquidus point ( a complete melt) it is necessary
to attain the ideal casting temperature. This period of “overheating” the alloys is referred to as the “heatsoaking
interval”. The ideal casting temperature is generally 50-200 °C higher than the liquidus point of the alloy and
it must be left at this temperature from 5 to 30 seconds according to its quantity.
– The operator will decide when it is the correct moment to cast according to his personal experience.
– If necessary, collect the unmolten pieces on the crucible bottom using the steel rod which will be introduced
through the lid on the crucible.

A100.059

SMARTCAST 15
 MELTING AND CASTING PROCESS

MELTING AND CASTING OF NON-PRECIOUS ALLOYS FOR THE CERAMIC TECHNIQUE OR

PRECIOUS ALLOYS WITH PALLADIUM CONTENTS OVER 30%.
♦ Non-precious alloys used for the ceramic technique melt in a particular way and do not always run together and
become a fluid mass. Certain alloys are molten when the piece of metal loses its shape and slumps. Some of
them need a slow heating and only by experience it is possible to determine which heating power rate must be
used. Use crucible A100.481
♦ The alloy must be put in the crucible as described in the section Chrome-Cobalt-Molybdenum melting and
casting process. Consider the points mentioned on page 15.
♦ For the precious alloys with palladium it is possible to use the ceramic crucible A100.481 with a min. quantity
of 20 grs of alloy. We recommend the use of the Sinter glass carbon crucible A100.460 in which it is possible
to melt quantities of alloy from 5 to 80 grs.
♦ The use of the sinter crucible A100.460 requires a particular attention.
Put the alloy into the crucible and slowly heat it on a medium/high power position until the alloy reaches a dark
red colour. Increase the heating power slowly and gradually to enable the alloy to take the heat from the
crucible wall and reach the fluidity, checking that the colour of the crucible is same as the colour of the alloy.
If necessary use a very small portion of deoxidizer supplied by the precious alloys manufaturers or pure boric
acid (H3B03). The crucible has a long active life if it is used properly (40-60 castings).
♦ All alloys have a “melting interval” expressed in temperature degrees, indicating the start of the melt and the
liquidus point ex. 1150-1200 °C. After the alloy has reached its liquidus point ( a complete melt) it is necessary
to attain the ideal casting temperature. This period of “overheating” the alloys is referred to as the “heatsoaking
interval”. The ideal casting temperature is generally 50-200 °C higher than the liquidus point of the alloy and
it must be left at this temperature from 5 to 30 seconds according to its quantity.
– The operator will decide when it is the correct moment to cast according to his personal experience.
♦ Heating process must take place slowly and gradually. It might be necessary to collect the unmolten pieces on
the crucible bottom with the use of a steel rod. When the metal has slowly reached the complete melt, wait
5-10 seconds and then cast.

A100.481 A100.460

SMARTCAST 16
 MAINTENANCE

ATTENTION
UNPLUG THE MACHINE FOR ITS PERIODIC CLEANING AND USE A
VACUUM CLEANER OR DRY CLOTH: DO NOT USE COMPRESSED AIR,
WATER OR LIQUID CLEANSING AGENTS.

1 During normal operation if there are some difficulties to reach melting temperature or the power disconnects
automatically, check the conditions of the induction coil which might be short-circuited for several reasons:
excess of dust, small metal pieces between turns, turns touching each other etc. Clean the coil periodically
using a toothbrush.
To replace the induction coil unplug the machine.

2 When the casting machine has been working for several successive castings, condensation drops might be built
on the induction coil. They are caused by the low water temperature or by the high rate of ambient moisture.
Some minor adjustment of the water quantity may help to obtain 20/30 °C temperature of the circulating water
flow.

3 MAINTENANCE FOR THE CLOSED CIRCUIT WATER COOLING SYSTEM

– TANK: change the water twice a year and clean the tank walls.
Should the green led not illuminate, this may mean the lack of water circulation due to lack of water, clogged
water pump filter or pump jamming.

– To clean the water filter F unscrew the cover and remove it. Clean
it with compressed air or ultrasonic cleaner.

– PUMP: after long periods of inactivity the pump might be

mechanically jammed. Loosen the screw V of the metallic collar
which holds the water pump. Remove the pump and with a pair of
pliers or wrench turn the central clutch in order to rotate the pump R
and release it. Assemble as before and check the normal running.
Pump jamming causes the burning of the fuse located in the
fuse-holder. To replace it, unplug the machine, remove the front
panel and replace the 3A - 5x20 mm fuse for 50 Hz motor or the 5
A - 5x20 mm for 60 Hz motor.
PICTURE 8
– Should the water pressure need adjustment, turn the screw R about
1 turn: turning it clockwise the water pressure will be increased
and anticlockwise it will be decreased.
ATTENTION: IF THE MACHINE REGULATES THE WORK OF THE FACTORY IT IS
ADVISABLE TO KEEP IN STOCK THOSE PARTS WHICH ARE SUBJECT TO WEAR-OUT AND
MIGHT BE NOT AVAILABLE FOR A PROMPT DELIVERY FROM OUR STOCK: CRUCIBLES,
CRUCIBLE HOLDING PLATE.

ATTENTION
THE ELECTRONIC CASTING MACHINE MUST BE EXCLUSIVELY USED
WITH ORIGINAL ASEG GALLONI CRUCIBLES OTHERWISE THE
OPERATION OF THE MACHINE WILL BE JEOPARDIZED AND WARRANTY
FAILS.

SMARTCAST 17
 NORMAL OUTFIT

CODE DESCRIPTION QUANTITY

A032.026 5x20 - 3 A glass fuse for cooling water pump motor 50 Hz no.1
A032.039 5x20 - 5 A glass fuse for cooling water pump motor 60 Hz no.1

A032.014 5x20 - 200 mA fuse no.1

A032.025 5x20 - 2A fuse no.1

A100.425 Ceramic crucible no.1

A100.481 Silicon nitride ceramic crucible no. 1

A100.059 Crucible with internal graphite liner and cover no.1

A120.05 7x15 4ma screw no.2

A120.73 4x6 4ma cross screw no.2

A100.001 Ceramic container for small flasks no.1

P00138 Flask and crucibles tongs no.1

P04002 Steel rod to collect the metal on the crucible bottom no.1

A054.006 Eyebolt holes stopper no.4

A100.121 Eyebolt to be gripped when moving the machine no.4

A090.014 Rilsan hose diam. 4x6 mm for connection to compressor mt.2

A154.028 1/4”G fitting for rilsan hose diam. 4x6 mm no.1

Bottle of 2 litres capacity to check water outlet from the machine no.1

SMARTCAST 18
 WIRING DIAGRAM

19
SMARTCAST
 WIRING DIAGRAM COMPONENTS

SINGLEPHASE 230 V 50-60 HZ - P/A

REF DESCRIPTION COD. 50HZ

EMC Suppressing filter 2X16A A044.008
Q Luminous main switch 16A A042.068
G Mosfet generator 3 kW A060.100
L Impedance singlephase 10mH 10A A188.006
C Capacitor 2,4mf A015.155
B Induction coil *3642* P04944
U1 Feeder 24Vdc 1,1A A191.052
EM Safety electromagnet A026.009
K1 Motor contactor A018.134
K2 Power contactor A018.133
K3 Relay for electrovalve Ev1 A072.016
K4 Power contactor A018.133

EV1/2 EV1 => Electrovalve for raising of melting coil A027.059

EV2 => Electrovalve for lowering of melting coil
M1 Centrifuge motor (60Hz cod. A051.019) A051.018
M2 Water pump motor (60Hz cod. A051.078) A051.077
F Water pump fuse 5x20 5A A032.039
TR Potentiometer A128.015
S Switch for melting coil movement A063.052
P Water pressure switch A061.004
SC1 Lid cover microswitch A047.009
SC2 Safety microswitch A047.016
SC3 Coil down microswitch A047.006
SC4 Safert microswitch (coil down) A047.006
DL Orange led : generator alarm A076.035
ON Luminous green pushbutton A063.046
OFF Blue pushbutton A063.053
R 100 ohm 1 Watt resistor A073.166
C2 15000uf 35Vdc capacitor A015.157

SMARTCAST 20
 DEMOLITION AND DISPOSAL

The casting machine must not be disposed of as household waste but rather, when no
longer used, it must be collected separately according to EC Directive 2002/96.

ATTENTION: the components must be disassembled and gathered in groups according to their
composition.

The materials the casting machine is composed of are :

1 steel carpentry
2 panels and aluminium mechanical components
3 refractory materials of ceramic type
4 electronic parts (pc boards)
5 electric parts (cables)
6 rubber hoses
7 copper parts
8 brass parts
9 plastic parts
10 graphite parts

SMARTCAST 21
 THE WARRANTY

The WARRANTY (based on text issued by A N I E – National Electrotechnic Industries Association) covers the
free-of-charge replacement of faulty components, with the Buyer’s obligation to send back the damaged ones.
Shipping and fitting costs are to be borne by Buyer. Warranty does not extend to those components subject to
wear-out and to consumables. Nothing will be due to the Buyer for the time during which the machine remained
inactive nor he is allowed to require an indemnity for expenses, for accidents, for consequencial direct or indirect
damages
ASEG GALLONI SPA guarantee for the good performance of their machines provided they are utilized with
the crucible, spare parts and consumables produced by them. ASEG GALLONI SPA will be not held liable for
any damages or improper performance caused by non-original materials and warranty will fail.

For any technical or spare parts request it is

imperative to give us the serial number of the
machine, which is stamped on the name plate
placed on back side panel of the machine.

GALLONI
TECHNICAL SERVICE
FROM MONDAY TO FRIDAY
TEL. +39-0371-200233 a.r.
FAX +39-0371-898705
E-mail: info@galloni-aseg.com

SMARTCAST 22
 EXPLODED DRAWING: TABLE A

SMARTCAST 23
 COMPONENTS LIST - TABLE A

DESCRIPTION CODE

A1 Main switch A042.068

A4 Green “power on” switch functions operates when lit A063.046

A5 Blue “power off” switch to stop power and centrifugal A063.053

A6 Orange led lit when water exceeds 60°C or power generator fails A076.035

A7 Power control potentiometer A128.015

A8 Induction coil *3642* P04944

A9 Switch to move coil up and down A063.052

SMARTCAST 24
 EXPLODED DRAWING: TABLE B

SMARTCAST 25
 COMPONENTS LIST - TABLE B

DESCRIPTION CODE

B2 Switch to move coil up and down A063.052

B3 Potentiometer A128.015

B6 Line clamp A023.006

B7 K2 service contactor A018.133

B11 Water tank A079.005

B12 Pressure switch A061.004

B13 Water pump A028.004

B14 Water pump filter A038.003

B15 Water pump pressure regulating screw -

B16 Water pump motor 50Hz A051.077

Water pump motor 60Hz A051.078

B17 24Vdc feeder A191.052

B18 K1 centrifugal motor contactor A018.134

B19 Fixing plate of the cover locking key A194.657

B20 Blue glass filter for chrome-cobalt-molybdenum A096.000

B21 K3 relé - induction coil movement A072.016

B22 Water pump motor 5A fuse A032.039

B23 Cover microswitch A047.009

B25 Complete cover interlock safety switch assembly P5139006

B26 Cover interlock microswitch A047.016

B27 Cover interlock electromagnet A026.009

B28 Microswitches A047.006

B29 Compressed air valve A027.059

B30 Compressed air regulator A154.103

SMARTCAST 26
 EXPLODED DRAWING: TABLE C

SMARTCAST 27
 COMPONENTS LIST - TABLE C

DESCRIPTION CODE

C1 230V/50Hz centrifuge motor A051.018

230V/60Hz centrifuge motor A051.019

C2 Centrifuge motor starter V 230 Hz 50/60 A051.058

C3 K4 power contactor A018.133

C4 Compressed air filter A154.165

C5 Compressed air regulator -

C6 Air pressure gauge A154.109

C7 Power generator 3 kW A060.100

C8 60 °C thermostat A084.009

C9 Inductance A188.006

C10 R.F. mains suppressing filter A044.008

C11 Compressed air inlet pipe fitting A154.014

SMARTCAST 28
 EXPLODED DRAWING: TABLE D

SMARTCAST 29
 COMPONENTS LIST - TABLE D

DESCRIPTION CODE

D1 Counterweight P03772

D2 Arm blocking handwheel P03369

D3 Centrifugal arm P04960

D4 Bearing cover A195.199

D5 Radial bearing A022.013

D6 Pulley A067.003

D7 Centrifuge shaft P04940

D8 Shaft holder P04941

D9 Brass bush for crucible lid retainer P00318

D10 Crucible holding plate A107.126

D11 Centrifugal arm spring A010.012

D12 Centrifugal arm left rod P04974

D13 Centrifugal arm right rod P04973

D14 Crucible lid retainer P03487

D16 Spring for crucible lid retainer P00319

D18 Ring nut to stop the travel of the crucible holding carriage P01274

D19 Left support for crucible holding plate P04922

D20 Right support for crucible holding plate P04921

D22 Reference pin P04923

D25 Flask cradle -

D26 Arm bars fixing plate P04714

D27 Insulating plate A107.129

D28 Capacitor holding plate P04994

D29 Capacitor holding plate P04994

D30 Plate reference pin block A107.124

D31 Coil support plate A107.125

D32 Melting coil *3642* P04944

D33 Coil holding tube - left P04920

D34 Coil holding tube - right P04920

SMARTCAST 30
 COMPONENTS LIST - TABLE D

DESCRIPTION CODE

D37 Capacitor A015.155

D38 Pneumatic cylinder A193.044

D39 Holder plate for coil holding tubes A107.127

D40 Elbow water fitting A154.091

D41 Centrifugal bottom P04975

D42 Microswitches A047.006

D43 Motor pulley A067.008

D44 Trapezoidal belt A017.005

SMARTCAST 31
 REVISIONS

EDITION CONTENTS REVISION

01 DTD. 10/2006 00 DTD. 10/2006
01 DTD. 07/2008
02 DTD. 04/2011

SMARTCAST 32