Important!

Please read this handbook

before using your Neutec/Rio Grande™ J-2r.

Neutec®
J-2r
Operator’s Handbook
7500 Bluewater Road NW
Albuquerque, NM, 87121 USA
Technical Support: 505.839.3558
Neutec® Sales: 505.839.3010 • Fax 505.839.3016

Rev. G
710-990
©2015 Neutec/Rio Grande™
Contents
Section Six
Section One
Installing the Thermocouple 6-1
About Your Neutec/Rio Grande™ J-2r
Introduction 1-1 Section Seven
Site Requirements 1-2
Installing the Stirring Rod 7-1
Features 1-2

Section Eight
Section Two
Operating the Temperature Controller
Safety
Setting the Casting Temperature 8-1
Introduction 2-1
Setting the Casting Balance 8-2
Recommended Safety Gear 2-2
General Safety Warnings 2-3
Section Nine
Compressed Gas 2-3
Environmental Concerns 2-4 Casting With Your J-2r
Fire Extinguisher Equipment 2-4 Startup Checklist 9-1
Starting the J-2r 9-1
Section Three Charging the Crucible with Metal 9-2
Positioning the Flask 9-3
Set-Up
Casting 9-4
Start-Up Kit 3-1
Shutting Down 9-6
Setting Up Your J-2r 3-2

Appendices
Section Four
A NeuSprue™ Wax-to-Metal
Crucible Chamber Parts
Weight Conversion
Removing the Hood 4-1
Removing the Filling Cone 4-1 B Controller Parameters
Removing the Crucible Chamber Parts 4-2
C J-2r Parts and Accessories
Installing the Crucible Chamber Parts 4-2
D Alloy Melting Points
Section Five
E Troubleshooting
Sealing Rod
Removing the Sealing Rod Assembly 5-1 F Revision History
Installing the Sealing Rod Assembly 5-2
Adjusting the Sealing Rod Tension 5-2

www.neutec.com Page iii

Section One: About Your J-2r
Introduction
The J-2r from Neutec/Rio Grande™ incorporates
many of the important casting features found in
the Neutec® systematic approach to casting. It is
resistance-heated, meaning that it uses a
low-voltage electric coil to heat the melting
crucible, and has a sophisticated temperature
controller. The J-2r is an excellent choice for the
craftsman/designer working out of a small shop
where high production levels are not a daily
necessity. Cost/benefit ratios make it possible to
own a J-2r even when one-of-a-kind casting is
the majority of your workflow. The J-2r includes:
• Accurate temperature control.
• PID fuzzy logic controllers
• Protective inert-gas (nitrogen or argon)
atmosphere prevents oxidation.
• Bottom-pour crucible preserves metal
temperature during the pour and leaves any
slag or other contaminants in the button,
not in your casting.
• Closed-system stirring of alloys maintains
the protective atmosphere in the crucible.
• Low-voltage coil prevents electrical shock
and provides a long service life.
Metal Working Capacity
(grams) (dwt)
24KY 1,300 850
18KY 1,050 650
14KY 900 550
10KY 750 500
Sterling 700 450
J-2r crucible working capacity
Melting Time: For an initial cycle, starting
with a cool crucible, heating time is about 40
minutes; subsequent casting cycles range from
6–8 minutes depending on the size of the load.
Maximum Flask Size:
102mm diameter x 229mm H (4" dia. x 9"H).
Power Requirements: 208–240 volts, single-
phase, 1.5kW; requires a 15-amp circuit with
a circuit breaker.
Inert Gas Requirements: Nitrogen or argon;
8 lpm minimum at 0.7 bar (10 psi).
Important! Gas must be pure and
contain no oxygen or any combustible gas.
Dimensions: 46cmW x 46cmD x 76cmH
(18"W x 18"D x 311/2"H).

After initial heat up, casting cycles average Weight: 54kg (119 lbs.);
about 8 minutes, depending on metal type and shipping weight: 60kg (132 lbs.).
load size. The entire cycle assumes an attentive
Vacuum Requirements: one external 5cfm
operator reading the display and taking the
vacuum pump.
appropriate actions at the appropriate times.

Crucible Capacity: The maximum working

capacities of the J-2r are shown in the following
chart. Working capacity (the amount of casting
grain the crucible can hold before melting) is
approximately 60% of the crucible liquid
capacity. The working capacity varies depending
on the size and shape of your casting grain.

www.neutec.com About Your J-2r Page 1-1

Site Requirements
• Allow at least 25cm (10") of clearance
Maximize the benefits of the J-2r by making on all sides of the machine.
sure these site requirements are met:
• Make sure the J-2r has its own electrical
• Install the machine in a well-ventilated area. circuit. If you are not sure your electrical
• Do not place the machine on or near supply is compatible with the machine’s
flammable materials. requirements, consult an electrician.

Features • Temperature
Controller
Indicates/controls
metal temperature
casting temperature

• Nitrogen flow meter

Indicates gas flow
in liters per minute

Crucible Chamber Nitrogen Input Port

Hood Handles Attach nitrogen
Turns hood to unlock it supply to this port
to be lifted off of machine with supplied fittings

Flask Chamber Crucible Chamber

Locking Lever Melts the metal
Locks the flask chamber in a bottom-pour
firmly against the crucible graphite crucible
chamber

Vacuum Gauge
Indicates vacuum is
being pulled on a flask Flask Chamber
Handle
Vacuum Pump Opens flask chamber
Hose Connection after it is unlocked
Vacuum pump hose
connection point

Flask Chamber Main Power Switch

Swings out to accept Activates machine
a flask up to 102mm power
x 229mm (4" x 9")

505.839.3010 Neutec/Rio Grande™ J-2r Rev. G Page 1-2

Features (continued)

• Sealing Rod Holder

Holds the sealing
rod assembly and
thermocouple Stirring Handle
Connects to the graphite
stirring rod in the crucible

Thermocouple Receptacle
Holds the type-K
thermocouple

Sealing Rod Locking

Collar
Turns to lock collar on
tube for proper sealing
rod tension; allows turning
of the rod to seat it in the
crucible
Heating Coil On Light
(Behind handle) Indicates
power is on to the coil and
it is heating

Nitrogen Flow
Adjustment Knob
Hood Door Hood Hold-Down Lug Indicator is a small black
Opens for adding Secures the hood with bead in center of gauge;
metal to the crucible tabs that slide under this shows liters per minute
hook-shaped lug
Locking Mechanism
Locks sealing rod
in the up position

Sealing Rod Lifting Lever

Pushing down lifts sealing
rod assembly to release
the metal into the flask

www.neutec.com About Your J-2r Page 1-3

Section Two: Safety Safety Symbol Meanings

The J-2r is specifically designed to melt Wear Protective Apron

common jewelry metals (except platinum)
and their alloys at or below 1200°C (2192°F) and
to cast these metals into investment molds Wear Protective Shoes
using the lost-wax method.

These metals or alloys must contain only Wear Protective Gloves

the following elements:
• gold (Au) • nickel (Ni) • gallium (Ga) Wear Hearing Protection
• silver (Ag) • palladium (Pd) • silicon (Si)
• copper (Cu) • tin (Sn) • boron (B) Wear Full Face Protection
• zinc (Zn) • indium (In) • zirconium (Zr)
• cobalt (Co) • iridium (Ir) • ruthenium (Ru)
Do Not Touch
The Neutec® J-2r can be serviced or
modified only by a Neutec-qualified
Keep Dry
Field Service Engineer (FSE). This machine
is a safe and powerful tool when operated
as intended. It can become dangerous if Alert / Warning / Use Caution
improperly modified, abused, or used for
any other application. The J-2r is designed
to work with Neutec consumables. Using Hot—Will Cause Burns
consumables not manufactured by Neutec will
result in poor castings and can cause damage
Danger of Electrical Shock
to the machine. Non-Neutec crucibles will not
perform well and can cause carbon inclusions in
your castings. Danger of Fire
Please read the following information carefully
and completely before attempting to install,
Danger of Explosion
use, or maintain your J-2r casting machine.
Failure to comply with these cautions may
result in serious personal injury and/or Danger of Electrical Shock If Wet
property damage. Protect yourself and others
by observing all safety rules at all times.

www.neutec.com Safety Page 2-1

Recommended Safety Gear and Devices
Neutec/Rio Grande™ recommends the following safety gear and devices be used
at all times to minimize the risk of injury to the operator and observers.

Item Description Neutec/Rio Grande™

Order #
Lightweight Face shield gives complete face and neck protection. a. Headgear and shield:
Face Shield Allows full, unrestricted vision and has fully 201-746
adjustable headgear. b. Shield only: 201-747
Safety Glasses Glasses with polycarbonate lens material and side 115-729
guards.
Protective Wear only clothing made of cotton or wool. Clothing *
Clothing made from man-made fibers will melt and stick to
your skin if it comes in contact with hot metal or
flames.
Asbestos-Free Flame-resistant gloves made from Kevlar® thermal 704-105
Casting Gloves material. Contain no fiberglass or asbestos.
45.7cm (18") elbow length.
Protective Leather shoes or boots with built-in, steel toe *
Shoes protection.
Flask Tongs These special flask tongs lessen the chance of injury 710-568, 710-551
to workers and damage to flasks. They help reduce 710-569, 710-571
hand and wrist strain. With larger and heavier flasks,
the operator has a secure grasp on the flask.
Crucible Cooling jar cools a hot crucible and gives it longer 710-527
Cooling Jar life. Holds any Neutec® crucible
Crucible For hot crucible changes, use these special tongs. 710-208
Tongs Tongs are designed to safely open and close the
crucible cooling jar.
Graphite Use the rod to stir molten metal in the crucible, Rod: 710-034
Stirring Rod ensuring homogeneity. Holder: 710-207
& Rod Holder
Respirator Lightweight half-mask, NIOSH-MSHA approved. 201-683
Cartridge for above mask meets NIOSH 42 CFR 84
P100 requirements. Protects against respirable silica,
metal fumes, dust, fumes, radio nuclides, and airborne
asbestos.
Heavy-Duty 710-529
Tweezers

*Not available from Neutec/Rio Grande.

505.839.3010 Neutec/Rio Grande™ J-2r Rev. G Page 2-2

General Safety:
• Neutec recommends always using
appropriate safety gear and devices to
avoid personal injury to yourself and to
those around you. Please refer to the chart
of safety gear and devices on the facing
page.
• Verify that all guards and doors are in place
before operating the machine to avoid
injury to the operator.
• The hood-door glass is very hot during
machine operation.
• Warning! If you touch the hood-door
glass while the machine is operating, you
will be burned.
• The parts inside the crucible and flask
chambers are very hot while the machine
is operating.
• Warning! If you touch hot parts, you will
be burned. Be very careful when removing
and handling hot crucible chamber parts
and flask adapters. Use the appropriate
safety gear and devices as recommended
by the manufacturer.
• Do not put water or wet metal into the
machine. Moisture added to hot metal will
cause a steam explosion which can eject
hot or molten metal from the machine and
injure you or others nearby.
• Overheating the metal in the crucible can
result in metal splatter that can cause
serious burns. Follow the operating
instructions carefully to avoid overheating
the metal.
• Follow the Neutec® specifications regarding
size, shape, and physical properties of metal
to be put into the crucible.
• Follow the correct operating procedure
sequences as specified by Neutec®. Failure to
observe proper procedures can render the
J-2r unsafe to operate.
www.neutec.com Safety Page 2-3
• Use only genuine Neutec® replacement parts
and consumables to ensure correct opera-
tion of the machine and to avoid
serious personal injury.
• Unplug the machine whenever you are
performing maintenance on it. Restore
machine power with the main switch in
the OFF position to avoid a surge of current.
• Acquaint yourself with the Material Safety
Data Sheets applicable to the machine.
These are available from Neutec®.
Handling and Use of Compressed Gas
Cylinders and Pressure Regulators
Neutec/Rio Grande™ casting machines require
inert gas to provide an oxygen-free atmosphere
in the crucible and flask chambers. Nitrogen or
argon can be used for this purpose.
• Warning! In this handbook, the use of the
term “gas” does not refer to natural gas, stove
gas, or any other combustible gas.
Compressed inert-gas cylinders must be
handled with care. Do not allow them to fall or
to be roughly or carelessly handled. Cylinders
must be secured against falling during use and
storage. They cannot be used as work rests
or rollers and must not be exposed to
temperatures lower than -30°C (-22°F) or
higher than 55°C (130°F). Any of these abuses
can cause the cylinder to fail with deadly
consequences. Cylinders should always be used
and stored in an upright position.
The metal cap that protects the release
valve and safety release must always be
threaded completely onto the cylinder
and hand-tightened in place except when
the cylinder is in use. The protection cap
must never be used to lift the cylinder.
—continued on next page
Before using any compressed gas cylinder, its
contents must be positively identified. You
cannot rely on cylinder color, banding or shape
for identification. If a cylinder is not properly
labeled, do not use it; return it to the supplier.
Be sure that you are familiar with and follow all
local and state laws pertaining to the use and
handling of compressed gas cylinders.
Gas Withdrawal
Many high-pressure gas cylinders are filled
to pressures of 138 bars (2000psi) or more.
A proper pressure-reducing regulator such as
the nitrogen regulator shown below (710-105;
not included) must be used on the inert gas
cylinder for your J-2r to ensure safe operation.
Pressure-reducing regulator
(not included in the start-up kit)
Always use a regulator made specifically for the
gas you are using. Simple needle valves should
never be used. Before connecting the regula-
tor to the tank, clean the tank valve and open it
briefly to blow out any debris in the valve area.
Then attach the regulator to the tank.
The pressure regulator is comprised of two
gauges and a pressure adjustment handle
(“T” handle). Before opening the tank valve,
always release the pressure adjustment valve:
1. Turn the T-handle on the regulator counter-
clockwise until it turns freely.
505.839.3010 Neutec/Rio Grande™ J-2r Rev. F Page 2-4
2. Open the main tank valve slowly and
completely. The gauge on the right will
indicate the pressure of the gas in the tank.
3. Once the connection is properly made
between the regulator and the casting
machine, slowly turn the T-handle clockwise
until the left-hand gauge reads the desired
pressure for the J-2r (usually 0.7 bar or
10psi).
When you are finished using the gas, first close
the tank valve and then release the regulator
valve (in that sequence).
Air Quality
Melting some jewelry-making alloys can
produce small quantities of poisonous gases
that should not be inhaled. Design your casting
area with adequate ventilation to avoid
breathing either these gases or those produced
during burnout of the casting flasks.
Dismantling
Follow normal methods for machinery disposal
according to the regulations of the community
where the disposal takes place.
Fire Extinguishing Equipment
• Warning! Do not use water, sand,
carbon dioxide, soda-acid, or halogen-based
extinguishers for any fire inside the J-2r. Should
a fire occur inside the machine, use a Type ABC
extinguisher. Type ABC extinguishers contain
monoammonium phosphate and
ammonium sulphate as well as particulate
matter (muscovite mica and Fuller’s earth)
to make the application pattern visible.
Install the extinguisher near the machine for
quick access but not so close that it might
become inaccessible during a serious fire.
Section Three:
Setting Up Your J-2r
When you unpack your J-2r,
in addition to the machine,
you will find start-up items 10
listed below (shown at right). 1
Check these parts to be sure 6 13 Pre-installed
you have everything. 14 in the
11 15 machine
1. Silver tubing for inert 7
(nitrogen) gas, 8mm dia.
x 8 ft. long
2. One hose for vacuum 2
pump, 12.7mm dia. x 8
2.13 meters long (0.5" 9
dia. x 7 ft. long) 18

3. One hose clamp 3

4
4. Thermocouple 12 17
5. Sealing rod 16 5
6. Filling cone
7. Crucible
8. Crucible bottom gasket Included but not shown:
9. Crucible stand
• One inert gas inlet fitting (use nitrogen or
10. Flask adapter ring with
argon gas)
O-ring for 102mm (4") diameter flasks
• Owner’s Handbook
11. Woven flask Gasket, 102mm (4") • 6.4mm (1/4") barb fitting & 14.3mm (9/16")
12. Stirring rod compression nut for connecting blue inert
13. Sealing rod lift collar assembly gas hose to the machine
14. Stirring rod fixture
15. Sealing rod holder assembly You will also need:
16. 9.5 x 12.7mm (3/8" x 1/2" ) vacuum hose
barb for pump outlet • A vacuum pump capable of 142
liters/minute (5cfm) free air displacement,
17. 5mm Allen wrench
1 bar at sea level (29.9" of mercury at sea
18. Vacuum grease level)
• One nitrogen/argon regulator
• One tank of technical-grade nitrogen
or argon

www.neutec.com Setting Up the J-2r Page 3-1

Connect Gas, Vacuum and Power
1. Using the supplied hose clamp, connect
the vacuum pump hose to the vacuum inlet
on the lower left side of the flask chamber.
Tighten the hose clamp with a straight slot
screwdriver.
6. Be sure you have a compatible outlet,
providing 208–240-volt, single-phase,
15-amp power, readily available for
the power plug.
Please Note: If your incoming outlet power
is 240VAC/single phase/20-amp power, the
J-2r must be re-wired to accomodate 240
volt. See wiring diagram # N19094 at the
end of this manual.
• Caution! Do not plug in the machine
until you are ready to operate it.

Connect pump hose to vacuum inlet.

2. Attach the other end of the hose to your

vacuum pump (142 lpm, 5cfm free air
displacement, 1 bar at sea level ) using
the fittings provided.
3. Attach the nitrogen gas inlet fitting to the
pressure reducing regulator (see pg. 2-4)
and tighten. Please Note: This is a metric
fitting.

Slide the compression nut onto the plastic tubing.

4. Push the plastic tubing into the fitting

as far as it will go.
5. Attach the other end of the hose to your J2r
nitrogen input port.

505.839.3010 Neutec/Rio Grande™ J-2r Rev. G Page 3-2

Section Four: Installing/
Changing Crucible Chamber
Parts
If you are installing a crucible for the first time in
a new machine, skip to page 4-2 and follow the
instructions for “Install Crucible Chamber Parts.”
You must install the crucible assembly in your
J-2r before operation. Unplug the thermocouple wire.

3. Support the sealing rod holding tube,

Important! The following procedures should
be performed on a cool machine. If you have
to replace a part such as a crucible while your
machine is hot, use all recommended
protective gear.
loosen the sealing rod collar screw
and pull the tubing all the way up.
4. Lightly tighten the collar screw.
5. Twist the hood counter-clockwise until
the hood lugs are clear of the brackets.

• Warning! Hot parts may not look hot. Parts

with temperatures of several hundred degrees
look the same as cool ones. The sealing rod
could be hot enough to start a fire. Severe burns
will result from touching hot parts.
• Think about where you will put down
the hood assembly before removing it.
• Never place a hot hood, sealing rod or
crucible assembly part where you or
someone else might accidentally bump
Twist the hood until it clears the brackets.
into it or pick it up.
6. Carefully lift the hood off the machine.
Remove the Hood 7. Remove the filling cone.
1. Make sure the machine is off.
2. Unplug the thermocouple lead wire and pull
the thermocouple up and out of the sealing
rod.

Remove the filling cone.

www.neutec.com Crucible Parts Page 4-1

Remove Crucible Chamber Parts
1. Remove the crucible.
• Warning! If the machine is hot, use the
crucible tongs and set the hot crucible in a
Neutec® cooling jar (listed in the parts table).
Remove the crucible.
2. Remove the crucible bottom gasket.
Remove the bottom gasket.
3. Remove the ceramic crucible stand.
Remove the crucible stand.
505.839.3010 Neutec/Rio Grande™ J-2r Rev. G Page 4-2
Install Crucible Chamber Parts
1. Vacuum-clean the bottom of the crucible
chamber. Be sure there are no pieces of
metal or other debris in the chamber.
Be sure that the crucible chamber is clean.
2. Install a new crucible stand. Make sure
it is clean and centered over the pour hole.
3. Install a new crucible bottom gasket,
making sure it is properly seated inside the
crucible stand rim. This component is very
important and must never be left out. The
gasket is specially impregnated with a black
material that helps protect the crucible from
deterioration.
Install a new bottom gasket.
Please Note: The crucible bottom gasket
must be changed when it begins to turn
white. As the gasket turns white, it is less
and less able to protect the crucible.
4. Wipe the new crucible inside and out
with a paper towel, making sure it is
clean and free of any debris.
7. Install the filling cone. Rotate filling cone on
crucible chamber to help center the crucible.
Please Note: The filling cone is extremely
important. It prevents casting grain from
falling between the crucible and the heating
coil, fusing with the coil, and causing the coil
to fail.

Wipe the crucible inside and out.

5. Check the pour hole on the inside

of the crucible to make sure there are no
obstructions or imperfections that could
prevent a good seal. Install the filling cone.
6. Install the crucible in the machine. Center
8. Check the sealing rod for wear. Install
the crucible.
a new one if needed (see Section 5).
Important! Ensure that the crucible is not 9. Re-install the hood, turning it clockwise
touching the walls of the crucible chamber until the ball-detent clamps click into place.
coils.
• Warning! Never look up from under the
crucible chamber.
Important! Change the crucible if:
A) the sealing area around the pour hole
is damaged.
B) the crucible side-wall is thinned by
one-third or more.
Turn the hood clockwise until clamps click into place.
C) any cracks or other imperfections are
present. 10. Loosen the sealing rod collar screw, lower
the sealing rod holding tube into place and
Using a crucible past its safe life can cause
tighten the collar screw. See Section 5 to
a metal spill inside the crucible chamber.
adjust sealing rod tension before using the
Spilled metal in the crucible chamber can
machine.
damage the coil and leave your machine
unusable. 11. Insert the thermocouple into the sealing rod
and plug it in (see photo, page 4-1).

www.neutec.com Crucible Parts Page 4-3

Section Five:
Removing & Installing the
Sealing Rod
Neutec® strongly recommends this procedure
be done only on a cool machine. If the machine
has been running, the thermocouple will be hot
and could cause severe burns if you handle it
without protection. Use gloves or other safety
gear that will let you perform the task without
burning yourself.
1. Unplug the thermocouple lead wire from
the machine.
2. Pull the thermocouple up and out of the Turn the hood counter-clockwise.
sealing rod.
5. Lift the hood carefully off of the machine,
and lay it face up on a non-flammable work
surface.
6. Loosen the sealing rod collar screw and
remove the sealing rod and its holder from
the hood by sliding it down and out.
7. Loosen the sealing rod clamp with a 5mm
Allen wrench and remove the worn sealing
rod.

Unplug and remove the thermocouple.

3. Hold the sealing rod holder tube, loosen

the sealing rod collar screw, pull the tube all
the way up, and lightly tighten the
collar screw.
4. Turn the hood counter-clockwise until the
hood lugs are clear.

Loosen the sealing rod clamp.

www.neutec.com Sealing Rod Page 5-1

Installing the Rod Assembly
1. Place new sealing rod in the holder. Hold the
metal tube with the holder in one hand and
tighten the clamp with a 5mm Allen key.
Please Note: When the sealing rod holder
gets hot, the metal parts expand more than
the sealing rod. Be sure the clamp is well
tightened so the rod will not drop out after
being heated. Do not over-tighten the clamp
because you may break the rod. A good rule
of thumb is to turn the Allen screw until it
starts to offer resistance and then turn it an
additional one-quarter turn.
Tighten the clamp on the sealing rod.
2. Clean the inside of the hood and all sealing
rod parts before re-assembling.
3. Push the sealing rod holder tube up through
the top of the hood and lift the collar as far
as possible.
4. Lightly tighten the collar screw to hold
the sealing rod in the up position. This will
ensure that the sealing rod will not hit the
bottom of the crucible when the hood is put
back on the machine.
505.839.3010 Neutec/Rio Grande™ J-2r Rev. G Page 5-2
5. Re-install the hood on the machine. See
“Adjusting Sealing Rod Tension,” below.
6. Re-install the thermocouple in the sealing
rod and plug it into the machine.
Adjusting Sealing Rod Tension
Good contact and sufficient pressure between
the sealing rod and the crucible prevent molten
metal from leaking. Proper adjustment of the
tension on the sealing rod, described below,
helps prevent leakage.
• Warning! If the machine has been in use, the
parts involved in this procedure will be hot and
can cause severe burns if you handle them
without protection. Use gloves and other safety
gear to protect yourself.
1. Begin with the crucible in place and the
sealing rod assembly securely clamped in
its holder.
Crucible should be in place and the sealing rod installed.
2. Loosen the sealing rod collar screw on top
of the crucible chamber hood. Hold the steel
tube to prevent it from dropping into the
crucible.
3. Push down lightly on the top of the steel
tube. This will move the whole sealing rod
and ball assembly down.
4. Firmly seat the sealing ball in the bottom
of the crucible.
5. Holding the steel tube down with one hand,
squeeze the casting lever until there is a gap
of about 5mm (3/16") between the bottom
of the sealing rod locking collar and the top
of the stirring assembly bushing.

Set a 5mm gap between the locking collar and bushing.

6. Making sure the steel tube has not moved,

lightly tighten the sealing rod collar screw.

Lightly tighten the screw to hold the steel tube.

7. Using the sealing rod collar screw as a

handle, rotate the sealing rod assembly back
and forth three times to ensure the sealing
ball is well-seated in the crucible.
8. Re-check the gap. If the gap has altered,
loosen the collar screw, reset the gap to
5mm (3/16"), and re-tighten the collar screw.

www.neutec.com Sealing Rod Page 5-3

Section Six: Installing the
Thermocouple
The J-2r is equipped with a special type-K NiCr/
Ni thermocouple. The temperature controller
is designed and programmed to work with this
thermocouple.
Important! Do not use any substitute!
The thermocouple must be properly seated
inside the sealing rod for accurate temperature
control. Because of the expansion and
contraction caused by constant heating and Insert the thermocouple into the sealing rod.
cooling, the J-2r thermocouple is a consumable
part that requires periodic replacement. Important! Always monitor the crucible as it
A thermocouple failure usually results in an heats up for the first time after a sealing rod
open condition (infinite resistance) and the change. If the crucible color becomes white-hot
J-2r display will show “uuuu” (as it does and the temperature reading is several hundred
when the thermocouple is not plugged into the degrees below the set-point, it is likely the
receptacle). This condition prevents the machine thermocouple is not seated in the sealing rod.
from heating until it is corrected. This can happen if the ceramic rod becomes
warped from repeated heating and cooling.
Install the Thermocouple 2. Plug the thermocouple lead wire into
1. Push the thermocouple down inside the the receptacle next to the controller.
sealing rod until it stops. Make sure it
reaches the bottom of the sealing rod or
the temperature will not be read correctly.
Faulty temperature readings can result in
severe overheating of the crucible and coil
area, possibly causing a coil burnout,
damage to the crucible, and/or damage
to the surrounding parts.

Plug the thermocouple into its socket.

www.neutec.com Thermocouple Page 6-1

Section Seven: Installing the
Stirring Rod
Your J-2r is equipped with an internal stirring
rod that allows you to stir the molten metal
without opening the hood door and
compromising the inert gas atmosphere inside.

The stirring rod is rotated in an arc around

the sealing rod using the handle with the round
Unplug the thermocouple.
knob. The stirring rod is made of graphite and
requires periodic replacement. This is best done 2. Turn the hood counter-clockwise until
when the machine is cool. Check the stirring the hood lugs are clear.
rod condition as part of your regular pre-casting 3. Lift the hood carefully off the machine,
inspection each time you prepare to turn the and lay it face up on a non-flammable
machine on. work surface.
If you must replace the stirring rod when the
machine is hot, use extra caution to avoid
getting burned or causing a fire.

• Warning! Hot parts may not look hot. Parts

with temperatures of several hundred degrees
look the same as cool ones. The sealing rod
could be hot enough to start a fire. Severe burns
will result from touching a hot part.
• Think about where you will put down the
hood assembly before removing it.
• Never place a hot hood, sealing rod or
crucible assembly part where you or
someone else might accidentally bump
into it or pick it up.
Turn the hood counter-clockwise and lift it.
Install the Stirring Rod 4. Open the hood door. Loosen the stirring
1. Unplug the thermocouple and remove it rod clamp with a 5mm Allen key.
from the tube.

www.neutec.com Stirring Rod Page 7-1


Loosen the stirring rod clamp.
5. Remove the worn stirring rod.
6. Make sure the sealing rod clamp screw (to
the left of the stirring rod) is facing you. This
is necessary to assure a 180° stirring radius.
Make sure the sealing rod is facing you.
505.839.3010 Neutec/Rio Grande™ J-2r Rev. G Page 7-2
7. Insert the new stirring rod and tighten the
clamp.
Insert the stirring rod and tighten the clamp.
8. Check to make sure the stirring rod is secure.
9. Loosen the sealing rod collar screw and slide
the whole sealing rod assembly up. Tighten
the sealing rod collar screw. This will keep
the sealing rod from hitting the bottom of
the crucible when you replace the hood on
the machine.
10. Replace the hood.
11. Plug thermocouple into the machine.
12. Refer to Section 5 for adjusting the sealing
rod tension.
Section Eight: Operating the
Temperature Controller
Neutec/Rio Grande™ programs the Fuji
temperature controller in your J-2r to operate
well with most jewelry alloys.
Under normal circumstances, all you need to
do is set the casting temperature for the metal
you'll be using and the balance for the
temperature you’ll be using. For a detailed
guide on how to restore factory settings or
how to update the programming in your
temperature controller, refer to Appendix B.
• Please Note: All J-2r controllers are
pre-set at the factory to indicate temperature in
Celsius. If you prefer the controller indicate
temperatures in Fahrenheit, see the instructions
on page 8-2 for changing the controller display.
In the J-2r, the pour occurs as the tempera-
ture is rising instead of on the way back down
from an over-shoot. You need not over-shoot
to ensure the correct temperature. This helps
shorten your casting cycle times.
A typical casting cycle begins when you charge
a hot crucible with metal. The temperature
rapidly drops between 150°–250°C (300°–500°F)
as the new metal cools the chamber. The
temperature then begins a steady climb toward
the casting temperature you have set for your
alloy. As the metal begins to melt, the
temperature climb slows down. This occurs
during the transition of the metal from a solid
to a liquid. This change in the metal state
requires a lot of heat energy, and is called “the
heat of transformation.” Once the alloy becomes
liquid, the temperature rises quickly toward the
set casting temperature.
www.neutec.com Temperature Controller Page 8-1
Setting the Casting Temperature
Check with your alloy supplier for the
recommended casting temperature of the
metal you’ll be using.
• Please Note: Many variables affect the
ideal casting temperatures for your particular
patterns, such as:
• flask temperature
• how the spruing is done
• the design and size of your pieces.
You may need to experiment, based on these
and other variables, to find the ideal casting
temperatures for the items you are casting. Your
Neutec® representative can advise you on how
to make these judgments.
1. Turn on your J-2r, using the on/off switch on
the lower right-hand corner of the machine.
2. Turn on the nitrogen gas to the machine and
set the flow to 7 lpm.
3. Be sure the thermocouple is plugged in.
Shortly after the temperature controller lights
go on, the crucible chamber will begin to heat. If
you do not want the crucible chamber to begin
heating at this time, unplug the thermocouple
from the machine. This will prevent the machine
from heating the crucible. When you’re ready to
begin heating, plug the thermocouple back into
the machine.
4. The temperature controller lights should
be on, the SV light illuminated and the
set-point displayed in the lower row. The
crucible temperature is displayed in the
upper row.
5. Press the up or down arrow (∧ or ∨) to set
the desired casting temperature.
Setting the Casting Balance
The balance (bAL) controls the amount of
under-shoot or over-shoot that occurs when
coming to a specific set-point temperature.
Temperature controller
To set the balance for your cast:
1. Locate the temperature set-point you’re
working with on the balance table below.
Note the balance value shown in the right
hand column for the range within which
your temperature falls. For example, if you
are using 1875°F the balance value is 75.
Balance Chart
915°–960°C 1680°–1765°F bAL = 50.0
960°–1050°C 1765°–1925°F bAL = 75.0
1050°–1180°C 1925°–2150°F bAL = 90.0
2. Press “SEL” for 3 seconds until “bAL” shows in
the SV row.
3. Push “SEL” again and press the up or down
arrow (∧ or ∨) until the bAL value is the
same as noted from the chart.
4. Press “SEL” for 3 seconds until the SV light
comes on and the bottom row displays the
casting set-point, then release the button.
505.839.3010 Neutec/Rio Grande™ J-2r Rev. G Page 8-2
The machine is now ready to cast. If you
subsequently change your casting set-point
enough to be in a different temperature range,
reset the balance value as described above.
Changing the Temperature Display
from °C to °F
1. Unplug the thermocouple and turn on the
J-2r. “UUUU” will appear on the top display.
2. Press “SEL” for 3 seconds until “bAL” shows in
the SV row. Press down arrow (∨) until “P-F”
is displayed.
3. Push “SEL” again and lower display will flash.
Press the up (∧) arrow until “F” is displayed.
4. Push “SEL” once to enter the value then press
the up arrow for the next parameter.
5. Repeat steps 3 and 4 using the following
chart to reset the remaining parameters.
°F °C
BaL 90.0 90.0
Ar 10 6
P-SL 32 0
P-SU 2196 1200
P-F F C
6. After all parameters have been set, repeat the
action to verify that nothing has changed.
7. Turn off the J-2r.
Important! If the J-2r seems to be acting
strangely or erratically in relation to the
controller, check the factory settings in
the controller. Appendix B will show you
how to restore the settings.
Section Nine: Casting With
Your J-2r
Each day, before starting your J-2r, go through
the following checklist to ensure both operator
safety and successful castings.
Important! Be sure you read and understand
all safety precautions before operating the
machine.
Start-Up Checklist
1. Disconnect the thermocouple, then remove
the crucible chamber hood and inspect the
sealing ball, sealing rod, and stirring rod
for wear. Replace if needed.
2. Remove the filling cone, crucible, crucible
bottom gasket, and crucible stand.
3. Vacuum-clean the bottom of the crucible
chamber. Inspect the coil area for metal
pieces or worn spots. Remove all metal
pieces and repair worn spots with IZ-100
high temperature cement.
4. Inspect crucible stand for wear or
contamination. Replace if necessary.
5. Replace crucible gasket with a new one
if it is not uniformly black.
6. Inspect the crucible for wear, damage, or
contamination. Replace it if necessary. If the
crucible is in good condition, wipe it clean
and place it in the crucible chamber.
7. Inspect filling cone for wear. Replace
if necessary.
8. Re-install hood on crucible chamber.
9. Reset sealing rod tension.
www.neutec.com Casting Page 9-1
Important! Do not rotate the sealing rod
and ball until the crucible chamber has been
pre-heated. If there is solidified metal left
on the sealing ball, it can score the crucible
seat, causing leakage.
10. Re-connect the thermocouple. Make sure
the thermocouple is seated all the way
down inside the sealing rod and is making
contact at the bottom.
11. Check the inert gas (nitrogen or argon) tank.
Replace tank if it is low or empty.
12. Check your vacuum pump oil level. Add oil if
needed.
Starting the J-2r
1. Plug the machine in.
2. Set the regulator on your inert gas
(nitrogen or argon) tank to 0.1 bar (10psi).
3. Turn the machine on with the on/off switch.
Please Note: When the machine is on, you
will hear or see the cooling fan running
and the temperature control panel lights
should go on. The coil on light near the on/
off switch will cycle on and off as power is
applied to the heating coil.
Important! When the machine is heated for
the first time with new parts installed, you
may notice smoke and an odor of scorching.
This is normal.
4. Set the temperature controller to the
desired casting temperature. See Section 8
for information on using and adjusting the
temperature controller.
5. Set the inert gas flow meter on the machine
for 6–8 liters per minute. In general, more
gas is better—especially with larger metal
loads and larger flask sizes.
 1. When the temperature reaches set-point
(casting temperature), open the hood door
and charge the crucible with the correct
amount of metal for the flask to be cast.

Caution! Add metal carefully! Metal

pieces that spill outside the crucible
into the coil area will destroy the coil.

Set the gas flow meter for 6-8 lpm.

6. Wait for the machine to pre-heat

(approximately 40 minutes).
Please Note: As the machine heats up for
the first time after a sealing rod change,
Add metal carefully when set-point is reached.
monitor the crucible. If the crucible becomes
white-hot and the temperature reading is 2. Close the hood door.
several hundred degrees below the
set-point, the thermocouple may not Important! This machine is designed
be fully inserted in the sealing rod. to be used with casting grain. If you are using
previously cast metal (no more than 50% is
7. Seat the sealing rod by rotating the sealing recommended), make sure the metal pieces are
rod collar screw back and forth three times. small enough to be added to the crucible. Large
pieces can dislocate the sealing rod, causing a
Charging the Crucible leak or causing erroneous temperature readings
It is imperative that you use the correct amount and leading to over-heating of the metal.
of metal for the flask you’re casting. Too much
metal will cause a flask over-fill (leaving a
continuous column of metal between the flask
and the crucible when the metal solidifies). This
can damage parts of the machine and make
flask removal very difficult.

To determine the proper metal amount, consult

a lost-wax casting reference. If you are using
the Neutec® NeuSprue™ system (strongly
recommended), see the NeuSprue wax to metal
weight conversion table in Appendix A.

505.839.3010 Neutec/Rio Grande™ J-2r Rev. G Page 9-2

Positioning the Flask
1. With the vacuum valve on the machine
closed, turn on the vacuum pump.
Turn on the vacuum pump.
2. Move the cam lever all the way to the left to
release the flask chamber lifting cam on the
left side of the machine.
Move the cam lever to the left.
3. Using the flask chamber handle on the
upper right-hand side of the chamber,
swing the flask chamber out.
Swing the flask chamber out.
www.neutec.com Casting Page 9-3
4. Check that the flange gasket is the right size
for the flask you will use.
5. Using flask tongs, take the flask from your
burnout oven and place it in the chamber.
Important! Timing is essential; the flask
should be put into the machine just as the
metal melts. When the metal is about 28°C
(50°F) below the melting point, you have
about 20 seconds before the metal is com-
pletely melted. This should be just enough
time to retrieve and insert the flask.
Using flask tongs, insert the flask.
6. Move the vacuum valve lever to the open
position (parallel to the pipe). The vacuum
gauge should indicate that a vacuum is
being pulled on the flask.
Open the vacuum valve.
If you’re not getting a vacuum on the flask,
try rotating the flask with tongs to improve
the seal.
 Casting the Flask
1. When the metal is molten and within
a few degrees of set-point temperature,
rotate the stirring rod lever several times
to stir the alloy.
Important! Never attempt to stir
the metal before it is well above its melting
temperature. Any solids remaining in the
crucible may dislocate the sealing rod and
cause molten metal to leak.
Rotate the flask if necessary to improve the vacuum.

If the vacuum is still less than 21 inches/Hg,

remove the flask and replace the flange
gasket or clean the sealing face of the flange
on the flask before proceeding.
7. Swing the flask chamber back under the
crucible chamber and rotate the lifting cam
lever to the right. This will lift and lock the
flask chamber against the crucible chamber.
Rotate the stirring rod to stir the molten alloy.

2. At the moment the metal reaches the

casting set-point, squeeze the sealing
rod handle for five seconds. This lifts
the sealing rod and allows the molten
metal to flow into the flask.

Squeeze the handle to cast the metal.

Close and secure the flask chamber.

3. Release the sealing rod handle.
4. Rotate the sealing rod adjusting knob three
8. Time the flask insertion to allow 10–20 times to seat the sealing ball against the
seconds for the nitrogen gas to replace bottom of the crucible for the next cast.
the air in the mold cavity before set-point
temperature is reached and casting occurs.

505.839.3010 Neutec/Rio Grande™ J-2r Rev. G Page 9-4


Rotate the adjusting knob to re-seat the sealing rod.
5. While the flask is still in the flask chamber
with vacuum being pulled on it, open the
hood door and charge the crucible with the
appropriate amount of alloy for your next
flask. Close the door.
6. After 45 seconds, rotate the flask chamber
locking cam lever to the left to unlock and
lower the flask chamber from the crucible
chamber.
7. Swing the flask chamber open.
8. Check that the sprue button has solidified.
9. Turn the vacuum valve to the off position to
release the vacuum in the flask chamber and
allow you to remove the flask.
www.neutec.com Casting Page 9-5
Please Note: Your vacuum pump will run cooler
and last longer at high vacuum. Keep the flask
chamber vacuum valve closed between castings
while allowing the vacuum pump to run.
10. Using flask tongs, remove the cast flask.
Continue through the steps above for each cast
until all flasks are cast.
Important! If you’re casting different alloys, we
strongly recommend that you change crucibles
to avoid any cross-contamination.
• Warning! Be extremely careful when
changing crucibles in a hot machine. The
crucible, stirring and sealing rods, crucible
chamber hood, and other parts around the
crucible can cause severe burns when hot.
Use all recommended safety precautions and
equipment.
Exposing a hot crucible to the air causes the
crucible to oxidize rapidly, significantly
shortening the life of the crucible. Use a Neutec®
crucible cooling jar to isolate and
protect the crucible while it cools.
Shutting Down
At the end of your casting day, shut down your
J-2r and allow it to cool.
1. Adjust the temperature controller down to
0°C (32°F). This will turn off the power and
still allow you to monitor the temperature
of the crucible as the machine cools. 1 2
2. Open the vacuum valve first, and then turn
off the vacuum pump.
3. Squeeze the casting lever and engage the
locking mechanism on the lever assembly 1) Squeeze the handle and 2) push the locking
mechanism into the notch.
to lock the sealing rod assembly in the up
position. This keeps the sealing rod from
sticking to the crucible during cooling. 5. Once the crucible cools to this temperature,
turn off the gas and the power.
4. Leave the inert gas (nitrogen or argon)
on at about 4 lpm and let the crucible cool 6. Turn off the inert gas at the tank.
until it turns dark gray (about 300°C/600°F).

Remember!
Think safety at all times.
Re-read all instructions
and review all safety precautions
regularly!

505.839.3010 Neutec/Rio Grande™ J-2r Rev. G Page 9-6

Appendix A
Wax Weight to Metal Weight Conversion Chart for the NeuSprue™
No extra metal is necessary for the button when using the NeuSprue™ system.

Wax Sterling 8K 9K 10K 14K 18K 21K 22K 24K Wax Sterling 8K 9K 10K 14K 18K 21K 22K 24K
Weight Silver Gold Gold Gold Gold Gold Gold Gold Gold Weight Silver Gold Gold Gold Gold Gold Gold Gold Gold
(gram) Weight Weight Weight Weight Weight Weight Weight Weight Weight (gram) Weight Weight Weight Weight Weight Weight Weight Weight Weight
(gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram) (gram)
10 109 107 109 119 141 161 179 186 201 56 610 601 613 665 788 904 1002 1041 1127
11 120 118 120 131 155 178 197 204 221 57 621 612 623 677 802 920 1019 1059 1147
12 131 129 131 143 169 194 215 223 242 58 632 622 634 689 816 936 1037 1078 1167
13 142 139 142 154 183 210 233 242 262 59 643 633 645 701 830 953 1055 1096 1187
14 153 150 153 166 197 226 250 260 282 60 654 644 656 713 844 969 1073 1115 1208
15 163 161 164 178 211 242 268 279 302 61 665 654 667 724 858 985 1091 1134 1228
16 174 172 175 190 225 258 286 297 322 62 676 665 678 736 872 1001 1109 1152 1248
17 185 182 186 202 239 274 304 316 342 63 686 676 689 748 886 1017 1127 1171 1268
18 196 193 197 214 253 291 322 335 362 64 697 687 700 760 900 1033 1145 1189 1288
19 207 204 208 226 267 307 340 353 382 65 708 697 711 772 914 1049 1163 1208 1308
20 218 215 219 238 281 323 358 372 403 66 719 708 722 784 928 1066 1180 1227 1328
21 229 225 230 249 295 339 376 390 423 67 730 719 733 796 942 1082 1198 1245 1348
22 240 236 241 261 309 355 393 409 443 68 741 730 744 808 956 1098 1216 1264 1369
23 251 247 252 273 323 371 411 427 463 69 752 740 755 819 970 1114 1234 1282 1389
24 262 258 263 285 338 388 429 446 483 70 763 751 766 831 984 1130 1252 1301 1409
25 272 268 273 297 352 404 447 465 503 71 774 762 777 843 998 1146 1270 1319 1429
26 283 279 284 309 366 420 465 483 523 72 785 773 788 855 1013 1163 1288 1338 1449
27 294 290 295 321 380 436 483 502 543 73 795 783 798 867 1027 1179 1306 1357 1469
28 305 300 306 333 394 452 501 520 564 74 806 794 809 879 1041 1195 1324 1375 1489
29 316 311 317 344 408 468 519 539 584 75 817 805 820 891 1055 1211 1341 1394 1509
30 327 322 328 356 422 484 537 558 604 76 828 815 831 903 1069 1227 1359 1412 1530
31 338 333 339 368 436 501 554 576 624 77 839 826 842 914 1083 1243 1377 1431 1550
32 349 343 350 380 450 517 572 595 644 78 850 837 853 926 1097 1259 1395 1450 1570
33 360 354 361 392 464 533 590 613 664 79 861 848 864 938 1111 1276 1413 1468 1590
34 370 365 372 404 478 549 608 632 684 80 872 858 875 950 1125 1292 1431 1487 1610
35 381 376 383 416 492 565 626 650 704 81 883 869 886 962 1139 1308 1449 1505 1630
36 392 386 394 428 506 581 644 669 725 82 893 880 897 974 1153 1324 1467 1524 1650
37 403 397 405 439 520 597 662 688 745 83 904 891 908 986 1167 1340 1484 1542 1670
38 414 408 416 451 534 614 680 706 765 84 915 901 919 998 1181 1356 1502 1561 1691
39 425 418 427 463 548 630 698 725 785 85 926 912 930 1009 1195 1372 1520 1580 1711
40 436 429 438 475 563 646 715 743 805 86 937 923 941 1021 1209 1389 1538 1598 1731
41 447 440 448 487 577 662 733 762 825 87 948 933 952 1033 1223 1405 1556 1617 1751
42 458 451 459 499 591 678 751 781 845 88 959 944 963 1045 1238 1421 1574 1635 1771
43 469 461 470 511 605 694 769 799 865 89 970 955 973 1057 1252 1437 1592 1654 1791
44 479 472 481 523 619 710 787 818 886 90 981 966 984 1069 1266 1453 1610 1673 1811
45 490 483 492 534 633 727 805 836 906 91 992 976 995 1081 1280 1469 1628 1691 1831
46 501 494 503 546 647 743 823 855 926 92 1002 987 1006 1093 1294 1485 1645 1710 1852
47 512 504 514 558 661 759 841 873 946 93 1013 998 1017 1104 1308 1502 1663 1728 1872
48 523 515 525 570 675 775 859 892 966 94 1024 1009 1028 1116 1322 1518 1681 1747 1892
49 534 526 536 582 689 791 876 911 986 95 1035 1019 1039 1128 1336 1534 1699 1765 1912
50 545 536 547 594 703 807 894 929 1006 96 1046 1030 1050 1140 1350 1550 1717 1784 1932
51 556 547 558 606 717 823 912 948 1026 97 1057 1041 1061 1152 1364 1566 1735 1803 1952
52 567 558 569 618 731 840 930 966 1047 98 1068 1051 1072 1164 1378 1582 1753 1821 1972
53 577 569 580 629 745 856 948 985 1067 99 1079 1062 1083 1176 1392 1598 1771 1840 1992
54 588 579 591 641 759 872 966 1004 1087 100 1090 1073 1094 1188 1406 1615 1789 1858 2013
55 599 590 602 653 773 888 984 1022 1107

505.839.3010 Neutec/Rio Grande™ J-2r Rev. F Page A-1

Appendix B: Open and Set dSP Factory Settings
1. Unplug the thermocouple and turn on the
Controller Parameters J-2r. The SV light comes on and the set-point
value is displayed.
Parameters for PXR-4 Controllers
2. Press the “SEL” button for 6 seconds until:
This instruction applies to the Fuji Electric PID “Su-L” displays in the upper row.
Controller with Fuzzy Logic, Model PXR-4 used 3. Press the down arrow (∨) until you see
on the Neutec® J-2r casting machine. “dSP1” on the display.
4. Push “SEL.” Press the up or down arrow
NOTE: If you have a PXW-4 refer to page B-3 for
(∧ or ∨) until “255” is displayed (see dSP
parameter settings
factory settings chart below).
These instructions are used to improve the 5. Push “SEL” once to enter value for dSP1.
heating speed to set-point, improve set-point 6. Push the down arrow to access the next
stability, and reduce overshoot in the event the parameter, dSP2.
cast point (set-point) is missed. Additionally, the
machine operation has been programmed to
Display Setting
use the “cast on the way up” method applied on
dSP1 255
the larger Neutec® J-series machines. The
dSP2 255
programming uses the full capabilities of the
dSP3 113
Fuji temperature controller including the Fuzzy dSP4 44
Logic feature, alert indicator light, and variable dSP5 192
balance adjustment. dSP6 255
dSP7 255
dSP8 255
dSP9 159
dP10 255
dP11 243
dP12 225
dP13 127

dSP factory settings, open

7. Repeat steps 3–6 using the dSP factory

settings chart (above) to enter factory
Controller face
settings.

Purpose
The purpose of this procedure is to reset or
verify that the controller parameters are correct
for the desired temperature in °C and °F.

505.839.3010 Appendix B Page B-1

Open and Set Group 1 Factory Settings Open and Set Group 2 Factory Settings
1. Press “SEL” 5 seconds until the parameter “P” 1. Press “SEL” for 6 seconds until “Su-L” is
is displayed, then push “SEL”. lighted.
2. Press the up or down arrow (∧ or ∨) 2. Push "SEL" once until lower display flashes.
until 2.5 is displayed (see group 1 factory Press up or down arrow (∧ or ∨) until “0” is
settings chart below). displayed.
3. Push “SEL” once to enter value for P. 3. Push "SEL" once to enter value then press
Display Setting down arrow (∨) for the next parameter.
°C °F
P 2.5 2.5 Display Setting
°C °F
i 120 120
Su-L 0 0
d 30.0 30.0
Su-H 1200 2196
bAL 90.0 90.0
PLC1 -3.0 -3.0
Ar 6 10
PHC1 103.0 103.0
CtrL FUZY FUZY
rCJ on on
TC 10 10
Gain 1.000 1.000
P-n2 3 3
AdJO 0 0
P-SL 0 32
AdJS 0 0
P-SU 1200 2196
dSP1 255 255
P-dP 0 0
dSP2 255 255
P-F °C °F
dSP3 127 127
PVOF 0 0
dSP4 126 126
SVOF 0 0
dSP5 250 250
P-dF 1.0 1.0
dSP6 255 255
Group 1 factory settings chart dSP7 255 255
dSP8 255 255
4. Push the down arrow (∨) for next dSP9 159 159
parameter (see chart) dP10 255 255
5. Repeat steps 2–4 using the Group 1 factory dP11 243 243
settings chart to enter values. Use the dP12 225 225
dP13 127 127
values in the appropriate column for either
°C or °F, depending on how you want the Group 2 factory settings chart
controller to display. Parameter P–F allows
you to set the controller to display in either 4. Push the down arrow (∨) for next
Celsius or Fahrenheit. parameter (see chart).
6. Press “SEL” for 3 seconds until the SV light 5. Repeat steps 2–4 using the Group 2 factory
comes on and the row displays the casting settings chart to enter values.
set-point. Release the button. 6. Turn off the J-2r. The revised factory settings
are permanently stored and masked in the
controller. The J-2r is ready for casting.
Important: Remember to re-enter your
casting temperature set-point and your
casting balance after you have made any
changes to your J-2r programming settings.

505.839.3010 Neutec/Rio Grande™ J-2r Rev. F Page B-2

Parameters for PXW-4 Controllers Open and Set dSP Factory Settings
1. Unplug the thermocouple and turn on the
The following instructions apply to the Fuji J-2r. The SV light comes on and the set-point
Electric PID Controller with Fuzzy Logic, Model value is displayed.
PXW4-RAY1-4V, PXW4-RCY1-4V, and PXW4- 2. Press the “SEL” button for 9 seconds until
TCY1-4V used on the Neutec® J-2r casting “FUZY,” “P-n1,” or “dSP1” displays in the upper
machine. row.
These instructions are used to improve the 3. Press the down arrow (∨) until you see
heating speed to set-point, improve set-point “dSP1” on the display.
stability, and reduce overshoot in the event the 4. Push “SEL.” Press the up or down arrow
cast point (set-point) is missed. Additionally, the (∧ or ∨) until “104” is displayed (see dSP
machine operation has been programmed factory settings chart below).
to use the “cast on the way up” method applied 5. Push “SEL” once to enter value for dSP1.
on the larger Neutec® J-series machines. The
programming uses the full capabilities of the 6. Push the down arrow to access the next
Fuji temperature controller including the Fuzzy parameter, dSP2.
logic feature, alert indicator light, and variable
balance adjustment. Display Setting
dSP1 104
dSP2 120
dSP3 32
dSP4 252
dSP5 255
dSP6 128
dSP7 65
dSP factory settings, open
Controller face

7. Repeat steps 3–6 using the dSP factory

settings chart (above) to enter factory
Purpose
settings.
The purpose of this procedure is to reset or
verify that the controller parameters are correct
for the desired temperature in °C and °F, or
to change the controller parameters to toggle
the controller between °C and °F modes of
operaton.

505.839.3010 Appendix B Page B-3

Open and Set Group 1 Factory Settings Open and Set Group 2 Factory Settings
1. Press “SEL” for 7 seconds until the parameter 1. Press “SEL” for 3 seconds until “roFF” is
“P” is displayed, then push “SEL”. lighted.
2. Press the up or down arrow (∧ or ∨) 2. Push “SEL” once. The LED light beside the
until 2.5 is displayed (see group 1 factory letter “H” (H-light) starts blinking. Press the
settings chart below). down arrow (∨) until you see “0”.
3. Push “SEL” once to enter value for P. 3. Push “SEL” once. The LED light beside the
letter “L” (L-light) starts blinking. Press the up
Display Setting arrow (∧) until you see “20”.
°C °F 4. Push “SEL” once. You should see “AT 0”.
P 2.5 2.5 5. Press “SEL” for 9 seconds until you see
i 120 120 “P-n1.” Push “SEL.”
d 30.0 30.0 6. Press the up or down arrow (∧ or ∨) until
you see “0” (see group 2 factory settings
TC 10 10
chart below).
bAL 90.0 90.0
7. Push "SEL" once to enter the value for P-n1.
AR 6 10
P-n2 3 3 Display Setting
P-SL 0 32 P-n1 0
P-SU 1200 2192 P-dF 1.0
P-dP 0 0 P-An 0
P-AL 13 13 rCJ on
PVOF 0 0 PLC1 -3.0
SVOF 0 0 PHC1 103
P-F °C °F PCUT 0
FUZY on
Group 1 factory settings chart
GAin 1.0
AdJO 0
4. Push the down arrow (∨) for next
parameter (see chart) AdJS 0
5. Repeat steps 2–4 using the Group 1 factory Group 2 factory settings chart
settings chart to enter values. Use the
values in the appropriate column for either
8. Push the down arrow (∨) for next
°C or °F, depending on how you want the
parameter (see chart).
controller to display. Parameter P–F allows
you to set the controller to display in either 9. Repeat steps 6–8 using the Group 2 factory
Celsius or Fahrenheit. settings chart to enter values.
6. Press “SEL” for 3 seconds until the SV light
comes on and the row displays the casting
set-point. Release the button.

505.839.3010 Neutec/Rio Grande™ J-2r Rev. F Page B-4

Verify Factory Parameter Settings
1. Press “SEL” for 3 seconds until the SV light
comes on and the row displays the casting
set-point. Release the button.
2. Turn the J-2r off and then on again.
3. Repeat all the above steps to check all
the settings. Some parameters are linked
to other parameters, so the setting must
be verified.
Important: Use care when stepping through
the parameters to be sure you don’t
mistakenly change a value. All values must
be correct for the controller to work properly.

Close dSP Factory Settings

1. After checking all the settings, push the
down arrow (∨) again until you see dSP1 (or
press “SEL” 9 seconds until you see “P-n1” and
then press the down arrow (∨) until you see
“dSP1”.
2. Continue setting the values from the dSP
factory settings chart below.

Display Setting
dSP1 251
dSP2 127
dSP3 255
dSP4 255
dSP5 255
dSP6 255
dSP7 127
dSP factory settings, closed

3. Turn off the J-2r. The correct settings are

now permanently stored in the controller.
The machine is ready for operation.
Important: Remember to re-enter your
casting temperature set-point and your
casting balance after you have made any
changes to your J-2r programming settings.

505.839.3010 Appendix B Page B-5

Appendix C
Consumables, Replacement Parts and Accessories
Description Part Number Quantity
J-2r, Series IV Casting Machine 710-040 or 1 ea.
710-040CE
Busch Vacuum Pump Oil 706-016 1 quart
Replacement Fuse, 16A, 250V 710-095 1 ea.
O-Ring Lubricant 710-217 5.3 oz. tube
Casting Crucible, 80 x 60mm; 8mm Hole 710-192 1 ea.
Casting Crucible, 80 x 60mm; 9.5mm Hole 710-193 1 ea.
Sealing Rod, One-Piece R81 Graphite 710-370 pkg/6
Sealing Rod, 165mm Hollow Ceramic 710-375 pkg/6
Graphite Sealing Ball 710-378 pkg/24
IZ-100 High-Temperature Cement 710-223 1 ea.
Stirring Rod, Graphite, 8mm (5/16") dia. 710-034 pkg/10
Crucible Bottom Gasket 710-340 pkg/6
Crucible Stand 710-090 pkg/3
Filling Cone 710-191 pkg/2
Thermocouple, Type K 710-364 1 ea.
Teflon Metal Dispenser 704-116 1 ea.
Instructional Video 560-059 1 ea.
Flask Gasket, Woven, 102mm (4") dia. 710-407 pkg/6
Flask Gasket, Woven, 89mm (3.5") dia. 710-406 pkg/6
Flask Gasket, Woven, 76mm (3") dia. 710-410 pkg/6
Flask Gasket, Woven, 64mm (2.5") dia. 710-411 pkg/6
Flask Gasket, Silicone, 102mm (4") dia. 710-393 pkg/6
Flask Gasket, Silicone, 89mm (3.5") dia. 710-392 pkg/6
Flask Gasket, Silicone, 76mm (3") dia. 710-391 pkg/6
Flask Gasket, Silicone, 64mm (2.5") dia. 710-390 pkg/6
Flask Gasket, Graphite, 102mm (4") dia. 710-399 pkg/6
Flask Gasket, Graphite, 89mm (3.5") dia. 710-398 pkg/6
Flask Gasket, Graphite, 76mm (3") dia. 710-397 pkg/6
Flask Gasket, Graphite, 64mm (2.5") dia. 710-396 pkg/6
Flask Adapter Ring, 102mm (4") 710-198 1 ea.
Flask Adapter Ring, 89mm (3.5") 710-199 1 ea.
Flask Adapter Ring, 76mm (3") 710-200 1 ea.
Flask Adapter Ring, 64mm (2.5") 710-099 1 ea.
O-Ring for Outside of All Adapter Rings 710-197 pkg/6
O-Ring for 102mm (4") Flask Adapter 710-562 pkg/6
O-Ring for 89mm (3.5") Flask Adapter 710-561 pkg/6
O-Ring for 76mm (3") Flask Adapter 710-560 pkg/6
O-Ring for 64mm (2.5") Flask Adapter 710-545 pkg/6
Sight Glass/Hood Door Glass 710-195 1 ea.
Vacuum Gauge 710-216 1 ea.
Crucible Chamber Muffle Kit 710-016 1 ea.
Crucible Chamber Insulator 710-189 1 ea.
Crucible Chamber Gasket Set 710-211 1 set
Red Fiber Washer (inert gas inlet) P38-036 1 ea.
5 CFM (142 lpm) Vacuum Pump 700-350/220 1 ea.
Nitrogen Regulator 710-105 1 ea.
Face Shield, Lightweight, with Headgear 201-746 1 ea.
Replacement Face Shield 201-747 1 ea.
Gloves, Flame-Resistant, Non-Asbestos, Elbow Length 704-105 1 pair
Flask Tongs for 89mm (3.5") Flasks 710-271 1 ea.
Flask Tongs for 102mm (4") Flasks 710-272 1 ea.
Crucible Tongs 710-208 1 ea.
Neutec® Crucible Cooling Jar 710-527 1 ea.

505.839.3010 Appendix C Page C-1

Appendix D
Alloy Compositions and Melting Points
Casting
Specific % % % % % Melting Temp
Alloy/Metal Gravity Gold Silver Copper Zinc Other Point °C/°F
Brass 8.5 70 30 954°C / 1749°F
Red Brass 8.8 90 10 1044°C / 1910°F
Bronze 8.8 96 4 Tin 1060°C / 1945°F
Nu-Gold 8.7 88 12 1030°C / 1886°F
Copper Cu 8.9 100 1083°C / 1981°F
Gold (Fine) Au 19.3 100 1063°C / 1945°F
22K Yellow Gold 17.3 92 4 4 977°C / 1790°F
18K Yellow Gold 15.5 75 15 10 882°C / 1620°F
18K Yellow Gold 15.5 75 12.5 12.5 904°C / 1660°F
18K Green Gold 15.6 75 25 966°C / 1770°F
18K Rose Gold 15.5 75 5 20 932°C / 1710°F
18K White Gold 15.7 75 25 Palladium 904°C / 1660°F
14K Yellow Gold 13.4 58 25 17 802°C / 1476°F
14K Green Gold 13.6 58 35 7 835°C / 1535°F
14K Rose Gold 13.4 58 10 32 827°C / 1520°F
14K White Gold 13.7 58 42 Palladium 927°C / 1700°F
10K Yellow Gold 11.6 42 12 41 5 786°C / 1447°F
10K Yellow Gold 11.6 42 7 48 3 876°C / 1609°F
10K Green Gold 11.7 42 58 804°C / 1480°F
10K Rose Gold 11.6 42 10 48 810°C / 1490°F
10K White Gold 11.8 42 58 Palladium 927°C / 1760°F
Nickel (German) 8.8 65 17 18 Nickel 1110°C / 2030°F
Silver
Coin Silver 10.3 90 10 890°C / 1634°F
Sterling 10.4 92.5 7.5 893°C / 1640°F
Silver (Fine) Ag 10.6 100 961°C / 1762°F

Use this chart to record the casting temperatures of the various metals you use. As a general rule,
the casting temperature will be anywhere from 50°C to 100°C (90°F to 180°F) higher than the
melting point of the metal.

505.839.3010 Appendix D Page D-1

 Appendix E
Casting Troubleshooting

Symptom Cause Remedy

Gas porosity
Shrinkage porosity
Castings appear to have been cast at
a higher temperature than indicated
Metal is reacting with the investment
because casting temperature is too high.
Burnout was incomplete.
Metal is contaminated.
Turbulence: pour hole is worn or NeuSprue™
was not used for the waxes.
Sprue gates are in the wrong position on model.
Thick-thin-thick design of pattern.
Gates are solidifying too soon.
Metal and/or flask temperature is too hot
or too cool.
Flask temperature too high.
Flask chamber is closed before metal in the
crucible is liquid.
Metal temperature is higher than indicated.
Increase sprue size and lower flask and/or
metal temperature.
Steam dewax before burnout. Make sure
investment is snow-white after burnout.
Use fresh metal.
Make sure crucible pour hole is smooth (replace
crucible and/or crucible bottom gasket). Use
NeuSprue™ for your wax trees.
Test different feed positions for gates until a
good cast is made.
Use larger sprue gates or adjust feed position.
Increase gate size (volume).
Test cast the pattern at different flask and metal
temperatures until the correct combination is
found for the alloy and the pattern.
Hold flasks in the oven at casting temperature
for four hours.
Close flask chamber just as the metal is
completely liquid. Closing the chamber too early
will cause the metal temperature to be higher
than the displayed temperature.
Make sure thermocouple is completely seated in
bottom of sealing rod.

505.839.3010 Appendix E Page E-1


Symptom
Castings appear to have been cast at
a lower temperature than indicated
Incomplete fill on items that
previously filled at the same
temperature.
Top of tree fills poorly or not at all
while bottom fills completely.
505.839.3010
Casting Troubleshooting (continued)
Cause
Flask temperature is too low.
Flask is allowed to sit in chamber too long
while vacuum is on.
Metal is contaminated.
Poor vacuum.
Poor vacuum due to dirty vacuum filter.
Vacuum leak.
Faulty vacuum pump.
Oven temperature not correct; flask is too cold.
Crucible is starting to leak just before the pour.
Neutec/Rio Grande™ J-2r Rev.F
Remedy
Check burn-out oven for proper operation and
temperatures.
Correct procedure to insert flask just prior to
metal completely melting.
Use fresh metal.
Check flask adapter gasket. Check for cracked
investment. Replace vacuum filter. Check for
vacuum leaks.
Replace vacuum filter.
Call a Neutec® qualified technician.
Call a Neutec® qualified technician.
Check oven temperature for accuracy.
Silicon, boron or flux residue in bottom of
crucible between sealing rod and crucible melts
and allows metal to leak, blocking top of tree.
Use an alloy that does not leave a depost in
crucible.
Page E-2
 Casting Troubleshooting (continued)

Symptom Cause Remedy

Ring shanks are cracking at the gate
(feed sprue) junction: alloys without
silicon.
Ring shanks are cracking at points
other than the gate (feed sprue)
junction: alloys with silicon.
Carbon inclusions in casting.
Casting has fins or flashing.
System temperature is too high because
adjustment was made for too small a sprue or
incomplete fill in sprue area.
Flask temperature is higher than indicated.
Metal temperature is higher than indicated.
Main sprue is too large causing gate (sprue)
junction to cool too slowly.
Flask was quenched too soon after casting.
Incomplete burnout.
Crucible bottom gasket not changed soon enough. Change crucible bottom gasket when it begins
Bad or low-grade consumables.
Investment is cracked from rough handling.
Burnout oven was too hot when flask was put in. Use proven burnout cycle configurations for
Partial blowout; not enough investment at end
of flask.
Increase gate (sprue) size so pattern will fill at
a lower flask or metal temperature.
Check burn-out cycle to be sure flasks are held
at casting temperature long enough for them to
stabalize (usually about 4 hours).
Thermocouple is not completely seated
in bottom of sealing rod.
Use NeuSprue™ sprues.
Let flask cool longer before quenching.
Steam dewax before burnout. Make sure
investment is snow-white after burnout.
to turn gray or white.
Use only high-grade Neutec/Rio Grande™
consumables.
Handle flask more carefully.
time and temperature.
Use a taller flask or modify tree design so there
is at least 13mm (1/2") of investment between
tree or model and end of flask.

505.839.3010 Appendix E Page E-3