Ivoclar Programat S1 Operating Instructions

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Programat® S1 1600
Valid from
software V5.0
Operating Instructions
Page 2
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Table of Contents
1.1 Preface
1.2 Signs and symbols
1.3 Notes regarding the Operating Instructions
1.4 Notes regarding the country-specific voltage versions
2.1 Indications
2.2 Health and safety instructions
3.1 Components
3.2 Hazardous areas and safety equipment
3.3 Description of functions
3.4 Accessories
3.5 Indications / contraindications
4.1 Unpacking and checking the contents
4.2 Selecting the location
4.3 Assembly
4.4 Demounting the furnace head
4.5 Initial start-up
5.1 Introduction to the operation
5.2 Explanation of the key functions
5.3 Basic meaning of the display elements
5.4 Program structure
5.5 Adjustable parameters and possible value ranges
5.6 Settings / test programs and information
5.7 Explanation of the display symbols
5.8 Explanation of the acoustic signals
5.9 OSD
6.1 Switching on the furnace
6.2 Loading the Programat S1 1600
6.3 Sintering using a standard program
6.4 Sintering using an individual program
6.5 Additional possibilities and special features of the furnace
6.6 Programming
7.1 Cleaning of the sintering chamber and the heating elements
7.2 Further monitoring and maintenance work
7.3 Cleaning
7.4 Test programs
7.5 Stand-by
7.6 Temperature calibration
7.Z Service hint
8.1 Error messages
8.2 Technical malfunctions
8.3 Repair
9.1 Delivery form
9.2 Technical data
9.3 Acceptable operating conditions
9.4 Acceptable transportation and storage conditions
10.1 Program table
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List of Parts
1 Insulation
2 Thermocouple
3 Sinter tray
4 Display
5 Frame plate
6 Sinter chamber
7 Furnace housing
8 Membrane-sealed keypad
9 On/Off switch
10 Heater fuse
11 Fuse holder
12 Power cord
13 Power socket
14 Rating plate
15 Rubber foot
16 Furnace head housing
17 Thermocouple plug
18 Power electronics plug
19 Plug fuse
20 Heater plug
21 Socket for the heater plug
22 Socket for the thermocouple plug
23 Socket for the power electronics plug
24 Leave spring
25 Air vents base
26 Cooling tray
27 Cooling tray fastening screw
28 Silicone washer
29 Hood
30 Attachment screw for hood
31 Air vents furnace head
32 Air vents rear panel
33 Furnace head mounting mark
34 Furnace base mounting mark
35 Furnace head mounting
36 Heating element
37 Sinter tray rest
38 Thermocouple cable
39 Power electronics cable
40 Connecting rod axis
41 Plug-in console
42 USB device interface
44 OSD indicator
45 Spacer
46 Grounding band
47 Screw for grounding band
Please note that the list of parts applies to the entire
Operating Instructions. These parts and their numbers are often referred to in later chapters.
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44
16
26
4
8
27
15
25
1
3
6
5
37
2
7
5
Page 6
30
31
29
14
10/11
9
10/11
42
42
45
32
13
12
46
38
17
22
39
47 19
18 23
21
20 9
24
6
35
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1
33
40
41
34
36
Operating unit:
71 ESC key
72 ENTER key
73 Start key
74 Start LED
75 Stop key
76 + key
77 - key
78 Settings key
79 Cursor right key
80 Cursor left key
81 Information key
82 Program 1 key
83 Program 2 key
84 Program 3 key
85 Program 4 key
86 Next program key
87 Open furnace head
88 Close furnace head
2
78
87
81
88
75
72
79
80 77
76
71
73
74
82
83
84
85
86
100 Sinter tray
101 Sinter tray fork
100
101
102 Cleaning brush 103 Programat Dosto Tray
103
102
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1. Introduction / Signs and Symbols
1.1 Preface
Dear Customer
Thank you for having purchased the Programat S1 1600. It is a sinter furnace for dental laboratories requiring such a furnace for the CAD/CAM technique. The Programat S1 1600 permits the sintering
materials. It has been especially designed and constructed for
of ZrO
2
this purpose.
The furnace has also been designed according to the latest industry standards. However, inappropriate use may damage the equipment and be harmful to personnel. Please observe the relevant safety instructions and read these Operating Instructions carefully.
Enjoy working with the Programat S1 1600.
1.2 Signs and symbols
The signs and symbols in these Operating Instructions facilitate the finding of important points and have the following meanings:
Risks and dangers
1.3 Notes regarding the Operating Instructions
Furnace concerned: Programat S1 1600 Target group: Dental technologists
These Operating Instructions facilitate the correct, safe and economic use of the Programat S1 1600 furnace.
Should you lose the Operating Instructions, extra copies can be ordered at a nominal fee from your local Ivoclar Vivadent Service Center or downloaded from the Internet free of charge (www.ivoclarvivadent.com).
1.4 Notes regarding the country-specific voltage versions
The furnace has been designed for the following voltage range:
118–240V / 50 - 60 Hz
No manual switch-over is required for the use of the different voltage versions. Make sure that the local power supply complies with the voltage indicated on the rating plate before operating the furnace.
Important information
Contraindication
Burn hazard
Risk of crushing
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2. Safety First
This chapter is especially important for personnel who work with the Programat S1 1600 or who have to carry out maintenance or repair work. This chapter must be read and the corresponding instructions followed.
2.1 Indications
The Programat S1 1600 is intended to sinter ZrO2 ceramic materials used in dentistry and it should be used for this purpose only. Other uses than the ones stipulated, e.g. cooking of food, firing of other materials etc., are contraindicated. The manufacturer does not assume any liability for damage resulting from misuse. The user is solely respon­sible for any risk resulting from failure to observe these Instructions.
Further instructions to assure proper use of the furnace:
– The instructions, regulations and notes in these Operating
Instructions must be observed.
– The instructions, regulations and notes in the material’s
Instructions for Use must be observed.
– The furnace must be operated under the indicated environmental
and operating conditions (see Chapter 9).
– The Programat S1 1600 must be properly maintained.
Do not use colouring liquids containing chlorine or hydro­chloric acid in Programat S1 1600 furnaces. Due to the aggressive components of the liquids, the furnace surface or individual parts may be chemically corroded or dam-
aged.
If colouring liquids containing chlorine or hydrochloric acid are used, irritating gases may develop during the heating phase. These gases pose a risk to users particularly when infiltrated frameworks are not correctly pre-dried.
2.1.1
Contraindication
The furnace must not be carried by the cooling tray.
2.1.2
Contraindication
The furnace head must not be carried by the cables, since cables and connec­tions may be damaged by such action.
2.1.3
Contraindication
The furnace head must not be removed from the furnace base as long as the furnace head is connected by means of one of the cables or the grounding band.
2.1.4
2.1.5
Contraindication
The furnace head is equipped with an electric drive and can be operated by means of the electronic controls. Never open the furnace head by hand, since this will damage the transmission.
Contraindication
Do not touch the thermocouple and the heating element in the sintering chamber. Avoid skin contact (grease contamination), since this will speed up the degradation of the components.
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2.1.6
Contraindication
2.1.11
Burn hazard
2.1.7
2.1.8
Contraindication
Contraindication
Never use the furnace without the sinter tray. Use only the original Progra­mat sinter tray. Do not use the firing trays or honey-combed trays from conventional ceramic furnaces. Further­more, check the sinter tray for damage, cracks or contamination before every sintering cycle. If the table is damaged, it must no longer be used. A maximum of one sinter tray is to be placed in the sintering chamber. Do not stack the sinter trays.
The sinter tray must not be placed outside the firing table, since this will obstruct the closing of the furnace head.
Foreign objects must not be placed on the furnace head or the air vents. Make sure that no liquids or other for­eign objects enter the air vents, since this may result in an electrical shock.
Never place objects in the sintering chamber by hand, since there is a burn hazard. Always use the sinter tray fork (accessories) supplied for this purpose. Never touch the hot surface of the furnace head, as there is a burn hazard. Please also refer to the warnings on the furnace.
2.1.12
Risk of crushing and burn hazard
Never reach under the furnace head with the hand or other parts of the body during operation, since there is a risk of crushing and a burn hazard.
2.1.13
Risks and dangers
This product contains ceramic fibres and may release fibre dust. Do not use compressed air, or blow, on the furnace, thus distributing the dust in the environment, and observe the additional notes on page 11.
2.1.14
Risks and dangers
2.1.9
2.1.10
Contraindication
Contraindication
Do not use the furnace without spacer, since the distance to the back wall has to be kept!
Make sure that no liquids or other foreign objects enter the furnace.
2.1.15
Risks and dangers
The furnace must not be operated if the heating element in the sintering chamber is damaged. There is a risk of electric shock upon contact with the heating wire.
Do not insert any foreign objects into the air vents. There is a risk of electrical shock.
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2.1.16
Contraindication
For safety reasons, the furnace must not be operated without the cooling tray.
2.1.17
Risks and dangers
The furnace must not be connected to the power supply without the rear cover in place.
2.2 Health and Safety Instructions
This furnace has been designed according to the applicable standards and has been shipped from the manufacturer in excellent condition as far as safety regulations are concerned. To maintain this condition and to assure risk-free operation, the user must observe the notes and warnings contained in these Operating Instructions.
– The user must especially become familiar with the warnings and
the operating conditions to prevent injury to personnel or damage to materials. The manufacturer is not responsible for damage resulting from misuse or failure to observe the Operating Instructions. Warranty claims cannot be accepted in such cases.
– Before switching on the furnace, make sure that the voltage
indicated on the rating plate complies with your local power supply.
– The power socket must be equipped with a residual current circuit
breaker.
– The furnace must be plugged into a socket with protected
contacts.
– Place furnace on a fire-proof table (observe local regulations, e.g.
distance to combustible substances or objects etc.)
– Always keep the air vents at the rear and the side of the furnace
free from obstruction.
– Do not touch any parts that become hot during the operation of
the furnace. There is a burn hazard!
– Clean furnace only with a soft, dry cloth. Do not use solvents!
Disconnect power before cleaning and allow the furnace to cool down!
– The furnace must be cool before it is packed for transportation
purposes.
– Use original packaging for transportation purposes.
– Before calibration, maintenance, repair or exchange of parts, the
furnace must be cooled down and the power disconnected if the furnace is to be opened.
– If calibration, maintenance or repair has to be carried out with the
power connected and the furnace open, only qualified personnel from the field of electrical engineering who are familiar with the risks and dangers may perform these procedures.
– After maintenance, the required safety tests (high voltage
resistance, protective conductor etc.) have to be carried out.
– Ensure that only fuses of the indicated type and rated current are
used.
– If it is assumed that safe operation is no longer possible, the
power must be disconnected to avoid accidental operation. Safe operation is no longer possible if – the furnace is visibly damaged – the furnace does not work – the furnace has been stored under unfavourable conditions
over an extended period of time
– Use only original spare parts.
– The temperature range for faultless operation is +5 °C to +40 °C
(+41 °F to +104 °F).
– If the furnace has been stored at very low temperatures or high
atmospheric humidity, the head has to be opened and the furnace
dried or left to adjust to room temperature for approximately
4 hours (do not connect the power yet).
– The furnace has been tested for use at altitudes of up to 2000 m
(6562 ft) above sea level.
– The furnace may only be used indoors.
– Before leaving the factory, the furnace functions were tested for
several hours. It is therefore possible that these tests have caused
slight discolouration of the insulation. Nevertheless, your
Programat S1 1600 is still a brand new furnace.
Any disruption of the protective conductor either inside
or outside the furnace or any loosening of the protective conductor connection may lead to danger for the user in case of malfunction. Deliberate interruptions are not tolerated.
Materials developing harmful gases must not be fired.
Warning regarding the removal of the sintering chamber
This product contains ceramic fibres and may release fibre dust. Fibre dust has proved to be carcinogenic in animal experiments. The sintering chamber must only be disassembled by a certified After Sales Service Center. Information regarding the Safety Data Sheet is also available from your Service Center.
Warning
The insulation of this product contains refractory ceramic fibres (RCF), which pose a possible cancer hazard, if agitated and inhaled. May be irritating to the skin, eyes or respiratory tract if insulation is cracked or corrupted.
California Proposition 65 Warning: ”This product contains Refractory Ceramic Fibres, a substance known to the State of California to cause cancer.”
Disposal:
The furnaces must not be disposed of in the normal domestic waste. Please correctly dispose of old furnaces according to the corresponding EU council directive. Information on the correct disposal may also be found on your local Ivoclar Vivadent home­page.
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3. Product Description
3.1 Components
The Programat S1 1600 consists of the following components: – Furnace base with electronic controls – Furnace head with sintering chamber – Sinter tray – Cooling tray – Power cord – Sinter tray fork – Cleaning brush
3.2 Hazardous areas and safety equipment
Description of the hazardous areas of the furnace:
Hazardous area Type of risk
Sintering chamber Risk of burning
Opening and closing mechanism
Electrical components Risk of electrical shock
Risk of crushing
Description of the safety equipment of the furnace:
Safety equipment Protective effect
Protective conductor Protection from electrical shock
Electrical fuses Protection from electrical shock
Furnace housing and covering ends
Protection from electrical shock, burning and crushing
3.3 Description of functions
The sintering chamber may be heated up to max. 1600 °C by means of a heating element. The sintering process is controlled with the corresponding electronic controls and software. Moreover, the set and actual temperatures are continuously compared.
3.4 Accessories
– Sinter Furnace Temperature Checking Set MTH (1500 °C)
3.5 Indication / contraindication
Indication
– Sintering of ZrO2 materials
Contraindication
– The Programat S1 1600 is not suitable as a ceramic furnace for
dental laboratories.
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4. Installation and Initial Start-Up
28
27
28
27
4.1 Unpacking and checking the contents
The packaging provides the following advantages: – Reusable packaging – Closing mechanism with integrated transportation grips – Ideal protection by foam inserts – Easy handling / optimum unpacking – The packaging may be used in several ways (modules)
Remove the furnace components from their packaging and place it on a suitable table. Please observe the instructions on the outer packaging. There are no special transportation grips on the furnace. Support the bottom of the furnace to carry it.
1
2
4 5
3
4.2 Selecting the location
Place the furnace on a flat table using the rubber feet. Make sure that the furnace is not placed in the immediate vicinity of heaters or other sources of heat. Make sure that air may properly circulate between the wall and the furnace and that there is enough space for the swivel movement of the furnace head (at least 110 mm). Therefore, mounting the spacer (45) is absolutely mandatory.
Also ensure that there is enough space between the furnace and the user, as the furnace releases heat during the opening of the furnace head.
The furnace should neither be placed nor operated in areas where there is an explosion hazard. The furnace must not be connected to the power supply prior to or during the assembly.
4.3 Assembly
Make sure the voltage indicated on the rating plate (14) complies with the local power supply. If this is not the case, the furnace must not be connected.
Check the delivery for completeness (see delivery form in Chapter 9) and transportation damage. If parts are damaged or missing, contact your local Ivoclar Vivadent Service Center. The packaging may be disposed of with the regular household refuse.
Packing and shipping of individual components
The packaging permits simple and safe shipping of individual compo­nents. Simply use the two corresponding inserts. Fold the side flaps (2) and combine the two packaging parts by means of the transpor­tation flaps.
1
Step 1: Assembling the cooling tray (26)
Remove both screws (27) including the silicone washer (28).
14
2 3
4 5
We recommend keeping the original packaging for future
service and transportation purposes.
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Place the cooling tray (26) on the frame plate (5).
27
28
Make sure that the cooling tray (26) is correctly positioned on the frame plate (5) and that the danger symbols are visible from above.
Secure the cooling tray (26) with the two screws (27) including the silicone washer (28).
5
26
Step 2: Mounting the spacer
The spacer (45) can be mounted to the rear of the furnace with the help of the fastening pin intended for this purpose. Press the spacer strongly against the rear of the furnace. For safety reasons, the spacer must always be mounted.
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Step 3:
33
34
40
41
47
46
Mounting the furnace head
The complete furnace head is best mounted with the rear panel of the furnace pointing towards the user. Lift the furnace head with both hands as shown in the picture (with the rear hand gripping the holding area lined with sandpaper on the furnace head), and carefully position it on the furnace head mounting (35).
Ensure that the furnace head mounting mark (33) is aligned with the furnace base mounting mark (34).
Make sure that the sinter chamber and the insulation (5) are not damaged by mounting the furnace head.
35
Step 4: Attaching the grounding band
Attach the grounding band (46) to the corresponding connection of the furnace housing using the screw for the grounding band (47).
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Step 5:
20
20
18
17
Connections
Connect the cables of the furnace head with the furnace base. Proceed as follows:
– Insert the thermocouple plug (17) (make sure
that the polarity of the plug is correct) – Insert the heater plug (20) – Insert the power electronics plug (18)
Secure the heater plug (20) by turning it until the heater plug (20) has been secured.
Step 6: Mounting the hood (29)
Once all cables are properly connected to the furnace base, the hood (29) can be mounted.
Subsequently, secure the hood with the knurled screw (30).
The furnace may only be operated with the hood mounted.
Step 7: Establishing additional connections
Power connection
Please make sure that the voltage indicated on the rating plate complies with the local power supply. Connect the power cord (12) with the power sock­et (13) of the furnace.
30
29
13
12
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4.4 Demounting the furnace head
Before the hood (29) is removed, the furnace has to be switched off, cooled down and the power cord (12) disconnected from the power socket (13).
1. Loosen the attachment screw (30) for the
hood (29) and remove it
2. Remove the hood
3. Disconnect the thermocouple plug (17)
4. Disconnect the heater plug (20)
5. Disconnect the power electronics plug (18)
6. Loosen and remove the grounding band (46)
7. Press the leaf spring (24) with a finger, lift off
the furnace head at the same time and remove it
Make sure the furnace head has completely cooled down before it is removed (fire hazard).
4.5 Initial start-up
1. Connect the power cord (12) with the wall
socket
2. Put the On/Off switch (9) at the rear of the
furnace on position “I”
Stand-by indication
The stand-by indication is shown after the self-test. The last program used before the furnace was switched off is loaded.
The furnace will now automatically conduct a self­test. The performance of all furnace components is automatically checked. The display shows the following indications during the self-test:
a) Progress bar
b)
b) Firing hours c) Software version d) Current supply voltage
92
90
90 Program number 91 Current temperature 92 Furnace status 93 Program name 94 Material name
c)
a)
d)
91
94
93
If any component is defective, the corresponding error number (ER xxx) will be indicated in the display. If everything is in working order, the display will change to the stand-by indication.
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5. Operation and Calibration
78
81
79
80 77
82
83
84
85
86
72
71
74
73
75
76
88
87
5.1 Introduction to the operation
The Programat S1 1600 is equipped with a graphic display with backlighting. The numeric and command keys can be used to pro­gram and control the furnace.
5.2 Explanation of the key functions
– Settings key (78)
After pressing the Settings key, the settings required for the
furnace can be displayed one after the other and changed, if
necessary.
– Information key (81)
After pressing the Information key, information about the furnace
can be displayed one after the other.
– Cursor keys (79, 80)
In the stand-by display, the cursor keys can be used to change the
program. The cursor keys are also used to scroll through the settings or
information pages. In the parameter list, the current cursor position is indicated by a
solid (non-flashing) frame around the numeric value.
– –/+ keys (76, 77)
Changing the settings or entering a numeric value is achieved by
means of the -/+ keys. Each entry by means of the – or + key is immediately accepted,
provided the corresponding value range is observed. Once the
value range limit has been reached, the value can no longer be
changed.
– ESC key (71)
This key is used to end the error display. Furthermore, any page
of the display can be left with this key.
– ENTER key (72)
With this key, settings may be changed or entries confirmed.
– Start key (73)
This key starts the selected program.
– Start LED (74)
Lights up once a program has started. It flashes when the
program is paused.
– Stop key (75)
Pressing 1 x (pause program) Pressing 2 x (program is aborted) The STOP key also stops the furnace head movement and the
acoustic signal.
– Open furnace head key (87)
Furnace head is opened (not during a program in progress, or if
the temperature in the sintering chamber is higher than 600°C/1112°F).
– Close furnace head key (88)
Furnace head is closed (not during a program in progress).
– Program 1 key (82)
Program 1 (P1) is selected with this key (not during a program in
progress).
– Program 2 key (83)
Program 2 (P2) is selected with this key (not during a program in
progress).
– Program 3 key (84)
Program 3 (P3) is selected with this key (not during a program in
progress).
– Program 4 key (85)
Program 4 (P4) is selected with this key (not during a program in
progress).
– Next program key (86)
The next program (P5, P6) is selected with this key (not during a
program in progress).
5.3 Basic meaning of the display elements
– Stand-by
Furnace or program status
Main area
In the main area, the most important information (e.g. the currently selected program) is indicated
– Program progress indicator
Furnace or program status
Main area
Currently selected program
18
Status area
Recommendation area
Status area
Current temperature of the furnace
The corresponding symbol suggests the next, most likely action (keystroke)
Current temperature of the furnace
Remaining time
Progress bar
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5.4 Program structure
Heating Cooling Opening
The sinter furnace basically offers two types of programs:
a) Standard program for materials of the
Ivoclar Vivadent group (see enclosed
Program Table)
b) Free programs
All the free programs are equal and available as full-fledged programs. All the parameters can be individually set in each program.
When the furnace is delivered ex
works, the standard programs already contain the recommended material parameter settings.
The programs have been designed in such a way that the 3 heating stages, 2 cooling stages, and 1 opening time can be set.
5.5 Adjustable parameters and possible value ranges
Parameters
Symbol
t1
Heating
T1
stage 1
H1
t2
Heating
T2
stage 2
H2
t3
Heating
T3
stage 3
H3
t4
Cooling
T4
stage 1
H4
t5
Cooling
T5
stage 2
H5
O
Opening time
* If T3 1530°C: t3 max 50°C/min If T3 > 1530°C: t3 max 10°C/min ** If T3 2786°F: t3 max 90°F/min If T3 > 2786°F: t3 max 18°F/min
Temperature increase rate
Holding temperature
Holding time
Temperature increase rate
Holding temperature
Holding time
Temperature increase rate
Holding temperature
Holding time
Temperature decrease rate
Holding temperature
Holding time
Temperature decrease rate
Holding temperature
Holding time
Opening time
Value range °C Value range °F
min max min max Unit
5 90 9 162
700 1200 1292 2192
00:00 05:00 00:00 05:00
1 50 2 90
0/700 1530 0/1292 2786
00:00 05:00 00:00 05:00
1 50* 2 90**
0/700 1600 0/1292 2912
00:00 05:00 00:00 05:00
1 50 2 90
100 1100 212 2012
00:00 05:00 00:00 05:00
1 50 2 90
0/100 1100 0/212 2012
00:00 05:00 00:00 05:00
00:15 05:00
Unit
°C/min
°C
hh:mm
°C/min
°C
hh:mm
°C/min
°C
hh:mm
°C/min
°C
hh:mm
°C/min
°C
hh:mm
hh:mm 00:15 05:00
°F/min
°F
hh:mm
°F/min
°F
hh:mm
°F/min
°F
hh:mm
°F/min
°F
hh:mm
°F/min
°F
hh:mm
hh:mm
Automatic plausibility check of the parameters
The furnace is equipped with an automatic plausibility check function. The parameters are checked upon each program start. In case of contradictory parameter combina­tions, the program stops automatically and the respective error number is indicated.
Graphic overview of the program parameters
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5.6 Settings / test program and information
By pressing the Settings key (78) you will reach the setting screen (the latest setting selected will be shown).
Settings Display Short Description
Date
The date can be set using the -/+ keys
The cursor keys (79, 80) can be used to toggle between the possible settings. This screen can be left by pressing ESC (71) or by pressing one of the program keys (82, 83, …).
5.6.1 Settings / test programs
Settings Display Short Description
Contrast
The contrast can be adjusted with the -/+ keys.
Temperature unit
The -/+ keys are used to toggle between °C and °F.
Language selection
Enables the language selection.
Temperature calibration
With this program, the temperature calibration program can be started. See Chapter 7.6 Temperature Calibra­tion for more details.
Volume
The desired volume can be set using the
-/+ keys
Tune
The desired tune may be set using the -/+ keys
Programming
Enables the pro­gramming of the parameters for the currently selected program *
Renaming
Enables the renaming of the currently selected program *
Enables the renaming of the material
General write protection
Heater test program
Keypad test
Cleaning program
Protocol
Start delay
Operating Status Display
Service interval
Load factory settings
Important information
For certain settings, the user code (359) is required.
Enables the activation or deactivation of the general write protec­tion by means of the
-/+ keys after enter­ing the user code. The write protection covers all programs
Enables a check of the heating system
Enables a check of the membrane-sealed keypad
With this program, the heating muffle, including the insula­tion materials, can be cleaned by means of a heat process
Enables the creation of protocols of the sintering procedures
Activating this func­tion enables the delayed start of sintering programs
With this menu item, the Operating Status Display can be activated/deactivated
Turn service reminder off or set new reminder in 12 months
With this setting option, all the values and parameters can be reset to the original factory settings. Note: All the individual programs that you have generated and saved will be deleted by this function
Time
The time can be set using the -/+ keys
* Some programs (P1–P7) are protected with a code. If changes are necessary, the corresponding code will be provided.
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5.6.2 Information
By pressing the Information key (81), you will reach the information screen (the last selected information is displayed). The cursor keys (79, 80) can be used to toggle between the possible information. This screen can be left with the ESC key (71) or one of the program keys (82, 83, …).
Information Display Short Description
Serial number
Software version
Furnace head firing hours
Furnace operating hours
Last start of the calibration program
Calibration value
Mains voltage
Error list
Serial number of the furnace
Shows the date of the last calibartion for the sintering temperature range
Calibration value at 1500 °C/2732 °F. The value is displayed in accordance with the selected temperature mode in °C or °F.
Shows the current mains voltage
Enables the display of the last error messages.
5.7 Explanation of the display symbols
Symbol Name Meaning Symbol
Open furnace head Shown in the recommen-
Close furnace head Shown in the recommen-
Press START Shown in the recommen-
Press STOP Shown in the recommen-
Press ENTER Shown in the recommen-
Press ESC Shown in the recommen-
Use cursor keys Shown in the recommen-
Use –/+ keys Shown in the recommen-
General write protection
Individual write protection active
Individual write protection not active
dation area, where the next most likely action is suggested.
dation area, where the next most likely action is suggested.
dation area, where the next most likely action is suggested.
dation area, where a possible action is suggested.
dation area, where a possible action is suggested.
dation area, where a possible action is suggested.
dation area, where a possible action is suggested.
dation area, where a possible action is suggested.
Shows in the parameter list that the general write protection for all programs has been activated by means of the user code.
Shows in the parameter list that the individual write protection for this program is active.
Shows in the parameter list that this program is not write-protected.
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5.8 Explanation of the acoustic signal
Basically, all the acoustic signals are played using the tune and volume selected by the user.
The acoustic signal can only be stopped by pressing the STOP key.
– After the self-test has been completed
In order to inform the user that the automatic self-test has been
successfully completed, an acoustic signal is played.
– In case of error messages
Error messages are acoustically supported by the error tune (end-
less). The acoustic signal may be stopped with the STOP key, while
the error message remains visible in the display. If the error mes-
sage is acknowledged with ESC, the acoustic signal also stops.
– At the end of a program
In order to inform the user that the sintering process has been
completed, an acoustic signal is played.
5.9 OSD
The OSD (Optical Status Display) integrated in the furnace head shows the most important statuses of the furnace. The following activities are shown:
Colour Activity
green Furnace is ready for use (self-test has been
completed)
red Sintering process active, furnace busy
yellow (flashing) Information, notification or error message
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6. Practical Use
The operating procedure for the Programat S1 1600 will be explained with the help of two examples: one standard and one indi­vidual program.
6.1 Switching on the furnace
Put On/Off switch (9) on position “I“. The furnace conducts an automatic self-test, which will be indicated in the beginning. Subsequently, a status bar shows the progress of the self-test. Make sure that the furnace is not manipulated during this time.
6.1.1 Stand-by screen
If the self-test has been successful, the stand-by screen will appear in the display and the desired pro­gram can be selected using the program selection keys.
Once the furnace head has been opened and the loaded sinter tray placed, the program can be started using the START key. For that pur­pose, the START key is shown in the recommendation area.
6.1.2 Program progress indicator
When the program is started using the START key, the program progress indicator is shown in the display.
The following information is provided: a) Program status b) Remaining time (hh:mm) c) Current temperature d) Program number e) Program name f) Progress bar
Note:
For safety reasons, the furnace head can only be opened once the temperature has dropped below 600 °C/1112 °F.
a)
b)
d)
e)
c)
f)
6.2 Loading the Programat S1 1600
The Programat sinter tray (100) holds up to approximately 20 sin­gle-tooth restorations. With the Programat Dosto Tray (103) restora­tions can be placed on the lower and upper level of the tray. Make sure that the objects do not touch in order to prevent them from sintering together. The ZrO2 sinter beads are usually not required for this process.
In case of stack milling, the individual objects have to be separated from the stack, the corresponding margins adjusted and the attachment points smoothed out by grinding. CAD/CAM fabricated support structures (for large frameworks with a pronounced curvature) should not be separated for the sintering process. In order to achieve optimum sintering results, the objects should be placed on their occlusal or labial surface (not on the cervical margin). Furthermore, no objects should be placed on the groove in the sinter tray, if possible. After that, the sinter tray is placed in the center of the sinter chamber by means of the sinter tray fork (101).
Please read the following processing notes very
carefully
The individual pre-drying times of the ZrO
be observed. They depend on the size of the restoration and the pre-drying temperature. For more detailed information, please refer to the instructions for use of the corresponding material.
If the Colouring Liquids are used, several points must be
observed:
– The restorations stained with Colouring Liquid must be
adequately pre-dried in a pre-drying furnace. Air drying is not sufficient in these cases and may result in cracks in the objects during the sintering process.
– After the sintering process, clean contaminated areas of the
furnace with a soft cloth.
– In case of severe contamination
of the sinter chamber or the insulation, conduct a cleaning firing.
Once the sintering process is com­pleted, the sinter tray is removed from the furnace using the sinter tray fork. If the tray is placed on the cooling tray, make sure that it is securely positioned.
For safety reasons,
always use the sinter tray fork when placing the sinter tray in or removing it from the furnace.
objects must
2
6.3 Sintering using a standard program
Step 1:
Select the desired program using the program keys.
Note
If the sintering program has been aborted, the furnace head can be only opened once the temperature has dropped below 600 °C/1112 °F.
Step 2:
Open the furnace head using the Open furnace head key (87) and place the loaded sinter tray into the furnace.
Step 3:
Press the Start key (73) and the program will start. You can observe the cycle on the program progress indicator.
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6.4 Sintering using an individual program
Step 1:
Select a free program.
Step 2:
Select the parameters list via Settings – Programming, and then change the program parameters using the -/+ keys. Then return to the stand-by screen using ESC or a program key.
Schritt 3:
Open the furnace head using the “Open furnace head“ key (87) and place the loaded sinter tray into the furnace. Press the Start key (73) and the program will start. You can observe the cycle on the program progress indicator.
6.5 Additional possibilities and special features of the furnace
6.5.1 General write protection
If all programs are write-protected, a closed, black lock appears. The setting ‘Renaming‘ cannot be selected if the general write protection is activated. As an indication, a closed lock is shown next to the keyboard symbol.
6.6 Programming*
The parameter list can be selected via Settings – Programming. This list contains all the program parameters. The desired parameter is selected with the cursor keys. The value is adjusted using the
-/+keys. This screen can be left by pressing ESC or one of the program keys.
The parameters for heating and cooling stages are located in a separate program stage screen. Please refer to “Operation and configuration“ for explanations of the parameters.
Symbol "Change program stage screen"
If the cursor is placed on the “Change program stage screen“ symbol, pressing ENTER permits changing the program stage screen. The holding times and the opening time are entered in hh:mm.
* The standard programs are protected by a code. If changes are necessary, the corresponding code is provided.
6.5.2 Stopping the running program
A program in progress can be paused by pressing the STOP key once. If a program has been paused, the green LED in the START key flashes. Furthermore, the status shows as “Pause“. By pressing STOP a second time, the program can be aborted. It can be resumed by pressing START.
Note
If the sintering program has been aborted, the furnace head can be only opened once the temperature has dropped below 600 °C/1112 °F.
6.5.3 Individual program write protection
For standard programs, the individual program write protection is activated by default to prevent accidental changes of the parameters. The individual program write protection (symbol) can be changed for each program via Settings – Programming using the -/+ keys.
6.5.4 Renaming
Via Settings – Renaming, the keyboard can be selected, provided the currently selected program is not write-protected. The desired letters can be selected using the cursor keys (circular). The letter is selected with the ENTER key. Individual letters may be deleted using the delete key (arrow symbol). Changes are saved by pressing the save (disk symbol) or ESC key. This will also close the keyboard screen.
This key enables switching to lower case letters, numbers/ symbols and back to capital letters.
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7. Maintenance, Cleaning and Diagnosis
a)
102
This chapter describes the user maintenance and cleaning procedures for the Programat S1 1600. All the other tasks must be performed by qualified service personnel at a certified Ivoclar Vivadent Service Center.
7.1 Cleaning of the sintering chamber and the heating elements
7.1.1 Visual inspection of the sintering chamber
Inspect the sintering chamber visually prior to every sintering procedure. No foreign objects or dirt particles must be present in the sintering chamber during the sintering procedure. Contaminations may be due to a chipping of the oxide / protective layer of the heating element surface, among others. This type of contamination may have an effect on the optical properties (discol­ouration) of the sintered object. Contaminations resulting from chipping-off of the oxide layer can be classified as follows:
Type of contamination
Glass particles The insulation of the lower part of the
Fine glass dust The insulation of the lower part of the
Indicator
furnace / the sinter tray rest shows residue of clearly visible, glassy transparent particles (see image a).
furnace and the cooling tray show residue of fine glass dust. This type of contamina­tion is more difficult to discern.
7.1.2 Cleaning of the sintering chamber
Use the enclosed cleaning brush (102) for cleaning. Do not use compressed air for cleaning under any circumstances. After cleaning, conduct a cycle with the Program 1 (IPS e.max ZirCAD crown) with the firing chamber empty. In case of severe contamination it is rec­ommended to conduct the cleaning program (see section 5.6.1).
7.1.3 Cleaning of the heating elements
The cleaning program (see section 5.6.1.) recreates the chipped off oxide / protective layer on the heating elements. If no smooth protective layer is visible on the heating elements after a cleaning firing, several subsequent cleaning firings may be necessary. Do not place ZrO
Clean the sintering chamber prior to conducting the cleaning program.
objects in the furnace for these firings.
2
If glass particles or fine glass dust are noticed during the visual inspection, the sintering chamber needs to be cleaned (see section
7.1.2) and a firing cycle with Program 1 (IPS e.max ZirCAD crown)
must be conducted with an empty firing chamber. For this cycle, no ZrO
objects must be placed in the furnace.
2
Large parts of the protective layer on the left heating element have chipped off. The heating element on the right side is in a sound, stable condition and shows an intact oxide / protective layer. The cleaning program must be repeated until the surface is free from contamination and appears glassy.
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7.2 Further monitoring and mainenance work
The time for these maintenance procedures depends on the frequency of use and the working habits of the users. For that reason, the recommended times are only approximations.
This furnace has been developed for typical use in dental laboratories. If the product is used in a production enter-
premature ageing of the expendable parts has to be expected.
The expendable parts are as follows: – Heating muffle – Insulation material
Expendable parts are not covered by the warranty. Please also observe the shorter service and maintenance intervals.
prise, for industrial applications and for continuous use,
What: Measure: When:
Check all plug-in connections for correct fit Var. external connections weekly
Check if the furnace head opens smoothly and without excessive noise Opening mechanism monthly
Check if the thermocouple is straight and in the right place Thermocouple (2) weekly
Check the insulation for cracks and damages. If the insulation is worn down it has to be replaced by a certified Ivoclar Vivadent Service Centre. Fine hair­line cracks on the surface of the insulation are harmless and do not influence the function of the furnace in a negative fashion.
Check the keypad for visible damage. If the keypad is damaged, it has to be replaced by a certified Ivoclar Vivadent Service Centre.
Check temperature. Use the temperature checking set to check and adjust the temperature in the furnace.
Insulation (1) monthly
Keypad (8) weekly
Sintering chamber twice a year
If the furnace head is replaced with a furnace head from another Programat S1 1600, calibration is required.
7.3 Cleaning
The furnace may only be cleaned when it is cool, since
there is a burn hazard. Do not use any cleaning solutions.
Disconnect the furnace from the power source before
cleaning.
The following parts have to be cleaned from time to time:
Item: Frequency: Cleaning Material:
Furnace housing (7) and furnace head
Membrane-sealed keypad (8)
Cooling tray (26) daily cleaning brush*
Isolation (1) daily cleaning brush*
if required soft, dry cloth
weekly soft, dry cloth
*Never use compressed air!
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7.4 Test programs
Press the Settings key and scroll to the desired test program using the cursor keys.
Heater test program
The heater test automatically checks the heating system. The test should only be performed with the sintering chamber empty, since any mass placed in the furnace (e.g. sinter tray) would influence the result.
Keypad test program
Each pressing of a key results in a short acoustic signal. The keypad test can be closed using the ESC key.
Cleaning program
The heating elements are “cleaned“ and/or regenerated using the cleaning program.
7.5 Stand-by
We recommend keeping the furnace head closed during stand-by to prevent damage.
7.6 Temperature calibration
The temperature level in the sintering chamber may change after prolonged operating hours (e.g. by contamination, wear and tear of the heating elements etc.). For optimum function, regular recalibra­tion is required. The Sinter Furnace Temperature Checking Set MTH (1500 °C) has been specially developed for this purpose. This set is used to calibrate the temperature of your sinter furnace.
The calibration with temperature control rings enables the verifica­tion of the holding temperature of 1500 °C/2732 °F required for sin­tering the ZrO During the sinter process, the rings change their dimensions due to shrinkage. The shrinkage of the temperature control rings is decisive for the correction value of the furnace and can be found on the con­version table. Conduct the temperature calibration only when the furnace is cold.
For calibration, you need temperature control rings, a measuring device (slide gauge) and a conversion table (in the insert of the Sinter Furnace Temperature Checking Set MTH 1500°).
Procedure:
1. Press the Settings key (78) to
access the Settings screen. Select “Temperature Calibration“ using the cursor keys (79/80). The following display appears:
blocks in the sintering chamber.
2
Make sure that the temperature control ring with the stamp “MTH“ is used. The use of an incorrect temperature control ring may damage the sinter tray.
3. Press the START key. The furnace head is automatically closed and the calibration program started.
4. After the end of the program, carefully remove the sintered temperature control ring and allow it to cool to room tem­perature on the cooling tray.
5. Place the cool ring on an even surface and determine the exact diameter using the slide gauge. Make sure that the ring is flush with the two arms of the slide gauge. Conduct the measure­ment in the area where the diameter is the smallest.
6. Find the measured diameter in the conversion table and read off
the corresponding temperature correction value. Only if the devia-
tions is more than 10 °C / 18°F must the furnace be readjusted.
7. If the temperature difference is higher than 10 °C / 18 °F (target temperature = 1500 °C/2732 °F) the correction value can be transferred to the furnace with the help of the -/+ keys (76/77). Each keystroke changes the furnace temperature by 1 °C. The correction value must be added to the current temperature of the furnace. Once the desired correction value has been entered, the program can be closed by pressing the ESC key (71).
Calibration is now complete. Close the furnace head or select a sintering program.
For further information about the calibration, please refer to the note accompanying the Sinter Furnace Temperature Checking Set MTH (1500°).
7.7 Service Hint
When the Service Hint appears for the first time (Hint 1700), 2 years have passed or the heating elements have been in use for more than 1200 firing hours. For this reason, Ivoclar Vivadent recommends a maintenance and service procedure. After the acknowledgement of the Service Hint, Hint 1700 will appear again after 12 months. The message can be turned off under Settings (see 5.6.1).
The calibration program is
selected with the ENTER key. The following display appears:
2. Position the temperature control ring with the stamp “MTH“ (a) in the centre of the sinter tray (b).
a)
b)
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8. What if ...
This chapter will help you to recognize malfunctions and take appropriate measures.
8.1 Error messages
The furnace continuously monitors all functions during operation. As soon as an error is found, a corresponding error message will appear. In case of an error, the heater is switched off for safety reasons.
The following error messages may be displayed:
Error / Hint No.
17 Power failure >10 s during a
20 **
27 *,**
28 **
103 Program start blocked Starting a program is not possible due to a technical malfunction.
107 Incorrect time settings
700 Supply voltage outside the
701 ***
702 Short power failure during a
707 Incorrect supply voltage The furnace is operated with the incorrect supply voltage. Make sure that the furnace is operated
1310 Calibration reminder Some time has passed since the last calibration. Conduct a calibration procedure soon.
1600 T1 < B Enter a reasonable value for T.
1601 T2 < T1 Enter a reasonable value for T.
1602 T3 < T2 for T2 > 0,
1603 T4 > Tx (T1, T2, T3) Enter a reasonable value for T.
1604 T5 > T4 Enter a reasonable value for T.
1605 Gradient 3 too large If the holding temperature T3 is higher than 1530°C, the gradient t3 must not exceed 10°C/min.
1613 **
1626 Current Temperature
1650 PwrUnit Error Power-Unit. Check the fuse and the electric plug-in connections to the furnace head. The unit
1660 HeadOpenDisabled (T too high) Temperature too high for opening the furnace head
1661 Power outage >10 sec with the
1662 Power out >10 sec with the
1700 Service Hint More than two years have passed since the last technical inspection or the heating elements have
* ** A program in progress is stopped *** The error cannot be acknowledged; the programs cannot be started!
Conti­nuation possible
no Error in the heating system Check the heater fuse. If the fuse is OK, contact your local Service Center.
no Furnace head cannot be initi-
no Start-up aborted due to an error The self-test of the furnace was interrupted by an error. It is not possible to work with the furnace!
Furnace head opens if this error occurs
Error Error Message Text
program in progress
alized
Furnace head does not reach the target position.
(date / time)
acceptable range
program in progress
T3 > 0 for T2=0
Current temperature after Start > Tx + 80 °C/176 °F.
> 700 °C/1292 °F upon Start
sintering program started and in the heating stage
sintering program started and in the critical heating stage
A firing program in progress was interrupted for more than 10 s. The program cannot be continued!
The furnace head cannot be moved to the final position. It might be blocked by an external mechanical source! If this is not the case, please contact your local Service Center!
The furnace head does not open/close correctly. The furnace head was manually moved or is obstructed. The furnace head must only be moved using the keys intended for this purpose!
The clock settings are incorrect. Please set a correct date and a correct time!
The supply voltage is outside the acceptable range. Check the supply voltage.
Switch the furnace off and on again, once the error has been rectified.
A program in progress was interrupted by a short power failure. The program continues.
with the supply voltage indicated on the rating plate.
Enter a reasonable value for T.
Caution! Excess Temperature! The program was aborted.
Sintering chamber is too hot for the start of a sintering program.
is not ready for operation! Please contact your local Service Center.
Long power outage during a sintering program in progress. Repeat the sintering program.
Long power outage during a sintering program in progress. The objects are probably not OK.
been in use for more than 1200 firing hours. For this reason, Ivoclar Vivadent recommends a main­tenance and service procedure. For further information, please refer to the Equipment Service Passport or the Operating Instructions. The interval until the next appearance of the Service Hint can be selected in the settings (see Chapter 5.6.1).
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If one of the following error numbers appear, contact your local Ivoclar Vivadent After Sales Service:
25, 29, 54, 56, 705, 706, 1010, 1011, 1012, 1013, 1014, 1015, 1016, 1024, 1025, 1026, 1028, 1202, 1203, 1204, 1205, 1206, 1207, 1400, 1401, 1402, 1500, 1630, 1631, 1632, 1651, 1652
If an ongoing sinter process is interrupted by an error message, the objects should not be used for patient cases. This note does not apply to the error messages 702 and 1661.
8.2 Technical malfunctions
These malfunctions may occur without an error message being displayed:
Error Double Check Measure
Display indication incomplete
Writing in the display is very hard to read Is the contrast properly set? Adjust contrast
Display is not illuminated
Buzzer does not sound Is the buzzer switched off (Tune 0)? Select tune 1–5
Furnace head does not open
Incorrect or illogical temperature indication
Cracks in the insulation of the sintering chamber
Damage of a heating element
Damage of the thermocouple Is the thermocouple damaged or broken off? Contact the Ivoclar Vivadent After Sales Service
Is the furnace properly connected according to the Operation Instructions and switched on?
Was the furnace head opened manually? Open the furnace head only by using the corres-
Is the thermocouple bent or fractured? Contact the Ivoclar Vivadent After Sales Service
Is the thermocouple correctly connected? Correctly connect the thermocouple
Is the thermocouple plug defective? Contact the Ivoclar Vivadent After Sales Service
Are the cracks very small and insignificant (hairline cracks)?
Are the cracks large or have parts of the sintering chamber broken off?
Is a heating element bent or fractured? Switch off the furnace and contact the Ivoclar
Activate the display test program and contact the Ivoclar Vivadent After Sales Service.
Correctly connect the furnace and switch it on.
ponding keys. Switch the furnace on and off again.
Small cracks in the insulation do not negatively influence the furnace.
Contact the Ivoclar Vivadent After Sales Service
Vivadent After Sales Service
8.3 Repair
Repairs may only be carried out by a certified Ivoclar Vivadent After Sales Service Centre. Please refer to the addresses in
Chapter 10.
If repairs during the warranty period are not carried out by a certified Ivoclar Vivadent After Sales Service Center, the warranty will expire immediately. Please also refer to the corresponding warranty regulations.
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9. Product Specifications
9.1 Delivery form
– Programat S1 1600 – Power cord – Sinter Furnace Temperature Checking Set Starter Kit – Operating Instructions – Sinter tray – Programat Dosto Tray – Sinter tray fork – USB download cable – Various accessories
9.2 Technical data
Power supply 118–240 V / 50–60 Hz
Overvoltage category II Contamination level 2
Acceptable voltage fluctuations +/- 10%
Max. power consumption 16 A at 118 V
8 A at 240 V
Electrical fuses 250 V / T16 A high breaking (heating circuit)
Dimensions electrical fuses Diameter 5 x 20 mm
Dimensions of the closed furnace Depth: 430 mm / Width: 310 mm / 390 mm (with cooling tray) Height: 570 mm
Usable size of the sintering chamber Diameter 80 mm Height 80 mm
Max. sintering temperature 1600 °C/2912 °F
Weight Furnace base: 10 kg Furnace head: 17 kg
9.3 Acceptable operating conditions
Acceptable ambient temperature range:
+5°C to +40°C (+41°F to +104°F)
Acceptable humidity range:
80 % maximum relative humidity for temperatures up to 31°C (87.8° F) gradually decreasing to 50 % relative humidity at 40°C (104°F); condensation excluded.
Acceptable ambient pressure:
The furnace is tested for use at altitudes of up to 2000 m above sea level.
9.4 Acceptable transportation and storage conditions
Acceptable temperature range -20 to +65°C (-4°F to +149°F) Acceptable humidity range Max. 80% relative humidity Acceptable ambient pressure 500 mbar to 1060 mbar
Use only original packaging of the Programat S1 1600 together with the respective foam insert for shipping purposes.
Safety information
The sinter furnace complies with the following guidelines: – IEC 61010-1: 2010 – EN 61010-1: 2010 – UL 61010-1: 2012-2015 – CSA 61010-1: 2012 – 2015 – IEC 61010-2-010: 2014 – EN 61010-2-010: 2014 – UL 61010-2-010: 2015 – CSA 61010-2-010: 2015
Radio protections / electromagnetic compatibility EMC tested
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10. Miscellaneous
10.1 Program table
A program table is enclosed in these Operating Instructions. Should this not be the case, please contact the Ivoclar Vivadent Service Center.
Important information
The current program tables are also available at:
www.ivoclarvivadent.com/downloadcenter
The program tables can be downloaded from the Internet as PDF files. Please note, that the version of the program table should correspond to the software version which is used on your furnace.
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Ivoclar Vivadent – worldwide
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: Tesvikiye Mahallesi Sakayik Sokak Nisantas’ Plaza No:38/2 Kat:5 Daire:24 34021 Sisli – Istanbul Turkey Tel. +90 212 343 0802 Fax +90 212 343 0842 www.ivoclarvivadent.com
Ivoclar Vivadent Limited
Compass Building Feldspar Close Warrens Business Park Enderby Leicester LE19 4SD United Kingdom Tel. +44 116 284 7880 Fax +44 116 284 7881 www.ivoclarvivadent.co.uk
Ivoclar Vivadent, Inc.
175 Pineview Drive Amherst, N.Y. 14228 USA Tel. +1 800 533 6825 Fax +1 716 691 2285 www.ivoclarvivadent.us
Version: 3 Date of issue: 2017-04
This apparatus has been developed solely for use in dentistry. Start-up and opera­tion should be carried out strictly according to the Operating Instructions. Liability cannot be accepted for damages resulting from misuse or failure to observe the Instructions. The user is solely responsible for testing the apparatus for its suitability for any purpose not explicitly stated in the Instructions. Descriptions and data constitute no warranty of attributes.
Printed in Austria © Ivoclar Vivadent AG, Schaan/Liechtenstein 681082/en
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