EP5000-G2
Operating Instructions
Programat
®
EP 5000 G2
Valid as of
Software Version 6.0
2
3
Views of the Furnace, List of Parts 4
1. Introduction / Signs and Symbols 8
1.1 Preface
1.2 Introduction
1.3 Notes regarding the Operating Instructions
1.4 Notes on the different voltage versions
2. Safety First 9
2.1 Indications
2.2 Health and safety instructions
3. Product Description 12
3.1 Components
3.2 Hazardous areas and safety equipment
3.3 Functional description
3.4 Accessories
4. Installation and Initial Start-Up 13
4.1 Unpacking and checking the contents
4.2 Selecting the location
4.3 Assembly
4.4 Removing the furnace head
4.5 Initial start-up
4.6 Dehumidification
5. Operation and Configuration 19
5.1 Introduction to the operation
5.2 Explanation of the key functions
5.3 Program structure
5.4 Adjustable parameters and possible value ranges
5.5 Settings and information
5.6 Explanation of the symbols on the display
5.7 Explanation of the speaker signals
5.8 OSD (Optical Status Display)
6. Practical Use 26
6.1 Switching on/off
6.2 Firing programs
6.3 Pressing programs
6.4 Other options and special features of the furnace
7. Maintenance, Cleaning and Diagnosis 31
7.1 Monitoring and maintenance
7.2 Cleaning
7.3 Special programs
7.4 Temperature Calibration
7.5 Service Information
7.6 Stand-by
7.7 Press power calibration
7.8 Replacing the press plunger
8. What if ... 34
8.1 Error messages
8.2 Technical malfunctions
8.3 Repair
8.4 Load factory settings
9. Product Specifications 37
9.1 Delivery form
9.2 Technical data
9.3 Acceptable operating conditions
9.4 Acceptable transportation and storage conditions
10. Appendix 38
10.1 Program table
10.2 Menu structure
Table of Contents
4
List of parts
1 Sealing surface
2 Furnace head sealing ring
3 Insulation
4 Thermocouple
5 Firing plate 2
6 Touch screen
7 Frame plate
8 QTK heating muffle
9 Housing base
10 Keypad
11 On/Off switch
12 Heating element fuse
13 Vacuum pump fuse
15 Fuse holder
16 Power cord
17 Power socket
18 Vacuum pump socket
19 Rating plate
20 Screw for furnace head cover
21 Vacuum hose connection
22 Head insulation
23 Rubber feet
26 Thermocouple plug
27 Plug fuse
28 Heater plug
29 Heater plug socket
30 Thermocouple plug socket
31 Grounding band connector
32 Leaf spring
33 Air vents (base)
34 Cooling tray
35 Screw for cooling tray
36 Hood
37 Knurled screw for hood
38 Air vents furnace head
39 Air vents rear panel
40 Warnings
41 Furnace head mounting mark
42 Furnace base mounting mark
43 Furnace head mounting
44 Quartz-glass tube
46 Vacuum hose
47 Silicone washer
48 Firing plate holder
49 Thermocouple cable
50 Connecting rod axis
51 OSD (Optical Status Display)
52 USB connection
53 USB interface
54 Plug-in console
55 Operating unit fixture
56 Cover for press drive
57 Ethernet Interface
58 Furnace head, compl.
59 Press plunger 120
60 Press drive plug
61 Press electronics
62 Cover for press electronics
63 Fan
64 Split taper socket for press plunger
65 Terminal screw for press plunger
66 Press drive cable
67 Press drive plug socket
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.
5
40
38
56
34
6
10
35
51
7
1
2
3
9
5
8
55
23 33
36
58
20
63
52
6
49 66 26 30 60 67 29 27 28 11
32
43
22
61
63
59
22
64
62
65
11
36
37
39
12
13
53
57
19
12
11
13
15
19
53
57
21
17
18
7
Control unit:
70 Program key
71 ESC key
72 ENTER key
73 START key
74 Start LED
75 STOP key
76 + key
77 - key
78 Settings / information
79 Cursor key up
80 Cursor key down
90 Open furnace head
91 Close furnace head
92 Numeric keys
93 Firing / Pressing
94 Home key
95 Help key
96 Power Saving Key
8
59
4
44
3
50
54
41
42
100 Programat firing tray
101 Metal pin A
102 Metal pin B
103 Metal pin C
115 Cooling grid
(complet)
110 USB data cable
100
115
101
103
102
120 Automatic Temperature
Control Set 2 – ATK 2
120
110
105 USB stick Programat
106 Protective cover
105
106
78
93
95
94
96
79
80
70
77
76
72 92
71
73
74
75
91
90
8
1. Introduction / Signs and Symbols
1.1 Preface
Dear Customer
Thank you for having purchased
the Programat EP 5000/G2. It is
a state-of-the-art furnace for
dental applications.
The furnace has been designed
according to the latest industry
standards. 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 EP 5000/G2.
1.2 Introduction
The signs and symbols in these
Operating Instructions facilitate
the finding of important points
and have the following
meanings:
Risks and dangers
Important
information
Contraindication
Burn hazard
Risk of crushing
The Operating
Instructions must
be read
1.3 Notes regarding the
Operating Instructions
Furnace concerned:
Programat EP 5000/G2
Target group:
Dental technologists
These Operating Instructions
facilitate the correct, safe, and
economic use of the Programat
EP 5000/G2 furnace.
Should you lose the Operating
Instructions, extra copies can be
ordered at a nominal fee from
your local Ivoclar Vivadent
Service Center or downladed
from www.ivoclarvivadent.com/
downloadcenter.
1.4 Notes on the different
voltage versions
The furnace is available with
different voltage versions.
– 110–120 V / 50–60 Hz
– 200–240 V / 50–60 Hz
In the Operating Instructions,
the furnace is described in the
200-240 V voltage version.
Please note that the voltage
range shown on the images
(e.g. rating plate) may differ
depending on the voltage
version of your furnace.
9
2. Safety First
This chapter is especially important for personnel who work with the
Programat EP 5000/G2 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 EP 5000/G2 must only be used to fire and/or press
dental ceramic materials 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 (Chapter 9).
– The Programat EP 5000/G2 must be properly maintained.
2.1.1
Risks and dangers
The furnace head should not be
removed from the furnace base as
long as the furnace head is con-
nected by means of the
heater cable.
2.1.2
Risks and dangers
Make sure that no liquids or other
foreign objects enter the furnace.
2.1.3
Contraindication
Firing trays must not be placed in
the area surrounding the firing
table, since this will obstruct the
closing of the furnace head.
2.1.4
Contraindication
Foreign objects must not be
placed on the air vents. Make sure
that no liquids or other foreign
objects enter the air vents, since
this may result in an electrical
shock.
2.1.5
Risks and dangers
Never place objects in the firing
chamber by hand, since there is a
burn hazard. Always use the tongs
(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.
10
2.1.6
Risks and dangers
Do not carry the furnace by the
cooling tray.
2.1.7
Risks and dangers
Do not carry the furnace head by
the cables, since the cables and
connections may be damaged.
2.1.8
Risks and dangers
The furnace has an electric drive
and must be operated by means
of the electronic controls. Never
open the furnace head by hand,
since the mechanism will be
damaged.
2.1.9
Contraindication
Never use the furnace without a
firing table.
2.1.10
Contraindication
Do not touch the thermocouple or
the quartz tube in the firing
chamber. Avoid contact with the
skin (grease contamination), as
the parts may be damaged.
2.1.11
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.
2.1.12
Contraindication
Do not insert any foreign objects
into the air vents. There is a risk of
electrical shock.
2.1.13
Contraindication
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
Contraindication
Do not cool the hot investment
ring on the cooling tray. Use only
the cooling grid for that purpose.
2.1.15
Risks and dangers
The furnace must not be operated if the quartz tube or
the insulation in the firing chamber is damaged. There is a risk of
electric shock upon contact with the heating wire.
Avoid any damage of the insulation by contact with the investment
tongs or firing tongs. Make sure to keep the firing plate for the
investment ring clean.
2.1.16
Contraindication
Only use original ring bases from Ivoclar Vivadent.
Observe the maximum height (57 mm) and diameter (35 mm and
50 mm) of the investment ring.
11
2.2 Health and Safety Instructions
This furnace has been designed according to EN 61010-1 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.
– 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 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 dry or slightly moist cloth. Do not use
any solvents! Disconnect power before cleaning.
– Use original packaging for transportation purposes.
– The furnace must be cool before it is packed for transportation
purposes.
– 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.
– Before calibration, maintenance, repair, or exchange of parts, the
power must be 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, 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 unit
dried or left to adjust to room temperature for approx. 1 hour (do
not connect the power yet).
– The furnace has been tested for use at altitudes of up to 2000 m
above sea level.
– The furnace may only be used indoors.
– Do not run the furnace via an extension cord.
– When placing and removing the investment ring, make sure not
to hit the insulation of the firing chamber.
– There is a burn hazard at the cooling tray if the furnace is
continuously operated in the press mode (Stand-by = 700 °C).
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.
Warnings regarding the removal of the heating muffle
This product contains ceramic fibres and may release fibre
dust. Fibre dust has proved to be carcinogenic in animal
experiments.
The heating muffle must only be disassembled by a certified After
Sales Service Centre. Information regarding the Safety Data Sheet is
also available from your After Sales Service Centre.
Warning
The insulation on 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 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.
12
3. Product Description
3.1 Components
The Programat EP 5000/G2
comprises the following
components:
– Furnace base with electronic
controls
– Furnace head with firing
chamber and press drive
– Firing plate
– Cooling tray
– Power cord and hose for
vacuum pump
– Vacuum pump (accessory)
3.2 Hazardous areas and safety equipment
Description of the risk areas of the furnace:
3.3 Functional description
The firing/pressing chamber may be heated up to
max. 1200 °C (2192 °F) by means of a heating
element. Furthermore, the firing chamber has
been designed in such a way that a vacuum may
be created with a vacuum pump. The presssure for
the press procedure is generated by a press drive.
The firing/pressing programs are controlled with
the corresponding electronic controls and
software. Moreover, the set and actual
temperatures are continuously compared.
3.4 Accessories
(not part of the delivery form)
– Automatic Temperature Checking Set 2 (ATK 2)
– Programat Accessories Set (Programat firing
trays, Silicone Nitride Firing Tray “K”, firing
tongs, Automatic Temperature Checking Set 2
(ATK 2)
– Vacuum pump
Description of the safety equipment of the furnace:
Safety equipment Protective effect
Protective conductor Protection from electrical shock
Electrical fuses Protection from electrical shock
Housing and covers Protection from electrical shock, burn hazard and
crushing
Hazardous area Type of risk
Firing chamber Risk of burning
Opening/closing mechanism Risk of crushing
Electrical components Risk of electrical shock
13
4. Installation and Initial Start-Up
4.1 Unpacking and checking the contents
The packaging provides the following advantages:
– Reusable packaging
– Closing mechanism with integrated transportation grips
– Ideal protection by Styrofoam 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.
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.
Packing and shipping of individual components
The packaging of the EP 5000/G2 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. The packaging may be disposed
with the regular household refuse.
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.
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.
4.3 Assembly
Make sure the voltage indicated on the rating plate (19) complies
with the local power supply. If this is not the case, the furnace must
not be connected.
Keep the original packaging for future service and
transportation purposes.
Step 1:
Assembling the cooling tray (34)
Remove both screws (35) including the silicone washer (47) for the
cooling tray (34).
19
47
35
47
35
14
Step 2:
Mounting the furnace head
The complete furnace head (58) is best mounted
with the rear panel of the furnace pointing
towards the user. Lift the furnace head with both
hands (see picture) and carefully position it on the
furnace head mounting (43).
Secure the cooling tray (34) with the two screws
(35) including the silicone washer (47).
Place the cooling tray (34) on the frame plate (7).
Make sure that the cooling tray (34) is correctly
positioned on the frame plate (7).
34
58
7
35
47
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