Thermo-Star Denta-Star S1, Instruction Manual

Page 1: ...for sintering of oxide ceramics Please read this instruction manual carefully and if necessary other documents related to the product to ensure safe and proper application The manual must be given to the end user who should keep it throughout the service life until disposal ...

Page 2: ...est prior to dispatch and the packaging content was checked for completeness The figures and illustrations used in this document contribute to basic understanding and may be different from the product design You can find a list of tables and illustrations in the Appendix 2 edition status January 2018 Thermo Star GmbH Krantzstr 7 Geb 37 52070 Aachen Germany Phone 49 241 60845 0 Fax 49 241 60845 100...

Page 3: ...13 3 3 STORAGE 13 4 DESCRIPTION OF THE PRODUCT 14 4 1 SCOPE OF SUPPLY 14 4 2 PRODUCT CHARACTERISTICS 15 4 2 1 SHORT DESCRIPTION OF THE FURNACE 15 4 2 2 CHARACTERISTICS AND TECHNICAL DATA 15 4 3 COMPONENTS 16 4 4 FUNCTIONALITY 17 4 5 TYPE PLATE 17 4 6 ACCESSORIES 17 5 INSTALLATION 18 5 1 SAFE INSTALLATION 18 5 2 INSTALLING THE FURNACE 19 5 2 1 LOCATION 19 5 2 2 SETTING UP THE FURNACE 19 5 2 3 MOUNT...

Page 4: ...AL 33 8 3 MAINTENANCE WORK FOR THE USER 33 8 3 1 DAILY CONTROLS 33 8 3 2 MAINTENANCE WORK AS NEEDED 33 8 3 3 REGULAR MAINTENANCE WORK 33 9 TROUBLESHOOTING 34 9 1 SAFE TROUBLESHOOTING 34 9 2 FAULT FINDING 34 10 REPAIR 35 10 1 SAFE REPAIR 35 10 2 REPLACING HEATING ELEMENTS 35 10 3 OTHER REPAIRS SPARE PARTS 35 11 TAKING OUT OF SERVICE DISPOSAL 36 11 1 SAFE TAKING OUT OF SERVICE 36 11 2 TAKING OUT OF ...

Page 5: ...tomer service at Thermo Star GmbH Krantzstr 7 Geb 37 52070 Aachen Germany Phone 49 241 60845 0 Fax 49 241 60845 100 info thermo star de 1 2 STATUTORY DEFECTS LIABILITY For more information about statutory defects liability please see our General Terms and Conditions http www thermo star de tl_files docs Thermo Star AGB 20Thermo Star 20GmbH pdf 1 3 SYMBOLS USED IN THIS INSTRUCTION MANUAL The symbol...

Page 6: ...tus of delivery or other areas of application or utilization are not permitted or may only be carried out after consulting the manufacturer 2 1 2 IMPROPER USE Improper use is for example Drying of all kinds of materials Sintering of chemically treated ceramics Non compliance with these instructions or other product related documents Use in potentially explosive areas Use of defective components de...

Page 7: ...on in freight securing Safe handling of lifting aids and accessories Knowledge about handling of hazardous substances Installation Supplier owner user Knowledge of electrical supply lines and ambient conditions Use Owner user Knowledge of information in this instruction manual Simple maintenance Owner user Knowledge of information in this instruction manual Basic knowledge of measuring devices for...

Page 8: ...sonal protective equipment Symbol Meaning Explanation Use foot protection Safety shoes offer slip resistance on slippery floors puncture resistance and protection from falling objects Use eye protection Protective goggles protect the eyes from dust and other particles or small objects Use hand protection Protective gloves protect the hands from bruises cuts chemical burns and hot surfaces Use prot...

Page 9: ...g on hot surfaces DANGER Danger from hand injuries Sections marked with this symbol indicate hazardous situations presenting danger from hand crushing NOTICE Refers to a situation that if not avoided could result in damage to the furnace its components or objects in its environment Warning example SIGNAL WORD Warning Cause Effects Protective measure s 2 5 UNAUTHORIZED PARTS Before market launch th...

Page 10: ...he furnace operates in cycles Thermal hazards arise from the furnace door during operation Because of its design the furnace door will not cool down completely Please note the safety notes on the furnace 2 7 ELECTROMAGNETIC COMPATIBILITY The device does not cause any electromagnetic emission levels or faults in other devices ...

Page 11: ...hapter 4 5 TYPE PLATE Provide sufficient personal protective equipment and ensure that it is worn Chapter 2 3 PERSONAL PROTECTIVE EQUIPMENT Provide the full instruction manual on site and instruct personnel accordingly First aid we refer to local and internal corporate provisions when dealing with accidents Ensure that sufficient staff are trained in first aid The operator must provide suitable fi...

Page 12: ...ersons Physical injuries because of too heavy weight 2 persons are required for transport Chapter 3 2 TRANSPORT Chapter 4 2 2 CHARACTERISTICS AND TECHNICAL DATA Transport using truck or industrial truck Serious crushing impacts and accidents as a result of inappropriate handling Wear personal protective equipment Chapter 2 3 PERSONAL PROTECTIVE EQUIPMENT Transport the furnace as it was delivered p...

Page 13: ...ing points Table 04 Types of transport Type of transport Permitted lifting points 3 3 STORAGE Inappropriate storage might damage the furnace Make sure you meet or exceed these requirements If possible store the furnace in the transport packaging Avoid dusty or corrosive atmospheres Temperature 20 C TStorage 60 C Humidity 80 rH non condensing ...

Page 14: ...rt box 1 x mains cable Mains cable 1 8m 1 5mm IEC 320 C19 Plastic wrapped 1 x sintering beads Sintering beads 200g PET bottle 1 x protective cover Protective cover 100x70x30mm Cardboard 4 x spacers Spacer h 20mm Cardboard 1 x setter Setter 100x70x2mm Cardboard 1 x base plate Base plate 100x70x8mm Cardboard 3 x heating elements Heating element Transport sleeve TwistPack if not pre assembled 2 x con...

Page 15: ...le The furnace is operated using an industrial controller positioned on the front of the furnace A door switch located below can be used for extended operation The main switch and the supply connections for power are located on the back of the furnace 4 2 2 CHARACTERISTICS AND TECHNICAL DATA Table 06 Characteristics and technical data General Alumina fiber insulation Al2O3 3 molybdenum disilicide ...

Page 16: ...the descriptions given in the following chapters to be assigned to the individual components Figure 01 Furnace overview 01 Cooling air outlet top 04 Setter 02 Cooling air outlet side 05 Controller 03 Furnace door 06 Door opener 07 Connection to power supply main switch back of the furnace 01 03 04 02 06 ...

Page 17: ... the process The temperature inside the furnace chamber is controlled electronically and modified in accordance with the selected program The furnace passes into an automated cooling phase after ending a process i e when the end segment in the active program has been reached You can open the furnace at temperatures 300 C to remove sintered products The furnace can now be reloaded and is ready for ...

Page 18: ...tion personnel are qualified as required Chapter 2 2 QUALIFIED PERSONS Mechanical hazards Physical injuries because of too heavy weight 2 persons are required for transport Chapter 3 2 TRANSPORT Chapter 4 2 2 CHARACTERISTICS AND TECHNICAL DATA Serious crushing due to falling components such as furnace gas bottle etc Wear personal protective equipment Chapter 2 3 PERSONAL PROTECTIVE EQUIPMENT Elect...

Page 19: ...nce to flammable objects should be 50cm on each side The distance to hot objects should be 50cm on each side monitor and check to exclude potential interactions Socket with grounding contact and separate electric circuit Fuse preferably with automatic cut out line protection switch D16A or fusible cut out 5 2 2 SETTING UP THE FURNACE Step 1 Open the transport packaging on each side and remove The ...

Page 20: ...sport sleeves and insert carefully into the holding fixtures Chapter 4 1 SCOPE OF SUPPLY Table 05 Contact heating elements Connect pre installed connecting strips P2E 150 and P2E 200 to the ends of 2 nearest heating elements Connect all heating elements using 5 connecting strips E2E 100 Torque 3 Nm Fit cover and insert cover screws at front and back and screw on tightly ...

Page 21: ...iple sockets Avoid extension cables if possible However if necessary a qualified electrician should carry out the assembly to ensure that the length and line cross section are in accordance with the conditions on site The grounded plug at the end of the mains cable disconnects the furnace from the power supply Chapter 4 3 COMPONENTS Figure 02 ...

Page 22: ...erature display Follow the safety notes Wear personal protective equipment Chapter 2 3 PERSONAL PROTECTIVE EQUIPMENT 6 2 PUTTING INTO SERVICE Requirements for putting into service are Installation is completed Chapter 5 2 2 SETTING UP THE FURNACE Material to be sintered is available Temperature time profile for the material is known Persons required during putting into service are Briefing service...

Page 23: ...be used as a crucible when using sintering beads Avoid damage to the sintering aids while sintering and ensure sufficient heat radiation from below Use ceramic spacers Use setters when sintering without sintering beads The surfaces are much smoother than the surfaces of the base plates and reduce stiction significantly during sintering Hot spots may occur when heating and may cause high temperatur...

Page 24: ...E When reloading the furnace please refer to the procedure described in Chapter 6 2 2 FIRST LOADING THE FURNACE starting with step 3 6 2 5 FURNACE EMERGENCY STOP 1 Stop the furnace program and interrupt the process Chapter 7 4 PROGRAM EXECUTION 2 Turn the main switch to position on 3 Do not disconnect the furnace from the mains supply and do not interrupt the ventilators 4 Allow the furnace to coo...

Page 25: ... OPENING AND CLOSING THE FURNACE To unlock the door push and hold the button While holding the button push the furnace door slightly and pull it open Make sure that the temperature is below 300 C when opening the door To close the door push it until you can hear and feel that it has locked into position Figure 04 Door unlock ...

Page 26: ...P5 The controller shows the maximum temperature of the selected program in the bottom line While selecting a program do not activate any other button Figure 06 Controller The illustration above changes after only a few seconds without pushing any keys and displays information about the program segment with the highest temperature Push the START STOPP button when you are sure that you have selected...

Page 27: ...e end of this segment and the increase i e the speed or temperature change used to reach the setpoint define the ramp Dwell time Hold A dwell time is used to hold the temperature reached in the previous segment for a specified period of time Its duration is defined using a specific time period End End signalizes to the controller that the program ends with the previous segment and does not require...

Page 28: ... 28 7 2 PROGRAMMING THE CONTROLLER 7 2 1 PROGRAMMING SEGMENTS Segment 1 Segment 2 Figures 07 08 Programming the controller 7 2 2 SEGMENT FUNCTIONS Hold Ramp time controlled Ramp gradient controlled ...

Page 29: ...iod of time Enter the temperature from the previous segment again when setting the dwell time Observe the function display while programming Table 08 Functions No function Program delay Ramp increase Dwell time Hold Ramp decrease 7 2 2 2 RAMP GRADIENT CONTROLLED When using a gradient controlled ramp you specify the heating rate rt xxx C and target temperature The controller will reach the target t...

Page 30: ... button until the Program Segment display shows P5 Wait approx 35 seconds until P5 is replaced by a flashing number Push the LEFT ARROW button until the Program Segment display shows 00 Segment 00 in each program allows setting a program delay using the format hh mm hour hour minute minute to realize a timer start Entering the value 0 00 starts the controller immediately after pushing the button P...

Page 31: ...l time see 6 2 2 and 6 2 1 using the respective parameters Push the RIGHT ARROW button once to change to segment 05 Define a ramp see 6 2 2 and 6 2 1 using the respective parameters Push the RIGHT ARROW button once to change to segment 06 Define an end time see 6 2 2 and 6 2 1 using the respective parameters Wait a few seconds until the display changes automatically Programming has been completed ...

Page 32: ...hapter 2 2 QUALIFIED PERSONS Disconnect the furnace from the mains supply before any maintenance work is carried out Allow the furnace to cool down sufficiently The user may only carry out work that is described in this instruction manual All other work requires comprehensive specialist knowledge and fundamental experience in handling high temperature and electrical technology Electrical hazards S...

Page 33: ...ections fit tightly 8 3 2 MAINTENANCE WORK AS NEEDED Use only standard non aggressive and non abrasive detergents to prevent property damage and consequential damage Never spray detergents directly on furnace parts Do not immerse spray wash or wet clean the furnace Carry out the following work if required Clean the furnace housing Clean the sintering aids Clean the firing support and remove dust u...

Page 34: ...rsonnel Electrical hazards Serious injuries or death through contact with live parts Disconnect power plug before opening the furnace Open the furnace only when required for maintenance purposes Never carry out modifications 9 2 FAULT FINDING The controller will detect all events that affect proper operation of the furnace The controller indicates them as warning or error messages Readout messages...

Page 35: ...manual All other work requires qualified personnel Electrical hazards Serious injuries or death through contact with live parts Disconnect power plug before opening the furnace Open the furnace only when required for maintenance purposes Never carry out modifications 10 2 REPLACING HEATING ELEMENTS The user can replace a broken and defective heating element For information on how to replace heatin...

Page 36: ... following hazards must be expected DANGER Read the following safety notes carefully before taking out of service Misuse can result in serious injuries or death Make sure that operating personnel are qualified as required Chapter 2 2 QUALIFIED PERSONS Electrical hazards Serious injuries or death through contact with live parts Disconnect power plug before opening the furnace Open the furnace only ...

Page 37: ... furnace chamber Remove all loose parts Step 3 Close the furnace Step 4 Turn off the furnace using the main switch and disconnect the power plug 11 4 DISPOSAL Non professional waste disposal is environmentally hazardous Electrical equipment cannot be disposed of with the regular household waste in accordance with Directive 2002 96 EC on Waste Electrical and Electronic Equipment WEEE and its German...

Page 38: ...manufacturer of Denta Star S1 Description of unit High temperature furnace Product name Denta Star S1 Useful volume 0 7 x 1 0 x 0 7 dm W x D x H Max operating temperature 1 550 C Serial No xxyy zzz S1 The serial No comprises xx yearyear yy monthmonth zzz cont_No S1 14 xx 20 01 yy 12 1 zzz 999 Essential EC Directives DIRECTIVE 2006 42 EC on machinery of 17 May 2006 DIRECTIVE 2006 95 EC on low volta...

Page 39: ...ply of the furnace 13 06 Characteristics and technical data 14 07 Requirements for installation 17 08 Functions 28 09 Example programming 29 13 2 INDEX OF ILLUSTRATIONS No Depiction Page 01 Furnace overview 15 02 Example type plate 16 03 Replacing heating elements 19 04 Door unlock 24 05 Controller scheme 25 06 Controller 25 07 Programming the controller 27 08 Programming the controller 27 ...

Page 40: ... 40 14 NOTES Use this page for notes ...

Page 41: ... 41 Thermo Star GmbH Krantzstr 7 Geb 37 52070 Aachen Germany TS_OOM_DS_S1_en_20180130 Phone Fax 49 241 60845 0 49 241 60845 100 info thermo star de www thermo star de ...