MiniSTAR S with Scan Technology

Operation Manual
MiniSTAR S with Scan Technology
®
200 Cooper Avenue
Tonawanda, New York 14150
1.800.828.7626
Website: www.greatlakesortho.com
®
Congratulations on the purchase of your MiniSTAR S with Scan Technology.
In addition to this operation manual, Great Lakes offers a wealth of information for all Biostar/MiniSTAR S owners.
You can access this information by joining our Bio/Mini Users Group today at www.bioministar.com.
This site allows you to:
• View our thermal-forming material and applications chart
• Watch appliance fabrication videos
• Learn specialized tips and techniques from our experts
• Find out about our new and featured products
• Submit questions
®
The most comprehensive information to maximize the potential of your MiniSTAR S is at your fingertips at
www.bioministar.com
02
ISSUE
Star
NOVEMBER
2011
BIO MINI
EDUCATION
S O U R C E
I N F O R M AT I O N T O M A X I M I Z E T H E P O T E N T I A L O F Y O U R B I O S TA R ® O R M I N I S TA R ®
BIOMINISTAR.COM
Biostar & MiniSTAR Information at Your Fingertips!
Thermal Forming
Material and
Applications Chart
Great Lakes has created an
easy-to-use chart of all the
thermal forming sheet material.
BIOSTAR & MINISTAR
®
®
THERMAL FORMING
MATERIAL
& APPLICATIONS
Thermal-Forming
maTerial & applicaTions
Clear Material
Clear Material
Trays
Trays
Custom
●
Temporar
ies
●
25
Bonding
retainers
30
021-025
Bleaching
021-024
.040
Splints
40
.030
1 mm
Indirect
Invisible
Thickness
(millimete
rs)
Thickness
(Inches)
Item#
#/pkg.
021-023
.75 mm
Model duplicatio
n
Soft Splints
Nightguar /
ds
Applications
retainers
125 mm
round = ●
Square =❑
Mouthgua
Positioner rds /
s
Specifications
Clear Material
Includes: White, Pink & Blue Tray Material
SPLINT BIOCRYL
A Great Lakes
exclusive.
Offers fast fabrication,
uniform thickness,
and consistent high
quality.
Do you need
help with a
technique?
Clear - Round
.5 mm
1.5 mm
2 mm
2.5 mm
3 mm
.020
.060
.080
.100
.120
021-026
021-027
021-028
●
●
15
●
10
●
10
●
9
●
021-029
025-006
40
025-007
30
025-008
25
●
●
●
Clear - Square
.5 mm
.020
.75 mm
.030
❑
❑
1 mm
.040
1.5 mm
.060
025-009
15
2 mm
.080
025-010
10
❑
3 mm
.120
025-011
9
❑
030-035
10
❑
❑
❑
❑
DURAN *
®
Highly transparent,
hard elastic.
Bonds to acrylic.
Clear - Round
.5 mm
.625 mm
.020
.025
030-036
10
●
●
.75 mm
.030
030-037
10
●
1 mm
.040
030-038
10
●
1.5 mm
.060
030-039
10
●
10
●
IMPRELON*
Offers fast fabrication, uniform thickness,
and consistent high quality.
Clear - Round
3 mm
.120
030-006
White - Round
3 mm
.120
030-028
10
●
DURASOFT® * (Hard/Soft Dual Laminate) - Pre-dry in Biostar® Drying Oven
Break and abrasionresistant. Offers fast
fabrication, uniform
thickness, and consistent
high quality. Hard side
bonds to acrylic.
Clear - Round
1.8 mm
2.5 mm
.070
.100
030-001
10
●
030-027
10
●
035-001
10
❑
Clear - Square
1.8 mm
.070
2.5 mm
.100
035-027
10
❑
*Manufactured by Scheu Dental Technology.
Note: • Printed images may vary from actual material colors and should only be used as a reference.
• Square material will fit vacuum machines.
order by phone 1.800.828.7626 (u.S. & Canada) 716.871.1161 (Worldwide) or Fax 716.871.0550
1
order onLIne WWW.GreaTLaKeSorTho.CoM
9
order oNLINe WWW.GREATLAKESORTHO.COM
It is divided up into four
sections:
• Clear Material: Pgs. 1-4
• Colored / Patterned Retainer
Material: Pgs. 5-6
• Multi-Colored Mouthguard
Material: Pg. 7
• Colored Mouthguard Material:
Pgs. 8-9
The chart lists material sizes,
Post a
question or
a unique
fabrication
technique.
Learn how you
can save big
on products.
Are you
interested in
new products?
Join the Bio/Mini Users Group NOW!
1 Go to www.bioministar.com
item nos., and quantities. It also
includes a description of each
material and the appropriate
applications.
You can download the chart
from the Bio/Mini Users site or
contact us and we will be happy
to send it to you.
2 If you are a first time user,
a brief survey will pop-up
3 Complete the survey and you will
have immediate access to all the
support materials, literature, &
videos.
4 If you are a returning user, just
enter your email and you are all set.
▲
Join the Bio/Mini Users Group at www.bioministar.com or contact us by
phone at 1.800.828.7626 or fax 716.871.0550
Continued
®
MiniSTAR S with Scan Technology
A smaller, less expensive version of the Biostar was introduced in 1991 called the MiniSTAR. The compact design
utilizes the same principles as the computerized Biostar, with reduced pressure and a modified timing mechanism
used for heating and pressure-cooling cycles. In 2011, a barcode scanner was added to the MiniSTAR S. This
feature automatically enters the correct processing information for the thermal-plastic material.
Technical Data:
•
•
•
•
•
Voltage
Power
Pressure
WxDxH
Weight
115V (AC) - 50/60 Hz
750 W
60 psi / 4 bar
17.25”” x 14.25” x 8.25”
20lbs. / 9.07kg
Installation
Before removing the machine and its components from the shipping box, determine the location for the MiniSTAR S
in the laboratory. The machine’s size and weight are outlined above. Make sure sufficient workspace around the
machine is available and that nothing will interfere with operation of the heating element.
Reminder: Keep any flammable material away from the heating element.
The shipping box contains:
•
•
•
•
•
•
•
•
MiniSTAR S unit
Pellet drawer
Clamping frame
Model platform
High pressure hose with hose clamps and air filter
Container of pellets
Pellet brush with magnet
Replacement air filter
After inspecting the items, remove all packing material, and position the MiniSTAR S unit on the laboratory bench. To
prevent machine malfunctions as a result of excessive dust, do not place the unit near etcher catchers, micro etchers,
or any other dust generating equipment. The air source should be within reach of the machine using the high-pressure
hose as a reference guide. The air pressure should be capable of supplying a minimum of 60 psi to the unit.
SMPI1Rev013112
S-184
1
The following information provides a brief description of the MiniSTAR S’s basic components.
Front View
A
B
C
I
F
E
H
D
A
B
C
D
E
F
G
H
I
Infrared Heater
Control Panel
Locking Handle
Barcode Scanner
Pellet Cup
Platform
Pellet Drawer
Pressure Chamber
Locking Ring Clamp
G
Infrared Heater:
Found on left side of unit, swings from back of machine (rest position), forward over
thermal plastic held on the chamber.
Control Panel:
Contains operating controls including electrical power switch, +/- time input buttons,
air pressure verification button, and digital timer.
Locking Handle:
Locks chamber onto pellet cup and switches air pressure on.
Barcode Scanner:
Automatically enters the correct processing information for the thermal plastic.
Pellet Cup:
Used in every molding process and is fixed on the MiniSTAR S table. The pellet cup
holds the dental model, pellets, and platform.
Platform:
Circular plate that is placed on the inner lip of the master pellet cup.
Pellet Drawer:
Removable front compartment that holds overflow of pellets.
Pressure Chamber:
Thermal plastic is held and air pressure incorporated for molding.
Locking Ring Clamp: Circular metal clamp that secures material to pressure chamber.
2
Control Panel
C
A
B
D
F
E
G
A
B
C
D
E
F
G
ON/OFF Switch
Digital Panel
Duo LED Light
+/- Time Input Buttons
Air Pressure Verification Button
Blue LED Light
Scan Button
On/Off Switch:
Supplies electricity to operate the machine.
Digital Panel:
Indicates heating/cooling time and measures air pressure.
Duo LED:
The green LED indicates operating mode (heater ready) and the red LED indicates
heating mode (heating started).
+/- Time Input Buttons:
Heating times can be programmed in 5-second intervals.
Air Pressure Verification Button:
Used for air pressure verification/depressurization of the chamber.
Blue LED:
Indicates chamber pressurized (continuous light) and depressurized (flashing light).
Scan Button:
Activates the barcode scanner.
Back View
C
A
B
A
B
C
D
Compressed Air Supply
Pressure Regulator
Fuse Holders
Plug
D
Compressed Air Supply:
A threaded air valve to clamp the air-pressure hose to the machine.
Pressure Regulator:
Dial to increase or decrease air pressure used in the MiniSTAR S machine.
Fuse Holders: Two compartments that house miniature fuses.
Plug:
Three-prong electrical socket for detachable power cord.
3
B
A
C
Initial Setup and Use
1. Plug the electrical cord in the back of the MiniSTAR S (A)
into a three-prong 110v outlet. The fuses are located in the
back of the machine above the electrical connection (B)
(Miniature Fuse: 2x10A LAZY).
2. Connect the MiniSTAR S to the air source using the highpressure hose. Slip one end of the hose onto the air valve (C)
of the MiniSTAR S, and slip the other end over the air pressure
line. Secure each end in place with a hose clamp.
Note: Route the electrical cord and pressure hose
away from the heating element.
3. Secure the clamping frame to the pressure chamber by
referencing the clamp handle at a 4-5 o’clock position over
the chamber. Slip the clips of the clamping frame into the
grooves on the outside of the chamber and slide the
clamping handle to the left (blue arrow).
D
E
4. With pellets provided, fill cup (D) half full with pellets.
5. Pour remaining pellets in the pellet drawer (E) and
clip it onto the front of the MiniSTAR S table.
6. Place platform on inner lip of the pellet cup, with the
pellet level half full. Make sure the inner lip of the
cup is clear of pellets.
Working pressure of 4 bar (60 psi) is pre-set in the machine. Confirm or
adjust MiniSTAR S air pressure by first turning on the main air source.
Release the locking cap on the regulator by pulling it outward. Set
the pressure by turning the regulator dial on the back of the machine
clockwise to increase the pressure, counterclockwise to decrease.
Identify the proper pressure by the gauge. Once pressure is set, lock regulator by pushing the cap in towards the machine.
Maximum pressure is approximately 4 bar, or only what the main line is capable of supplying.
4
Reminder: Do not use material thicker than 5mm within the clamping mechanism. This may cause
the MiniSTAR S to malfunction while pressure is in the chamber. Always wear safety glasses when
using this machine and during all fabrication procedures.
Maintenance
A regular maintenance schedule should be followed. Proper maintenance will assure better fabrication results. Refrain
from using water in the MiniSTAR S machine. Water may cause certain components to rust or corrode. When the machine
is not being used, engage the clamping frame to the chamber and position the chamber on the pellet cup. This prevents
lab dust from entering the pellet cup and chamber.
Pellets will become dirty with regular use. Clean pellets by
placing them in a strainer and rinsing with hot water. Spread
pellets on a towel and let air dry before placing them back in
the MiniSTAR S. Check pellets monthly. Discard and replace
pellets in the bottom third of the cup.
Air escape holes are present in the base of the pellet cup and
should be checked monthly to ensure that they remain open.
Use a .036” diameter or smaller wire to open plugged holes.
Clean and inspect top and side of the adjusting ring* every
4-6 months.
A
With a fingertip, apply a drop of liquid dish soap to both the
side of the aluminum ring (B) and side gasket (C). Identify
potential gasket cuts or irregularities.
Remove the soap with a soft, dry cloth.
* Adjusting Ring is assembled from three components:
A. Chamber sealing ring
B. Aluminum ring
C. Side gasket
C
B
Adjusting ring* should move freely in the chamber. If not,
after cleaning, apply a thin coat of Silicone Grease (016-021)
to outer ring of the chamber, 4 adjusting pins, and outside
edge of the adjusting ring (see white arrows).
5
Check the air filter clamped to air line for discoloration and/or
moisture monthly.
If replacing the filter, turn off the air source and bleed the
high-pressure hose of air. Loosen clamps holding the filter
and slide it off the hose. Position the new filter by referencing
the arrow on the filter case toward the back of the MiniSTAR S.
The heating surface (A) should be parallel to the heating
element (B). Adjust the position of the chamber by turning
the screw (C) located under the chamber support frame with
a small screwdriver. Clockwise adjustment of the screw
lowers the chamber from the heater, counterclockwise
raises the chamber closer to the heater.
B
A
Check the position of the chamber when heating materials.
CC
Operation
There are three basic functions to operate the MiniSTAR S including:
• Model preparation
• Heating cycle
• Pressure molding process
Model Preparation
Prepare models for the thermal-forming process by removing bubbles or filling voids whether using the platform or
pellets. The platform is used when forming soft or thin plastics. Pellets are used when forming thick, less flexible
materials. The pellets prevent the plastic from forming to unwanted areas of the dental cast.
Platform Use
The platform is used to expose the entire dental mold to the formation of the thermal plastic. It eliminates having to
use pellets. Pellets are difficult to remove from softer material (i.e., soft mouthguard material) and can create a higher
occurrence of air leaks during the pressure-forming process when using thinner thermal plastics (i.e., < 1mm thick).
6
Empty cup or reduce the pellet line to the half-way level
(white line). Make sure the inner lip of the cup is clean.
Place the outer ring of the platform on the inner lip of the
pellet cup with the flat platform surface on top. To remove the platform,
use the MiniSTAR S Brush with Magnet (016-021). Engage the tip and lift up.
Remove model bubbles and detail the oral anatomy with a
laboratory knife. Fill holes in the model with a quick-setting
stone.
When referencing the model to the platform, make sure the
base of the model is reduced flat, parallel to the occlusal
surface. In some cases, the base is removed creating a flat
horseshoe model to eliminate excessive material thinning.
For some materials, a liquid separating foil is applied to allow
for easy removal of formed material.
Position the model in the center of the platform, referencing
the heel toward the material in the pressure chamber.
Pellet Use
A five-pound container of lead pellets is supplied with each MiniSTAR S. Pellets are used to prevent the thermal-plastic
materials from stretching over areas of the model that are not part of the appliance design. The soft metal alloy will flatten
if compressed by the pressure chamber on the rim of the cup, preventing machine damage. Stainless steel pellets are
available upon request, but will cause damage to the cup’s rim if compressed by the pressure chamber. Use of materials
other than the manufacturer’s recommended pellets may result in machine malfunction and could void the warranty.
Work models are placed in cylindrical pellets:
• to support the model so that the occlusal-incisal plane is as level as possible with the rim of the cup.
• to prevent the material from forming on the facial surfaces of the teeth, making it hard to remove the appliance
from the work model.
• to prevent heated material from melting the wax supporting the wires on facial areas.
• to allow air to pass through the pellets as the material is forming over the model, preventing back pressure.
7
Enough pellets must be placed in the pellet cup to hold the
model at a proper level. Material termination areas, located
on the facial surface of the model, should be referenced at
the same height as the top ledge of the pellet cup.
Note: Mounted models may be referenced slightly higher
than indicated.
Remove the pellet drawer (A) from the machine by sliding the
drawer up and away from the machine.
A
B
Sliding the drawer upward positions the magnetic clip (B)
above the rim to prevent the pellets from spilling over the
edge of the machine’s table.
To replace the pellet drawer, line up the groove on the back of
the drawer (A) with the block (B) on the magnetic clip.
Once engaged, slide the drawer down to its rest position in
the slots.
Pour pellets between the model and the inner wall of the
cup. Apply more than enough pellets in this area.
Use a MiniSTAR S Brush (010-046), or MiniSTAR S Brush with
Magnet (016-021) to remove excess pellets, and level the
pellet line from the occlusal-incisal plane to the top rim of
the cup. Hold the brush at an angle to sweep excess pellets
from the rim of the cup and the palatal area of the model.
Sweep excess pellets around the outside of the cup into
the pellet drawer.
8
When constructing an orthodontic retainer, the pellets placed
against the occlusal-incisal margin cover the wax holding
the wires facially and act as an insulator when the heated
material is formed.
Improper packing of a model can cause a blowout, air leak,
or machine malfunction. It is important that there is no
sudden drop of the pellet margin at the inner cup wall or that
the model is not positioned too high or low within the cup.
This allows the material to be overstretched, thinning it to
where a hole is created and air blows through.
In some instances, an air leak could cause inferior material
adaptation that can result in a poorly fitted appliance.
Mounted models should be splitcast. If the model cannot be
removed from the mounting, the pellet level will need to be at
a slight incline to appliance termination areas.
Heating Cycle
There are two options to program the heating times:
1.) Manual Entry A
Press the power switch (A) of the MiniSTAR S to activate the
machine. Input appropriate heating time for the material to
be thermal formed (follow manufacturer’s suggested heating
time).
Press the +/- button to set time. Heating time increases and
decreases in 5 second intervals.
During long heating cycles or continual use, the lamp can
become extremely hot.
- Caution is advised to prevent skin burns -
9
2.) Barcode Scan -
The barcode scanner automatically enters the correct
processing information for your material. Press the
“Scan” button to activate the scanner.
A
Great Lakes Material: the barcode is located on an easy-to-scan barcode strip (A) inside each box of material. Hold the barcode strip under the scanner until you hear a “beep”
indicating the barcode has been read. The
heating time will automatically show on the display.
Scheu Material: the barcode is printed directly B on the material (B). Hold the material under the scanner until you hear a “beep” indicating the barcode has been read. The heating time will automatically show on the display.
Position a 125mm diameter round disc on the spring-loaded
adjusting ring of the pressure chamber.
Align the clamping frame over the material so that the
spring clips slip under the bevel of the locking device on
the sides of the chamber.
Tighten by turning the handle clockwise, so that
the chamber and clamping handles are parallel.
10
Swing the heating element from its rest position over the
material on the pressure chamber. When the heater is
placed over the material, the heating element illuminates
and the set heating time begins.
With 5 seconds remaining, warning beeps will sound.
Once heating time has elapsed, the beeping will be
continuous until the heater is removed from the material.
Material heating times will vary based on compound, color, and thickness. Recommended heating times are
identified on an easy-to-scan barcode strip inside each box of material. If proper adaptation is not obtained,
it may be necessary to extend or decrease the recommended heating times by 5-15 seconds.
Pressure Molding Process
A
C
B
After the recommended time is reached, swing the heater (A)
back to the rest position and flip the pressure chamber (B)
onto the cup so the material can be thermal formed over the
model. Turn the locking handle (C) from the straight back rest
position 180º toward the front of the machine. This secures
the chamber over the cup and allows air pressure to enter the
chamber. Once the pressure is turned on, the digital clock on
the control panel will automatically initiate a cool-down time.
At the end of the cooling time, short beeps will sound. Press
the air button marked on the control panel to release the air
pressure from the chamber. Short beeps will sound indicating
full pressure evacuation. If a shorter cooling cycle is required,
the programmed time can be erased by pressing and holding
the air button for 5 seconds. Once the time has been erased,
press the air button again to release the pressure.
A
C
B
To unlock the chamber, swing the locking handle (A) on the
right side of the machine from the front of the MiniSTAR S to
the straight back rest position. Unlock the material held on
the chamber by sliding the clamping frame arm (B) to the left.
Flip the chamber (C) open to the left and remove the model
with the formed plastic.
11
®
MiniSTAR S with Scan Technology Troubleshooting & Fabrication Tips
Use the following tips to address:
• Air leaks
• Poor adaptation
• Blowouts
• Material thinning
If adjusting ring does not move
freely, remove it and clean with a
small amount of liquid dish soap,
applied and removed with a soft,
dry cloth.
• Material heating unevenly
• Mounted model too high for pellet cup
Remove and clean the 4 pins and
springs. Then lubricate with a small
amount of Silicone Grease (016-021).
Insert pins, springs, and adjusting
ring. Depress adjusting ring once or
twice to make sure it moves freely.
Wipe off any excess grease with a
soft, dry cloth.
Remove pellets from cup. Make sure the 12 air escape holes
are not plugged. Use a .036” diameter or smaller wire to
open plugged holes.
For mounted models, remove the
majority of pellets, leaving only
enough under the model to allow air
to flow. Build up the pellets, leaving
exposed only the area to be covered
by acrylic material.
Note: The MinSTAR S is preset at
60 psi, or 4 bars of working pressure.
Make sure the heating
surface is parallel to the
heating element. See
Maintenance Tips to
adjust.
Make sure all pellets are removed
from the edge of the cup where the
chamber locks into place.
Performing a Cold Test:
A. Turn unit off. Make sure
platform is in place. Clamp a
sheet of 2mm (or thicker) hard
material onto pressure chamber.
Secure clamping frame.
B. Enter 5 seconds heating time.
Swing the heating element over
the material to activate heat.
Immediately return heating
element to rest position.
C. Swing pressure chamber
over the model platform.
Activate air pressure.
D. If you hear a constant rush
of air during pressurization,
contact your customer service
representative.
Pellets should be even with the top
of the pellet cup.
Great Lakes recommends all soft or semi-soft material should be formed on the
platform. See photo on left: the base of the model is even and flat.
Use pellets for hard material: see photo on right.
1.800.828.7626
www.greatlakesortho.com
®
MiniSTAR S with Scan Technology Maintenance Tips
A regular maintenance schedule should be followed. Proper
maintenance will assure better fabrication results. Refrain
from using water in the MiniSTAR S machine. Water may
cause certain components to rust or corrode. When the
machine is not being used, engage the clamping frame to
the chamber and position the chamber on the pellet cup.
This prevents lab dust from entering the pellet cup and
chamber.
Pellets will become dirty with regular use. Clean
pellets by placing them in a strainer and rinsing
with hot water. Spread pellets on a towel and let
air dry before placing them back in the MiniSTAR
S. Check pellets monthly. Discard and replace
pellets in the bottom third of the cup.
Air escape holes are present in the base of the pellet cup and
should be checked monthly to ensure that they remain open.
Use a .036” diameter or smaller wire to open plugged holes.
A
B
C
A
B
B
B
A
B
B
C
Clean and inspect top of the
chamber sealing ring (A) and
side gasket (B) every 4-6
months. With a fingertip, apply
a drop of liquid dish soap to the
side gasket on the adjusting
ring. Identify potential gasket
cuts or irregularities. Remove
soap from the gasket with a
soft, dry cloth.
Adjusting ring should move freely
in the chamber. If not, apply a thin
coat of Silicone Grease (016-021)
to outer ring of the chamber (A),
4 adjusting pins (B), and outside
edge of adjusting ring (C).
1.800.828.7626
www.greatlakesortho.com
Check the air filter clamped
to air line for discoloration
and/or moisture monthly. If
replacing the filter, turn off the
air source and bleed the highpressure hose of air. Loosen
clamps holding the filter and
slide it off the hose. Position
the new filter by referencing
the arrow on the filter case
toward the back of the
MiniSTAR S.
The heating surface (A) should
be parallel to the heating
element (B). Adjust the position
of the chamber by turning the
screw (C) located under the
chamber support frame with
a small screwdriver. Clockwise
adjustment of the screw lowers
the chamber from the heater,
counter clockwise raises the
chamber closer to the heater.
Check the position of the
chamber when heating
materials.
200 Cooper Avenue
Tonawanda, New York 14150
1.800.828.7626
Website: www.greatlakesortho.com