Planmeca PlanMill 40 S User manual

Planmeca PlanMill® 40 S
User Manual

Table of Contents
PlanMill 40 S Introduction........................................................................................4
Indications for Use.......................................................................................................................................... 4
Startup Procedure........................................................................................................................................... 4
Lid Lights ......................................................................................................................................................... 4
Shutdown Procedure...................................................................................................................................... 4
Relocating the Mill.......................................................................................................................................... 4
System Information and Upgrades ............................................................................................................... 5
Software and Hardware ..................................................................................................................... 5
Mill Software Version.......................................................................................................................... 5
PlanMill 40 S Safety ..................................................................................................6
Operating the Mill.....................................................................................................7
Pending Jobs ................................................................................................................................................... 7
Inserting Blocks .............................................................................................................................................. 7
Horizontal Orientation................................................................................................................. 8
Vertical Orientation ...................................................................................................................... 8
Composite Block Defoaming Solution .......................................................................................................... 9
Milling Zirconia ............................................................................................................................................... 9
Scale Factor .......................................................................................................................................... 9
Cleaning the Tank................................................................................................................................ 9
Long Tools Required ........................................................................................................................... 9
Starting Milling ............................................................................................................................................... 9
Finished Jobs................................................................................................................................................. 10
Deleting Jobs................................................................................................................................................. 11
Automatic Tool Changer...............................................................................................................................11
Tool Status.......................................................................................................................................... 11
Broken Tools ..................................................................................................................................... 12
Restoration Inspection ..................................................................................................................... 12
Replacing/Inserting Tools................................................................................................................. 12
Block Usage........................................................................................................................................ 14
Maintenance ...................................................................................................................................... 14
Tool Performance.............................................................................................................................. 15
Mill Troubleshooting/Repair ..................................................................................16
Mill .................................................................................................................................................................16
Preventive Maintenance/Cleaning ........................................................................17
Routine Mill Maintenance ............................................................................................................................ 17
Clean Outside of Mil...................................................................................................................................... 17
Clean Fluid Tank: ............................................................................................................................... 17
Rell milling uids: ..................................................................................................................... 17
Zirconia Mill Maintenance............................................................................................................................ 17
Spindle Cap and Collet Cleaning ................................................................................................................. 18
Importing for Milling ..............................................................................................19
Managing Patients in Planmeca Romexis...................................................................................................19
Creating new patients....................................................................................................................... 19
Searching Patients............................................................................................................................. 19
Sorting patients ................................................................................................................................. 19
Selecting and opening patients ....................................................................................................... 20
Managing Cases ............................................................................................................................................20
Deleting Files.................................................................................................................................................20
Import for Milling..........................................................................................................................................20
©January 2020 Planmeca All rights reserved
10829800.K
Planmeca PlanMill 40 S User Manual 2

Mill Screen .....................................................................................................................................................21
Specify the Material .......................................................................................................................... 21
Select a Block Size ............................................................................................................................. 21
Sprue Placement ............................................................................................................................... 21
Restoration Positioning .................................................................................................................... 22
Mill Simulation ................................................................................................................................... 22
IPS e.max ZirCAD Simulation and Milling ................................................................................ 22
Evaluate the Simulation............................................................................................................. 23
Evaluating the Connectors on Bridges........................................................................................................ 23
Send to Mill....................................................................................................................................................25
Mill Tab Settings............................................................................................................................................ 25
Mill Network Settings ................................................................................................................. 25
Material/Shade Settings............................................................................................................. 25
Margin Thickness Settings......................................................................................................... 25
Milling Settings............................................................................................................................ 26
Simulation Settings..................................................................................................................... 26
Mill System Specications ......................................................................................27
Applicable Standards ................................................................................................................. 27
Approvals..................................................................................................................................... 28
Labels.............................................................................................................................................................28
Symbols .............................................................................................................................................. 28
Product Identication Labels....................................................................................................................... 29
Attention Labels ................................................................................................................................ 29
External Components and Connectors.................................................................................... 30
Protected Earth Ground Label......................................................................................................... 30
UL Laboratory Equipment Listing.................................................................................................... 30
Planmeca PlanMill 40 S User Manual 3

PlanMill 40 S Introduction
Indications for Use
The PlanMill 40 S is a dental milling machine used to fabricate restorations from compatible dental materials.
Startup Procedure
Press the green button on the front of the mill to turn it ON.
When the mill software loads, the initializing screen appears. Close the lid rmly and wait for the software to automatically load.
Lid Lights
The lid lights change color based on the status of the mill.
Lid Color Description
Blue (solid) Mill is initializing
Green (solid) Mill is idle or is milling. It can accept instructions (select restorations, cancel
milling, replace tools, etc.)
Green (ashing) Milling complete. The restoration has completed milling and the lid is open.
Red (ashing) The mill has faulted. Warning screen: Re-initialize to clear the fault or enter
the diagnostic state to attempt to diagnose the problem.
White Lid is open.
Yellow Warning message displayed.
Shutdown Procedure
The mill should remain ON during the week. Turn it OFF at the end of the week.
1 Touch the Xin the top-right corner of the display. Averication screen appears, touch OK.
2 Close the lid if it is open. The lid stays closed while the mill runs its closing procedure. The lid opens automatically, leave the lid
open.
The desktop for the operating system (Windows) appears.
3 Ensure that all mill motor movement has stopped. Press and hold down the green power button for approximately 10
seconds. This process will prompt the operating system (Windows) to shut down.
The screen and red button will go dark.
Relocating the Mill
Warning: The mill weighs approximately 170 lb. (77 kg). Always follow these guidelines when relocating the machine.
When relocating the mill, remove the tank from the machine.
The Mill is designed to operate on a level and stable surface in an environment free from excessive moisture or dust. When
choosing a location for the mill, adhere to all clearance requirements stated in System Specications.
1 Ensure no milling operations are in progress.
2 Open the front access panel and remove the uid reservoir.
3 Empty the uid reservoir according to your approved material disposal protocols.
Planmeca PlanMill 40 S User Manual PlanMill 40 S Introduction 4

Planmeca PlanMill 40 S User Manual PlanMill 40 S Introduction 5
4 Turn OFF the mill.
5 Disconnect all power and data connections.
6 Move the mill onto a cart that is capable of supporting the weight of the mill and its accessories. You are advised to use a
suitable cart rather than moving the mill by hand. Lifting and carrying should be kept to a minimum.
The mill weighs approximately 170lbs (70 kg). Lifting the mill requires at least two people.
Those lifting the mill should:
• Stand close to the mill with their feet approximately shoulder width apart, and one foot slightly in front of the other for
optimal balance.
• Squat down by bending at the knees, not at the waist, keeping their backs as vertical as possible.
• Firmly grasp the mill before beginning the lift.
Be certain to lift the mill by the underside metal bottom plate located on each side of the mill, not by the plastic covers..
• Refrain from twisting their bodies and slowly begin lifting, using their legs, not their back, to lift.
• Keep the mill as close to the body as possible to minimize stress on the back.
• If turning is required, turn by shuing their feet, not by twisting their body.
• If it is necessary to place the mill below the level of their waists, each person lifting should follow these procedures in
reverse order, keeping their backs vertical and bending at the knees.
• Be careful to avoid obstacles.
System Information and Upgrades
Software and Hardware
System software and hardware upgrades are initiated through Planmeca only. No software or hardware should be added or
deleted to/from the Planmeca systems without prior approval of Planmeca. Doing so may result in damage to the system and will
void the product warranty.
Mill Software Version
The version number is displayed on the home screen.
When placing a call for service or support, you may be asked to provide the serial number, model number, software version
number, or similar identifying data. The serial number and model number are located on the Product Identication Label, axed
to the rear of each unit.“Labels” on page 28.

Planmeca PlanMill 40 S User Manual PlanMill 40 S Safety 6
PlanMill 40 S Safety
Warning: Failure to adhere to all safety warnings may result in personal injury, equipment damage, or data loss.
The mill weighs approximately 170 lb. (77 kg). When lifting or moving the mill, follow the guidelines in “Relocating the Mill” on
page 4 .
Always ensure the mill is on a surface capable of supporting its weight of approximately 170 lb. (77 kg).
Use caution when handling the mill’s cutting tools.
Before milling a restoration, ensure the mill has adequate milling uid. Adequate milling uid is required to prevent overheating
and possible damage to the restoration blank and cutting tools.
Do not open the mill’s lid while a milling operation is in progress. Doing so will result in the loss of data and restoration block; the
milling process will have to be repeated.
This equipment is intended to be grounded. Connect the products to earth grounded outlet only. Power strips or extension cords
should not be used.
If a power cord (other than the one provided with the equipment) is used for connecting to the power source, ensure it meets all
of the following requirements:
• Detachable power supply cord
• Type SJT
• 18 AWG 3 conductor
• Rated 10 A or better
• For products outside of the United States and Canada, the power cord must be marked “HAR” or with a suitable agency
marking from the country of intended use. The attachment plug and appliance coupler must be marked with a suitable
agency marking from the country of intended use.
Do not use the products for any purpose other than its intended and labeled use.
To prevent electrical shock, do not open any sealed or user restricted access panels or connectors.
A detachable non-locking type power cord has been provided with this equipment as the disconnect device. Do not block access
to the power cord. In case of emergency, remove power from the device by unplugging the cord at either end.
Do not block any of the product’s cooling vents located on each side and lower rear panel. Doing so may result in overheating and
damage to the products and will void the product warranty.
When placing components, adhere to all clearances stated in “Minimum Clearance” on page 27 .
Do not make any unauthorized repairs or modications to the system software or hardware. This includes installing unauthorized
software on the computer system or altering or bypassing any safety switches or mechanisms.
Do not install or operate the products in an environment where an explosion hazard exists, e.g., high oxygen area.
Comply with all applicable regulations when disposing of waste materials.
Do not attach any equipment or devices to the mill unless their use has been specically authorized by E4D Technologies or
Planmeca.
The wireless components in the products may be interfered with by other equipment, even if the other equipment is fully
compliant with CISPR (International Special Committee on Radio Interference) emission requirements.
When possible, electrical equipment should not be used when adjacent to other electrical equipment. If adjacent use is necessary,
the equipment should be observed to verify normal operation in the conguration in which it will be used.
When connecting the components, use only the cables supplied with the products. Failure to do so may result in increased
electromagnetic emissions or reduced immunity to external electromagnetic emissions.
Ensure your mill is properly maintained through periodic maintenance.
If you suspect equipment malfunction or failure, discontinue using the mill and contact Planmeca Customer Support immediately.
Do not attempt to make any repairs on the mill.
Read and comply with all safety, warning, and instructional labels on the mill.

Planmeca PlanMill 40 S User Manual Operating the Mill 7
Operating the Mill
Pending Jobs
The Pending Jobs list is the default screen.
Always wait until the lid lights turn green before making any selections on the touch screen.
1 Scroll to nd the desired restoration by dragging a nger up and down the restoration list. Touch the desired job to select it.
2 The system opens the lid and prompts you to insert the block that matches the material selected in the Design software.
Touch the Stop button to return to the jobs list.
Inserting Blocks
Blocks can be inserted vertically or horizontally. The Insert Block screen species the block orientation. Notice the notches face
right in the examples below. If the notch is pointing to the left, you will not be able to insert the block. Round blocks use the
vertical orientation of the mandrel.
The mandrel is the metal piece of the restoration block that is inserted into the mill to hold the block steady
duringmilling.

Planmeca PlanMill 40 S User Manual Operating the Mill 8
Horizontal Orientation
For the horizontal orientation, the wide side of the rectangular block faces up, with the mandrel notch points to the top right. This
side will usually have the printed label. Note the position in the picture below.
Vertical Orientation
For the vertical orientation, the narrow side of the rectangular block faces up, with the mandrel notch points to the bottom right.
The round blocks are inserted with vertical orientation.
1 If you are unable to insert the block fully, insert the Mandrel T-Handle into the cam and turn 180 degrees counter-clockwise to
loosen the cam.
2 Insert the block in the correct position and lock the block in place by tightening the cam.

Planmeca PlanMill 40 S User Manual Operating the Mill 9
Composite Block Defoaming Solution
A Defoaming Solution is recommended when milling resin-containing or composite blocks. Without the defoaming solution, the
milling uid may foam and overow.
1 After inserting the composite block into the milling chamber, shake the bottle of defoaming solution and position it over the
chamber.
2 Press down once to release the solution directly into the milling chamber.
3 Close the chamber and begin the milling process as explained below.
Milling Zirconia
See the manufacturer’s Instructions for Use provided with the zirconia blocks for processing instructions.
Scale Factor
Zirconia shrinks in the sintering oven. There are numbers on the side of the blocks. The Mill asks for the Scale Factor before a
zirconia block is milled. The system will increase the size of the restoration according to this number. This means you cannot test
the t of the restoration before sintering.
Cleaning the Tank
The mill will prompt you to clean the tank. It is necessary to clean the mill and change the water before milling zirconia. If the
zirconia is contaminated with other materials, it will turn green when sintered. Cleaning after milling is recommended because
the zirconia acts as a thickening agent with the water. It is not necessary to clean in between sequential zirconia jobs, although the
mill will ask if the tank is clean.
Long Tools Required
Longer tools are required to mill Zirconia: Conical 12.6 and Tapered 13.2
Starting Milling
Milling is an automated process that varies in length of time based on the restoration data.
1 After inserting the block, close the lid rmly and wait for the lid lights to turn green.
The system checks the positioning of the block and begins generating the toolpath.
Once the toolpath has been generated, the milling will begin and the milling time will be displayed.
See the Troubleshooting section if you experience a problem generating a tool path or if the mill timesout.
After the milling process is complete, the lid automatically opens.
2 Remove the restoration and any debris and close the lid rmly. This allows the mill to prepare for the next job.

Planmeca PlanMill 40 S User Manual Operating the Mill 10
Finished Jobs
Previously nished jobs can be milled again if desired.
1 On the main screen, touch Finished Jobs.
The Finished Jobs list appears.
2 Touch the desired job to select it.
3 Touch the Play button to start the job or the Stop button to return to the case list.
You are prompted to insert the appropriate block. Milling continues as usual.

Planmeca PlanMill 40 S User Manual Operating the Mill 11
Deleting Jobs
Click the trash can next to a job to delete it. Deleted jobs cannot be recovered on the mill, but can be resent from the design
software.
Automatic Tool Changer
The Mill’s automated tool changer holds an array of grinding tools. The tool changer switches between grinding tools as the
milling task demands.
The main screens display a graphic that indicates the status and type of tool in each spindle.
Tool Type Tool Stripe Color
Ellipsoidal Yellow
Tapered White
Conical Blue
Tool Status
The color of the tool tip changes based on the number of minutes used in milling.
Change the tool when it turns red.
Too worn down to be used Broken
See “Replacing/Inserting Tools” on page 12 to ll the tool changer, exchange tool shapes, or to replace broken tools.

Planmeca PlanMill 40 S User Manual Operating the Mill 12
Broken Tools
If toolbreak is detected during a job, the toolpath is suspended and the tool length is checked to conrm the break.
• If the tool break is conrmed and a suitable replacement is available in the Tool Changer, then the tool is automatically
loaded and continues with no operator intervention required.
• If the tool break is conrmed but a suitable replacement is not available in the Tool Changer, then the operator is
prompted to load a replacement tool or abort the job.
• If the tool length is found to be normal then the job continues with no operator intervention.
Restoration Inspection
If a conical tool breaks halfway instead of at the shoulder, the broken tool may not be detected right away. If the broken tool
continues to mill, it can cause damage or put black marks on the restoration.
By default, the new Restoration Inspection feature is activated.
If a tool breaks:
• The lid lights turn blue and the lid pops open
• The operator assesses the restoration and closes the lid
Once the lid is closed, a new message displays.
If the restoration has black marks or has come o of the mandrel, click No. The lid pops open. Remove the block. Select the job to
restart milling. The system will prompt you to insert a new block at the beginning of the restarted milling process.
To continue milling with a new tool, click Yes.
To deactivate this feature, contact Customer Support.
Replacing/Inserting Tools
If a needed tool is not already in the tool changer, the following message will appear.

Planmeca PlanMill 40 S User Manual Operating the Mill 13
Possible reasons for replacing a tool include:
• Tool(s) needed for the restoration are not in the tool changer.
• Fill empty slots in tool changer.
• Tool is broken or too worn down to use.
1 On the main screen, touch Options.
2 Touch Tool Manager.
3 Touch the desired tool or empty slot to see more information and options.
The tool or empty slot changes color when selected.
4 Select the desired option and follow the on-screen instructions.
• Put in Spindle - move a tool from the tool changer to the spindle
• Put tool away - move a tool from the spindle to the tool changer
• Remove from mill - take tool out of the mill and leave this spot empty
• Replace this tool - remove this tool from the mill and replace with a new one
• Measure this tool - calculate the length of the tool
• Verify tools - displays screen to visually inspect all tools and change tool types in the software if needed
When placing a new tool in the collet, ensure it is pushed all the way in (fully seated). Hold the tool in place and touch Next Collet.
The system measures new tools and suggests a tool shape. Select a dierent tool type if necessary.
Close the lid rmly when nished.
Reports
1 On the main screen, touch Options.
2 Touch Reports.
3 Touch one of the reports to view it.
4 Select the desired Time Frame.
5 In Block Usage and Tool Performance, touch a month on the graph to see detailed information on the right.

Planmeca PlanMill 40 S User Manual Operating the Mill 14
Block Usage
• Graph represents the total number of blocks used each month
• The number of Total Blocks Used is for the selected Time Frame.
• Touch a month to see how many of each block type was used that month. The selected month displays as a dark green.
Maintenance
• The graph represents how many times the collets, caps, and tank have been serviced each month.

Planmeca PlanMill 40 S User Manual Operating the Mill 15
Tool Performance
• Graph represents the total minutes of grinding time per month
• The number of Total Tools Used is for the selected Time Frame.
• Touch a month to see how many of each tool type was used that month and what the average grinding time was for each
tool. The selected month displays as a dark green.

Planmeca PlanMill 40 S User Manual Mill Troubleshooting/Repair 16
Mill Troubleshooting/Repair
If you have questions, please contact Customer Support at
Toll Free 800-537-6070
E-mail [email protected]
Hours of Operation 7 am – 6 pm CST
Web site www.planmeca.com
Mailing Address Planmeca USA
2600 Forbs Ave
Homan Estate, IL 60192
Mill
Symptom Probable Cause Corrective Action
Mill does not turn ON Power cable unplugged
Power supply switch turned OFF
Faulty ON/OFF switch
Verify power cable is plugged into a live AC outlet.
Set power supply rocker switch at rear of mill to ON position.
Call Customer Support.
Block orientation on mill
incorrect.
Dirty Block Orientation Sensor Using a small/long object, push very gently on the sensor switch
two or three times.
Pump making fast
thumping noise.
Dirty tank and/or lter Clean tank and lter.
Air failure
message
Loss of air pressure
Air line loose
Ensure there is power to the oce compressor.
Secure air line from compressor to mill.
Fluid Level Low Message Low water supply
Faulty sensors
Fill tank with water.
Clean or replace sensors (Call Customer Support)
Tool stuck in collet Collet rusty or caked with ceramics
Tool jammed due to air pressure
Remove tools manually. Done in the maintenance/command
screen on mill. (Call Customer Support for assistance).
Verify the supply air pressure 50 psig. Verify the pressure multiplier
is maxed out. i.e. the adjustment knob is turned fully clockwise
this doubles the pressure to 100psig.
Not generating tool path Incomplete information from the Job Server Restart Mill.
Milling is not completing
on the facial surface of an
anterior tooth
Restoration is longer than normal On the design software, change the block selection to Multi Block,
but be sure to select the same block size. You can then insert a
standard Empress LT or HT block of the same size. The Mill makes
multiple passes on Multi blocks while other materials use a single
pass.
Unpleasant odor Improper cleaning of the mil. Normal weekly
changing of the milling unit’s circulation
system coolant should be all that’s required to
keep the coolant tank clean and eective
A bleach ush can eectively correct the problem. Have bleach
on hand and ready, then call Customer Support for help with the
process.

Planmeca PlanMill 40 S User Manual Preventive Maintenance/Cleaning 17
Preventive Maintenance/Cleaning
Routine Mill Maintenance
Cleaning Cycle: High volume oces should clean daily. Most oces will need to clean weekly.
The mill must be cleaned more often when e.max or zirconia blocks are used.
Cleaning the chamber and replacing milling uid are required to ensure proper operation of the mill.
Warning: Operating the Mill with insucient milling uid will damage the mill, void your warranty, and destroy the restoration
that is being milled.
Clean Outside of Mil
Wipe down the outside of the mill with damp paper towels. Do not spray or pour liquid directly on the touch screen.
Clean Fluid Tank:
The Clean Fluid Tank icon turns red when the tank is scheduled to be cleaned. Touch the icon at any time to see how
many milling hours are estimated before the tank needs to be cleaned.
1 Touch and hold the Clean Fluid Tank icon.
2 A message appears and shows the number of hours remaining before a scheduled cleaning is needed. Touch Next to
continue.
3 Follow the on-screen instructions.
The tank and lter should be cleaned once a week to prevent mold growth or build-up of ceramic material and for optimal
circulation. High volume oces need to clean the tank and lter more frequently.
Rell milling uids:
The water level icon shows when the water level is too low to continue milling.
Add water to the tank before starting your next job.
1 Slowly pour one gallon of water into the chamber and watch the ll indicator. Stop when it blinks green.
2 Continue with the normal milling procedure.
Zirconia Mill Maintenance
It is necessary to clean the mill and change the water before milling zirconia. If the zirconia is contaminated with other materials,
it will turn green when sintered. Cleaning after milling is recommended because the zirconia acts as a thickening agent with the
water.

Planmeca PlanMill 40 S User Manual Preventive Maintenance/Cleaning 18
Spindle Cap and Collet Cleaning
Cleaning Cycle: As Needed
Over time, residue from the milling process may build up in the spindle caps and/or on the collet. This inhibits coolant
delivery and/or reduces the spindle’s tool holding capability. Clean the collets and spindle caps when the icon turns red
or the tools “walk” (do not stay ush with the spindle) during a restoration. Replace the uid regularly to reduce residue
buildup.
The Collet Cleaning icon turns red when the collets or spindle caps are scheduled to be cleaned. Touch the icon at any time to see
how many milling hours are estimated before they need to be cleaned.
1 Click Next to proceed with cleaning.
2 Select the Guided or Advanced wizard.
3 Follow the on-screen instructions.
4 Close the lid rmly when nished.

Planmeca PlanMill 40 S User Manual Importing for Milling 19
Importing for Milling
STL les can be imported and sent to the mill. A patient must be created for these cases.
Managing Patients in Planmeca Romexis
Creating new patients
1 In Patient Management, click the Add Patient button.
The Add Patient screen opens.
2 Enter the necessary information and add a face photo if desired.
The obligatory elds are in bold text. See the Romexis User Manual for more information.
3 To save the patient into the database click the Save button in any section.
The changes are not saved unless Save button is used.
To view the newly created patient on the list, perform new patient search.
Searching Patients
Patients can be searched by ID or by name.
In Patient Management, type any part of the patient’s name or ID number into the Search eld. Matching items automatically
appear as you type.
The system looks for the letters or numbers anywhere in the patient’s name or ID. Angela, Angie, and Dangereld are
all matches for “ang” in the Search eld.
Sorting patients
Patients in the patient list can be sorted by the Date their records were previously accessed, their ID number, or their last Name.
To sort patients click the desired sort button.

Planmeca PlanMill 40 S User Manual Importing for Milling 20
Selecting and opening patients
1 Click the patient name in the patient list.
The patient’s le opens.
The name of the active patient is always visible in the upper right corner of the screen. Several patient records can be open at a
time but only one of the open records is active at a time.
To close the active patient click the Close Patient button.
To view all open patients click the arrow of the drop-down menu.
To select and modify another open patient, select the name from the drop-down menu.
2 Click Go to CAD/CAM in the Next Steps section at the bottom of the screen or on the Charms menu on the left side of the
screen.
Managing Cases
1 Open the desired patient.
2 Click Go to CAD/CAM.
Select what you want to do:
• Start a new restoration - See below for more information
• Open an existing restoration - See below for more information
• Import 3D models - See Planmeca Romexis User’s manual for more information
• Export 3D models - See Planmeca Romexis User’s manual for more information
Deleting Files
To delete an image (stl le) from the patient’s case les right-click on the le and select Inactivate STL.
To delete a case from the patient’s case les right-click on the case and select Inactivate restoration.
To reactivate or permanently delete a case from the database see the Romexis User Manual.
Import for Milling
1 Open the patient le.
2 Open the CAD/CAM module.
3 Under Import 3D Models, click Import for Milling.
Follow the on screen prompts to nd the les and import them.
4 Double click the Patient’s Case File to open it.
5 The case opens in the Mill screen.