Zirkon zahn ZIRKONOFEN 700 Installation instructions

Zirkonofen 7oo /
7oo Ultra-vakuum
operator’s and maintenance manual

0202
Operator’s and Maintenance Manual
Sintering furnace
Machine type: 700 & 700 Ultra-Vakuum
Version: 05/11/2018
Copyright 2018
Zirkonzahn Gais S.r.l.

0303

0404
Symbols used in this Operator’s and Maintenance Manual .............................. 08
Pictograms on the Zirkonofen 700 & 700 Ultra-Vakuum ............................... 09
Checklist of components - Standard version ......................................... 09
Safety/ResidualRisks.......................................................... 11
Manufacturer.............................................................. 11
Information ............................................................... 11
Service................................................................... 11
Purpose .................................................................. 12
Intendeduse .......................................................... 12
Improper use .......................................................... 12
Obligationsoftheuser .................................................. 12
Warranty................................................................. 13
Warranty claim ........................................................ 13
Lossofwarranty....................................................... 13
Thewarrantydoesnotcover.............................................. 13
Technical development .................................................. 14
Safety regulations .......................................................... 14
Safetyconcept......................................................... 14
Personalsafetyequipment ............................................... 14
Safety measures when cleaning the device ................................... 14
Workplace, handling, references to safety ................................... 15
Troubleshooting ....................................................... 15
Restart protection after power failure ....................................... 15
Sourcesofdangerandrisks .................................................. 15
Possiblesourcesofdanger ............................................... 15
Residualrisks ......................................................... 15
Dangerofexplosion .................................................... 15
Transport, unpacking and setting up of the equipment ............................. 16
Safety procedures at the site of the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dispatch and freight costs.................................................... 16
TABLE OF CONTENTS

0505
5)5CPF%$%GTVKſECVKQP .................................................... 17
Components .................................................................. 19
Zirkonofen 700 & 700 Ultra-Vakuum sintering furnaces............................ 20
Technical data ................................................................. 21
Zirkonofen 700 sintering furnace .............................................. 21
Zirkonofen 700 Ultra-Vakuum sintering furnace .................................. 21
Device ID plate ............................................................ 22
Installation / First start-up........................................................ 23
Transport and unpacking..................................................... 23
Setting up and installation.................................................... 24
Important instructions for setting up the system............................... 24
Firststart-up .............................................................. 25
Software ................................................................. 25
Starting a programme ................................................... 25
Cancel a programme .................................................... 26
Troubleshooting ....................................................... 26
Operation..................................................................... 27
Training and practice ....................................................... 27
Shuttingdownthedevice.................................................... 27
Normal shutdown ...................................................... 27
Emergencyshutdown................................................... 27
Sintering programmes........................................................... 29
Cleaning and maintenance ....................................................... 31
Safety measures when cleaning the device....................................... 31
Disconnect the device from power supply ................................... 31
Dry cleaning .............................................................. 31
Cleaning instructions ....................................................... 32
Maintenanceandcontrol..................................................... 32
Regularcontrols ....................................................... 32
Monthly.............................................................. 32
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Repairs / Troubleshooting........................................................ 35

0606
Detected faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
E-box exchange............................................................ 35
Replacing heating elements .................................................. 36
Replacing the thermal sensor ................................................. 39
Return................................................................... 42
Dismantling............................................................... 42
Disposal.................................................................. 42

0707

0808
SYMBOLS USED IN THIS OPERATOR’S AND MAINTENANCE MANUAL
Caution: Source of danger!
Caution: Hazardous voltage!
Caution: Danger of explosion!
Caution: Hot surface, burn risk!
Prohibition: Access by unauthorised personnel is strictly forbidden!
Prohibition: Carrying out repair and maintenance works while the machine is running!
Prohibition: The use of water, compressed air or solvents is strictly forbidden!
Mandatory sign: Unplug from mains power!
Mandatory sign: Breathing protection is essential!
Mandatory sign: Use eye protection!
Mandatory sign: Use protective gloves!
This symbol refers to the operating company’s binding legal rules or requirements.
This symbol refers to particularly important text passages in the Operator’s and
Maintenance Manual.
This symbol indicates the necessity to document work processes.

0909
PICTOGRAMS ON THE ZIRKONOFEN 700 & 700 ULTRA-VAKUUM
The symbols (indications) listed below are attached to the device and serve to indicate uncertain
and dangerous situations. The symbols have to be kept clean and immediately exchanged, if they
detach or if they are damaged.
Please read this Operator’s and Maintenance Manual very carefully before using
 VJGFGXKEGHQTVJGſTUVVKOG
Pay attention to hot surfaces when opening the furnace.
If symbols or pictograms (hazard and behaviour information) on the furnace are not recognizable
anymore or if they came off, the operator has to replace them immediately.
CHECKLIST OF COMPONENTS - STANDARD VERSION
Packing list - Equipment:
Zirkonofen 700 or 700 Ultra-Vakuum with 4 heating elements
Firing tray
Power cable
USB cable to connect a PC to the furnace, if necessary
Fuse T 20A
Fuse F 0,25A
Sinter Metal Furnace Adapter (only for the Zirkonofen 700 Ultra-Vakuum)
If one of the components listed above is not contained in the supply, immediately contact your
Zirkonzahn partner.

1010

1111CHAPTER
SAFETY / RESIDUAL RISKS
MANUFACTURER
Zirkonzahn S.r.l., Headquarters Italy – 39030 Gais – BZ, is the manufacturer of the Zirkonofen
700 & 700 Ultra-Vakuum sintering furnaces and is referred throughout the Operator’s and
Maintenance Manual as Zirkonzahn.
INFORMATION
This Operator’s and Maintenance Manual is an integral part of the Zirkonofen 700 & 700 Ultra-
Vakuum sintering furnaces and must be kept in a place known to the operator and easily and
immediately accessible at all times. Only adequately trained personnel must handle the Zirkonofen
700 & 700 Ultra-Vakuum sintering furnaces.
This Operator’s and Maintenance Manual covers all you need to know for safe use and
maintenance of the Zirkonofen 700 & 700 Ultra-Vakuum sintering furnaces produced by
Zirkonzahn S.r.l.
This manual is subject to amendments at Zirkonzahn's sole discretion in the event of technical
further development.
SERVICE
If any points of these instructions remain unclear or if indications, instructions, safety
instructions or technical explanations have not been fully understood, do not hesitate to
contact Zirkonzahn headquarters (phone [phone] or e-mail: [email protected]) or
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SAFETY / RESIDUAL
RISKS

1212CHAPTERL
SAFETY / RESIDUAL RISKS
PURPOSE
The intended use of the device is outlined in this chapter.
In this connection a hazard analysis was done on the Zirkonofen 700 & 700 Ultra-Vakuum
sintering furnaces. The manufacturer does not accept any responsibility for applications not
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Intended use
All Zirkonofen 700 & 700 Ultra-Vakuum sintering furnaces must be used only for sintering the
pre-sintered zirconia produced by Zirkonzahn.
Improper use
No materials, tools and accessories from manufacturers other than Zirkonzahn must be employed
in the Zirkonofen 700 & 700 Ultra-Vakuum sintering furnaces.
Obligations of the user
The operator must make sure to:
- prevent touching of the device’s hot surfaces (burn risk),
- prevent that no other objects are placed on top of or beside the device (burn risk),
- prevent improper use,
- prevent other people staying within the working area of the equipment during operation,
- operate the system only with all intended safety devices closed and intact (front glass,
security switch, side covers etc.),
- use the personal safety equipment,
- disconnect the device from power supply by pulling the mains plug before any
intervention,
- operate the device only in a well lit environment of at least 500 lux,
- neither use water nor compressed air or solvents for cleaning,
- prevent maintenance work being carried out during operation.
Caution!
During operation, the device’s surfaces are hot and therefore must not be touched!
No objects must be placed on top of or beside the device!
Unplug from mains power when carrying out any connection and maintenance work!

1313CHAPTER
SAFETY / RESIDUAL RISKS
WARRANTY
In order to make use of the warranty service, exclusively original consumable materials (sinter metal
and pre-sintered zirconia) provided by Zirkonzahn must be used. Wear parts (heating elements) are
excluded from the warranty.
From the moment the new furnace is delivered, Zirkonzahn grants a warranty of 12 months for the
equipment (except wear parts).
If the furnace is passed on to third parties, the warranty obligation is recognised only if the passing
on occurs within the set warranty period of 12 months.
Zirkonzahn recommends a general inspection of the device after 2 years of use. With the assistance
of Zirkonzahn, the inspection can be carried out by the user.
Warranty claim
For warranty claims the customer must prove the date of purchase (i.e. copy of invoice).
The warranty covers the free replacement of parts found faulty by Zirkonzahn (material or
production fault). Wear parts (heating elements) are excluded from the warranty.
Loss of warranty
The loss of the warranty claim occurs in the following cases:
- poor maintenance,
- improper, non-intended use,
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Maintenance Manual,
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authorised by Zirkonzahn,
- use of materials and tools that have not been produced or authorised by Zirkonzahn,
- use of non-original spare parts.
The warranty does not cover
- Damage during transport and supply (it is the forwarding company’s liability; only if noted on
the delivery note when receiving the goods!).
- Loss in sales.
- Wear parts (heating elements).
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1414CHAPTERL
SAFETY / RESIDUAL RISKS
Technical development
Zirkonzahn is not required to make any technical amendments or improvements related to
subsequent design changes.
SAFETY REGULATIONS
Read and follow the safety instructions in this Operator’s and Maintenance Manual to avoid
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Safety concept
The safety concept of the Zirkonofen 700 & 700 Ultra-Vakuum sintering furnaces as well
as this Operator’s and Maintenance Manual were compiled according to the requirements of
the Machinery Directive 98/37/EC in force until 29 December 2009 and the Machinery Directive
2006/42/EC valid thereafter as well as the European Low Voltage Directive (LVD) 2006/95/ EC.
Personal safety equipment
When working with the Zirkonofen 700 & 700 Ultra-Vakuum sintering furnaces, the following
personal safety equipment is required:
- Protective gloves.
Personal safety equipment required by law may vary from country to country.
The user is committed to use the safety equipment in accordance with the national
industrial safety regulations.
Safety measures when cleaning the device
- Safety goggles.
- Face mask.
- Protective gloves.
- Unplug from mains power!

1515CHAPTER
SAFETY / RESIDUAL RISKS
Workplace, handling, references to safety
- Provide optimal work height.
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- Position the equipment in order to access all operating elements without problems.
Troubleshooting
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Manual, the Zirkonofen 700 & 700 Ultra-Vakuum sintering furnaces must be turned off. Prevent
unauthorised operation. Please contact your Zirkonzahn partner for troubleshooting.
Restart protection after power failure
In the event of a malfunction of the system during a working phase (e. g. power failure for
a short time), the device restarts automatically.
SOURCES OF DANGER AND RISKS
Possible sources of danger
- Burn risk due to hot surfaces.
Residual risks
- Avoid residual risks by increased attentiveness.
- Pay attention to risks at the installation site.
- Risk of bruising when handling the device improperly.
- Stab and cut injuries through tools.
- Risk of bruising during transport and installation of the equipment.
- Defective power supply lines.
- Fire hazard when placing objects on top of or beside the device.
Danger of explosion
It is strictly forbidden to use the sintering furnace in explosive atmospheres and to clean it
with solvents.

01 0302
1616CHAPTERL
SAFETY / RESIDUAL RISKS
TRANSPORT, UNPACKING AND SETTING UP OF THE EQUIPMENT
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industrial safety regulations.
- A forklift or a lift tray truck (> 300 kg) are recommended for the transport of the pallet.
Caution when lifting!
- The sintering furnace has to be moved and put down on surfaces with suitable stability, in a dry
place and in a non-corrosive environment.
- Stable, non-slip installation surface, which can bear a minimum weight of 300 kg.
-CAUTION: Remove the packaging material in the combustion chamber.
- Caution when removing the packaging.
- Caution when unpacking and setting up the sintering furnace: risk of injury.
- The power supply must be installed and attached by an expert.
- The device must not be connected to the electric circuit during the installation phase:
danger of electric shock.
- The original packaging has to be kept for at least 1 year.
SAFETY PROCEDURES AT THE SITE OF THE INSTALLATION
- Stable, non-slip installation surface, which can bear a minimum weight of 300 kg.
- Safety distance of min. 2 m to combustible material.
- Safety distance of min. 2 m to water.
- Safety distance of min. 1.5 m to all sides (for cooling air, access).
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DISPATCH AND FREIGHT COSTS
Unless otherwise agreed in writing, the buyer is responsible for dispatch, freight and possible
import fees.
Check the delivery for completeness and integrity immediately after receipt. Evident defects must be
noted on the delivery notes, in order to claim for compensation against the forwarding company.

1717CHAPTER
SAFETY / RESIDUAL RISKS
In case of complaints, have the transport documents countersigned by the carrier and send a copy
to Zirkonzahn.
Indication on transport packaging (fragile, this side up).
SGS AND CB CERTIFICATION

1818CHAPTERL
SAFETY / RESIDUAL RISKS

1919CHAPTER 2
COMPONENTS
COMPONENTS

09
10 08
02 + 03
11
13
15
12 14
01
04
05
06
07
2020CHAPTERL 2
COMPONENTS
ZIRKONOFEN 700 & 700 ULTRA-VAKUUM SINTERING FURNACES
01. Control panel with display
02. Heating elements
03. Thermal sensor
04. Ventilator
05. Sinter Metal Furnace Adapter
(Zirkonofen 700 Ultra-Vakuum)
06. Vacuum tube
07. Vacuum hose (Zirkonofen 700 Ultra-Vakuum)
08. Mains plug
09. ON/OFF switch
10. Security switch
11. Electronics
12. Cooling air input
13. Cooling air output
14. Cooling air regulator
15. Shielding gas connections