cad/cam system „5-tec“

operator‘s and
maintenance manual
Operator‘s and Maintenance Manual
CAD/CAM System 5-TEC
(Scanner – Milling unit)

Machine type: ZZ S600

Machine type: ZZ M5

Version 1.4
Copyright 2009
Zirkonzahn Gais

2
Dear customer,

We thank you for your trust in our quality products. With the
purchase of the CAD CAM System 5-Tec you have acquired
a device engineered to meet the dental technician‘s highest
demands for accuracy of fit and user friendliness. In particu-
lar, in further developing the software we have focused our
attention on its practical suitability by integrating innovative
functions which will enable you to quickly realize even the
most demanding work.
We are convinced that you will work with our
CAD/CAM System 5-Tec efficiently, in health-friendly wor-
king conditions with a lot of enjoyment.
Please read carefully and observe the instructions contained
in this Operator‘s and Maintenance Manual strictly. We wish
you much success with using our System.

3
Table of Contents

Check List of Components - – Standard Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Symbols in the Operator‘s and Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety / Residual Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Obligation of the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warranty Claim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Loss of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Technical Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety measures when cleaning the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Workplace, handling, references to safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Re-start protection after power failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Sources of Danger and Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Possible sources of danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Danger of explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Transport, Unpacking and Setting up of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety procedures at the site of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dispatch and Freight Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4
 Scanner S600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Milling System M5 - Interior View and 5 Milling Axes Display . . . . . . . . . . . . . . . . . . . . . . . . . 24
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Scanner S600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Technical data - Scanner S600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Functional description of the equipment and identification of the components . . . . . . . . . . 31
Device ID plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Milling Unit M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Technical data of the milling unit M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Functional description of the equipment and identification of the components . . . . . . . . . . 33
Device ID plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation / First start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Transport and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Setting up and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Important instructions for setting up the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connection of the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connection of the Scanner S600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connection of the Milling Unit M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
First start-up: Scanner S600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
First start-up: Milling Unit M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Training and Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Preparing and Installing Scanner S600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operating Instructions Scanner S600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operating Instructions Milling Unit M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Tool Change Milling Unit M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Shutting Down the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Normal shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cleaning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Safety measures when cleaning the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Disconnect the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5
 Dry Cleaning Scanner S600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Dry cleaning milling unit M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cleaning instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Emptying and draining the compressed air regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cleaning compressed air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cleaning the chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Maintenance and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Used tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Regular Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Bimonthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Maintenance of the dust extraction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Calibrating (Zeroing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Repairs / Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Detected faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Spindle exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Electronic Box Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Circuit boards exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Front Plate Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Archive Software (Zirkonzahn.Archiv) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Explanation of the tool bar icons displayed at the upper edge of the picture . . . . . . . . . . . . 54
Dentist menu (Clients) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Patient menu (Treatment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Technician menu (Technician) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Determining the work (Select treatment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Scan Software (Zirkonzahn.Scan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Tool bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6
 Scan process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Calibration of the scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Mock-up Software (Zirkonzahn.Modellier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Nesting (Zirkonzahn.Nesting). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Tool bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Nesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
CAM-Software (CNC Creator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Milling Software (Zirkonzahn.Fräsen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Tool bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Milling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

7
Check List of Components - – Standard Version

Packing list - equipment:  Electric cable for PC

 Milling unit M5  Electric cable for screen
 Scanner S600  Connecting cable suction unit to milling unit M5
 Computer  LAN cable RJ45 - 3 m (for milling unit M5)
 PC  LAN cable RJ45 - 3 m (for scanner S600)
 Keyboard  LAN cable RJ45 - 3 m (for network switch)
 Mouse  Network switch, incl. power supply unit and
 Screen power supply cable
 Video cable for the screen  External power supply for network switch
 Instruction and Maintenance Manual on CD  USB cable 2 m
 Measuring probe of milling unit
Equipment accessories:  2 Sicherungen 6,3 A 2 fuses 6,3 A
 Remote program for TeamViewer  Dongle
 Calibrating plate for scanner  Set Allen-key Set
 Universal mock-up support  Cleaning and Maintenance Set for Milling
 Electric cable for milling unit M5 Handpieces
 Electric cable for scanner S600  Backup CD

If one of the components specified above should not be contained in the supply, please consult your
Zirkonzahn partner without delay.

Symbols in the Operator‘s and Maintenance Manual

Source of danger

Caution – hazardous voltage

Danger of explosion

Caution laser beam

Access by unauthorized personnel is strictly forbidden

Touching moving parts is strictly forbidden

Repair and maintenance work on moving machine and system parts is strictly forbidden!

The use of water, compressed air or solvents is strictly forbidden

Unplug from mains power

Mandatory sign: Breathing protection is essential!

Mandatory sign: Must use eye protection!

Mandatory sign: Must use personal 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

8
Safety /
Residual Risks
Manufacturer

Zirkonzahn GmbH, Headquarters Italy – 39030 Gais – BZ, is the manufacturer of this
CAD/CAM System 5-Tec 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 CAD/CAM System 5-Tec and must
be kept in a place known to the operator and be easily and immediately accessible at all times. The
CAD/CAM System 5-Tec must be operated exclusively by properly trained persons.
This Operator‘s and Maintenance Manual covers all you need to know for safe use and maintenance
of the CAD/CAM System 5-Tec produced by Zirkonzahn GmbH. However, it is not intended to
replace a training course with regard to the scope of application. The participation in a training course
specifically offered for the CAD/CAM System 5-Tec is recommended.
Operational capability and long-term value of the system can only be guaranteed if service and main-
tenance work prescribed in this Operator‘s and Maintenance Manual are carried out.
This manual is subject to amendments at our sole discretion in the event of technical further develop-
ment.

Service

If any points of these instructions remain unclear to the customer or if indications, instructions, safety
instructions or technical explanations have not been fully understood, do not hesitate to contact
Zirkonzahn head office (on ph: +39 0474 066660 or e-mail on: info@zirkonzahn.com) or the service
centers specified in your maintenance contract.

9
Purpose

The intended use of the system is outlined in this chapter. In this connection a hazard analysis was
done on the CAD/CAM System 5-Tec. The manufacturer does not accept any responsibility for appli-
cations not described here which do not fall within the definition of intended use.

Intended use

The CAD/CAM system 5-Tec was conceived exclusively for manufacturing of dental prosthesis.
It must be operated exclusively with original Zirkonzahn milling-burs. The milling unit is inten-
ded solely for milling pre-sintered, non-processed zirconia blocks and synthetic material for dental
applications, manufactured by Zirkonzahn (diameter of the blocks: 95 mm). Dental technical basic
knowledge is presupposed for the use. The participation in a training course specifically offered for
the CAD/CAM System 5-Tec is recommended.
The CAD/CAM System 5-Tec may be operated only with a suitable Dust Extraction Unit (extraction
performance 3000 l/min, vacuum 20 kPa, surface fine filter > 1 m²). Zirkonzahn does not assume any
liability for damages to health caused by possible dust exposure.
Direct contact between rotating tools and the user is excluded when the system is used correctly.

Improper use

Never use the CAD/CAM System 5-Tec for processing of already sintered zirconia, metal, metal
alloys, wood and any other kind of materials.
Do not use inadequate tools such as grinding pencils, drills and the like with the
CAD/CAM System 5-Tec.
The pre-sintered zirconia oxide must not be processed, e.g. impregnated with liquids or subjected to
temperature treatments, before milling.

Obligation of the user

The operator must make sure to:

- prevent abuse.
- operate the system only with all intended safety devices.
- prevent other persons staying within the working area of the equipment during operation.
- use the personal safety equipment.
- operate the CAD/CAM System 5-Tec only in a well lit environment of at least 500 lux.
- disconnect the CAD/CAM System 5-Tec from power supply by pulling the mains plug. Disconnect
the compressed air supply before any intervention.

Caution!

Turn off air supply before connecting air hose. Failure to do so can lead to injuries because of esca-
ping compressed air. (Never hold compressed air line towards the body; danger by circulating material
or dust). The compressed air connection must be installed by an expert.

10
Unplug from mains power when carrying out any connection and maintenance work!
(Emergency stop ≠ disconnected from power supply)

Warranty

In order to make use of the warranty service, original consumable materials, tools and spare parts from
Zirkonzahn should be used exclusively.
From the time of the new CAD/CAM System 5-Tec delivery Zirkonzahn grants a warranty of
12 month for the equipment (except wear parts).
In the case of the passing on to third parties the warranty obligation is recognized within the warranty
period from altogether 12 months.

Warranty Claim

The CAD/CAM System 5-Tec is covered by product liability insurance for persons and/or damage to
property.
For warranty claims the customer must prove the date of purchase (i.e. copy of invoice).
The warranty covers replacement of parts found faulty (material or production fault).

Loss of Warranty

A warranty claim is invalid in the following cases:

- Poor maintenance.
- Unprofessional use and use not intended for the CAD CAM System 5 Tec.
- Incompliance with references and prescriptions specified in the Operator‘s and Maintenance
Manual.
- Modifications carried out by the customer or by third parties.
- Use of other than Zirkonzahn spare parts.

The warranty does not cover:

- Damage during transport and supply (forwarding company‘s liability; only if noted on the delivery
note when receiving the goods!).
- Loss in sales.

Technical Improvements

Zirkonzahn is not obliged to carry out technical amendments to equipment produced at earlier stages.

11
EC Declaration of Conformity
Acc. to Machinery Directive 98/37/EC

The manufacturer
ZIRKONZAHN Srl

Registered Office
An der Ahr 7, 39030 Gais – Italy

Hereby DECLARES that the product of new construction in different models:

Denomination: Scanner
Type: SCANNER S600
as outlined below is in Conformity with the following guidelines and legal regulations.

EC Reference
For machines: 2006/42/EC 98/37/EC
For low voltage: 2006/95/EC
For EMC rules: 2004/108/EC

Harmonizing Standards
EN ISO 12100 Safety requirements for machines
EN 60204 Safety requirements for electric machines
EN 61000-6-4 Safety requirements for electromagnetic compatibility

A warranty claim will be invalid in the event of modifications of the system carried out without previ-
ous agreement of the manufacturer.

(Legal representative)

If the Certificate of Conformity is not available when taking delivery of the system, please request it
from the Zirkonzahn Company.

12
EC Declaration of Conformity
Acc. to Machinery Directive 98/37/EC

The manufacturer
ZIRKONZAHN Srl

Registered Office
An der Ahr 7, 39030 Gais – Italy

Hereby DECLARES that the product of new construction in different models:

Denomination: Dental Milling machine

Type: Fräsgerät M5
as outlined below is in Conformity with the following guidelines and legal regulations.

EC Reference
For Machines: 2006/42/EC 98/37/EC
For low voltage: 2006/95/EC
For EMC rules: 2004/108/EC

Harmonizing Standards
EN ISO 12100 Safety requirements for machines
EN 12417 Safety requirements for machining centers
EN 983 Safety requirements for pneumatics
EN 60204 Safety requirements for electric machines
EN 61000-6-4 Safety requirements for electromagnetic compatibility

A warranty claim will be invalid in the event of modifications of the system carried out without previ-
ous agreement of the manufacturer.

(Legal representative)

If the Certificate of Conformity is not available when taking delivery of the system, please request it
from the Zirkonzahn Company.

13
Safety Regulations

Read and follow the safety instructions in this operator‘s manual to avoid danger to persons and dama-
ge to property. Your safety comes first!

Safety concept

The safety concept of the CAD/CAM System 5-Tec as well as this Operator‘s and Maintenance Ma-
nual were accomplished according to the requirements of the Machinery Directive 98/37/EC in force
until 29th 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 CAD/CAM System 5-Tec the following personal safety equipment is
required:
Face mask for breathing
Safety goggles
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

- Wear face mask when cleaning the device

- Unplug from mains power (Emergency off ≠ disconnected from power supply!)

Compressed air

The compressed air supply is interrupted by switching off the device.

Before any intervention on the CAD/CAM 5-Tec, unplug from mains power and disconnect the com-
pressed air supply.

Workplace, handling, references to safety

- Provide optimal work height.

- Provide for sufficient room lighting (at least 500 lux).
- Do not use the system when interior lighting of the equipment is defective.
- Do not expose the system to direct solar radiation.

14
- Do not put your hands in the rotating spindle.
- Equipment position for a good accessibility of the operating elements.
- Clockwise direction of the spindle rotation.
- A tool change is prohibited when the spindle is rotating.
- Clean chuck before each milling tool change. (See „Cleaning of the chuck“).

Trouble shooting

Only instructed qualified personnel are allowed to undertake trouble shooting. If a malfunction cannot
be rectified through the information provided in the Operator‘s Manual, the CAD/CAM System 5-Tec
must be turned off. Prevent unauthorized operation. Please contact your Zirkonzahn partner for troub-
le shooting.

Re-start protection after power failure

In the event of malfunction of the system during a phase of work (e.g. power failure) the device must
be re-started.

Sources of Danger and Risks

Possible sources of danger

According to the safety technical hazard analysis 09/02/2009, Machinery Directive 2006/42/EG;
98/37/EC; Low voltage directive ( LVD ) 2006/95/EC.
- Risk of injury by using sharp milling tools
- Rotating parts
- Moving parts
- Compressed air lines
- Front plate
- Components under electrical voltage
- Solvents
- Insufficient bearing capacity of the installation surface for the equipment
- Laser beam of the scanner

Residual risks

- In the event of equipment defects push EMERGENCY SHUTDOWN button and follow hazard
warnings.
- Avoid residual risks by increased attentiveness.
- Pay attention to risks at the installation site.
- Risk of crushing in handling improperly the front plate.
- Stab and cut injuries through processing tools.

15
 - Risk of crushing during transport and installation of the equipment.
- Compressed air line break.
- Defective power supply lines.

Danger of explosion

It is strictly forbidden to use the CAD/CAM System 5-Tec in explosive atmospheres and to clean it
with solvents.

Transport, Unpacking and Setting up of the System

- The transport must be carried out only with sufficient personnel, according to the national industrial
safety regulations.
Notes on the
transport packet - A forklift or a lift tray truck is suitable for transport of the pallet (weight approx. 500 kgs). Caution
when lifting!
(Fragile – This
End Up) - The CAD/CAM System 5-Tec may only 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 100 kgs (scanner) and
300 kgs (milling unit).
- Caution when removing the cardboard casing (glass lining).
- Pay attention to danger of injury when unpacking and setting up the system.
- Power supply and compressed air supply must be installed and attached by an expert.
- The system must not be connected to the electric circuit during the installation phase: Danger of
electric shock.

Safety procedures at the site of the installation

- Stable, flat and dry installation surfaces for the equipment.

- Safety margin of > 2 m to combustible material.
- Safety margin of >2 m to water.
- Minimum distance of > 0,75 m to walls, etc. (for cooling air, access)

Dispatch and Freight Costs

Dispatch, freight and possible import fees are responsibility of the buyer, unless otherwise agreed in
writing.
Check immediately after receipt of the delivery for completeness and integrity of the system. Evident
defects must be noted on the delivery documents, in order to claim for compensation against the carri-
er company.
In case of complaints, have the transport documents countersigned by the carrier and send a copy to
Zirkonzahn.

16
Components
Scanner S600

17
 01 02 03 04 03 02 Projector (4)

05 05
06
09
07
08
10

11

12
13
14
15

16

Scanner S600 Interior view - front side

17 18

18
01. Ventilation fan
02. FireWire B
03. Trigger
04. Projector
05. 2x Front plate hinges
06. 2x Camera
07. 2x Objective
08. 2x Lens
09. Mirror
10. Projector lens
11. Tilting axis arm
12. Fixing screw
13. Adjusting screw
14. Mock-up support
15. Anti-lock - mock-up support
16. Rotation axis
17. Main switch
18. Circuit breaker - projector

06

09
07

08
10

Cameras (06); enlarged view

19
 19 22

23
20

21

Projector control

27

24

25

26

Ports / Connectors

20
19. Projector plug
20. Projector circuit board
21. PC serial port
22. Camera trigger cables
23. Circuit board power supply
24. Laser control connector
25. Motor, encoder, limit switch, tilting axis connector
26. Motor, encoder, limit switch, rotary table connector
27. Cooling fan and scan board power supply

Laser connector (24) enlarged view

30

28 31

29 32

Mock-up support (14) and laser (30)

28. Locking screw

29. Limit switch
30. Laser
31. Adjusting screw
32. Mock-up support locking screw

21
 35

33

36

34

37

Rear side

22
33. Tilting axis limit switch
34. Motor – encoder, tilting axis
35. Cooling fan filter
36. Projector circuit board
37. Cooling fan and scan board power supply

Scanner ports; rear side

38 39 40 41 42 43 44 45 46

38. Current input

39. Fuses
40. Current output 1
41. Current output 2
42. Service ports
43. LAN port
44. Optional axis outputs
45. FireWire B connection
46. Serial port (RS232)

23
Milling System M5 - Interior View and 5 Milling Axes Display

01 02 04 05 06 07 09 11 12
03 03 08 10

13 14 15 16 16 17 18 19 20 21 A

Axis Y Axis Z

Axis B

Axis A
Axis X

24
A Emergency switch
01. Orbit
02. Clamping mechanism protective cover
03. Y axis coupling
04. Milling spindle
05. Spindle support
06. Spindle motor cable inlet
07. Spindle cable
08. Z-axis motor connection
09. Air piston
10. Z-axis limit switch connection
11. Air filter with compressed air regulator
12. Electronic box front panel
13. Anti-dust brushes
14. Anti-dust plate
15. Webcam
16. Y-axis guide rail
17. Z-axis coupling
18. Z axis guide rail
19. Air piston proximity switch cable
20. Main switch
03 03 17 08 10

02 04 05 06 07 09 19

25
 22 22 23 24 33 27 24 34 35 35 22
22 22

Orbit – Front view Orbit – Rear view

25 26 27 28 29 30 31 32 22 23 23 22 36 32 37 29 28 31

21. Front plate safety switch

22. A-axis limit switch
23. A-axis brake connection
24. B-axis motor
25. A-axis brake
26. A-axis brake output
27. Dust collector ring
28. Zirconia blank

26
29. B-axis brake
30. Blank fixing screw
31. A-axis inner ring
32. Dust Extraction Unit connection
33. A-axis motor connection
34. B-axis motor connection
35. B-axis limit switch
36. B-axis brake connection

Cooling fan filter Milling unit webcam M5 (15)

Main switch(20) Emergency switch (A)

Front plate safety switch (21)

27
 38 39 40

Electronic box front panel

41 42 43 44 45 46 47 48

Electronic box connection front side Electronic box connection rear side

37. A-axis motor

38. Compressed air regulator input
39. Compressed air regulator output
40. Air piston ports
41. Air filter with compressed air regulator
42. Camera USB port
43. Zero point sensor port
44. Spindles ports
45. Air piston proximity switch connections
46. High-speed spindle ports (< 110.000 U/min.)
47. Input and output 230 V (115 V)

28
 49 50 51 52 53 54 54 55

48. Front plate safety switch connector

49. Electronic box - exterior view
50. Connector panel
51. Internal ports
52. Valve manifold
53. Y-axis limit switch
54. Y-axis motor connection

55. Webcam
56. Current input
57. Fuses
58. Current output 1
59. Current output 2 Connector panel (50) enlarged view

60. Optional axis outputs

61. Air connection input 56 57 58 59 60 61 62 63 64

62. LAN port

63. Camera USB port

29
 65
66
67
68
69
70
71

Connection diagram Valve manifold (52)

64. Sensor socket.

65. Compressed air piston connection 1
66. Compressed air piston connection 2
67. Compressed air piston connection 3
68. Compressed air piston connection 4
69. Compressed air piston connection 5
70. Sealing air connection
71. Compressed air extra port

30
Technical Data
Scanner S600

Technical data - Scanner S600

- Movement axes 2
- overall height 693 mm
- Depth 530 mm
- Width 477 mm
- Weight 68 kgs
- Front plate weight 5 kgs
- Front plate glass (glass lining) Hardened Sicurit glass UNI ISO 12150
- Operating voltage 230 V (115 V)
- Power input 0,9 A (1,9 A)
- Power capacity 200 W
- Frequency 50 Hz (60 Hz)
- Mains net fuse 6,3 A (fast)
- Control voltage 24 V
- Stepping motors 24 V, 1,2 A
- Noise level 55 dBA
- Illumination Projector light source

Functional description of the equipment and identification of the components

The scanner type S600 works based on object imaging by scanning the object using the strip-light-
projection. The image capture is done with two cameras.

31
In order to protect the mechanical, optical and electronic components from damage, they are arranged
in a sturdy tubular frame structure which is vibration-dampened by rubber buffers and enclosed at four
surfaces with special glass and at the rear side with a metal panel.
Follow strictly the above mentioned instructions during transport, installation, connection and first
start-up of the system.

Device ID plate

The Device ID plate of the Scanner S600 is attached on the rear of the equipment.

Milling Unit M5

Technical data of the milling unit M5

- Processing axes 5
- Milling unit overall height 690 mm
- Milling unit depth 530 mm
- Milling unit width 1232 mm
- Milling unit weight 210 kgs
- Front plate weight 12 kgs
- Front plate glass Hardened Sicurit glass UNI ISO 12150
- Electrical power 600 W
- Operating voltage 230 V (115 V)
- Power input 2,6 A (5,5 A)
- Frequency 50 Hz (60 Hz)
- Mains net fuse 6,3 A (fast)
- Control voltage 24 V
- Stepping motors 24 V 1,2 A

32
- Chuck Ø 3 mm
- Spindle speed Standard version: max. 45.000 R.p.m.
High-speed spindle: max. 110.000 R.p.m.
- Spindle motor 100 W
- Block diameter Ø 95 mm
- Milling area max. 5675 mm²
- Milling depth max. 30 mm
- Stand-by operation 82 W
- Operation during milling cycle 130 W
- Milling cycle with Dust Extraction
Unit (Renfert) level 1 590 W
- Milling cycle with Dust Extraction
Unit (Renfert) level 9 1102 W
- Noise level at max. spindle speed
no-load operation: < 66 dBA
- Equipment illumination > 250 Lux

Functional description of the equipment and identification of the components

The milling system M5 is conceived for 5 axes processing with up to 5 milling spindles. The CNC
control data of the cutting paths are generated by the CAM system.
In order to protect them from damage, the mechanical, pneumatic and electronic components are
arranged in a sturdy tubular frame structure which is vibration-dampened by rubber buffers and enc-
losed on four surfaces with special glass and at the rear side with a metal panel.
Only use Zirkonzahn original burs with a 3 mm shank diameter and a length of 57 mm!

Device ID plate

The Device ID plate of the Milling system M5 is attached on the rear of the equipment.

33
34
Installation /
First start-up
Transport and Unpacking
- Check if the supply is in accordance with the delivery note.
- Check immediately for completeness and integrity of the supply. Evident defects must be noted on
the transport documents, in order to claim for compensation against the carrier company.
- In case of complaints, have the transport documents countersigned by the carrier and send a copy to
Zirkonzahn.
- Follow the safety regulations for moving loads.
- A forklift or a lift tray truck are recommended for transport of the pallet (weight approx. 500 kgs)
(Pay attention to pictograms on packing).
- Transport weights: Scanner S600 68 kgs
Milling unit M5 210 kgs
PC incl. screen
Keyboard, mouse 28 kgs
Pallet 20 kgs

- The CAD/CAM System 5-Tec is supplied on a pallet and encased by a cardboard box.
- Do not put any other object on top of the cardboard encasing.
- Caution when removing the cardboard casing (glass lining).
- Pay attention to the danger of injury when unpacking and setting up the system.

35
Setting up and Installation

Important instructions for setting up the system

The CAD/CAM 5-Tec should be operated under the following conditions only:
- Up to 2000 m above sea level
- Ambient temperature range of 15°C to 30°C
- Do not expose the device to direct sun light
- Maximum relative air humidity of 75% at 30°C.
- The CAD/CAM System 5-Tec may only 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 securely bear a minimum weight of 100 kgs
(scanner) and 300 kgs (milling unit).
- Safety margin of > 2 m to combustible material.
- Safety margin of >2 m to water.
- Minimum distance of > 0,75 m to walls, etc. ( for cooling air, access)
- Place the table on flat ground and align the work surface horizontally.
- Provide for adequate work height (consider the height of the front plate in raised position)
- Work and danger area must be easily visible and lit (at least 500 Lux)
- Make sure the CAD/CAM System 5-Tec set position during operation allows easy removal of the
power plug in case of emergency.
- Provide power supply 230 V (115 V) as a fixed connection and lay connection cable protected
ensuring strain relief. The electrical connection and its mains fuse must be set up according to the
valid national standards. The function of earthing and the grounding wire must be checked before
starting up.
- The power supply and compressed air connection must be laid and installed by an expert. The
equipment must be easily accessible from all sides for operation and possible component exchange.
- The system must not be connected to the electric circuit during the installation phase: Danger of
electric shock.
Connection to the power supply system via differential protection circuit breaker:
- The devices are equipped with an integrated EMC mains filter to meet the current EMC standard
2004/108 EC.
- Due to the principle used, the EMC mains filter produces leakage current to ground (via PE).
- The leakage current is 20 mA AC; however, it can also be higher at the starting torque.
- Provide a suitable alternative protective measure, if necessary.
- Permissible residual current circuit breakers, Type A or B (30 mA).
- The use of residual current circuit breaker, Type AC, is prohibited!
Triggering by means of the residual current circuit breaker at the first startup is generally not caused
by an equipment fault, but by a defect in the power supply.

36
 Connection of the PC

01. Connect screen to PC.

02. Connect keyboard to PC.

01 03. Connect mouse to PC.

03 04. Connect LAN cable (RJ45) between switch and PC.

02 05. Plug in Dongle, if not yet connected to the PC.

07 06. Connect network switch together with the power supply

unit incl. power supply cable to the current.
07. Connect PC and screen to current.
08. Connect PC to Internet by means of LAN cable (RJ45)
(not included in the supply!).
08 05
06

04

Switch

Connection of the Scanner S600

09. Connect scanner with 3 cables to PC:

09a. 2x FireWire B and
09b. 1x Serial (RS232)
10. Connect scanner with LAN cable (RJ45) to network switch.
11. Connect scanner to power supply.
09a
11
09b

10

Switch

37
 Connection of the Milling Unit M5

12. Connect milling unit with LAN cable to network switch (RJ45).
13. Connect milling unit to power supply.
14. Connect compressed air line to milling unit.
15. Connect milling unit (webcam) with USB cable to PC.
16. Connect Dust Extraction Unit (not included in the supply)
to milling unit (rear side).
15
13

16 14

12

Switch

16

38
Compressed Air Connection

Compressed air connection: min. 6 bar, max. 10 bar.

Average air consumption = 50l/min.
Provide dry compressed air supply.

First start-up: Scanner S600

- Visual inspection of the device.
- Open the front plate.
- Switch on power supply by actuating the main switch (17) at the base plate, on the right.
- Insert the mock-up support together with the dental mock-up fixed on it into the rotation axis (XY-
axis)
- Place the mock-up center in the laser beam. (Laser is mounted on the right side panel.)
- Caution, do not look at the laser beam!
- The projector projects the strip light through the mirror onto the object.
- Both cameras capture the envisaged mock-up detail and transfer the images digitally via two
FireWire B connections to the PC.
- After each image the object is automatically positioned to take a new image.
- The scan functions are controlled and documented by the PC operator software.

First start-up: Milling Unit M5

- Visual inspection of the device.
- Open the device by pushing up the front plate.
- Main switch (20) on position „Zero“ (unlit).
- All spindles must be in the zero position (right).
- Insert the work-piece (blank) into the clamping ring of the orbit and secure it with three fixing
screws.
- Chucking the milling bur: By rotating the milling spindle (black part) clockwise the chuck opens.
Insert the bur up to the stop and then re-chuck it by turning it counterclockwise.
- Turn on the emergency switch to activate the main power supply.
- Turn on the mains switch (20; lights up green) and close the front plate.
- The bur is set in motion by the CNC software.

The milling process starts after selecting the desired milling program on the PC (see user manual of
the software) controlled by means of the electronic box (installed at the rear side of the milling unit).
- On two guide rails fixed on the console the slide is moved to the position given by the control
program.

39
- The orbit with the work-piece (blank) is rotated by the stepper motors to the position given by the
control program.
- The milling spindle is led by the pneumatic piston through the dust brushes to the machining plane.
- The work process starts: The stepper motors are activated and move the slides according to the
calculated cutting paths.
- If malfunctions should arise during the milling operation, press immediately the emergency switch
at the right side panel.

Mounting of additional spindles (see page 48).

40
Operation
Training and Practice

The training of the device operation with demos of the several possibilities of application is best made
by a CAD/CAM introductory course by Zirkonzahn. Professional handling, safety measures and the
most efficient use of the system will be conveyed during the course.
Training related information and schedules are available at your Zirkonzahn partner‘s or under
www.zirkonzahn.com

Preparing and Installing Scanner S600

The working model is fixed to its support outside the device.

Switch on the device by actuating the main switch (17) at the base plate on the right. Insert the mock-
up support into the rotation axis, position the mock-up center at the level of the laser beam and fix the
mock-up support by means of the holding screw. Then close the front plate. (Caution, do not look at
the laser beam!)
The scanning operation is started and controlled according to the chapter „Software“.

Operating Instructions Scanner S600

01. Preparation of the working model:

- Block out undercut areas at the stumps with opaque scan wax.
- Make a mush bite to be used as an antagonist.
- Spray scan spray evenly on the stumps.
02. Check power supply connection of the scanning device and connection to PC.

41
03. Open the front plate.
04. Switch on the main switch (17) at the base plate on the right (lights up green).
05. Fix the working model on the mock-up support by means of the holding screw.
06. Insert the mock-up support into the rotation axis.
07. Adjust height of the mock-up support. Ensure that the center of the tooth stumps is on the laser
beam line. (Caution, do not look at the laser beam!)
08. Fix the mock-up support at the adjusted height position by means of the holding screw.
09. Close the front plate.
10. Switch on the PC: The icons „Zirkonzahn Archive“ and „Zirkonzahn Scan“ appear on the
desktop.
11. Double-click on „Zirkonzahn Archive“. The archive software is opened. Here the scan project
can be filed or loaded (see „User Manual Archive Software“).
12. Double-click on „Zirkonzahn Scan“. The scan software is opened. A black window with text
and numbers appears in the upper left on the mask „Zirkonzahn Scan“. After a few seconds
the working model positioned in the scanner appears in the image on the right of the mask
„Zirkonzahn Scan“.
The scanning operation is started and controlled as outlined in the user manual of the software (see
page 53).

Operating Instructions Milling Unit M5

01. Check current, compressed air and dust extraction unit connections.
02. Open the front plate
03. Clean the device (see instructions) (page 45).
04. Insert the desired material blank into the orbit (position acc. to notch) and screw tightly with the
3 fixing screws.
05. Insert bur into the thoroughly cleaned chucks up to the stop and fix it by turning the handle (see
tool change page 43).
06. Switch on mains switch (20) (lights up green)
07. Close the front plate.
08. Switch on the PC.
09. Double-click on the desktop symbol „Zirkonzahn Milling“. The milling software opens.
10. Carry out reference run (a dialog field appears - confirm with OK).
11. Load CNC milling file. The milling process is calculated for the selected file.
12. Define position and size of the inserted burs by selecting the tool.
13. The calculated milling data are sent to the milling unit.

42
14. Start milling operation.
15. After completing the milling process the spindle slides return to starting position.
16. Take the milled block from the orbit and complete the work.

Tool Change Milling Unit M5

Due to risk of injury a change of the rotating tool or the chuck is only permitted at a complete stop of
the spindle (disconnected from power supply).

Turn the clamping sleeve counterclockwise. The clamping mechanism

opens.

Insert the bur until you notice the stop.

Now turn the clamping sleeve clockwise. The sleeve snaps into the
operating position. Pay attention to the snap sound. The tool is clam-
ped in the chuck.

Caution!

Always turn the clamping sleeve up to the stop. If the bur is not inserted perfectly, you may have an
unsatisfactory milling result. In addition there is an increased risk of injury.
Operators of the device must wear safety equipment!

Shutting Down the Device

Normal shutdown

Actuate mains switch (20).

Emergency shutdown

- Actuate emergency switch (A).

- Unplug power supply.
- Disconnect compressed air supply.

43
44
Cleaning and
Maintenance
Safety measures when cleaning the device
- Wear protective mask when cleaning the device
- Unplug from mains power (Emergency ≠ disconnect from power supply!)

CAUTION: When designing the device we assumed that all operators have a basic technical know-
ledge and all maintenance work can be carried out without problems. In case of doubt, consult Zirkon-
zahn or the service centers specified in your maintenance contract.

Disconnect the device

During any maintenance and cleaning work the CAD/CAM System 5-Tec must be disconnected from
power supply. Switch off the device and unplug from mains power. Furthermore disconnect the com-
pressed air supply.
Make sure no burs or the zero point sensor are clamped in the chucks during maintenance and
cleaning work.

Dry Cleaning Scanner S600

- IMPORTANT: The use of compressed air, water or solvent is prohibited!!
- Clean with a dry cloth, a brush and a vacuum cleaner only (visible dusty parts only)
- Do not wet clean or with solvent.
- Do not clean by compressed air to prevent dust from penetrating into the guides.

45
Dry cleaning milling unit M5
- IMPORTANT: The use of compressed air, water or solvent is prohibited!!
- Clean with a dry cloth, a brush and a vacuum cleaner only (visible dusty parts only)
- Do not wet clean or with solvent.
- Do not clean by compressed air to prevent dust from penetrating into the guides.

Cleaning instructions

Incorrect cleaning or failure to follow cleaning instructions may lead to componentry damage of the
device or seriously endanger operators!
Maintenance work may only be executed by well-trained, skilled staff. Personal safety equipment is
required!

Emptying and draining the compressed air regulator

The compressed air regulator must be checked before each use and, if necessary, the condensed water
must be emptied by opening the valve.

Cleaning compressed air filter

Clean air filters at regular intervals: Open air filter protective cover and remove dust. Then re-mount
filter and protective cover (see photo).

Cleaning the chuck

Open the clamping mechanism und unscrew the protecting cap

counter-clockwise.

Insert chuck key into the open chuck up to the stop and hold on the
spindle shaft with the open-end wrench. Remove the chuck with the
chuck key counter-clockwise.

46
 Clean the chuck inside and outside with the cleaning brush.

Clean the chuck inside and outside with the cleaning brush.

Insert the chuck by hand. Make sure the clamping system is still open.
Hold on the spindle shaft with the open-end wrench.
Screw in tightly the chuck up to the stop with the chuck key.
Screw on the protecting cap.

Maintenance and control

Used tools

Caution: Only use Zirkonzahn tools. The use of other than Zirkonzahn tools shall release Zirkonzahn
from any liability.
Make sure only unobjectionable faultless tools are used. Tools which show signs of wear (e.g. unba-
lance, worn blades, groves on the shaft), must be replaced immediately.

Regular Controls

Before commencing any operation with the CAD/CAM System 5-Tec, the following controls must be
executed in this order:
- Visual inspection of the mechanical components.
- Visual inspection of the electronical components.
- Functional check of the pneumatic system.
- Functional check of the electronical components.
- Functional check of the mechanical components.
- Visual inspection of the equipment interior on possible damages or impurity.

47
If after inspection defects are detected (defects to spindle, pneumatic system, lights, clamping mecha-
nism, etc.), the CAD/CAM System 5-Tec may not be used. It must be shut down and secured against
unauthorized access. For trouble shooting consult Zirkonzahn or the service centers specified in your
maintenance contract.

Monthly

Check fastening screws (in particular fastening screws of the front plate).

Bimonthly

Visual inspection of cables and electric contacts.

Maintenance of the dust extraction unit

The own dust extraction unit must be cleaned regularly according to the instructions of the manufactu-
rer. Zirkonzahn does not assume any liability for any possible hazard to health by dust exposure.

Calibrating (Zeroing)

Insert the zero point sensor into the chuck, connect cable to sensor socket. Select „zeroing“ in milling
software.

48
Repairs /
Trouble Shooting
Detected faults

If malfunctions or defects are detected during maintenance of the device, these must be promptly
remedied to ensure a trouble-free and safe operation.
Defects, damages and malfunctions must be reported without delay to Zirkonzahn or to the service
centers specified in your maintenance contract. Repairs and trouble shooting should be done only
under their supervision or in accordance with the Operator‘s and Maintenance Instructions.

Spindle exchange
- Unplug from mains power.
- Remove spindle cables and limit switch cables from the electronic box.
- Undo the 3 screws at the rear side of the spindle retaining plate (4 Allen wrench).
- Remove carefully spindle from dowel pins.
- Reassemble in reverse order.
- Put some thread locking compound on the screws und screw them in.
- Make sure the contact surfaces are clean (free from adhesive).
- Make sure the spindle is placed on the plate without any gap.
- Make sure the spindle can be pushed easily forwards and backwards.
- Pay attention to cable duct.

49
Electronic Box Exchange

Replacement should be only done under the instruction of Zirkonzahn, or the service centers specified
in your maintenance contract.

Circuit boards exchange

Replacement should be only done under the instruction of Zirkonzahn, or the service centers specified
in your maintenance contract.

Front Plate Exchange

Pay attention to the spring-loaded arm assembly when replacing the front plate! Replacement should
be only done under the instruction of Zirkonzahn, or the service centers specified in your maintenance
contract.

Trouble Shooting

Defects, damages and malfunctions must be reported without delay to Zirkonzahn or to the service
centers specified in your maintenance contract. Repairs and trouble shooting should be only done
under their supervision or in accordance with the Operator‘s and Maintenance Instructions.

Return

For trouble shooting consult Zirkonzahn or the service centers specified in your maintenance contract.
If a defect is detected, consult Zirkonzahn or the service centers specified in your maintenance con-
tract in order to discuss in detail further steps.
If return shipment is required, always use the original packaging.
Use suitable packings for possible returns of components!

50
Dismantling

In case of a disassembly proceed in reverse order of the equipment set-up. Follow the same safety
procedures (see first start-up and operation).

Disposal

The disposal of the device must be carried out according to local legal and environmental regulations
of the country concerned.
Under no circumstances dispose of the device into the environment or in normal garbage.

51
52
Software
This software was developed in cooperation with scientific partners. This resulted in an intuitive user
interface, built up logically with symbols and submenus.
The software is being continuously further developed. Keep track of updated operating instruction
manuals under www.zirkonzahn.com.

Archive Software (Zirkonzahn.Archiv)

User interface

53
Explanation of the tool bar icons displayed at the upper edge of the picture

Preparing a new patient project.

Loading a patient project already saved.

Saving the prepared patient project.

Printing the prepared patient project.

Transferring the prepared patient project to the Scan software.

Opening the CAD software for modelling the prepared patient project.

Dentist menu (Clients)

In the dentist menu, it is possible to select already stored dentist records according to names or
customer‘s number.
By clicking on „Edit“, a sub-menu opens with the list of all stored dentists up to now.

54
Click on „New entry“ to store new dentists. Enter dentist data in the appropriate fields.
Click on „Save“ to confirm the entry of the dentist data.
Click on „Close“ to close the entry window.

Patient menu (Treatment)

In the patient menu, it is possible to select already stored patient records. The tooth colour of the
patient can also be entered here.
By clicking on „Treatment“, a submenu with the overview of all patients stored up to now opens.

55
Click on „New entry“ to enter new patients. Enter the patients name in the appropriate fields and click
on „Save“.
Click on „Close“.

Click on the selection arrow to determine the type of antagonist; a selection menu opens.

Technician menu (Technician)

In the technician menu, the dental technician, which carries out the selected patient project, is selected.
By clicking on „Edit“, a sub-menu opens with the list of all stored technicians up to now.

56
Click on „New entry“ to enter new technicians. Enter the technician name in the appropriate fields.
Click on „Save“ to confirm the input of the dental technician data. Click on „Close“.
To be able to continue, all fields must be filled out in the dentist menu, patient menu and technician
menu.

Determining the work (Select treatment)

57
By clicking on the tooth to be treated, the submenu opens with the possibility of determining the
desired work, (e.g. copings, anatomic crown, etc.).
Moreover, parameters which can be taken automatically for further projects of this dentist can be
adjusted.
Changed values are marked at first in pink and after storing in yellow.
If an unrealistic value is entered, this will be saved at first, however will then be corrected
automatically to the maximum or minimum value in the mock-up software.
The undertaken adjustments can be transferred to other teeth by pressing and holding down the Ctrl
button and by selecting the teeth with the mouse.
By clicking on „Save“, the selected work is saved. At the same time, changed parameters will be
stored automatically in the dentist data and they can be used again for the next patient project.

View of the completed patient project. After clicking on „Save“ (2nd button in the tool bar) a folder
for the dentist will be created automatically. A folder for the stored patient will be created in this
folder. By clicking on „Open in Explorer“ (in the centre below), the patient folder opens.
An additional field is available for possible notes in this patient project.

Saving a created patient project before starting the scan operation.

By clicking on „Scanning“, the patient project will be transferred automatically to

the scan software. The user interface of the scan software opens.

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Scan Software (Zirkonzahn.Scan)

Tool bar

1 2 3 4 5 6 7 8 9 10 11 12 13 14

01. New project 08. Lower jaw scan

02. Load project 09. Upper jaw scan
03. Save 10. Mashbite scan
04. Individual photo 11. Double scan for gingiva, wax-up and in situ
05. Manual scan 12. Articulator scan
06. Individual tooth scan 13. New calibration scanner
07. Multi-tooth scan 14. Articulator registration

Caution! Only the object needed for the respective scanning must be in the working model (e.g. dies
or remaining teeth). Elements already scanned must be taken out when the scanning is over. The next
object to be scanned will then be placed in the working model. The front panel of the scanner must
always be closed after placing the scan objects and before starting the scanning process.

Scan process

59
The patient project file created and stored in the archive software (in the following called scan project)
is transferred automatically to the scan software.
Close the window „Set-up of New Project“ by clicking on „OK“.
Click on „Basic Settings“ (in the lower left window): The window for adjusting the exposure of the
working model opens. The exposure is changed by means of the side control.

CAUTION! The exposure must be set in such a way that on the image of the scan object no red points
or areas appear (due to overexposure).

By clicking on „Scanning Wizard“ (in the lower left window), the window with the scanning
instructions appears.
Recommendation! Dies which are not too close to each other should always be scanned together.
This enables one to increase the scanning speed and to ensure the right position of the dies in the
mock-up.

60
In the scan instructions, the objects to be scanned can be selected by clicking on the respective
check box in the window at the left hand side below. Multiple selection of dies is possible and
recommended. The software according to the choice made (e.g. individual tooth or multitooth scan)
provides the respective scan function automatically. The respective scan icon in the tool bar is marked
in colour.

Click on the icon marked in colour in the tool bar. A window (Identifier) opens, on which the selected
scan objects are shown numerically. Confirm the display by clicking on „OK“.

61
By clicking on the left mouse button, drag the margin recognition surface onto the Scan objects
(AOI = area of interest). With renewed left mouse-click fix the margin recognition field. By clicking
the middle mouse button (scroll wheel) into the margin recognition field (drawn up framework) the
3D preview is generated in the upper left window.

In the upper left window with the scroll wheel (centre mouse button) move freehandedly the cutting
plane underneath the scan objects. By clicking on „Continue“ in the lower left window, the scanning
process starts.

62
After approximately 2 minutes, the coloured 3D representation of the scanned object appears
automatically in the left upper window. Areas which the cameras could not capture are represented in
the surfaces as holes.

The holes within the crowns must be totally closed! In addition, rotate the 3D representation in the
direct display plane by keeping the left mouse button depressed. Click on the image with the right
mouse button: A submenu with different functions appears.
Click on „Move axis device“: The scanner arm turns the work model onto the desired position.

63
Click on icon „Single shot“ (4th button in the tool bar). For a few seconds the window „Add Single
Image“ appears, at the same time the 3D image disappears. It appears again after some seconds with
the holes filled out. If holes are still visible in the crown area, repeat the procedure.

Drag the yellow marked cutting plane „Cut Off Plane“ to the desired height (at least under the crown
margins) with the scroll wheel, in order to cut off the part not needed.
Click on „Continue“ (in the lower left window) to complete the scanning procedure. The scanner arm
goes back to home position and the scanner calculation starts.

The 3D representation of the completed scanned object appears in red in the upper left window.
Caution! Check in the upper left window whether the entire crown area and the adjacent dies‘ areas
directly at the crown margins are entirely marked in red!

64
Caution! If single grey surfaces are visible, it is essential that they are closed manually. In addition,
click on the 3D representation with the right mouse button. A submenu with different functions
appears.
Choose from „Selection“ and click on „Add“.

By clicking with the left mouse button around the hole (grey), the surface to be corrected, represented
by a green dotted line, is limited. The line must be totally closed by connecting the last and the first
dot (closed polygon).

65
By clicking the middle mouse button (scroll wheel) on the polygon, the grey area colours in red and
thus it is closed!

Delete unnecessary areas: Choose from „Selection“ and click on „Delete“.

66
By clicking with the left mouse button, limit the desired area with a closed dotted polygon and click
on the correction surface with the middle mouse button (scroll wheel).

The red area colours in grey and thus is deleted.

Caution! After using the functions „Add“ and/or „Delete“ the scanning must be saved by clicking on
the icon „Save“ (3rd button in the tool bar).

67
Note! In the scanning instructions, the objects currently being scanned are shown in the lower left
window as scanned with a checkmark in the respective check box and the note „Finished“. The objects
still to be scanned are not marked with a checkmark yet.

The dies already scanned must be taken out of the model and the parts for the next scanning must be
placed in the mock-up. The scanning procedure will be carried out as already described.
The remaining scan objects can be selected by clicking on the respective check box and the scan
procedures can start. All remaining scanning procedures belonging to the scan project must be
accomplished as already described.

68
Completed scan projects (in this example: Dies and „Existing residual teeth „).
If all scanning procedures belonging to the scan project are completed, the notice „Grab Sequence
finished“ appears in the lower left window.
Caution! All implemented scans are automatically stored in the patient file.

69
Calibration of the scanner

Switch on the scanner and start the scan software in order to carry out the calibration of the scanner.
Click on the Icon „New“ (1st button in the tool bar). The window „Setup new Project“ opens.
Click on „OK“.

Click on „Scanner new calibration“ (13th button in the tool bar) and follow the instruction in the
lower left window.

70
Remove the mock-up support from the scanner
and, instead, place the calibration plate up to
the stop. Fix the calibration plate by means of
the locking lever. Close the front panel.
Click on „Continue“ to start the calibration.

The calibration procedure is implemented automatically.

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„Calibration finished“ appears in the lower left window after successful calibration. Remove the
calibration plate and place the mock-up support.
Close the software. Open software again for scanning procedures.

Note! At regular intervals (approx. once every 10 days) the option window „System Calibration
Check“ appears when closing the scan software, in order to examine the scanner calibration. Confirm
the examination by selecting „Yes“.

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Mock-up Software (Zirkonzahn.Modellier)

The patient project created and stored in the archive software (called below Mock-up)
is loaded automatically into the CAD software by clicking on the CAD icon (in the
archive software). The mock-up software opens.

User’s instructions!
- Rotate the scanner by holding down the right mouse button.
- Shift the scanner with the arrow keys or by holding down the left and right mouse buttons.
- The point of rotation can be adjusted as required by clicking the middle mouse button (scroll
wheel) on the desired area (e.g. die).
- The Ctrl button is used for removing material (change of form) and for deleting the coloured areas
when carrying out step „Shrink“.

Tool bar

1 2 3 4 5 6 7 8 9 10 11 12 13
01. Wizard: Assistant during the mock-up procedure.
02. Save: The mock-up should be temporarily stored during processing. By clicking on this button,
the previous version will be overwritten. If this is not desired, the menu „Save scene under“
can be opened during the mock-up procedure and different scenes can be stored under the
appropriate names.
03. Top view
04. Screenshot
05. Language: language selection
06. Close project
07. Groups: By clicking on this button, a window opens where certain areas can be faded in or out
by activating/deactivating the check boxes.
08. Illumination: By clicking on this button, it is possible to change the exposure of the scanner/of
the mock-up.
09. Antagonist: The contact points of the mock-up to the antagonist are displayed in colour, even if
the antagonist is faded out.
10. Sectional view: The mock-up can be cut sagittally in different levels, so that the cross sections
become evident.
11. Ruler: Desired distances can be measured by setting starting and arriving points. The distances
are indicated in millimetres.
12. Mesh: for the exact positioning of abutments.
13. Nesting: Nesting is started.

73
At the upper left, the software indicates by which tooth it must be started.
Important! It is vital to observe the order given by the software!

„Add dot“: As many dots as desired can be placed on the preparation limit.
„Remove dot“: Select the dot to be deleted by mouse-click.
„Change line“: Click on the beginning of the deviation and drag the arrow to the
desired direction.
„Delete line“: Click on this button, in order to delete the entire line.
„Start“: To start the automatic recognition of the preparation limit after setting several
dots.
„Stop“: To cancel the recognition of the preparation limit
„Changing/Drawing“: To change to the processing mode. The red line turns to green.
„Drawing“: The existing line can be shifted and/or changed by setting new dots. Here
it must be preceded from an existing dot and the line must be connected with a further
existing dot.
„Take over of line“: To confirm the line drawn and changed.
„Move“: To move the line freely.
„Up/Down“: To move the line up and down; the line can be shifted automatically
upward or downward in millimetres by means of the automatic controller underneath.
„Fade out neighbouring teeth“: By activating the check box, neighbouring teeth can
be faded out by marking them by mouse-click.
Blue arrows: To undo and repeat the accomplished steps.

74
By clicking on the preparation limit of the die indicated by the software, one dot is set on the
preparation limit. The software recognizes automatically the process (represented by a red line).

Click on „Changing/Drawing“ to optimize the recognized line. The recognized line now appears in
green.

75
The position of the dots can now be optimized by clicking and dragging with the left mouse button.
As many dots as desired can be set; superfluous points can be deleted (click with left mouse button on
the point; the dot is represented in orange and can be deleted by a simultaneous and short click of the
right mouse button).

After accurate definition of the preparation limit, click on „Continue“.

76
By setting several new dots („Add dot“) on the preparation limit, the line that at first was not correctly
recognized will be optimized. Dots wrongly set can be deleted again by clicking on „Remove dot“.
For recognizing the line, click on „Start“.

With the margin recognition assistance (light coloured shading) the dots can be positioned accurately
on the preparation limit.

77
These steps must be repeated for all further dies in the order indicated by the software!
Click on „Continue“.

After determining the preparation limits of all dies, the parameters are faded in. Values taken over
automatically by the archive software can be changed as required.
Then click on „Continue“.

78
Model teeth are loaded.

The model teeth are scaled by means of the buttons at the left and correctly positioned. The sub-items
enable one to process in different „Directions“, therefore, a tooth can be moved or scaled e.g. in all
directions, only in mesial/distal direction, only in buccal/lingual direction, only in occlusal or only in
mesial/distal and buccal/lingual direction.
As an alternative to the buttons on the left hand side, the Ctrl key can be used to rotate and the
SHIFT key  to scale the teeth.

79
It is important to control and correct the position of the model teeth from all directions.
Click on „Continue“ in order to adapt the model teeth to the dies.

By using the buttons faded in „Cusp“, „Tooth area“, „Complete tooth“ and „Ridges“ in the left edge
of the image, the model teeth can be transformed by clicking and dragging onto the area of the model
teeth to be modified.

80
With the three modelling instruments „Standard“, „Point“ and „Cylinder“, displayed in the
centre of the left image, the teeth can be individually modelled by means of „Fill/ Remove“ and
„Smoothing out“. Filling is activated by clicking on „Fill/Remove“. Remove is activated by holding
down additionally the SHIFT key .
The modelling instrument „Standard“ should be used for larger surfaces, „Point“ mainly for the depth
of fissures and „Cylinder“ for chewing surfaces or other small areas. Thickness and size of the brush
can be adjusted with the slide control, as required.

By clicking on „Groups“ (7th button in the tool bar), a window opens wherein desired parts or groups
can be faded in or out by activating/deactivating the respective check box. This enables an optimal
treatment of each individual tooth.

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.

The pontics, basally regarded, protrude from the „Gingiva“ and must be reduced by clicking on
„Adapt gingiva“. The distance to the gingiva can adjusted by means of the slide control, i.e. the
pontics can be arranged resting upon, either shorter (for basal facings) or longer (for „Compressing“
the gingiva in the mouth).

Pontics, basally regarded, are adapted to the gingiva.

82
By fading out the jaw scanning data (click on „Groups“ in the tool bar), pontics can be smoothed out
basally and rounded off palatinally/lingually.
After completing the mock-up, click on „Continue“.

Now the mock-up can be shrunk. Minimum thickness of copings and shrinking depth can be adjusted
by means of the slide control or manually. If the mock-up is to be maintained fully anatomic, push the
slide control „Depth“ onto 0.

83
Besides, certain places can be excluded from shrinking, as required. For this purpose activate the
check box „Omit certain places“ at the left edge of the image and colour the desired places by keeping
the left mouse button pressed. The brush size can be defined with the slide control.
In order to delete already coloured areas, press additionally the Ctrl key.

In addition, palatal or lingual tooth areas can be shrunk proportionally.

For this purpose, adjust the desired value (in percentage) by means of the slide control. By activating/
deactivating the check box „For front teeth only“, this adjusted value can be determined (in
percentage) only for the front teeth („For front teeth only“ activated) or for the entire mock-up („For
front teeth only“ deactivated).
Carry out the contraction by clicking on „Apply“. If the result obtained corresponds to the
expectations, click on „Continue“ to carry out the next step.

The mock-up can be processed again, as required, by clicking on „Apply/Remove“ or by dragging the
areas concerned.

84
Note! Corners and edges must be smoothed out!

After completing the process, click on „Continue“.

85
The connectors are loaded automatically from the software. The size of the connectors (cross section
or height/width) can be individually adjusted. Select the function concerned at the upper left edge of
the screen.
Depending upon selection, one or two slide controls appear, by which the cross section can be
adjusted in mm² or the height and width in mm.
Five different connector shapes are available: square, round, drop-shaped, triangular, reverse drop-
shaped.
Changes made at cross section or at connector shape must be confirmed by clicking on „Use cross
section/Change of shape“.
If the connectors are displayed in yellow, their position can be changed by dragging and keeping the
mouse button depressed.
By clicking on „Define docking point“ (connectors are displayed in grey) the docking points of
connectors can be modified. For this purpose, click on the desired final position of the connectors.
By clicking again on „Define docking point“, the connectors will be again marked in yellow and now
they can be changed again.

86
When the connectors are positioned as desired, click on „Continue“.

Now the mock-up is joined together automatically (Merging). Click on „Terminate“.

87
Caution! This „scene“ must be saved in the patient file (click on „Save“ = 2nd button in the tool
bar or with right mouse button on „Save scene under“) in order to enable possible necessary
changes later on.
There is now the possibility of revising each step accomplished so far (with right mouse button the
window opens to recall the menu). In this way connectors, crown bottoms, etc. can be individually
modified as required by clicking with the right mouse button on the element to be processed.
Caution! If the mock-up was changed subsequently, click on „Save restorations“ to overwrite it (open
menu window with right mouse button)!
After the merging is completed, click on „Terminate“.

88
By clicking on „Nesting“ (13th button in the tool bar), a window opens for starting the nesting.
Nesting is used for positioning the mock-up in the material block.
Confirm the immediate execution of nesting with „Yes“. The system confirms the successful taking
over into the nesting software (Zirkonzahn.Nesting). Click on „OK“.
Now the nesting software (Zirkonzahn.Nesting) opens!

89
Nesting (Zirkonzahn.Nesting)

Tool bar

1 2 3 4 5 6 7

01. Top view

02. Screenshot
03. Close
04. Material block library
05. Queue
06. Nesting parts
07. Cutting path

Nesting

The mock-up is loaded automatically.

90
By clicking on the icon „Material block library“ in the tool bar, this can be opened and the requested
material block, already registered and used can be selected by clicking on „Charge“. Close the tab
after selecting the block. The data of the selected material block is now indicated at the top left in the
data window

For the registration of a new material block, click on „Register new block“. A window with a selection
of all available material blocks opens (resin, ICE zirconia, Prettau zirconia). Scroll with the scroll
wheel up to the appropriate block and click on it with the left mouse button.

91
The selected block is marked with colour. Click on „Registering“. The submenu
„Material block ID allocated“ opens. Assign a new block number (Only the
allocation of numbers from 1 to 255 is possible). Take all further data required for
detailed registration (shrinking value, lot number) from the material block
packing (see photo on the right). Enter them into the appropriate fields.
Subsequently, confirm the registration by clicking on „Apply immediately“.

A window confirms the successful block registration. Confirm with „OK“.

Note! Mark the material block by hand on the side panel with the assigned material block ID!
Confirm with „OK“.

92
The mock-up can be positioned by clicking on the desired place of the material block (left mouse
button).
With right mouse button pressed, the material block can be rotated into all directions, in order to
ensure that the mock-up does not protrude from the material block.
If this should be the case, deactivate the check box „Move in all directions“ (faded in left at the centre
of the screen edge) and carry out the central alignment of the mock up by means of the left mouse
button and the Ctrl key. Subsequently, activate the check box „Move in all directions“.

Display of the re-aligned mock-up.

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Click on „Punching“: The pre-adjusted 3 mm of material is removed (also adjustable manually up to
2.5 mm) around the mock-up and the connectors are set.
Note! With bridges you should absolutely ensure that the connectors are inserted on the palatal or
lingual side.
With buttons „Generating retaining pin“, „Modify retaining pin“ and „Remove retaining pin“ (left
screen centre), connectors can be generated, modified or deleted.

By clicking on „Sinter supporting base“, this will be calculated automatically and then charged.
Note! The sinter supporting base ensures an ideal sintering result (without distortions) and therefore it
is recommended!

94
Superfluous connectors can be deleted with the button „Remove retaining pin“ (left edge of screen).
For fixing the mock-up in the material block, some connectors must be inserted in the vestibular area.
Click on „Generate retaining pin“, then with left mouse button click on the desired place and drag the
connector with the mouse button depressed.
Caution! Sufficient connectors should be inserted. These should be aligned as horizontally as
possible!

Click on „Save nesting“. The material block file opens automatically for storing and designating the
zzn file (Zirkonzahn.Nesting-file). Click on „Save“!

95
After saving the zzn file it is the possible to delete the nested mock-up from the nesting queue.
Make the desired selection by clicking on the appropriate button.
Note! Confirm „Remove“, then the mock-up will be irrevocably deleted and is no longer available in
the nesting.

A window appears to start the CAM software. By clicking on „Yes“, the CAM Software opens.

96
CAM-Software (CNC Creator)

The CNC Creator window for the surface treatment of the material opens automatically.

For the selection of the margin treatment click on „Margin“. The options „Fine“ and „Extra fine“
open. Make the selection by clicking the desired surface treatment.

97
For selecting the treatment of the interior surface click on „Inside“. The options „Fine“ and „Extra
fine“ open. Make your selection by clicking on the desired surface treatment.

In order to select the treatment of the exterior surface click on „Outside“. The options „Rough“,
„Medium“, „Fine“ and „Extra fine“ open. Make your selection by clicking on the desired surface
treatment.

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By clicking on „Start“ the computation of the cutting path begins.

Computation of the cutting path in process.

99
When the calculation is completed, the Creator window can be closed. For safety‘s sake check
whether the computed CNC file is in the appropriate material block file.

Milling Software (Zirkonzahn.Fräsen)

Tool bar

1 2 3 4 5 6 7 8 9 10 11
01. Reference run
02. Home position
03. Go to position for change of bur
04. Go to position for change of material block
05. Screenshot
06. Vacuum cleaner on/off
07. Close
08. Settings
09. Service
10. Statistics
11. Help

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Milling procedure

With double click on the desktop symbol „Zirkonzahn.Fräsen“ the milling software is started.
The window „Execute reference run?“ opens. Confirm the execution of the reference run with „OK“
and the reference run is started.
Note! It is imperative to execute the reference run before each milling procedure.

Click on the icon „Settings“ (8th button in the tool bar). The window „Tool selection“ opens for tool
loading (bur selection) of the chucks. Left in the window, select the bur for the appropriate chuck and
check in the milling unit whether the selected burs correspond to each chuck.

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When all chucks are tool-loaded, click on „OK“.
Note! We recommend bur 2L in chuck 1, bur 1L in chuck 2 and bur 0,5S in chuck 3 (optional).
Now insert the material block required for the milling procedure and entered in the nesting software!

Click on the right image field on „Charge CNC milling file“.

A window opens for selecting the CNC file in the respective material block. In the left column
(„Current directory“) select the storage location of the CNC file (according to standard C:/Material
block). All CNC files stored in the selected material block file are shown in the neighbouring column
(all CNC milling files).

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Mark the desired file by clicking. Then add it to the list „Selected files“ by means of the button „Add
file“. Subsequently, click on „Mill selected files“ and the file is prepared for the milling procedure.

A reference field appears „Please wait! Position for reading transponder is being reached!“

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Here the nominal/actual values of the material block are compared with one another. The data of the
material block (actual value) which is in the milling unit are shown in the left hand column. The data
of the material block entered or selected in the nesting are specified in the right column (nominal
values).
Note! If all values of both columns correspond, all fields are marked in green and the milling
operation can be started. If the data do not correspond, the fields will become marked in red! Compare
the data of the material block entered in the nesting with those of the material block clamped in the
milling unit and, if necessary, clamp again the material block concerned. Re-start the milling software!
Then follow the steps already described.
If all fields are marked in green, click on „Continue“.

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The dialogue window „Tool selection“ opens. For safety‘s sake, check again whether the burs shown
correspond with the burs actually used in the milling unit. If this is the case, start the milling operation
by clicking on „OK, start milling procedure“.
The milling procedure starts now automatically.

In the right image field the status of the milling procedure is shown by a progress bar with percentage
values. At 100% the milling procedure is successfully completed.
Note! In the lower right field the Webcam installed in the milling unit transfers the current milling
process to the PC. Thus the milling procedure can be followed at any time at the PC.
When the milling procedure is successfully completed, the orbit returns to the position for change of
material block. Remove the milled material block and detach carefully the milled parts with a dia-
mond bur (approx. 1 mm - 1,5 mm Ø).

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ZIRKONZAHN World Wide - Tel +39 0474 066 680 - info@zirkonzahn.com - www.zirkonzahn.com