MiniSTAR S with Scan Technology

MiniSTAR S with Scan Technology

Operation Manual

200 Cooper Avenue

Tonawanda, New York 14150

1.800.828.7626

Website: www.greatlakesortho.com

Congratulations on the purchase of your MiniSTAR S

®

with Scan Technology.

In addition to this operation manual, Great Lakes offers a wealth of information for all Biostar/MiniSTAR S owners.

You can access this information by joining our Bio/Mini Users Group today at

www.bioministar.com

.

This site allows you to:

View our thermal-forming material and applications chart

Watch appliance fabrication videos

• Learn specialized tips and techniques from our experts

Find out about our new and featured products

Submit questions

The most comprehensive information to maximize the potential of your MiniSTAR S

® is at your fingertips at

I S S U E

02

Thermal Forming

Material and

Applications Chart

Great Lakes has created an easy-to-use chart of all the thermal forming sheet material.

N O V E M B E R

2 0 1 1

www.bioministar.com

BIO MINI

Star

EDUCATION

S O U R C E

I N F O R M AT I O N T O M A X I M I Z E T H E P O T E N T I A L O F Y O U R B I O S TA R ® O R M I N I S TA R ®

BIOMINISTAR.COM

Biostar & MiniSTAR Information at Your Fingertips!

Do you need help with a technique?

BIOSTAR

®

& MINISTAR

THERMAL FORMING

Thermal-Forming maTerial & applicaTions

Clear Material

®

Clear Material

Specifications

Clear Material

Includes: White, Pink & Blue Tray Material

125 mm round = ●

Square =❑

SPLINT BIOCRYL

A Great Lakes exclusive.

Offers fast fabrication, uniform thickness, quality.

Clear - Round

.5 mm .020

.75 mm

1 mm

.030

.040

1.5 mm

2 mm

2.5 mm

.060

.080

.100

3 mm .120

Clear - Square

.5 mm

.75 mm

.020

.030

1 mm

1.5 mm

2 mm

3 mm

.040

.060

.080

.120

DURAN®*

Highly transparent, hard elastic.

Bonds to acrylic.

Clear - Round

.5 mm .020

.625 mm

.75 mm

1 mm

1.5 mm

.025

.030

.040

.060

IMPRELON*

Offers fast fabrication, uniform thickness, and consistent high quality.

Clear - Round

3 mm .120

White - Round

3 mm .120

021-023

021-024

021-025

021-026

021-027

021-028

021-029

025-006

025-007

025-008

025-009

025-010

025-011

030-035

030-036

030-037

030-038

030-039

030-006 10

40

30

25

15

10

9

10

10

10

10

10

40

30

25

15

10

10

9

030-028 10

Applications

DURASOFT®* (Hard/Soft Dual Laminate) - Pre-dry in Biostar® Drying Oven

Break and abrasionresistant. Offers fast fabrication, uniform thickness, and consistent high quality. Hard side bonds to acrylic.

Clear - Round

1.8 mm

2.5 mm

1.8 mm

.070

.100

Clear - Square

.070

030-001

030-027

035-001

10

10

10

2.5 mm .100

035-027 10

*Manufactured by Scheu Dental Technology.

Note: • Printed images may vary from actual material colors and should only be used as a reference.

• Square material will fit vacuum machines.

1

order by phone 1.800.828.7626 (u.S. & Canada) 716.871.1161 (Worldwide) or Fax 716.871.0550 order onLIne WWW.GreaTLaKeSorTho.CoM

9

order oNLINe

WWW.GREATLAKESORTHO.COM

It is divided up into four sections:

• Clear Material: Pgs. 1-4

• Colored / Patterned Retainer

Material: Pgs. 5-6

• Multi-Colored Mouthguard

Material: Pg. 7

• Colored Mouthguard Material:

Pgs. 8-9

The chart lists material sizes, item nos., and quantities. It also includes a description of each material and the appropriate applications.

You can download the chart from the Bio/Mini Users site or contact us and we will be happy to send it to you.

Post a question or a unique fabrication technique.

Learn how you can save big on products.

1

Go to www.bioministar.com

2

If you are a fi rst time user, a brief survey will pop-up

3

Complete the survey and you will have immediate access to all the support materials, literature, & videos.

Are you interested in new products?

Join the Bio/Mini Users Group NOW!

4

If you are a returning user, just enter your email and you are all set.

Join the Bio/Mini Users Group at www.bioministar.com phone at 1.800.828.7626 or fax 716.871.0550

or contact us by

Continued

MiniSTAR

®

S with Scan Technology

A smaller, less expensive version of the Biostar was introduced in 1991 called the MiniSTAR. The compact design utilizes the same principles as the computerized Biostar, with reduced pressure and a modified timing mechanism used for heating and pressure-cooling cycles. In 2011, a barcode scanner was added to the MiniSTAR S. This feature automatically enters the correct processing information for the thermal-plastic material.

Voltage

• Power

• Pressure

• W x D x H

• Weight

115V (AC) - 50/60 Hz

750 W

60 psi / 4 bar

” x 14.25

20lbs. / 9.07kg

Installation

Before removing the machine and its components from the shipping box, determine the location for the MiniSTAR S in the laboratory. The machine’s size and weight are outlined above. Make sure sufficient workspace around the machine is available and that nothing will interfere with operation of the heating element.

Reminder: Keep any flammable material away from the heating element.

The shipping box contains:

• MiniSTAR S unit

• Pellet drawer

• Clamping frame

• Model platform

• High pressure hose with hose clamps and air filter

• Container of pellets

• Pellet brush with magnet

• Replacement air filter

After inspecting the items, remove all packing material, and position the MiniSTAR S unit on the laboratory bench. To prevent machine malfunctions as a result of excessive dust, do not place the unit near etcher catchers, micro etchers, or any other dust generating equipment. The air source should be within reach of the machine using the high-pressure hose as a reference guide. The air pressure should be capable of supplying a minimum of 60 psi to the unit.

SMPI1Rev013112

S-184

1

2

The following information provides a brief description of the MiniSTAR S’s basic components.

Front View

A

H

I

B

F

E

D

C

A

Infrared Heater

B

Control Panel

C

Locking Handle

D

Barcode Scanner

E

Pellet Cup

F

Platform

G

Pellet Drawer

H

Pressure Chamber

I

Locking Ring Clamp

G

Infrared Heater:

Found on left side of unit, swings from back of machine (rest position), forward over thermal plastic held on the chamber.

Control Panel:

Contains operating controls including electrical power switch, +/- time input buttons, air pressure verification button, and digital timer.

Locking Handle:

Locks chamber onto pellet cup and switches air pressure on.

Barcode Scanner:

Automatically enters the correct processing information for the thermal plastic.

Pellet Cup:

Used in every molding process and is fixed on the MiniSTAR S table. The pellet cup holds the dental model, pellets, and platform.

Platform:

Pellet Drawer:

Circular plate that is placed on the inner lip of the master pellet cup.

Removable front compartment that holds overflow of pellets.

Pressure Chamber:

Thermal plastic is held and air pressure incorporated for molding.

Locking Ring Clamp:

Circular metal clamp that secures material to pressure chamber.

A

B

C

F

D

E

G

Control Panel

A

ON/OFF Switch

B Digital Panel

C Duo LED Light

D +/- Time Input Buttons

E

Air Pressure Verification Button

F

Blue LED Light

G

Scan Button

On/Off Switch:

Digital Panel:

Supplies electricity to operate the machine.

Indicates heating/cooling time and measures air pressure.

Duo LED:

The green LED indicates operating mode (heater ready) and the red LED indicates mode

+/- Time Input Buttons:

Air Pressure Verification Button:

Blue LED:

Scan Button:

Heating times can be programmed in 5-second intervals.

Used for air pressure verification/depressurization of the chamber.

Indicates chamber pressurized (continuous light) and depressurized (flashing light).

Activates the barcode scanner.

A B

C

Back View

A

Compressed Air Supply

B

Pressure Regulator

C

Fuse Holders

D

Plug

D

Compressed Air Supply:

Pressure Regulator:

Fuse Holders:

Plug:

A threaded air valve to clamp the air-pressure hose to the machine.

Dial to increase or decrease air pressure used in the MiniSTAR S machine.

Two compartments that house miniature fuses.

Three-prong electrical socket for detachable power cord.

3

C

B

A

Initial Setup and Use

1. Plug the electrical cord in the back of the MiniSTAR S (

A

) into a three-prong 110v outlet. The fuses are located in the back of the machine above the electrical connection (

B

)

(Miniature Fuse: 2x10A LAZY)

.

2. Connect the MiniSTAR S to the air source using the highpressure hose. Slip one end of the hose onto the air valve (

C

) of the MiniSTAR S, and slip the other end over the air pressure line. Secure each end in place with a hose clamp.

Note:

away from the heating element.

3. Secure the clamping frame to the pressure chamber by referencing the clamp handle at a 4-5 o’clock position over the chamber. Slip the clips of the clamping frame into the grooves on the outside of the chamber and slide the clamping handle to the left (

blue arrow

).

D

E

4. With pellets provided, fill cup (

D

) half full with pellets.

5. Pour remaining pellets in the pellet drawer (

E

) and

clip it onto the front of the MiniSTAR S table.

6. Place platform on inner lip of the pellet cup, with the

pellet level half full.

Make sure the inner lip of the

cup is clear of pellets.

4

Working pressure of 4 bar (60 psi) is pre-set in the machine. Confirm or adjust MiniSTAR S air pressure by first turning on the main air source.

Release the locking cap on the regulator by pulling it outward. Set the pressure by turning the regulator dial on the back of the machine clockwise to increase the pressure, counterclockwise to decrease.

Identify the proper pressure by the gauge. Once pressure is set, lock regulator by pushing the cap in towards the machine.

Maximum pressure is approximately 4 bar, or only what the main line is capable of supplying.

Reminder:

Do not use material thicker than 5mm within the clamping mechanism. This may cause the MiniSTAR S to malfunction while pressure is in the chamber.

Always

wear safety glasses when using this machine and during all fabrication procedures.

Maintenance

A regular maintenance schedule should be followed. Proper maintenance will assure better fabrication results. Refrain from using water in the MiniSTAR S machine. Water may cause certain components to rust or corrode. When the machine is not being used, engage the clamping frame to the chamber and position the chamber on the pellet cup. This prevents lab dust from entering the pellet cup and chamber.

Pellets will become dirty with regular use. Clean pellets by placing them in a strainer and rinsing with hot water. Spread pellets on a towel and let air dry before placing them back in the MiniSTAR S. Check pellets monthly. Discard and replace pellets in the bottom third of the cup.

Air escape holes are present in the base of the pellet cup and should be checked monthly to ensure that they remain open.

Use a .036

” diameter or smaller wire to open plugged holes.

C

B

A

Clean and inspect top and side of the

adjusting ring *

every

4-6 months.

With a fingertip, apply a drop of liquid dish soap to both the side of the aluminum ring (

B

) and side gasket (

C

). Identify potential gasket cuts or irregularities.

Remove the soap with a soft, dry cloth.

*

Adjusting Ring is assembled from three components:

A. Chamber sealing ring

B. Aluminum ring

C. Side gasket

Adjusting ring *

should move freely in the chamber. If not, after cleaning, apply a thin coat of Silicone Grease (016-021) to outer ring of the chamber, 4 adjusting pins, and outside edge of the adjusting ring (see white arrows).

5

Check the air filter clamped to air line for discoloration and/or moisture monthly.

If replacing the filter, turn off the air source and bleed the high-pressure hose of air. Loosen clamps holding the filter and slide it off the hose. Position the new filter by referencing the arrow on the filter case toward the back of the MiniSTAR S.

B

A

The heating surface (

A

) should be parallel to the heating element (

B

). Adjust the position of the chamber by turning the screw (

C

) located under the chamber support frame with a small screwdriver. Clockwise adjustment of the screw lowers the chamber from the heater, counterclockwise raises the chamber closer to the heater.

Check the position of the chamber when heating materials.

C

C

6

Operation

There are three basic functions to operate the MiniSTAR S including:

Model preparation

Heating cycle

Pressure molding process

Model Preparation

Prepare models for the thermal-forming process by removing bubbles or filling voids whether using the platform or pellets. The platform is used when forming soft or thin plastics. Pellets are used when forming thick, less flexible materials. The pellets prevent the plastic from forming to unwanted areas of the dental cast.

Platform Use

The platform is used to expose the entire dental mold to the formation of the thermal plastic. It eliminates having to use pellets. Pellets are difficult to remove from softer material (i.e., soft mouthguard material) and can create a higher occurrence of air leaks during the pressure-forming process when using thinner thermal plastics (i.e., < 1mm thick).

Place the outer ring of the platform on the inner lip of the

Empty cup or reduce the pellet line to the half-way level

(white line).

Make sure the inner lip of the cup is clean.

pellet cup with the flat platform surface on top. To remove the platform, use the MiniSTAR S Brush with Magnet

(016-021). Engage the tip and lift up.

Remove model bubbles and detail the oral anatomy with a laboratory knife. Fill holes in the model with a quick-setting stone.

When referencing the model to the platform, make sure the base of the model is reduced flat, parallel to the occlusal surface. In some cases, the base is removed creating a flat horseshoe model to eliminate excessive material thinning.

For some materials, a liquid separating foil is applied to allow for easy removal of formed material.

Position the model in the center of the platform, referencing the heel toward the material in the pressure chamber.

Pellet Use

A five-pound container of lead pellets is supplied with each MiniSTAR S. Pellets are used to prevent the thermal-plastic materials from stretching over areas of the model that are not part of the appliance design. The soft metal alloy will flatten if compressed by the pressure chamber on the rim of the cup, preventing machine damage. Stainless steel pellets are available upon request, but will cause damage to the cup’s rim if compressed by the pressure chamber. Use of materials other than the manufacturer’s recommended pellets may result in machine malfunction and could void the warranty.

Work models are placed in cylindrical pellets:

• to support the model so that the occlusal-incisal plane is as level as possible with the rim of the cup.

• to prevent the material from forming on the facial surfaces of the teeth, making it hard to remove the appliance from the work model.

• to prevent heated material from melting the wax supporting the wires on facial areas.

• to allow air to pass through the pellets as the material is forming over the model, preventing back pressure.

7

8

A

B

Enough pellets must be placed in the pellet cup to hold the model at a proper level. Material termination areas, located on the facial surface of the model, should be referenced at the same height as the top ledge of the pellet cup.

Note: Mounted models may be referenced slightly higher than indicated.

Remove the pellet drawer (

A

) from the machine by sliding the drawer up and away from the machine.

Sliding the drawer upward positions the magnetic clip (

B

) above the rim to prevent the pellets from spilling over the edge of the machine’s table.

To replace the pellet drawer, line up the groove on the back of the drawer (

A

) with the block (

B

) on the magnetic clip.

Once engaged, slide the drawer down to its rest position in the slots.

Pour pellets between the model and the inner wall of the cup. Apply more than enough pellets in this area.

Use a MiniSTAR S Brush (010-046), or MiniSTAR S Brush with

Magnet (016-021) to remove excess pellets, and level the pellet line from the occlusal-incisal plane to the top rim of the cup. Hold the brush at an angle to sweep excess pellets from the rim of the cup and the palatal area of the model.

Sweep excess pellets around the outside of the cup into the pellet drawer.

When constructing an orthodontic retainer, the pellets placed against the occlusal-incisal margin cover the wax holding the wires facially and act as an insulator when the heated material is formed.

Improper packing of a model can cause a blowout, air leak, or machine malfunction. It is important that there is no sudden drop of the pellet margin at the inner cup wall or that the model is not positioned too high or low within the cup.

This allows the material to be overstretched, thinning it to where a hole is created and air blows through.

In some instances, an air leak could cause inferior material adaptation that can result in a poorly fitted appliance.

Mounted models should be splitcast. If the model cannot be removed from the mounting, the pellet level will need to be at a slight incline to appliance termination areas.

Heating Cycle

There are two options to program the heating times:

A

1.) Manual Entry -

Press the power switch (

A

) of the MiniSTAR S to activate the machine. Input appropriate heating time for the material to be thermal formed (follow manufacturer’s suggested heating time).

Press the +/- button to set time. Heating time increases and decreases in

5

second intervals.

During long heating cycles or continual use, the lamp can become extremely hot.

Caution is advised to prevent skin burns -

9

10

A

2.) Barcode Scan -

The barcode scanner automatically enters the correct processing information for your material. Press the

Scan

” button to activate the scanner.

B

Great Lakes Material: the barcode is located

on

barcode strip

(

A

) inside each box of material. Hold the barcode strip under the scanner until you hear a “

display.

beep

” indicating the barcode has been read. The heating time will automatically show on the

Scheu Material:

the barcode is printed directly

on (

B

). Hold the material under the scanner until you hear a “

beep

” indicating the barcode has been read. The heating time will automatically show on the display.

Position a 125mm diameter round disc on the spring-loaded adjusting ring of the pressure chamber.

Align the clamping frame over the material so that the spring clips slip under the bevel of the locking device on the sides of the chamber.

Tighten by turning the handle clockwise, so that the chamber and clamping handles are parallel.

Swing the heating element from its rest position over the material on the pressure chamber. When the heater is placed over the material, the heating element illuminates and the set heating time begins.

With

5

seconds remaining, warning beeps will sound.

Once heating time has elapsed, the beeping will be continuous until the heater is removed from the material.

Material heating times will vary based on compound, color, and thickness. Recommended heating times are identified on an easy-to-scan barcode strip inside each box of material. If proper adaptation is not obtained, it may be necessary to extend or decrease the recommended heating times by 5-15 seconds.

Pressure Molding Process

A

B

C

After the recommended time is reached, swing the heater (

A

) back to the rest position and flip the pressure chamber (

B

) onto the cup so the material can be thermal formed over the model. Turn the locking handle (

C

) from the straight back rest position 180º toward the front of the machine. This secures the chamber over the cup and allows air pressure to enter the chamber. Once the pressure is turned on, the digital clock on the control panel will automatically initiate a cool-down time.

At the end of the cooling time, short beeps will sound. Press the air button marked on the control panel to release the air pressure from the chamber. Short beeps will sound indicating full pressure evacuation. If a shorter cooling cycle is required, the programmed time can be erased by pressing and holding the air button for

5

seconds. Once the time has been erased, press the air button again to release the pressure.

C

B

A

To unlock the chamber, swing the locking handle (

A

) on the right side of the machine from the front of the MiniSTAR S to the straight back rest position. Unlock the material held on the chamber by sliding the clamping frame arm (

B

) to the left.

Flip the chamber (

C

) open to the left and remove the model with the formed plastic.

11

Use the following tips to address:

Air leaks

Blowouts

Poor adaptation

Material thinning

If adjusting ring does not move freely, remove it and clean with a small amount of liquid dish soap, applied and removed with a soft, dry cloth.

Material heating unevenly

Mounted model too high for pellet cup

Remove and clean the 4 pins and springs. Then lubricate with a small amount of Silicone Grease (016-021).

Insert pins, springs, and adjusting ring. Depress adjusting ring once or twice to make sure it moves freely.

Wipe off any excess grease with a soft, dry cloth.

Make sure the heating surface is parallel to the heating element. See

Maintenance Tips

to adjust.

Note: The MinSTAR S is preset at

60 psi, or 4 bars of working pressure.

Performing a Cold Test:

A.

Turn unit off. Make sure platform is in place. Clamp a sheet of 2mm (or thicker) hard material onto pressure chamber.

Secure clamping frame.

B.

Enter

5

seconds heating time.

Swing the heating element over the material to activate heat.

Immediately return heating element to rest position.

C.

Swing pressure chamber over the model platform.

Activate air pressure.

D.

If you hear a constant rush of air during pressurization, contact your customer service representative.

Remove pellets from cup. Make sure the 12 air escape holes are not plugged.

Use a .036” diameter or smaller wire to open plugged holes.

Make sure all pellets are removed from the edge of the cup where the chamber locks into place.

Pellets should be even with the top of the pellet cup.

For

mounted models

, remove the majority of pellets, leaving only enough under the model to allow air to flow. Build up the pellets, leaving exposed only the area to be covered by acrylic material.

Great Lakes recommends all soft or semi-soft material should be formed on the platform. See photo on left: the base of the model is even and flat.

Use pellets for hard material: see photo on right.

1.800.828.7626 www.greatlakesortho.com

A regular maintenance schedule should be followed. Proper maintenance will assure better fabrication results. Refrain from using water in the MiniSTAR S machine. Water may cause certain components to rust or corrode. When the machine is not being used, engage the clamping frame to the chamber and position the chamber on the pellet cup.

This prevents lab dust from entering the pellet cup and chamber.

Pellets will become dirty with regular use. Clean pellets by placing them in a strainer and rinsing with hot water. Spread pellets on a towel and let air dry before placing them back in the MiniSTAR

S. Check pellets monthly. Discard and replace pellets in the bottom third of the cup.

Air escape holes are present in the base of the pellet cup and should be checked monthly to ensure that they remain open.

Use a .036” diameter or smaller wire to open plugged holes.

A

C

B

B

A

B

A

B

B

B

Clean and inspect top of the chamber sealing ring (

A

) and side gasket (

B

) every 4-6 months. With a fingertip, apply a drop of liquid dish soap to the side gasket on the adjusting ring. Identify potential gasket cuts or irregularities. Remove soap from the gasket with a soft, dry cloth.

Adjusting ring should move freely in the chamber. If not, apply a thin coat of Silicone Grease (016-021) to outer ring of the chamber (

A

),

4 adjusting pins (

B

), and outside edge of adjusting ring (

C

).

Check the air filter clamped to air line for discoloration and/or moisture monthly. If replacing the filter, turn off the air source and bleed the high- pressure hose of air. Loosen clamps holding the filter and slide it off the hose. Position the new filter by referencing the arrow on the filter case toward the back of the

MiniSTAR S.

C

The heating surface (

A

) should be parallel to the heating element (

B

). Adjust the position of the chamber by turning the screw (

C

) located under the chamber support frame with a small screwdriver. Clockwise adjustment of the screw lowers the chamber from the heater, counter clockwise raises the chamber closer to the heater.

Check the position of the chamber when heating materials.

1.800.828.7626 www.greatlakesortho.com

200 Cooper Avenue

Tonawanda, New York 14150

1.800.828.7626

Website: www.greatlakesortho.com

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