Express Imaging Plate System

Instrumentarium Dental Express Imaging Plate System Service manual

Express

Service manual

204724 rev.5

204724 rev5 Instrumentarium Dental 2

Document code: D504667 rev 5

EXPRESS™ is a common law trademark of Instrumentarium Dental, Palodex Group Oy.

Manufacturer: Instrumentarium Dental,

Palodex Group Oy Nahkelantie 160 FI-04300 Tuusula Finland

Tel. +358 10 270 2000

www.instrumentariumdental.com

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INTRODUCTION......................................................................................................................... 7

ISCLAIMER

COPE

NSTRUCTION / COMMAND SYNTAX USED IN THE MANUAL

CRONYMS USED IN THIS MANUAL

................................................................................................................................. 7

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: ......................................................... 7

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OPERATING WARNINGS AND PRECAUTIONS ................................................................. 8

ERVICING PRECAUTIONS

.......................................................................................................... 8

INSTALLING AND SETTING-UP THE S2TERMINAL ........................................................ 9

ECOMMENDED HARDWARE AT INSTALLATION

PRE-

INSTALLATION REQUIREMENTS

EMI –

INTERFERENCE, VIBRATION AND OPERATION WITH

........................................................................................... 9

........................................................................... 9

UPS ................................................. 9

SYSTEM ARCHITECTURE .................................................................................................... 10

LOCK DIAGRAM

CANNER MECHANICS

LECTRONICS

IRMWARE

........................................................................................................................ 10

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UNIT STATUSES AND MODES .............................................................................................. 17

SERVICE TERMINAL .............................................................................................................. 19

CCESSING SERVICE TERMINAL

ORMAL AND SERVICE MODE OF THE UNIT

ERVICE COMMAND PRINCIPLES

ERVICE LOG

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CONFIGURATION PARAMETERS ....................................................................................... 23

HOWING / SETTING CONFIGURATION PARAMETERS

UTOSTART <AUTOSCAN

EEPER

NERGY SAVE MODE <IDLE

ROXIMITY SENSOR

UTOMATIC SHUTDOWN <OFF

ESTORING FACTORY SETTINGS

ERVICE COMMANDS ON FIELD SERVICE

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> ........................................................................................................ 23

> .................................................................................................... 23

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> ................................................................................................ 23

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MAINTENANCE ........................................................................................................................ 26

FIELD SERVICE PROCEDURES ........................................................................................... 28

ERVICE POLICY

ALIBRATING THE REFLECTIVE SENSOR

ALIBRATING RESONANT SCANNER AMPLITUDE

EAR RATIO CALIBRATION, COMMAND: <GEAR

DJUSTING THE PLATE CARRIER (<CALPR POSITION>, <EJECT> AND <START>

: ...................................................................................................................... 28

.................................................................................. 28

..................................................................... 29

> ..................................................................... 29

). ................. 31

FIRMWARE (=FW), CORE AND DISPLAY GRAPHICS UPGRADE .............................. 33

IRMWARE

ORE UPGRADE

RAPHICS FILE UPGRADING

(=FW)

UPGRADE

.................................................................................................... 34

........................................................................................................................ 34

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CHANGING HARDWARE PARTS ......................................................................................... 35

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EPLACING EXTERNAL POWER SUPPLY

EPLACING

EPLACING REFLECTIVE SENSOR

EPLACING HOME OPTO SWITCH

EPLACING ERASING LAMP

EPLACING SAFETY SWITCH

EPLACING MEMBRANE SWITCH PANEL

EPLACING THE PROXIMITY SENSOR

EPLACING THE SCANNER MODULE

R2100 P H1200 G H1300 I

OWER & ANALOG BOARD

ENERAL CONTROL BOARD

NTERFACE BOARD

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(GC) ............................................................ 35

CHECKING MECHANICAL PARTS ..................................................................................... 37

RIVE BELT: TENSION CHECK AND ADJUST, IF NECESSARY

LATE CARRIER BELT (CONVEYOR BELT): TENSION CHECK AND ADJUSTMENT

LATE CARRIER DRIVE MECHANISM: CLEANING AND LUBRICATING

.................................................... 37

........................... 38

.......................................... 40

TROUBLESHOOTING WITH ERROR CODES ................................................................... 41

RROR

032 C 033 T 034 T 035 T 036 C 037 CRC 038 H 039 L 040 C 041 T 042 T 043 E 044 P 045 P 046 I 047 S

ARRIER HOME TOO EARLY IMEOUT WHILE HOMING CARRIER IMEOUT WHILE TRYING TO GET LASER SYNC IMEOUT WHEN WAITING THE STABILIZING OF THE LASER SYNC

ONFIGURATION DATA INVALID

INVALID

IGH VOLTAGE NOT OK

OG AMP CALIBRATION FAILURE

ARRIER UNABLE TO LEAVE HOME POSITION IMEOUT WHILE TRYING TO GET LASER SYNC AVERAGES IMEOUT WHILE TRYING TO GET LASER SYNC DURING SCAN

RASING LAMP BLOWN LATE / REFLECTIVE SENSOR BROKEN (DETECTED DURING START UP LATE / REFLECTIVE SENSOR BROKEN (CALIBRATION FAILURE

NCOMPATIBLE DRIVER VERSION

AFETY SWITCH OPEN

........................................................................................................ 43

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) .......................... 46

(FW

VER

5.04

(FW

VER

5.05

AND NEWER

) ............................................. 46

) ............................. 46

) .............. 45

TROUBLESHOOTING WITHOUT ACTUAL ERROR CODE AVAILABLE ................. 47

RROR: DEGRADED IMAGE QUALITY

RROR: SHOWS COMPLETELY BLANK IMAGE

RROR: DOOR MECHANISM RELATED ERRORS

RROR: NOT EJECTING PROPERLY / EJECT FORCE VARIES / CHANGING <EJECT

NOT SOLVE THE PROBLEM

RROR: NOT STARTING IMAGE READOUT WHEN THE PLATE IS INSERTED PROPERLY OR

TARTS READOUT WITHOUT THE PLATE OR STARTS READOUT PLATE WRONG WAY ROUND

RROR: NO RESPONSE WHILE A KEY IS PRESSED

RROR: MEMBRANE SWITCH PANEL

RROR: UNIT STARTS UP BY ITSELF AFTER PLUGGING IN THE POWER CORD

RROR: UNIT GOES TO STANDBY-MODE BY ITSELF DURING OR AFTER STARTUP

......................................................................................................... 47

........................................................................................ 47

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........................................................................ 47

XXXX>

DOES

... 48

.................................................................... 48

LED

DIM, LIT CONSTANTLY OR NOT LIT AT ALL

............... 48

.......................... 49

.................... 49

TROUBLESHOOTING BASED ON IMAGE ERRORS ....................................................... 50

MPROPER USE OF THE HYGIENE ACCESSORIES

MPROPER X-RAY SETTINGS USED

HOST IMAGES, SHADOWS

MPROPER AIMING OF THE X-RAY

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....................................................................................................... 50

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NSHARP / BLURRED IMAGES

EOMETRY DISTORTION

ECREASED CONTRAST, SHADOWS/SHADING, GHOST IMAGES

HITE OR GREY DOTS/SPOTS/STAINS IN IMAGES

EARING OF THE IMAGING PLATES

MAGE SHOWS DIFFERENT SIZE THAN THE IP USED

IRCLE ON IMAGE

ERTICAL STRIPE(S

PMT

PROBLEMS

NCORRECT DIMENSIONS

RIANGULAR ARTIFACT IN THE LEFT BOTTOM CORNER OF THE IMAGE

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) ................................................................................................................. 52

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… ............................................ 51

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APPENDIX 1: TROUBLESHOOTING ERRORS 034, 035, 041 AND 042 .......................... 54

APPENDIX 2: SOLUTION FOR ERROR 039 LOG AMP CALIBRATION FAILURE ... 57

APPENDIX 3: SOLUTION FOR THE BLANK IMAGE AND “DEGRADED IMAGE

QUALITY”. ................................................................................................................................. 58

APPENDIX 4: DOOR AND PLATE CARRIER MECHANISM MOVEMENT RELATED

PROBLEMS ................................................................................................................................ 59

APPENDIX 5: TEST AFTER REPAIR ................................................................................... 61

APPENDIX 6: PMT FILTER LIGHT LEAK CHECK/REPAIR/REPLACEMENT ......... 62

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Introduction

Disclaimer

Instrumentarium Dental endeavors to produce product documentation that is accurate and up to date. However, our policy of continual product development may result in changes to products that are not reflected in the product documentation. Therefore, this document should not be regarded as an infallible guide to current product specifications. Instrumentarium Dental maintains the right to make changes and alterations without prior notice.

Scope

This manual provides the information necessary to perform field servicing and maintaining of the Instrumentarium Dental Express Digital imaging plate system (hereafter referred as a ”scanner unit”).

NOTE: THIS MANUAL IS NOT A STAND-ALONE MANUAL AND MUST BE READ TOGETHER WITH THE USER’S MANUAL

Only trained and approved service personnel of authorized distributors are allowed to service the unit.

Unit can be sent to manufacturer for repair if it can not be repaired by:

• Performing the calibrations instructed in this manual AND

• Replacing field serviceable parts

Instruction / command syntax used in the manual:

<text> The text inside the brackets is typed in exactly as instructed + followed by enter

Example <reset> means typing: reset (and pressing enter) Example <idle> Show the time unit waits before goes to standby Example <idle XXX> Sets time (XXX seconds) unit waits before goes to standby

Acronyms used in this manual

ADC Analog to Digital Converter Cmd Command DSD driver The device driver used together with an imaging application EMC Electromagnetic compatibility EMI Electromagnetic interference FW Firmware control the scanner unit operation HV High Voltage I/O Input/Output IP Imaging Plate IP address Internet Protocol Address, typically looks like 192.168.2.11 JXXXX Connector number Msg Message NIC Network Interface Card PMT Photo Multiplier Tube (=Photo detector) PSU External Power Supply Unit

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Operating Warnings and Precautions

CLASS 1 LASER EQUIPMENT

DANGER: Any failure to follow the recommendations and instructions in this manual may

expose the user to laser radiation exceeding the class 1 specifications.

CAUTION:

• Do not move or knock the scanner when it is scanning.

• The use of control or adjustment or performance of procedures other than those

specified herein may result in hazardous laser radiation exposure.

• This scanner must only be used to read image plates and must not be used for any other purpose. Only use the imaging plates and protective covers that are supplied by scanner unit manufacturer. NEVER use imaging plates or protective covers from other manufacturers with the scanner

• This scanner, or its accessories, must not be modified, altered or remanufactured in any way.

• Only the manufacturer’s authorized service personnel are authorized to carry out annual maintenance and repair. There are no user serviceable parts inside.

• This device can interfere with other devices due to its EMC characteristics.

• Other devices can interfere with this device due to their EMC characteristics.

• This device complies with IEC 60601-1 standard. Accessory equipment connected to

this device must be in compliance with the related nationally harmonized IEC standards.

• Equipment not suitable for use in the presence of flammable anesthetic mixture with air or with oxygen or nitrous oxide.

• Only use the power supply unit that is supplied with the scanner. Do not use any other power supply units with the scanner.

Servicing Precautions

Laser Radiation

There is a class 3B laser inside the scanner. The laser can be activated if the safety switch is defeated and the laser is switched on from the service terminal. Avoid direct exposure to the beam or its’ reflections (for instance from shiny tools etc).

High Voltage

There is a high voltage circuit between the photo multiplier tube and amplifier card. High voltage can be set on when the safety switch is defeated.

Light Sensitivity of Photo Multiplier Tube

The tube is very sensitive to light when it is active. Tube is activated when the high voltage is turned on and safety switch defeated. The tube is used to measure extremely small amounts of light and normal room light and brighter light sources damage HV-activated tube.

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Installing and Setting-up the s2terminal

Recommended hardware at installation

• Laptop-computer with:

o Imaging application software installed o All s2terminal related files (including s2terminal.exe and s2.dll) copied to folder

c:\s2terminal

o s2terminal communication and settings tested with scanner unit

• RJ45 UTP network cable, known as working

• Switch 10M / 100M / 1Gb/s, known as working (optional)

Pre-installation requirements

• scanner unit only works with the compatible imaging application software.

• You also have to install the necessary drivers during the installation of the imaging

application. Refer to the Application installation manual for more information.

• After successfully installing an imaging application you must get a suitable, unique IP address for the scanner unit so that you can attach it to the network. You can usually

get one from your local network administrator. All that is basically required is that the address is unique inside the given network.

• If several workstations are required to share the scanner unit (Express Share), determine which workstations will be used with the scanner unit and the names that the users wish to allocate to the workstations.

• You need administrator privileges to do both kinds of installations

• Please allow plenty of time to do Express Share installations, as they are more

complicated to do than normal installations.

• Make sure that the PC(s) and the scanner unit are connected correctly and then the scanner unit on. Wait until the self-test procedure has finished (this takes ~25-60 s.) and make sure that the unit indicates that the cables are connected correctly.

• It is recommended to use network cards (NIC) from the known manufacturer. Cheap, generic cards may cause problems. Here is a quick short list on recommended NICmanufacturers:

o Intel (card or integrated onto motherboard), 3Com, Linksys, D-Link, Netgear…

EMI –interference, vibration and operation with UPS

• scanner unit is tested as required by the medical device standards. However this testing does not guarantee that the device is totally immune to all possible interferences.

• The heavy levels of EMI will disturb the imaging chain and so the scanner may reject the calibration during the power-up or show as interference on the image.

• If the interference is temporarily happening during normal image readout, the 'Degraded Image Quality' -messages may appear.

• In addition to EMI also pure mechanical vibrations (even with small amplitudes) will cause the same effect if the vibration frequency is in the certain range.

• One practical example of vibration origin is if you have a computer reading CDROM (possibly a bit out of balance) next to scanner unit.

If you are operating scanner unit connected to the UPS (Uninterruptible Power System)

• Check any recommendations for the placement etc. The UPS may also generate mechanical vibrations at the frequency the scanner unit is sensitive to so try to locate the UPS on the floor for example

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System Architecture

Block diagram

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Scanner mechanics

External PSU is not shown here. See accessory catalog for details.

To open the unit covers you need 3mm hexagonal allen key.

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Electronics

Powering and grounding of the boards:

• INPUT voltage 24VDC from External Power Supply is connected to H1200 General Control board where supply voltage is split into two traces:

• To H1300 Interface Board

• R2100 Power and Analog Board

• Some of the boards are not powered directly = Their power is supplied and/or controlled

by other board(s).

• For proper operation all boards must be attached to the unit chassis.

External Power Supply Unit

• Universal input, auto switching (100-240 VAC / 47-63Hz).

• Output 24VDC / 2.9A / 70W (Powerbox type EMX805121 include adapters for most

commonly used power supply plugs) connected to the H1200 GC board.

• No serviceable parts inside. Do not open.

R2100 Power & Analog Board

• Analog signal processing circuitry

• Low voltage regulators for all boards & for laser

• High voltage power supply for PMT (J106 - thru R2500 connector brd)

• Analog signal from PMT J3

• Circuitry for checking the high voltage.

• Parallel data I/O between H1200 GC and this board

• 24Vdc input from H1200 (J201)

• +5Vdc digital supply to H1200 GC

• LED D2 is lit when high voltage is on

H1200 General Control Board

• System clock

• CPU inside FPGA (incl. Ethernet controller and other logic)

• System configuration flash-memory

• NAND flash memory

• General-purpose DDR2 memory

• Ethernet interface

• AD conversion

LEDs are used to indicate following voltages:

• D20 +5V

• D13 +1.2V

• D14 +1.8V

• D23 +3.3V

• If red led D19 is lit FPGA is in reset. This can mean that voltage +3.3V supplied to

FPGA is too low.

• LEDs 13, 14, 20 and 23 turn on after pressing power button

• D9 (L10) indicates that Ethernet PHY has established link at 10 Mbps

• D10 (L100) indicates that Ethernet PHY has established link at 100 Mbps

• D11 (L1000) indicates that Ethernet PHY has established link at 1000 Mbps (1Gbps)

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H1300 Interface Board

• Interface for multiple controls (motor, laser control, home opto switch and imaging plate detection), feedback and interface signals from and to H1200 -processor board.

• Controls erasing lamp on/off and generates a feedback of lamp current to CPU

H1400 Display & connector Board

• Interface between graphical display and H1200 GC Board

• Contains connector for proximity switch signals

• Connector for membrane switch panel push buttons and LED powering.

• Led D8 indicates if 5V is available at H1400 board.

R2500 High Voltage Connector Board

• Connects high voltage from HV-supply to the Photomultiplier tube (=PMT).

Membrane switch panel

• Membrane keyboard, which has one led and control keys in it.

• See user’s guide for more detailed description of keys and indicator light

NOTE! Membrane switch panel scan button and the proximity switch are parallel signals. You are able to wake up the unit from the power save mode either way. Please refer to the instructions of the <wakeup> command in service commands section for proper usage of the proximity sensor activation / de-activation.

R2700 Laser detector board

• Contains two pin diodes that are used to synchronize laser movement.

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graphic files

Service Output Msg

Driver Cmd

Msg

Image Data Msg

Image Data Request Msg

User Cmd Reply Msg

User Cmd Msg

Driver Cmd Reply Msg

visible to user

Firmware

Architecture

Workstation (PC)

Imaging Application (optional)

Ethernet

Driver (mandatory) All messages invisible to the user.

Service Terminal

(optional)

All messages

Imaging Application

• End user’s interface to acquired images.

• Handles image archiving and displaying.

Driver

• Handles the connection/communication to the unit

• Transfers and manipulates images.

• Unit cannot operate without Driver

There are two alternatives to be used as a driver:

1. DSD driver. Run from Application (or other imaging application)

2. s2terminal program. Run from the command prompt of Windows.

Service Terminal

• Optional part of the driver.

• Execute user commands

• View the service output of the unit.

There are two alternatives to be used as a Service terminal:

1. DSD driver. Run from Service Assistant of Application (or other imaging application).

2. s2terminal program. Run from the command prompt of Windows.

Scanner Firmware and Core (=FW, Inside the connected unit)

• Takes care of the normal unit operations.

• Operates either in normal mode or service mode.

o Normal mode: Unit is fully operational and images can be acquired. o Service mode: Unit does not react to any other inputs than those given by the user

through service terminal. To be activated only from Service Terminal.

NOTE! Updating scanner FW may need updating of maximally 3 different binary files:

• Firmware

• Core

• Display graphics file

The scanner unit

Scanner Firmware , Core and display

Normal mode

Service mode

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All updated files and related detailed instructions are described in the release letter of FW to be updated. Short description of the used commands is listed on the chapter Field service procedures.

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Unit statuses and modes

Start-up sequence

1. Unit is powered on when power ON / OFF key is pressed

2. INITIALIZATION & SELF TEST SEQUENCE is indicated by animation ran while performing following checks:

• Calculate the CRC

• Drive the plate carrier home (to reset the location counter)

• Drive the plate carrier back inside

• Calibrate PMT-signal amplifier

• Test high voltage (if safety switch is closed)

• Test erasing lamp

• Calibrate plate / reflective sensor DAC (if safety is closed)

• Wait the mirror scanner stabilizing (uses laser; close the safety switch after lamp

test to proceed without error if the cover is open)

• Drive the plate carrier to loading position

NOTE: if the light protection covers surrounding scanner module is removed (or safety switch defective / cable disconnected). Unit goes into error state after erase lamp test and self test sequence is halted (recovering from this needs restart of the unit)

However you are able to proceed with the start up sequence if safety switch is closed manually AFTER the erasing lamp has been ON shortly during the startup sequence

NOTE! If the safety switch is pressed before the erasing lamp test –the PMT may be damaged!!!!!

3. CHECK ANIMATIONS & ERROR CODE displayed if everything NOT OK

4. READY for operation (if connection to the application SW is OK)

Standby -mode

• Goes to standby –mode if not operated for a determined period of time:

o Factory set default can be changed by commanding <idle XXX>

 XXX=time in seconds

o Unit wakes up from the standby mode by activation of the proximity sensor or by

pressing the start key

Powering “OFF” the unit

• Ready state:

o Power ON / OFF key pressed shortly >> BEEPS, but does not power off the unit o Power ON / OFF key pressed more than one second >> powers off the unit

• Standby mode:

o Pressing of power ON / OFF key turn off the unit

Automatic shutdown

• Unit is powered off automatically if the unit stays in the standby mode for a longer period of time than set in the <off> parameter:.

o Factory set default can be changed by commanding <off XXX>

 XXX=time in minutes

Image read, but the connection lost during the read out of the imaging plate (application

etc.)

• Scanner unit display shows “check application animation” indicating that there is image in the memory which is not transferred to the driver

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• Drives the carrier in

• Will not shutdown automatically

• Does not allow switching off the power (continuously beep when pressed) until the

image is transferred.

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Service Terminal

Service terminal is not an end user interface and training to use it in advance is mandatory to prevent the changing of unit configuration (=resulting the unit to become inoperative) accidentally.

Be very careful not to use service commands without the necessary know-how. Gain knowledge by going through all useful commands and train their usage in practice with scanner unit.

All service terminal commands and functions are not explained in this manual. They are instructed in the scanner firmware help (which is accessible through service terminal). This arrangement is to keep the documentation up to date, since the service terminal instructions for commands are always up to date in the scanner firmware. Therefore this manual explains only the principles of the main commands.

More detailed instructions of Service Terminal commands can be found later in this document and in their help outputs <h [command]>.

Accessing Service Terminal

• Service terminal commands are controlled either from imaging applications Service Assistant or from s2terminal

NOTE: Only have either imaging application (Service Assistant) OR s2terminal open at one time.

• Service commands are executed by scanner unit

Access service terminal Using s2terminal Program

• THIS IS THE RECOMMENDED WAY TO ACCESS SERVICE TERMINAL

o Firmware and core upgrade can only be performed with s2terminal

• s2terminal program is run from the command prompt of Windows.

• Application must be closed when accessing service terminal from s2terminal If

Application is opened at the same time, you will have a “login fail (no connection)” error message on screen when trying to make the connection.

Note the difference of actual command prompt and the s2terminal program running in it:

• The input and output of the s2terminal and of the command prompt look similar.

• However, the functions and commands available in the command prompt are not

available in the s2terminal and vice versa.

• If you get confused it is good idea to check the title bar of the command prompt window

- it should read “s2terminal” when the s2terminal program is running.

- it reads “cmd.exe” when only Command Prompt is running

• Running the s2terminal program needs the following files:

• s2terminal.exe (Must be version dated 22/05/2009 or later)

• s2.dll (Must be version dated 21/05/2009 or later)

• W32N55.dll (Must be version dated 23/10/2007 or later)

• (s2terminal has to be version 3.2.127.0 or later)

1. Copy all these files to one same and dedicated service folder that you may need to create (in following example “c:\s2terminal” folder is used to store s2terminal files)

2. Select from Windows: Start / Programs / Accessories / Command Prompt

Select from Windows: Start / run

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3. Type into “Open” -field: <cmd>

4. Choose OK

Command prompt examples :

• <cd\> (Changes to the root directory =C:\)

• <cd s2terminal> (changes to directory “s2terminal”)

5. CHECK THAT Application IS NOT OPENED

6. Type <s2terminal> in the command prompt to see the instructions for the command syntax. Then execute the program using the unit’s IP -address.

7. Type <s2terminal 192.168.2.11>:

• Starts the Service Terminal for unit having ip 192.168.2.11 Or Type <s2terminal 192.168.2.11 –c>:

• Starts the service terminal and configures ip –address to scanner unit 192.168.2.11

NOTE: Keep start button pressed when entering <s2terminal 192.168.2.11 –c>:

8. If the IP-address is correct and the s2terminal program is able to connect to the unit, it prints out terminal output of the login command, which displays “s2terminal, the unit’s firmware version(s), serial number and some parameters”. Otherwise it displays an error message(s).

NOTE: It is normal that you may have few times “login fail (no connection)” –error also in normal functioning connection

9. Quit s2terminal program by <xq>

Access service terminal with Service assistant –utility from the imaging application

• THIS IS THE ALTERNATIVE WAY (backup) TO ACCESS SERVICE TERMINAL

o Use when imaging application –connection available o Firmware download CAN NOT be performed from Service Assistant

• Application connected, press CTRL+ALT+SHIFT+E simultaneously >> Opens imaging software Service Assistant

NOTE: If operating in Express Share configuration, the unit must be reserved before accessing service assistant by pressing “CTRL+ALT+SHIFT+E” buttons

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