Instrumentarium Dental OP-30 Service manual

Orthop antomograph® OP30
Digital Panoramic X-ray Unit
Service manual
Number 204875 rev. 2 (201005)
Orthopantomograph® OP30 Contents
Copyright
Documentation, trademark and the software are copyrighted with all rights reserved. Under the copyright laws the documentation may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine readable form in whole or part, without the prior written permission of Instrumentarium Dental.
The original language of this manual is English.
Instrumentarium Dental reserves the right to make changes in specification and features shown herein, or discontinue the product described at any time without notice or obligation. Contact your Instrumentarium Dental representative for the most current information.
Manufactured by
Instrumentarium Dental Nahkelantie 160 (P.O. Box 20) FI-04300 Tuusula FINLAND Tel. +358 (0)10 270 2000 Fax. +358 9 851 4048
For service, contact your local distributor.
Service manual 204875 I
Contents Orthopantomograph® OP30
II Service manual 204875
Orthopantomograph® OP30 Contents
Contents
1. General Information.......................................................................................... 1
1.1 Introduction ................................................................................................... 1
1.2 Associated documentation ............................................................................ 1
1.3 Service precautions and warnings ................................................................. 1
Servicing precautions .................................................................................... 1
Warning - Radiation Safety ............................................................................ 2
Warning - Mechanical safety .......................................................................... 2
Warning - Electrical Safety ............................................................................. 2
Caution - electrostatic discharge .................................................................... 3
Warning - Explosion hazard............................................................................ 4
Warning - Cleaning the unit ............................................................................ 4
1.4 Unauthorized Modifications ........................................................................... 4
1.5 Disclaimer .................................................................................................... 4
1.6 Yearly maintenance ....................................................................................... 5
mA test .......................................................................................................... 5
kV test ........................................................................................................... 6
Beam alignment test ...................................................................................... 6
Ground test .................................................................................................... 6
Motor movements .......................................................................................... 7
Position detectors .......................................................................................... 7
Patient Positioning Lights .............................................................................. 7
Mains power supply cable .............................................................................. 7
Tubehead ...................................................................................................... 8
Covers and Labels......................................................................................... 8
Fire risk ......................................................................................................... 8
1.7 Disposal ....................................................................................................... 9
2. Unit description .............................................................................................. 10
2.1 The Orthopantomograph® OP30................................................................. 10
2.2 The main parts and assemblies.................................................................... 11
2.3 Unit dimensions .......................................................................................... 14
2.4 Mechanical description ............................................................................... 15
Service manual 204875 III
Contents Orthopantomograph® OP30
2.5 Electrical description ................................................................................... 17
Circuit boards .............................................................................................. 17
Power supply ............................................................................................... 17
Main fuses ................................................................................................... 17
Unit control ................................................................................................... 18
Motors and motor control ............................................................................. 18
Exposure logic ............................................................................................. 19
Position control ............................................................................................ 20
A overview of the Imaging Chain .................................................................. 20
2.6 Wiring diagram - overview........................................................................... 23
2.7 Block diagram............................................................................................. 24
2.8 Fuse diagram ............................................................................................. 25
3. Circuit Boards................................................................................................. 27
3.1 L100, Z-Motor Driver ................................................................................... 27
3.2 L200, CCD Power Supply ........................................................................... 37
3.3 L900, Display adapter ................................................................................. 47
3.4 L1000, Generator Board ............................................................................. 58
DANGER: HIGH VOLTAGE ......................................................................... 58
3.5 L1100 Connector Board .............................................................................. 66
3.6 L1200 CPU Board ...................................................................................... 76
3.7 L1300 Interface Board ................................................................................ 94
3.8 N2500 Rotation Position Sensor Board ...................................................... 99
3.9 R5100, 3-Phase Microstepper Driver ........................................................ 103
3.10 CCD Sensor / Filter board ...................................................................... 107
4. Troubleshooting ............................................................................................1 10
4.1 Initial checks .............................................................................................. 110
Restarting the unit .......................................................................................110
Error Codes ................................................................................................110
Checking circuit boards .............................................................................. 110
Checking cables and connectors ................................................................ 111
Power supply problems ...............................................................................111
4.2 Problems during start up ............................................................................ 112
Nothing happens when the unit is switched on ............................................. 112
The on/off switch light does not come on. ...................................................... 112
The on/off switch light comes on but the display does not come on. .............. 112
Error E 5 (Line voltage out of limits) ............................................................ 114
Error E 18 (Display not connected) .............................................................114
IV Service manual 204875
Orthopantomograph® OP30 Contents
4.3 Problems while preparing the unit for an exposure ......................................115
Image of emergency button appears on main display .................................. 115
The side control panel Return key does not work ......................................... 115
Error E 7 (Opto or r-motor failed during r-movement) ...................................115
Rotating unit stop rotating, no error code .....................................................116
Patient positioning light(s) do not come on ..................................................116
One of lights does not come on. ..................................................................... 116
None of the lights come on. ............................................................................ 116
Up/down (Z-motor) keys do not work ...........................................................117
4.4 Problems during exposure .........................................................................119
Nothing happens when the exposure button is pressed ............................... 119
Error code H1 (Exposure interupted) ........................................................... 119
Error codes E0, E1 and E2 ........................................................................ 120
Error E 6 (Exposure timeout)...................................................................... 122
Error E 10 (CCD initialization/configuration failure) .................................... 122
Error E 11 (CCD power failure) .................................................................. 123
Error E 12 (CCD line failure) ...................................................................... 123
Error E 13 (CCD DMA failure).................................................................... 123
4.5 Problems after exposure ........................................................................... 124
Error E 4 (Tubehead too hot or too cold)..................................................... 124
Vertical white stripes on the image ............................................................. 124
Horizontal white stripes on the image ......................................................... 124
4.6 Bad quality images ................................................................................... 125
Incorrect patient positioning ....................................................................... 125
A badly aligned unit .................................................................................... 125
The CCD sensor is not calibrated .............................................................. 125
5. Service Assist ant and service functions .................................................... 126
5.1 Using the Service assistant ....................................................................... 126
5.2 The Service commands ............................................................................ 128
6. Updating unit firmware, core and display graphics................................... 138
6.1 The unit firmware ....................................................................................... 138
6.2 Updating the core ...................................................................................... 140
6.3 Updating the GUI graphics ........................................................................ 141
Service manual 204875 V
Contents Orthopantomograph® OP30
7. Replacing parts............................................................................................. 142
7.1 Removing covers ...................................................................................... 142
7.2 Replacing the tubehead ............................................................................ 143
7.3 Replacing the CCD sensor ....................................................................... 146
7.4 Replacing the collimator ............................................................................ 146
7.5 Replacing circuit boards............................................................................ 146
L900 Display adaptor - additional instructions ............................................ 146
L1000 Generator board - additional instructions ......................................... 147
L1100 Connector board - additional instructions ........................................ 147
L1200 CPU board - additional instructions ................................................. 147
8. Aligning the unit............................................................................................ 148
8.1 Removing the covers ................................................................................. 148
8.2 Checking and Aligning the CCD Sensor .................................................... 148
8.3 Checking and adjusting the position of the collimator ................................. 150
8.4 Checking and adjusting the Chin Support .................................................. 153
8.5 Checking and adjusting the focal trough .................................................... 155
8.6 Recheck the alignment .............................................................................. 157
8.7 Calibrating the CCD sensor ...................................................................... 157
VI Service manual 204875
Orthopantomograph® OP30 1. General information
1. General Information
1.1 Introduction
This manual describes how to service the Orthopantomograph® OP30 Digital Panoramic X-ray Unit (the unit).
1.2 Associated documentation
The unit user's manual. The unit installation manual. The unit spare-parts manual.
1.3 Service precautions and warnings
Servicing precautions
Only service personnel trained and approved by Instrumentarium Dental are allowed to service the unit.
Before attempting to service the unit make sure that you know how to operate it. Read the unit user's manual.
Read and familiarize yourself with the warnings and precautions listed in the unit user's manual.
Only use original Instrumentarium Dental spare parts when repairing the unit or replacing parts.
The unit is factory set to operate using either:
- 100 VAC or
- 115 VAC or
- 220 VAC or
- 230 VAC or
- 240 VAC The voltage of the unit can be found on the type label. Never connect the unit to a power supply different to the voltage marked on the type label.
Service manual 204875 1
1. General Information Orthopantomograph® OP30
Warning - Radiation Safety
Before servicing the unit familiarize yourself with local and national radiation safety standards and requirements relating to dental x-ray equipment.
When taking test exposures take adequate precautions to protect yourself from radiation. Stand behind a suitable radiation shield positioned at least two metres (six feet) from the unit.
Warning - Mechanical safety
Disconnect the unit from the main power supply before removing any covers.
Disconnect the unit from the main power supply before repairing or replacing mechanical parts or installing accessories.
Be careful when operating the unit not to get body parts or clothing trapped between moving parts.
During operation some surfaces and components may become hot. Take precautions to avoid burning yourself.
The aperture plate in the collimator is made of lead (Pb) which is toxic. Do not touch it with your bare hands.
Do not open the tubehead. There are no serviceable parts, mechanical or electrical, inside the tubehead.
Warning - Electrical Safety
Disconnect the unit from the main power supply before replacing circuit boards or other electrical components.
If there are capacitors on a circuit board or electrical component wait ten (10) minutes, after disconnecting the unit from the power supply, before handling the board or component.
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Orthopantomograph® OP30 1. General information
If you have to leave the unit unattended during servicing or maintenance, disconnect the unit from main power supply to protect people, who may touch the unit, from electric shock.
This unit should be used only in areas that are provided with a protective earth connection to ensure an equipotential ground connection.
Caution - electrostatic discharge
Electrostatic Discharge (ESD) can damage or destroy electronic components.
When servicing the unit take precautions to avoid electrostatic build up and discharge (ESD). Follow the recommendations for the prevention of ESD that are used in the country in which you are working. If no recom­mendations are available, follow the guidelines below:
- Leave all new or replacement circuit boards and electrical parts in their protective packaging until the boards are needed.
- Before handling circuit boards and electrical parts make sure that any static electricity charge that has built up in you body is discharged.
- When examining and checking circuit boards use an antistatic wrist wrap which is connected to a ground point through a 1 Mohm current limiting cable. For a ground point use water pipes, radiators or other objects that are known to be connected to the ground. Also use a cable to connect the unit to the same ground potential as the wrist wrap.
- When handling circuit boards hold them by their edges and do not touch any components or connectors.
- If an antistatic mat is used, connect the wrist wrap to the mat and the mat to the ground potential.
- Wash the wrist wrap and check that it is in good condition frequently.
Service manual 204875 3
1. General Information Orthopantomograph® OP30
Warning - Explosion hazard
Certain disinfectants and cleaning agents may vaporize to form an explosive vapour. If such chemicals are used the vapour should be allowed to disperse before switch­ing the unit on.
Warning - Cleaning the unit
Switch the unit off and disconnect it from the main power supply before cleaning or disinfecting the unit.
1.4 Unauthorized Modifications
Unauthorized changes or modifications to any part of the unit or its equipment can have hazardous consequences. Changes or modifications must not be made unless specifically authorized by Instrumentarium Dental.
1.5 Disclaimer
When properly assembled with a compatible beam­limiting unit, the diagnostic source assembly will fully meet the United States of America Federal Performance Standards for Diagnostic X-Ray Systems and Their Components (21 CFR 1020. 30-32) provided no compo­nents or parts are removed from the unit and no unauthor­ized adjustments are made to the beam-limiting unit or tube housing assembly. Never remove or remanufacture any part of the tube housing assembly or beam-limiting unit. Never adjust any part of the beam-limiting unit unless under the direction of Instrumentarium Dental or their authorized distributor.
Instrumentarium Dental shall have no liability for consequential damages, personal injury, loss, damage or expense directly or indirectly arising from the use of its products. No agent, distributor or other party is authorized to make any warranty or other liability on behalf of Instrumentarium Dental with respect to its products.
4 Service manual 204875
Orthopantomograph® OP30 1. General information
1.6 Yearly maintenance
The following tests and inspections must be carried out annually by an authorized service person to verify that the unit meets the specifications and performance criteria essential for correct and safe operation. When taking measurements that require a multimeter, always use a digital multimeter (DMM).
mA test
WARNING: X-rays are generated when this test is car-
ried out. PROTECT YOURSELF FROM RADIATION.
1. Connect the +probe of a DMM to test pin TP18 (mAfb) and the -probe to TP17(GND) on the Generator board.
2. Select service command exp and an exposure time
of 2000 ms (refer to section 4 Service assistant and service functions, in this manual).
3. Protect yourself from radiation and take an exposure. Check the feedback values from the DMM. The feedback values must be within the tolerance.
Selected mA mAfb (V) T olerance (V)
10 2 ±0.2 (1.8 - 2.2)
If the value is not within the tolerance, recalibrate the Generator board, see section 5.2 Service
Commands (the calib command).
Service manual 204875 5
1. General Information Orthopantomograph® OP30
kV test
WARNING: X-rays are generated when this test is car-
ried out. PROTECT YOURSELF FROM RADIATION.
1. Connect the +probe of a DMM to test pin TP14 (kVfb) and the -probe to TP17(GND) on the Generator board.
2. Select service command exp and an exposure time
of 2000 ms (refer to section 4 Service assistant and service functions, in this manual).
3. Protect yourself from radiation and take an exposure. Check the feedback values from the DMM. The feedback values must be within the tolerances.
Selected kV kVfb Tolerance (V)
66 3.0 ±0.2 (2.8 - 3.2) 77 3.5 ±0.2 (3.3 - 3.7)
If the values are not within the tolerances, recalibrate the Generator board, see section 5.2 Service
Commands (the calib command).
Beam alignment test
Check the beam alignment. Refer to the Installation and set-up manual for information on how to do this.
Ground test
Disconnect the unit from the main power supply before carrying out this test. For ME EQUIPMENT with an APPLIANCE INLET the impedance between the earth pin in the APPLIANCE INLET and any part that is PROTECTIVELY EARTHED shall not exceed 100 m ohm. The grounding resistance is measured between APPLIANCE INLET ground pin and any metal part of the unit. The resistance MUST be <0.1 ohm.
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Orthopantomograph® OP30 1. General information
Motor movements
Switch the unit off and then manually rotate the rotating unit to check that all the stepper motor moves freely and without any looseness.
Switch the T-mode "test" and then take an exposure to check that the motors operate smoothly and without any noise.
Press the up/down keys to check the Z-motor (vertical carriage movement). The motor must operate smoothly and without any noise.
Position detectors
Press the up key and drive the unit up. Make sure that the unit stops moving at its uppermost position. Press the down key and drive the unit down. Make sure that the unit stops moving at its lowermost position.
Manually rotate the rotating unit to one of its end positions and then press the return button and make sure that the rotating unit returns to the ready position. Repeat the test for the other end position.
Use service command optotest, see section 5.2 Service
Commands, to check the rotating unit optosensors. Manually turn the rotating unit in one direction and then press return. Repeat for the other direction.
Patient Positioning Lights
Check that the patient positioning lights work and are positioned correctly. Refer to the Installation and set-up manual for information on how to do this.
Mains power supply cable
Check the condition of main power supply cable and replace it if damaged.
Service manual 204875 7
1. General Information Orthopantomograph® OP30
Tubehead
Make sure that oil is not leaking from the tubehead. If the tubehead shows signs of oil leakage, replace it.
Covers and Labels
Check that all covers are correctly installed and in good condition. Also check that all the labels are attached to the unit and that they are all legible.
Fire risk
WARNING: Disconnect the unit from the main power
supply before carrying out the next task. Use a vacuum cleaner to remove all dust that has accumulated inside the unit to eliminate the risk of fire.
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Orthopantomograph® OP30 1. General information
1.7 Disposal
At the end of useful working life of the unit, its spare and replacement parts and accessories make sure that you follow all local, national and international regulations regarding the correct and safe disposal and/or recycling of the unit, its spare and replacement parts and accessories.
The unit and its spare parts and accessories may include parts that are made of or include materials that are non­environmentally friendly or hazardous. These parts must be disposed of in accordance with all local, national and international regulations regarding the disposal of non­environmentally friendly or hazardous materials.
The following hazardous materials and substances can be found in the unit, its spare and replacement parts and assemblies:
- Lead (Pb): circuit boards, tubehead, collimator
- Cadmium (Cd): none
- Mercury (Mg): none
- PBB Polybrominated biphenyls: none
- PBDE polybrominated diphenyl ethers: none
Other materials and substances in the unit, its spare parts and assemblies that could be hazardous and are non­environmentally friendly are:
- Mineral oil: tubehead
Service manual 204875 9
2. Unit Description Orthopantomograph® OP30
2. Unit description
2.1 The Orthopantomograph® OP30
The Orthopantomograph® OP30 extraoral x-ray unit is designed to take exposures of the dento-maxillofacial region. The unit cannot be used to take x-ray exposures of any other part of the human anatomy.
The unit can be used to take adult panoramic (full width), child panoramic (reduced width), TMJ and bitewing images.
The unit is factory set to operate using either:
- 100 VAC or
- 115 VAC or
- 220 VAC or
- 230 VAC or
- 240 VAC power supply. The voltage setting CANNOT be changed.
The unit is used with a PC in which Cliniview or some other MDD approved dental imaging software is installed.
10 Service Manual 204875
Orthopantomograph® OP30 2. Unit Description
2.2 The main parts and assemblies
1 Column 2 Upper shelf 3 Tubehead 4 CCD sensor
Tubehead (3) + CCD sensor (4) = Rot ating unit
5 Vertical carriage 6 Emergency stop button - Press to stop, rotate to release. 7 On / off switch (rear of column) 8 PC with MDD approved dental imaging software 9 Ethernet cable
Service Manual 204875 11
2. Unit Description Orthopantomograph® OP30
1 Head support 2 Midsaggital light 3 Mirror 4 Frankfort light and light positioning knob 5 Focal trough positioning knob 6 Patient support 7 Focal trough light 8 Patient support handles
12 Service Manual 204875
Orthopantomograph® OP30 2. Unit Description
A side control panel
1 Lights key - switches the patient positioning lights on and off 2 Up key - drives the unit up 3 Down key - drives the unit down 4 Return key - drive the unit to the patient in/out position (PIO)
B main control panel
5 Program selection keys - P1 = adult pan, P2 = child pan, P3 = TMJ,
BW = bitewing 6 kV selection keys 7 Exposure values 8 Test key - operated the unit without x-rays 9 Service mode key 10 Dose Area Product (DAP) 11 Ready indicator light - unit ready for an exposure
Service Manual 204875 13
2. Unit Description Orthopantomograph® OP30
2.3 Unit dimensions
14 Service Manual 204875
Orthopantomograph® OP30 2. Unit Description
2.4 Mechanical description
The unit comprises a column, a vertical carriage, an upper shelf, a rotating unit and a patient support assembly.
The column is permanently fixed to the wall, using wall
bracket, and the floor. If the unit needs to be free standing it can be attached to the show stand (part no. 9802666).
The vertical carriage is attached to the column and can slide up and down the column (Z-movement, for unit height adjustment). The upper shelf is attached to the top of the vertical carriage.
The rotating unit, which comprises the tubehead and collimator and the CCD sensor assembly, is attached to the underside of the upper shelf. The rotating unit
rotates to take panoramic exposures (R-movement).
Service Manual 204875 15
2. Unit Description Orthopantomograph® OP30
Inside the tubehead there is the x-ray tube. It is a fixed
tungsten anode type with a focal spot of 0.5 mm.
The patient support assembly is attached to the bottom of the vertical carriage. It comprises handles for
the patient to hold and a chin support.
The patient is held in position with a four-point support
system. The head support (attached to the rotating unit)
supports the patient's head with temple supports and the
forehead support. The patient support supports the
patients lower jaw on the chin support, using either the chin rest or lip support.
There are three patient positioning laser lights,
midsagittal light, Frankfort (horizontal) light and focal trough.
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Orthopantomograph® OP30 2. Unit Description
2.5 Electrical description Circuit boards
Circuit boards are described in detail in section 3. Circuit Boards.
Power supply
Power is supplied to the unit through L100 (Z-Motor Driver). The 230 VAC is is supplied directly to L100. Other voltages, 100, 115, 220, or 240 VAC, go through an autotransformer that first transforms these voltages to 230 VAC. From L100, power is routed through the Generator board to a transformer which produces low voltages that are supplied to L200, a linear mode power supply, which distributes the low voltages to the other boards in the unit. The transformer also produces 27VAC and 19VAC voltages that are supplied directly (not through L200) to the Generator board.
Main fuses
The power for the AC-motor (z-motor), 230 VAC, is taken directly from L100 and not from the Generator board.
Capacitors on the Generator board produce the 310V needed to power the tubehead from the 230VAC supplied by L100.
Two:
- T6.3 H, SPT (220/230/240 V AC) or
- T10A, SPT (100/1 15 V AC).
Dimensions 5 mm x 20mm, UL approved. They are located below the main power supply cable at the rear of the column.
Service Manual 204875 17
2. Unit Description Orthopantomograph® OP30
Unit control
The unit is controlled by a microprocessor on L1200 (CPU board). It continually monitors and controls the operation of the unit. A serial peripheral interface communication protocol (SPI - RS485) and direct digital I/ O are used to monitor most of the unit functions. The microprocessor:
- monitors the optosensors
- monitors control (touch) panel keys
- controls unit movements during exposures
- starts, controls and stops x-ray generation
- controls the digital imaging chain The necessary unit settings and parameters for all the imaging programs are stored in the memory which is also on L1200.
Motors and motor control
There is one stepper motor and one AC-motor in the unit. The stepper motor drives the rotating unit (R-movement). The stepper motor is driven and controlled by R5100 (3­Phase Microstepper Driver).
The AC-motor (Z-motor) adjusts the height of the unit (Z­movement), and the motor is activated by L100. To acti­vate the Z-motor L100 must receive a control signal from L1200 and a separate control (enable) signal from the Z­movement (up/down) keys. An emergency switch on the front of unit disables the Z­motor (Z-movement) and stepper motor (R-movement) when pressed.
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Orthopantomograph® OP30 2. Unit Description
Exposure logic
An exposure can only be taken when the unit is in the ready state (the exposure ready light on the control panel is on) and the exposure button is pressed and held down. The Generator board receives the correct kV and mA references from the CPU. A few milliseconds after the exposure button is pressed (Expsw) preheat is enabled (Preh). After 800ms the exposure will start (ExpEna). The tubehead will receive power from the Generator board and the Generator board will also start to regulate the mA and kV according to mA- and kV- feedback.
Service Manual 204875 19
2. Unit Description Orthopantomograph® OP30
Position control
The position of the rotating unit (R-movement) is moni­tored by optosensors on N2500 (Rotation Position Sensor Circuit). The optosensors indicate in which sector the rotating unit is. The optosensors ensure that the rotating unit is in the correct position, start or PIO (Patient In/Out), for an exposure. The statuses of the optosensors are monitored continually by the unit software.
The upper and lower limits of the vertical carriage (Z­movement) are monitored by microswitches.
A overview of the Imaging Chain
This description assumes that the unit is ready to take an exposure.
Image acquisition is controlled by the DSD software
component which is installed in the PC connected to the unit.
When an exposure is taken L1200 (the CPU) then sends a PPOWER (pan) and CCDON signal. CCDON signal activates linear regulators on L200 which then produce
the power supply voltages for the CCD sensor.
The CPU's control software continuously monitors the status of the connection with the DSD driver. After image exposure but before image transfer the CPU sends a label that includes the imaging parameters (—kV/—mA/ —s) and an imaging program identifier.
The CPU enables the IMAGE signal to activate pixel clocking. The CPU then produces the TDI clock signal, which clocks the pixels from the CCD sensor. Derivation of several CCD clock signals from the TDI clock is done by the CCD sensor board.
Radiation striking the CCD sensor is converted to visible light which is detected by the CCD cell. A binning procedure is carried out on individual pixels, i.e. two adjacent pixels in a row and column (2 x 2 binning) forms one large pixel (96μm x 96μm). The output voltage of the CCD is fed to a 14-bit A/D converter.
20 Service Manual 204875
Orthopantomograph® OP30 2. Unit Description
The CCD sensor board sends the image data (now 12 bits) to the CPU board where they are saved on the SDRAM. The image information is transferred to the PC via the Ethernet cable.
In the PC there is a Network Interface Card (NIC). After image data transfer the DSD preprocesses the raw image, for example it interpolates gaps between CCD chips, and carries out dark current correction and gain correction (the pixels do not have equal characteristics).
Service Manual 204875 21
2. Unit Description Orthopantomograph® OP30
22 Service Manual 204875
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