Sirona Cerec Service manual
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Sirona Dental Systems GmbH
Service Manual CEREC / inLab MC XL Contents
Contents
1 General information ................................................... 7
1.1 General information ........................................... 8
1.2 Additional information ........................................ 9
2 Description of the service software.......................... 12
2.1 General information ........................................... 13
2.2 Basic structure of test dialogs ........................... 14
2.3 Individual Test Points ........................................ 19
2.3.1 Serial Communication..................................... 19
2.3.2 Media supply .................................................. 20
2.3.3 Light Barriers, Door Switch, Temperature Sensor and
Motor Stop Positions....................................... 21
2.3.4 Stepping motor test ........................................ 23
2.3.5 Stepping motors - Single step......................... 24
2.3.6 Stepping motor - Step response..................... 26
2.3.7 DC motors 'Load/inlet'..................................... 27
2.3.8 DC motors 'Touch' .......................................... 28
2.3.9 DC motors 'Speed'.......................................... 29
2.3.10Sensor test ..................................................... 30
2.3.11Force sensor test ............................................ 31
2.3.12Continuous load.............................................. 32
2.3.13Camera quick test........................................... 32
2.3.14Milling Unit Info ............................................... 39
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3 Troubleshooting ......................................................... 42
3.1 Force measurement errors ................................ 43
3.2 Stepping motor does not move ......................... 44
3.3 Faulty locking of block chuck ............................. 46
3.4 DC motor does not lock ..................................... 47
3.5 Milling instruments come loose ......................... 48
3.6 Milling chamber door switch .............................. 49
3.7 Unit switches off ................................................ 50
3.8 Tank switch defect ............................................. 52
3.9 Edges break off ................................................. 53
3.10 Insufficient air pressure ..................................... 55
3.11 Holes in restoration ........................................... 56
3.12 Stepping motor cannot be controlled ................. 57
3.13 Faulty water pressure ........................................ 58
3.14 Unit cannot find starting position ....................... 60
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Sirona Dental Systems GmbH
Contents Service Manual CEREC / inLab MC XL
3.15 Unit cannot be turned on ................................... 61
3.16 Touch errors ...................................................... 62
3.17 Service life of milling instruments too short ....... 63
3.18 Milling unit not addressable ............................... 64
3.19 LAN communication problems .......................... 65
3.20 WLAN connection occasionally interrupted ....... 67
3.21 WLAN communication problems ....................... 68
4 Repair .......................................................................... 70
4.1 Removing/attaching covers ............................... 72
4.2 Replacing the (DC) spindle motors ................... 74
4.2.1 DC motor, single............................................. 74
4.2.2 DC motor, double ........................................... 79
4.2.3 Testing and setting the DC motor(s)............... 84
4.2.4 Chuck of milling instrument broken ................ 85
4.3 Replacing/retrofitting the scanner ..................... 86
4.3.1 Removal ......................................................... 86
4.3.2 Installation ...................................................... 87
4.3.3 Testing and setting the scanner ..................... 88
4.4 Replacing the controller board / microcontroller module
88
4.5 Replacing the WLAN module ............................ 91
4.6 Replacing the milling chamber lighting .............. 91
4.7 Replacing stepping motors ................................ 92
4.7.1 BR stepping motor.......................................... 92
4.7.2 GR / MR stepping motor................................. 93
4.8 Replacing the milling machine .......................... 94
4.8.1 Removing the milling machine........................ 94
4.8.2 Installing the milling machine.......................... 96
4.9 Replacing the tank switch ................................. 97
4.9.1 Preparations ................................................... 97
4.9.2 Removing the chassis insert........................... 98
4.9.3 Replacing the tank switch............................... 100
4.9.4 Installing the chassis insert............................. 100
4.9.5 Final work ....................................................... 101
4.10 Replacing the suction connection ..................... 101
4.10.1Preparations ................................................... 101
4.10.2Removing the chassis insert........................... 102
4.10.3Replacing the suction connection................... 102
4.10.4Installing the chassis insert............................. 102
4.10.5Final work ....................................................... 102
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Service Manual CEREC / inLab MC XL Contents
4.11 Replacing the light barrier ................................. 102
4.12 Replacing the milling chamber door .................. 103
4.13 Replacing the air pump ..................................... 104
4.14 Replacing the pressure switch .......................... 105
4.14.1Water pressure switch .................................... 105
4.14.2Air pressure switch ......................................... 105
4.14.3Air pressure sensor (CEREC MC XL only) ..... 106
4.15 Replacing the fan unit ........................................ 106
4.16 Replacing the cooling pack ............................... 107
4.17 Replacing the water pump ................................. 108
4.18 Replacing the display ........................................ 110
4.19 Adjusting the plunger pin ................................... 110
4.19.1G-axis and M-axis plunger pin ........................ 110
4.19.2B-axis plunger pin ........................................... 111
4.20 Replacing the block fastener ............................. 113
5 Cleaning the chucks................................................... 116
5.1 Block chuck and block clamping nut ................. 117
5.2 Milling instrument chucks .................................. 120
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CEREC / inLab MC XL
General information
Sirona Dental Systems GmbH 1 General information
Service Manual CEREC / inLab MC XL
1 General information
Contents
1.1 General information ........................................................... 8
1.2 Additional information ....................................................... 9
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1 General information Sirona Dental Systems GmbH
General information Service Manual CEREC / inLab MC XL
1.1 General information
Nominal line voltage ranges The CEREC MC XL / inLab MC XL milling unit can be operated in the
following
z nominal line voltage ranges: 100 - 230VAC; 50 / 60 Hz
Wireless phone interference with
medical electrical equipment:
ESD warning label
ESD warning label
ESD protective measur es
ESD protective measures
NOTE:
To ensure safe operation of medical electrical equipment, the use of mobile
wireless phones in practice or hospital environments is prohibited.
CAUTION:
Connector pins or sockets bearing ESD warning labels must not be touched
or interconnected without ESD protective measures.
ESD protective measures include:
z Procedures for preventing electrostatic charge build-up (e.g. air
conditioning, air moistening, conductive floor coverings and non-synthetic
clothing)
z Discharging the electrostatic charges of your own body on the frame of
the unit, the protective ground wire or large metallic objects
z Connecting yourself to ground using a wrist band.
Measurements Always switch off the unit before connecting the measuring instrument.
Select the correct current/voltage type and adjust the measuring range to
match the expected readings.
Perform continuity tests only on units which are switched off.
When replacing parts
WARNING: Potentially lethal shock hazard when working
near the power supply unit
Disconnect from the line power supply.
Check for zero potential.
Switch the unit off and disconnect the power plug before replacing parts.
The article numbers for ordering spare parts can be found in the spare parts
list, Order No. 61 45 853.
The diagrams contained in the spare parts list provide a useful guide when
replacing parts.
Before replacing the boards, observe the ESD protective measures.
Disposal Observe the information on disposal in the relevant operating instructions.
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Sirona Dental Systems GmbH 1 General information
Service Manual CEREC / inLab MC XL Additional information
Installation site Observe the information on the installation site in the relevant operating
instructions.
1.2 Additional information
In addition, you also require:
CEREC / inLab MC XL spare parts list
Order No.: „61 45 853“
CEREC / inLab MC XL wiring diagrams
Order No.: „61 39 278“
CEREC / inLab MC XL Operating Instructions
CEREC MC XL, Order No.: "61 46 885"
inLab MC XL, Order No.: "61 39 237"
Documents:
Operating the MC XL via LAN (61 90 503)
Operating MC XL via WLAN in the Ad-hoc mode (61 90 545)
Operating MC XL via WLAN in infrastructure mode, Restoring default settings
(61 90 560)
Tool s
z Allen key angled, size (mm) 1.27 (0.05”); 1.3;6
z Open-end wrench, size (mm) 6;10
z TORX screwdriver, size 6; 8; 10; 20
z Phillips screwdriver, size 1
z Blade screwdriver, insulated, sizes 2 and 3
z Box wrench: 6mm; 7mm
z Universal pliers
z Flat pliers
z Torque wrench, 1.1Nm
z Feeler gauge 0.1mm
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1 General information Sirona Dental Systems GmbH
Additional information Service Manual CEREC / inLab MC XL
Auxiliary tools & equipment
z Digital Multimeter, Accuracy Class 1
z Soldering tool for repairing cables
z Diagonal-nosed cutting pliers
z Cable ties
z Teflon tape
z Loctite 221
z Calibration set (supplied with unit)
z Step Bur 12 and Step Bur 20
z Torque wrench for changing the milling instruments
(order no: 61 19 346)
z Fuses (recommended):
F1 (2 pcs) T5H250V Order No.: 20 33 111
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CEREC / inLab MC XL
Description of the service software
2 Description of the service software Sirona Dental Systems GmbH
Service Manual CEREC / inLab MC XL
2 Description of the service software
Contents
2.1 General information ........................................................... 13
2.2 Basic structure of test dialogs.......................................... 14
2.3 Individual Test Points ........................................................ 19
2.3.1 Serial Communication ........................................ 19
2.3.2 Media supply ...................................................... 20
2.3.3 Light Barriers, Door Switch, Temperature Sensor and
Motor Stop Positions .......................................... 21
2.3.4 Stepping motor test ............................................ 23
2.3.5 Stepping motors - Single step ............................ 24
2.3.6 Stepping motor - Step response ........................ 26
2.3.7 DC motors 'Load/inlet' ........................................ 27
2.3.8 DC motors 'Touch'.............................................. 28
2.3.9 DC motors 'Speed' ............................................. 29
2.3.10 Sensor test ........................................................ 30
2.3.11 Force sensor test............................................... 31
2.3.12 Continuous load ................................................ 32
2.3.13 Camera quick test ............................................. 32
2.3.14 Milling Unit Info.................................................. 39
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Service Manual CEREC / inLab MC XL General information
2.1 General information
Test requirements Requirement for all tests:
z PC / acquisition unit is switched on and ready for operation.
z PC / acquisition unit and milling unit are interconnected (via network cable
or WLAN)
z The door of the milling chamber must remain closed as long as any
motors or the water pump are running. If the door of the milling chamber is
opened during the test, all motors and the water pump will switch off
immediately (same function as pressing the "STOP" button).
z The tools (burrs) must be installed already during operation of the water
pump.
z During operation of the water pump, the air pump mustalways be running
to protect the DC motors against water damage, i.e. the air pump is
started first. If the air pressure switch detects no air pressure, an error
message will appear and the test cannot be performed.
Service software log file The Service software generates a log file for all tests performed. This log file
is located in the folder on delivery.
c:\programme\Cerec\System\Service\Protocols and is named
Testdatei_XXXXXXXXXXXX.TXT
The Xs here denote the serial no. of the milling unit.
Each time the service software is started, a confirmation query appears
asking whether this file (if it already exists) should be deleted. If "No" (do not
delete) is selected, the tests subsequently performed will be appended to the
ones previously saved. Each test is labeled with a starting and ending date.
The test file can be viewed with the editor at any time. If the user quits a test
without saving it, he will be asked if he really wants to quit without saving. If
"Yes" (Quit without saving) is then selected, the data just measured will be
lost.
Assessment scores There are three different scores which can be assigned to test results:
z passed fully ("Passed fully", (green label)
z passed ("Passed", yellow label)
z not passed ("Not passed", red label)
The area which passed may be irrelevant for a specific test. In that case, n.a.
(not applicable) will be written to the log file for this area.
NOTE: Assessment scores
Passed fully: If all test results are scored "Passed fully", flawless
operation of the system is possible.
Passed: If the test results are scored"Passed", uncritical changes have
occurred.
Not passed: If the test results are scored "Not passed", you must find and
eliminate the cause.
CAUTION: Keep the cover closed
If the milling unit housing is left open, the temperature switch on the controller
board may cut out after a short time (T>90°C). The cooling fan can work
properly only with the cover closed.
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2 Description of the service software Sirona Dental Systems GmbH
Basic structure of test dialogs Service Manual CEREC / inLab MC XL
CEREC / InLab MC XL milling chamber
Milling chamber
Milling chamber
A Scanner E Bur Set 2
B Scanner window F Ceramic block
C Motor mount G Workpiece spindle
D Bur Set 1 H Block clamping nut D6/D10
NOTE: Availability of the test options
Some tests (e.g. motor set 2) are selectable only with inLab MC XL or with
CEREC MC XL with a second bur set (optional).
2.2 Basic structure of test dialogs
NOTE: Damage to system
The Service functions may be used only by authorized service engineers
who have been trained by Sirona.
Password The service software test dialogs are protected by a password to prevent
manipulations by unauthorized users.
The password has four digits. It changes daily and is generated from the
system date of the computer according to the following scheme:
Password
Generated from
number
1 2. number of the current month
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Service Manual CEREC / inLab MC XL Basic structure of test dialogs
Password
Generated from
number
2 1. number of the current month
3 2. number of the current day
4 1. number of the current day
Example: 02/28/2007 becomes 2082
CAUTION: Do not disclose the password scheme
Do not disclose the password creation scheme to others.
Before entering the password, always determine the date as inconspicuously
as possible.
Since the password is always valid for one single day only, it can be passed
on to the user in exceptional cases, e.g. to provide immediate telephone
support.
NOTE: Password input errors
If the commands are not enabled after you enter the password, check the
following:
- correct entry of the password,
- the system date set on the computer.
The dialog for setting the system time can be called up in all Windows
operating systems by double-clicking the time displayed in the systray.
Opening the Service software 1. Open the Service menu as follows.
CEREC MC XL:
"Start"/"Programs"/"CEREC"/"Service"
inLab MC XL:
"Start"/"Programs"/"inLab"/"Service"
ª The Service Login dialog box then opens for password entry.
2. Enter the password and confirm your entry with the "Yes" button.
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Basic structure of test dialogs Service Manual CEREC / inLab MC XL
NOTE: Select the milling unit
If there is no data link between the milling unit and the acquisition unit / PC or
several milling units are connected, the "Select milling unit" dialog
box will open.
¾ Establish a data link if necessary.
¾ Click the "Add automatically" button.
ª The acquisition unit / PC installs the milling unit.
¾ Select the relevant milling unit and confirm your choice with the "OK"
button.
Log file If a log file with the name of the milling unit you have selected already exists,
you will be asked if you want to delete this file.
z Click the "Yes" button:
The old file is then deleted and a new log file is created.
z Click the "No" button:
The old file is then not deleted and the data from the new test run is
appended to it.
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Service Manual CEREC / inLab MC XL Basic structure of test dialogs
Test selection dialog box
A Tests performed only at the
factory
In the "Test selection"dialog box you can select
z a test for the complete milling unit ("Total test") or
z an individual test.
The selected test dialog box then opens if you click "OK".
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Basic structure of test dialogs Service Manual CEREC / inLab MC XL
Example: Total test
Total test
A Number of test runs completed since the last time the Start
button was actuated.
B Progress bar for test currently being run.
C Check boxes for selecting (activating/deactivating) the tests
available in this test dialog.
D Check box for selecting the options possible in this test dialog.
E Number of test results since the last start:
Passed fully
Passed
Not passed
F Pressing the "Start" button starts the test run with the
selected settings. The test run is repeated until it is cancelled
by pressing the "Stop" button. The test run counter is then
reset to 0. Once started, the test run can be halted only with
"Stop". No other inputs are possible during the test run.
G The test is canceled as soon as possible with the "Stop"
button. The test in progress at the time of cancellation is not
counted. All inputs are now possible again.
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Service Manual CEREC / inLab MC XL Individual Test Points
H All existing data can be saved to the log file by pressing the
"Save" button. The data are appended to the previously
existing log file (if the current test run has not yet been saved).
If no data exist, a message to that effect will appear (confirm
with "OK"). Once a test run has been saved to the log file, a
new test run must be started before selecting the save function
again.
IPress "Back" to quit the test dialog and return to the service
dialog. If any data exist and have not yet been saved, you will
be asked whether or not the test data should be saved.
J Result:
No color: No measurement available yet.
green: Test passed fully.
yellow: Test passed.
red: Test not passed.
2.3 Individual Test Points
2.3.1 Serial Communication
The test is primarily used to measure the speed and quality of data
transmission. This is especially important if the system is not operated via the
network cable (LAN) but rather via other types of connections such as e.g.
WLAN (AdHoc, Infrastructure.
The transmission time between the beginning of transmission and the end of
reception is calculated for a specific record on the PC. A test run comprises
one complete transmission in both directions.
The values thus measured are then saved to the log file.
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Serial Communication
1 Result of last test run 3 Average measured
transmission time
2 Minimum measured
transmission time
4 Maximum measured
transmission time
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2 Description of the service software Sirona Dental Systems GmbH
Individual Test Points Service Manual CEREC / inLab MC XL
Typical values
Time
LAN 200 - 400 ms
WLAN 300 - 600 ms
2.3.2 Media supply
Purpose of Test: To check the media supply (air, water, fan) for proper functioning and test the
pressure switches and the function of the pump.
Procedure The pumps and the fan are switched on by nominal select control depending
on selection. The motor currents and the condition of the pressure switches
are registered. The points of time when the pressure detectors respond are
measured. After approx. 5 sec the pumps are switched off and the time
required until the pressure switch responds is measured and evaluated.
Save Save stores the measured values to the log file under the heading of Media
supply.
Media supply
Deviations of measurements Deviations may occur:
z During the first test run (if any air is still in the water circuit)
z If the amount of water in the water tank is insufficient
z After filling the water tank.
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Service Manual CEREC / inLab MC XL Individual Test Points
2.3.3 Light Barriers, Door Switch, Temperature
Sensor and Motor Stop Positions
Purpose of Test: This test serves to evaluate the safe functioning of the light barriers and check
the door switch, the temperature sensor and the motor stop positions.
Light barrier When the end position is located, the slot of the gear is measured via the
width and height at which the stepping motor positions are registered with the
flanks.
The light barriers to be tested can be selected in all variations. If no light
barrier is selected, the Start button is not active. Default setting: All light
barriers selected.
Switch - light barrier
Door switch/Tank switch The current state of the door switch and tank switch can be checked via a
status bar display.
Switches - Door and tank switch
Control keys The current state of the control keys can be checked via a status bar display.
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Switches - Control keys
Display / Illumination The selected pattern is shown on the display as a display test.
The "Illumination" button tests all colors of the milling chamber illumination:
z white (milling, default color)
z blue (scanning)
z green (operation completed)
z red (error / Stop button pressed)
Switches - Display / Illumination
Adjustment
ATTENTION: Open block / Close block
Place a block in the block axle to test the Open block / Close block function.
The motors are moved to these positions to test the motor stop positions.
Depending on which button is selected, the motors move to the
corresponding position and stop there. The motors can be reset to their home
positions by pressing the "Home" button.
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Switches - Adjustment
A Home position D Stop position for tool
change (set 2)
B Stop position for tool
change (set 1)
C Aux. position for replacing
components
E Open block
F Close block
2.3.4 Stepping motor test
Purpose of Test: This test serves to evaluate the functioning of the stepping motors. The
stepping motors are tested and evaluated for this purpose. In addition, this
test can also be used to break in the milling machine.
ATTENTION: Blocks in the block axle!
Remove any blocks possibly present from the block axle.
Procedure It is possible to individually trigger and test the stepping motors in various
combinations. The stepping motors are run at various speed settings and
evaluated via an acceleration table.
Display of test results In order to satisfy different requirements for adjustment and testing purposes,
this test also offers the option of choosing between data summation and
display of the results for individual test runs.
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Individual Test Points Service Manual CEREC / inLab MC XL
Stepping motor test
1 Activation of the stepping motors at a variously adjustable torque
(recommended setting: 4).
2 Longit. movement (linear)
3 Rotary movement (rotation)
2.3.5 Stepping motors - Single step
Warning on stepping motor test
NOTE:
Observe the warnings in the opened dialog.
Purpose of Test: The test is used to control the motors individually in case of malfunction.
Procedure Using the "Technique" buttons, you can move the individual motors in the
longitudinal and rotary directions.
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Service Manual CEREC / inLab MC XL Individual Test Points
Grind = left
Mill = right
Under the option "Longitudinal axis tolerance control"the
"Grind", "Block" and "Mill" axles can be extended by a permanently
set value. This specific feed supports servicing e.g. when replacing a DC
motor or cleaning the block chuck. It is activated by double-clicking the
corresponding activation button .
Left
(Grind)
Block Right
(Mill)
One longit. step (L) equals 6,25 μm 6,25 μm6,25 μm
One rotational step (R) equals approx.
0.01° (0.6')
approx.
0.06° (3.6')
approx.
0.01° (0.6')
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Individual Test Points Service Manual CEREC / inLab MC XL
2.3.6 Stepping motor - Step response
Purpose of Test: This test serves to detect the damping behavior of the stepping motors.
Stepping motor - Step response
1 Height of step (-7 to +7).
Recommended setting: +7
2 Response time of damping behavior in [ms]
Procedure A test cycle is run following each start.
If no motor is selected, the "START" button is not active.
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2.3.7 DC motors 'Load/inlet'
Purpose of Test: This test serves to run in the DC motors and check them for proper functioning
under continuous load.
Procedure The DC motors are tested through operation at a constant current. The
resulting speed provides an indication of the running resistance of the motor.
Stepping motors 'Load/Run-in'
1 Force reference value 3 Measure of speed
fluctuations
2 Actual speed
The two motors (left motor, right motor) can be selected together or
separately. The speed range of the DC motor can be tested selectively via the
adjustable motor current. If no motor is selected, the START button is not
active. Default: Both motors selected.
Test run: The test runs in an endless loop until the "Stop" button is actuated. The
current measured values are displayed. A test run consists of one part "run
time" and one part "pause" for each motor.
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2.3.8 DC motors 'Touch'
Purpose of Test: This test is used to check the two DC motors for proper functioning in the Low-
speed mode.
Procedure The DC motors are tested by adjusting them to the touch speed (in the
relevant directions of rotation). Then the relevant data are determined.
DC motors 'Touch'
1 Measure of speed fluctuation
2 Pulse-width modulation
The possible motors can be selected either together or separately.
If no motor is selected, the "Start" button is not active. Default: Both motors
selected.
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2.3.9 DC motors 'Speed'
Purpose of Test: This test is used to check the two DC motors for proper functioning in the
High-speed mode.
DC motors 'Speed'
1. Measured speed 3. Measured motor current
2. Fluctuation of speed 4. Fluctuation of motor
current
Procedure The DC motors are tested by accelerating them from a standing start to
operating speed and then measuring the relevant data, e.g. speed and
current.
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2.3.10Sensor test
Purpose of Test: This test serves to evaluate the functioning and accuracy of the scanner.
Sensor test
1 Laser active signal level 6 Measuring angle
2 Laser inactive signal level 7 Dimension of noise level
3 Distance between scanner
and measuring point
4 Focal size 9 Scanner
5 Selection of laser diode
Procedure The various required measurements are performed with the help of the
calibration phantom.
The functions to be tested can be selected in different variations. If no function
is selected, the "Start" button is not active. Default setting: Test all
functions.
8 This test is deactivated in
the factory setting
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