Sirona Cerec Service manual

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Sirona Dental Systems GmbH
Service Manual CEREC / inLab MC XL	Contents

Contents

1

2

General information ...................................................		7
1.1	General information ...........................................	8
1.2	Additional information ........................................	9
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

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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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

4.4Replacing 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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General information

CEREC / inLab MC XL

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

Nominal line voltage ranges

Wireless phone interference with medical electrical equipment:

ESD warning label

ESD protective measures

Measurements

When replacing parts

1.1General information

The CEREC MC XL / inLab MC XL milling unit can be operated in the following

znominal line voltage ranges: 100 - 230VAC; 50 / 60 Hz

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:

zProcedures for preventing electrostatic charge build-up (e.g. air conditioning, air moistening, conductive floor coverings and non-synthetic clothing)

zDischarging the electrostatic charges of your own body on the frame of the unit, the protective ground wire or large metallic objects

zConnecting yourself to ground using a wrist band.

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.

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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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)

Tools

zAllen key angled, size (mm) 1.27 (0.05”); 1.3;6

zOpen-end wrench, size (mm) 6;10

zTORX screwdriver, size 6; 8; 10; 20

zPhillips screwdriver, size 1

zBlade screwdriver, insulated, sizes 2 and 3

zBox wrench: 6mm; 7mm

zUniversal pliers

zFlat pliers

zTorque wrench, 1.1Nm

zFeeler 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

zDigital Multimeter, Accuracy Class 1

zSoldering tool for repairing cables

zDiagonal-nosed cutting pliers

zCable ties

zTeflon tape

zLoctite 221

zCalibration set (supplied with unit)

zStep Bur 12 and Step Bur 20

zTorque wrench for changing the milling instruments (order no: 61 19 346)

zFuses (recommended):

F1 (2 pcs)

T5H250V

Order No.: 20 33 111

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Description of the service software

CEREC / inLab MC XL

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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Basic structure of test dialogs	Service Manual CEREC / inLab MC XL

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).

2.2Basic 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.

¾Establish a data link if necessary.

¾Click the "Add automatically" button.

ªThe acquisition unit / PC installs the milling unit.

¾Select 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.

zClick the "Yes" button:

The old file is then deleted and a new log file is created.

zClick 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

ATests performed only at the factory

In the "Test selection"dialog box you can select

za test for the complete milling unit ("Total test") or

zan 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.
I	Press "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.

2.3Individual 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.

Serial Communication
1	Result of last test run	3	Average measured
			transmission time
2	Minimum measured	4	Maximum measured
	transmission time		transmission time

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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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	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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Individual Test Points	Service Manual CEREC / inLab MC XL

	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	E	Open block
	change (set 1)
C	Aux. position for replacing	F	Close block
	components

	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

1Activation of the stepping motors at a variously adjustable torque (recommended setting: 4).

2Longit. movement (linear)

3Rotary 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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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	Block	Right
	(Grind)		(Mill)
One longit. step (L) equals	6,25 μm	6,25 μm	6,25 μm
One rotational step (R) equals	approx.	approx.	approx.
	0.01° (0.6')	0.06° (3.6')	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'

1Measure of speed fluctuation

2Pulse-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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Sirona Dental Systems GmbH	2 Description of the service software
Service Manual CEREC / inLab MC XL	Individual Test Points

	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 Description of the service software	Sirona Dental Systems GmbH
Individual Test Points	Service Manual CEREC / inLab MC XL

	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	8	This test is deactivated in
		and measuring point		the factory setting
	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.

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