Sirona Cerec 3 Service manual
$
7IVZMGI1ERYEP
IMPORTANT:
• Please note that we have revised this version of the Service
Manual.
It is therefore necessary that you no longer use the first edition.
• In case of faults which you are unable to eliminate with the help
of this manual, please contact our Customer Service.
• It is essential that you take this Service Manual with you for
every visit to a customer.
Furthermore, you must always have the spare parts list and
the wiring diagrams with you as well.
You can order additional copies of this Service Manual under the
• order number
department
See reverse side of manual for address.
58 35 694
in Bensheim.
GZP
from our
:IVWMSR
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$
7IVZMGI1ERYEP
Additional requirements:
• Spare parts list
Order No. 58 62 581
• Circuit diagrams
Acquisition unit: Order No. 58 35 710
Milling unit: Order No. 58 35 728
CEREC 3 / CEREC Scan
• Tools
– Hexagonal screwdriver (90° offset): Sizes 1.5; 2; 2.5; 4; 6
– Fork wrench, sizes 5.5; 8; 10; 14
– Torque screw driver, sizes 5, 6, 20, 25, 40
– Philips-head screw driver Size 1
– Slot screw driver, insulated, Size 2, 3
– Socket wrench 8mm
– Cutting pliers
– Special tool for monitor nut
– Special tool for locking button: Order No.: 59 08 947
• Accessories
– Digital multimeter, accuracy class: 1
– Soldering tool for repairing cables
– Side cutting pliers
– Cable ties
– Teflon tape
– PS2 mouse (recommended)
– PS2 keyboard (recommended)
– 3.5” disk
– Calibration piece and pins (recommended)
– Fuses (recommended):
F1/F2 (2 pcs.) 5AT, Order No.: 20 33 111
F1/F2 (2 pcs) for acquisition unit starting with Ser. No.: 3300
6,3 AT, Order No.: 10 77 452
F3 1.25AL Order No.: 59 15 181
F4 2AT Order No.: 10 80 522
General 1
Service Software
Trouble Shooting: Milling Unit
Trouble shooting: Acquisition Unit
Settings
2
3
4
5
Acquisition Unit: Repairs
Milling Unit: Repairs
Installing Software
6
7
8
List of Contents
General ................................................................................................................................... 1-1
1
1.1 General Notes .............................................................................................................. 1-3
Service Software .................................................................................................................... 2-1
2
2.1 General Notes .............................................................................................................. 2-3
2.2 Basic Structure of Test Dialogs .................................................................................... 2-5
2.3 Individual Test Points ................................................................................................. 2-10
Trouble Shooting: Milling Unit................................................................................................. 3-1
3
3.1 Device cannot be switched ON. Green LED (Ready for operation) not illuminated... 3-5
3.2 No connection to PC / acquisition unit. Software cannot be installed .......................... 3-7
3.3 No air pressure ............................................................................................................. 3-9
3.4 Fan not running. Unit shuts down completely after a short time ................................ 3-11
3.5 Water pump: Pressure too low ................................................................................... 3-13
3.6 Defective light barrier ................................................................................................. 3-15
3.7 Door switch. Please close milling chamber door........................................................ 3-17
3.8 Motor locking positions: Problems changing grinders ................................................ 3-19
3.9 Stepping motors (milling unit). Loss of steps.............................................................. 3-21
3.10 Touch errors ............................................................................................................... 3-23
3.11 Trouble shooting. Defective CCP board..................................................................... 3-25
Trouble shooting: Acquisition Unit.......................................................................................... 4-1
4
4.1 System cannot be switched ON ................................................................................... 4-7
4.2 PC not booting properly I.............................................................................................. 4-9
4.3 PC not booting properly II........................................................................................... 4-11
4.4 PC does not respond during switch-on, PC power supply does not start .................. 4-12
4.5 Further PC faults ........................................................................................................ 4-14
4.6 Monitor image flickering ............................................................................................. 4-15
4.7 No monitor display...................................................................................................... 4-17
4.8 Incorrect monitor display format size.......................................................................... 4-19
4.9 Monitor: Color shade/gray scale is too weak.............................................................. 4-21
4.10 Trackball not functioning ............................................................................................ 4-23
4.11 Trackball buttons not functioning................................................................................ 4-25
4.12 Pedal not functioning .................................................................................................. 4-27
4.13 Keyboard not functioning /defective ........................................................................... 4-29
4.14 No camera image ....................................................................................................... 4-31
4.15 Incorrect measuring sensor setting ............................................................................ 4-33
4.16 Camera calibration: messages................................................................................... 4-35
4.17 Interference at radio interface .................................................................................... 4-37
4.18 No sound or sound level too low ................................................................................ 4-41
4.19 No Sirocam camera image......................................................................................... 4-43
4.20 Sirocam camera image interference .......................................................................... 4-45
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V
List of Contents
4.21 SIROCAM camera: Incorrect image settings .............................................................. 4-47
4.22 Digital X-ray problems ................................................................................................. 4-49
Settings....................................................................................................................................5-1
5
5.1 Monitor Settings ............................................................................................................ 5-3
5.2 Calibrating the 3D camera ............................................................................................ 5-4
5.3 Pairing the DECT-radio interface (EU) .......................................................................... 5-5
5.4 Replacing a module of the DECT radio interface (EU) ................................................. 5-8
5.5 Pairing the Futaba radio interface (USA/Japan) ........................................................... 5-9
Acquisition Unit: Repairs .........................................................................................................6-1
6
6.1 Electrical and Electromechanical Components............................................................. 6-4
6.2 Mechanical components ............................................................................................. 6-30
Milling Unit: Repairs.................................................................................................................7-1
7
7.1 Milling Unit: General Activities....................................................................................... 7-3
7.2 Replacing the Scanner.................................................................................................. 7-5
7.3 Replacing the Drive and/or Motor ............................................................................... 7-11
7.4 Checking / Adjusting Stop positions ............................................................................ 7-13
7.5 Stepping Motors: Replacing / Adjustment ................................................................... 7-15
Installing Software ...................................................................................................................8-1
8
8.1 Acquisition Unit: Network Installation ............................................................................ 8-3
8.2 How to install an MO drive .......................................................................................... 8-25
VI
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CEREC 3
1
General
List of Contents
General
List of Contents
1.1 General Notes ..................................................................................................................... 1-3
1 - 2
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1.1 General Notes
1.1 General Notes
Nominal line voltage ranges
Faults in electronic medical
equipment caused by mobile
phones
Opening the device
Measurements
The CEREC® 3 acquisition unit can be used in the following
voltage ranges
• Europe 230VAC / 50Hz
• USA 115VAC / 60Hz
• Japan 100VAC / 50Hz and 60Hz
The CEREC 3 / CEREC Scan milling unit can be used in the following
nominal line voltage ranges
• 100V
When opening the device:
Always switch OFF the device before connecting the measuring instrument.
Select the correct current/voltage type and adjust the measuring range to
match the expected readings.
:
:
230VAC; 50/60Hz
–
In order to ensure safe operation of electronic medical equipment,
the use of mobile phones in practices and hospital areas is strictly
prohibited.
Please observe the necessary precautions when handling
printed circuit boards (ESD).
Touch a ground point to discharge static electricity before
handling any components.
nominal line
1.1
When replacing parts
Repairing and/or upgrading the
PC drawer
Disposal
Perform continuity tests only on devices which are switched off.
Switch OFF the device before replacing any parts.
For safety reasons
supply when replacing parts around the line transformer.
The item numbers for ordering spare parts can be found in the
spare parts list, Order No. 58 62 581.
The diagrams contained in the spare parts list provide a useful guide when
replacing parts.
Replace the broken warranty seal on the bottom side of the PC drawer with
the supplied seal of conformity.
Please observe the instructions found in the relevant user guide.
the device should be disconnected from the power
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1 - 3
CEREC 3
2
Service Software
List of Contents
Service Software
List of Contents
2.1 General Notes ..................................................................................................................... 2-3
2.2 Basic Structure of Test Dialogs ........................................................................................... 2-5
2.3 Individual Test Points .......................................................................................................... 2-10
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2.1 General Notes
NOTE
i
2.1 General Notes
Test requirements
Service Software Log File
Requirement for all tests:
• PC / acquisition unit are switched on and ready for operation.
• PC / acquisition unit and milling unit are interconnected (per interface ca-
ble or radio link)
• The software has been loaded for the milling unit (see Operating Instructions for Milling Unit/Milling Unit Scan, Switching the units on,
start-up
• 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).
• The tools (burs) must be installed already during operation of the water
pump.
• During operation of the water pump, the air pump must always be running
to protect the gearing 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 can not be performed.
The service software is a component of the product software. This software
generates a log file for all tests performed.
This log file is located on delivery in the directory
c:\programme\Cerec\System\Service\Protocols
Test file_XXXXXXXXXXXX.TXT
The Xs here denote the serial no. of the controller board.
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 exits from 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.
).
and is named
Initial
2.1
Assessment scores
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After completing a test section, the log file must be saved under a new name
to a diskette belonging to the corresponding unit.
There are three different scores which can be assigned to test results:
• Passed fully (green label)
• Passed (yellow label)
• Not passed (red label)
These assessment categories apply starting with
R600
The score
case
n.a.
Passed
(not applicable) will be written to the log file for this score.
(yellow label) may be irrelevant for a specific test. In this
software version V1.1
2 - 3
2.1 General Notes
CAUTION
To ensure trouble-free operation of the system, all test results should be labeled
"Passed fully"
If the test results are marked
this point of time.
If the test results are labeled
fault(s)
.
"Passed"
"Not passed"
, uncritical changes have occurred at
, you must find and correct the
Example of test protocol:
Path:
c:\programme\Cerec\System\Service\Protocols
i
NOTE
If the milling unit housing is left open, the temperature switch on the CC PC
board may cut out after a short time (T>90°C). The cooling fan can work properly only with the cover closed.
Overview of gearing unit:
Gearing 3
Gearing 1
Gearing 2
(without function)
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2.2 Basic Structure of Test Dialogs
NOTE
i
CAUTION
NOTE
i
CAUTION
NOTE
i
2.2 Basic Structure of Test Dialogs
For a functional description of the menu items, see the user’s manual.
Password protection
Via the
• select a wide range of Service functions with
The Service functions may be used only by authorized service technicians
who have been trained by Sirona.
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:
Example: 24.05.2001 becomes 5042
Service
Password
number
1 2. number of the current month
2 1. number of the current month
3 2. number of the current day
4 1. number of the current day
menu you can ...
Settings/Service...
Generated from
2.2
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Since the password is thus valid for only one day, it may be passed on to the
user in exceptional cases, e.g. when providing him with emergency help over
the phone.
The password should always be treated confidentially. Before entering the
password, always determine the date as inconspicuously as possible.
If you enter the correct password, and the commands are nevertheless not enabled, first check the system date of 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 status line.
2 - 5
2.2 Basic Structure of Test Dialogs
Now enter the password.
Log file
If you confirm this
open.
i
NOTE
If a log file named after the milling unit already exists at the time of the program
start, a confirmation query will appear asking if the data from the new test run
should be appended to the existing file or it should be deleted first.
i
NOTE
If the display "…0000.txt" appears, this means that there is no connection to
the milling unit.
Service
dialog with
Yes
, the
Test selection
dialog box will
2 - 6
Possible causes:
• The CEREC 3 program has been started more than once
• There is no (cable or radio-link) connection between the milling unit and
the acquisition unit/PC
• The software download to the milling unit has not been completed.
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Test selection dialog
Tests performed only at
the factory
2.2 Basic Structure of Test Dialogs
2.2
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In the
Test selection
• a
Total test
• an individual test.
The selected test dialog is then opened by clicking on
dialog you can select …
(default selection on delivery) or
OK
.
2 - 7
2.2 Basic Structure of Test Dialogs
Example: Total test
1
2
10
3
4
5
6 789
Number of test runs completed since the last time the
1.
tuated.
Status bar for current state of test run.
2.
Check boxes for selecting (activating/deactivating) the tests available in
3.
this test dialog.
Check box for selecting the options possible in this test dialog.
4.
Number of test results since the last
5.
– Passed fully
– Passe d
– Not passed
Pressing
6.
The test run will be repeated until it is interrupted with 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.
The test is canceled as soon as possible with
7.
The test in progress at the time of cancellation is not counted. All inputs are
now possible again.
stores all existing data to the log file. The data are appended to the
Save
8.
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
Once a test run has been saved to the log file, a new test run must be started before selecting the save function again.
initiates the test run with the selecting settings.
Start
Start:
Stop
.
button was ac-
Start
OK
).
2 - 8
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2.2 Basic Structure of Test Dialogs
Press
9.
If any data exist and have not yet been saved, you will be queried whether
or not the test data should be saved.
Result:
10.
• No color =>
• Green => Measurement shows that test was
• Yellow => Measurement shows that test was
• Red => Measurement shows that test was
to quit the test dialog and return to the service dialog.
Back
measurement available yet
No
fully
passed
Passed
Passed
Not
2.2
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2.3 Individual Test Points
g
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 through the
standard line (RS-232 max. 10 m), but via other types of connections instead
e.g. an infrared link, a DECT coupling or over longer distances via interface
converters e.g. RS-422.
The transmission time between the beginning of transmission and the end of
reception is calculated for a specific data 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.
Result of last test run
Minimum measured transmission time
e measured transmission time
Avera
Maximum measured transmission time
Typical values:
COM1
Baud rate: 115200
Cable 400-500ms –
Radio
i
The limiting values and color coding refer to a
baud rate of 115200.
Europe 600-750ms –
USA/Japan – 2-3s
NOTE
COM1
Baud rate: 19200
Purpose of Test:
2 - 10
2.3.2 Media supply
To check the media supply (air, water, fan) for proper functioning and test the
pressure switches and the run-up time of the pump.
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2.3 Individual Test Points
NOTE
i
Procedure
Save
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 seconds the pumps are switched off and the time
required until the pressure switch responds is measured and evaluated.
Save stores the measured values to the log file under the heading of Media
supply.
2.3
Deviations of measurements
The limiting values apply to a completely filled water circuit.
Deviations may occur:
• During the first test run (if any air is still in the water circuit)
• If the amount of water in the water tank is insufficient
• After filling the water tank.
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2.3 Individual Test Points
2.3.3 Light Barriers, Door Switch, Temperature Sensor and Motor Stop Positions
Purpose of Test:
Light Barriers
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.
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.
Door Switch/Control Keys
2 - 12
The current state of the door switch and control keys can be checked via a
status bar display.
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2.3 Individual Test Points
Temperature
Motor Stop Positions
A temperature display has been realized to check the temperature of the milling machine.
In the
Test selection
setting.
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
dialog,
Motor stop positions
is defined as the default
button.
Home
2.3
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Stop position for tool change
Aux. position for replacing components
If the home position can not be reached or lost steps occur during motor
movement, this will be reported.
2 - 13
2.3 Individual Test Points
2.3.4 Stepping Motor Test
CAUTION
Observe the warnings in the
Testpiece
dialog.
Purpose of Test:
Procedure
Display of Test Results
Longit. movement
This test serves to evaluate the functioning of the stepping motors. The stepping motors are tested and evaluated for this purpose. The evaluation is made
based on a factor for the reserve capacity of each stepping motor. In addition,
this test can also be used for installation and adjustment purposes as well as
to break in the milling machine.
It is possible to individually trigger and test the stepping motors in various
combinations.
The stepping motors are run at various speed settings via an acceleration
table and the resulting step losses are measured. The number of step loss
events is then registered and evaluated. Finally, a reserve capacity is
assigned to each motor based on this data.
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.
Rotation
2 - 14
Standard
Refers to Stage 2
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2.3 Individual Test Points
CAUTION
2.3.5 Stepping Motors - Single Step
Observe the warnings in the opened dialog.
2.3
Purpose of Test:
Procedure
The test is used to control the motors individually in case of malfunction.
Using the
nal and rotation directions.
buttons, you can move the individual motors in the longitudi-
Move
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One longitudinal step (L)
equals
One rotational step (R)
equals
Grind Block Mill
12.5µm 12.5µm 12.5µm
approx. 0.04°
(2.5’)
approx. 0.13°
(7.7’)
approx. 0.04°
(2.5’)
2 - 15
2.3 Individual Test Points
2.3.6 DC Motors "Inlet/Load"
Purpose of Test:
Procedure
Motor current
Always 0, since motor current preset
Actual speed
Measure of speed fluctuation
This test serves to run in the DC motors and check them for proper functioning
under continuous load.
The DC motors are tested through operation at a constant current. The resulting speed provides an indication of the running resistance of the gearing units.
The two motors (Motor 1 and Motor 3) can be selected together or separately.
If no motor is selected, the Start button is not active. Default: Both motors
selected.
The test runs in an endless loop until the
Test Run
The current measured values are displayed. A test run consists of one part
run time and one part pause for each motor.
:
button is actuated.
Stop
Purpose of Test:
2 - 16
2.3.7 DC motors "Touch"
This test is used to check the two DC motors for proper functioning in the Lowspeed mode.
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2.3 Individual Test Points
Procedure
Measured motor current
Measured speed
Fluctuation of speed
The DC motors are tested by adjusting them to the touch speed (in the relevant directions of rotation). Then the relevant data are determined.
The possible gearing units (1,3) can be selected either together or separately.
The
Default: Both motors selected.
button remains inactive as long as no gearing has been selected.
Start
2.3
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2.3 Individual Test Points
(
2.3.8 DC motors ”Speed”
Purpose of Test:
Fluctuation of speed
Measured motor current
Fluctuation of motor current
Run-up time to 100%
Run-up time to 70%
This test is used to check the two DC motors and their gearings for flawless
functioning in the High-speed mode.
Measured speed
Maximum value of
measured speed
Minimum value of
measured speed
n
r.p.m.)
Max. speed
100%
70%
Procedure
The DC motors are tested by accelerating them from a standing start to working speed and then measuring the relevant data.
i
NOTE
The current is monitored during all measurements. The maximum current
must not stop for longer than 2 seconds; otherwise the test will immediately be
interrupted by an error message.
Min. speed
RMS speed
t (s)
2 - 18
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