Welch Allyn Kreativ Mach 6 User manual

Mach 6.0

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Operator Manual

Air Abrasion Unit

SERVICE MANUAL

Manufactured by

Welch Allyn Kreativ, Inc. (USA) 7360 Carroll Road San Diego, CA 92121

990277 Rev. A

reproduced without written permission from Kreativ, Inc.

European Authorized Representative

Welch Allyn LTD.

Navan, Co. Meath

Republic of Ireland

Ph: 353-46-79060

1. GENERAL INFORMATION......................................................................................................................................................5

1.1 INTRODUCTION.......................................................................................................................................................................5

1.2 PURPOSE OF MANUAL...........................................................................................................................................................5

1.3 SAFETY SUMMARY................................................................................................................................................................5

1.4 APPLICATIONS........................................................................................................................................................................6

1.5 CONTRAINDICATIONS............................................................................................................................................................7

1.6 E NVIRONMENTAL CONSIDERATIONS..................................................................................................................................7

1.7 SYSTEM SPECIFICATIONS .....................................................................................................................................................8

2. THEORY OF OPERATION.......................................................................................................................................................9

2.1 INTRODUCTION.......................................................................................................................................................................9

2.2 FUNCTIONAL DESCRIPTION.................................................................................................................................................9

2.3 CONTROLS AND CONNE CTIONS MACH 6.0........................................................................................................................9

2.4 PNEUMATIC COMPONENTS DESCRIPTION.....................................................................................................................14

2.5 E LECTRICAL / ELECTRONIC COMPONENT DESCRIPTION.............................................................................................16

3. ROUTINE MAINTENANCE .....................................................................................................................................................19

3.1 ROUTINE MAINTENANCE OF THE MACH 6.0 .................................................................................................................19

3.2 DAILY REQUIREMENTS.......................................................................................................................................................19

3.3 WEEKLY REQUIREMENTS...................................................................................................................................................20

3.4 MONTHLY REQUIREMENTS...............................................................................................................................................20

3.4 QUARTERLY REQUIREMENTS............................................................................................................................................21

3.5 BI-ANNUAL REQUIREMENTS.............................................................................................................................................21

3.6 ANNUAL REQUIREMENTS...................................................................................................................................................22

3.7 MAINTENANCE SCHEDULE................................................................................................................................................23

3.7 MAINTENANCE PROCEDURES............................................................................................................................................24

4. TROUBLESHOOTING............................................................................................................................................................32

4.1 POWDER FLOW PROBLEMS.................................................................................................................................................32

5. INSTALLATION CONSIDERATIONS ................................................................................................................................33

5.1 SITE PREPARATION FOR KREATIV AIR ABRASION SYSTEMS......................................................................................33

5.2 PNEUMATIC FOOTSWITCH ADAPTER INSTALLATION INSTRUCTION.......................................................................36

6. SPARE PARTS LIST...............................................................................................................................................................37

6.1 POWDER FEED CHAMBER (K170180) COMPONENTS......................................................................................................37

6.2 PINCH TUBE V ALVE (K170179) COMPONENTS................................................................................................................38

6.3 SYSTEM MANIFOLD ASSEMBLY (K170175)......................................................................................................................39

6.4 AIR IN FILTER ASSEMBLY (K170198) COMPONENTS.....................................................................................................39

6.5 AIR OUT FILTER ASSEMBLY (K170203) COMPONENTS.................................................................................................40

6.6 MACH 6 MANIFOLD ASSEMBLY K170202) COMPONENTS...........................................................................................40

6.7 E XHAUST CATCH ASSEMBLY (K170204) COMPONENTS................................................................................................41

6.8 PINCH V ALVE REGULATOR ASSEMBLY (K170187) COMPONENTS...............................................................................42

6.9 SYSTEM REGULATOR ASSEMBLY (K170181) COMPONENTS.........................................................................................43

6.10 TUBING.................................................................................................................................................................................43

6.11ACCESSORIES , HANDPIECES, NOZZLES, AND MISCELLANEOUS..................................................................................43

6.12 ADHESIVES...........................................................................................................................................................................44

6.13 CHASSIS COMPONENTS......................................................................................................................................................44

6.14 E LECTRICAL COMPONENTS..............................................................................................................................................44

6.15 SHIPPING ACCESSORIES.....................................................................................................................................................44

6.16 MAINTENANCE KITS.........................................................................................................................................................44

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7. WARRANTY, RETURNS AND ADJUSTMENTS...............................................................................................................45

7.1 RETURNS AND ADJUSTMENTS...........................................................................................................................................45

7.2 L IMITED WARRANTY..........................................................................................................................................................45

6.3 STORAGE AND SHIPMENT ..................................................................................................................................................45

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TABLE OF FIGURES

FIGURE 1 SYSTEMS REAR PANEL CONNECTIONS......................................................................................................................11

FIGURE 2 SYSTEM FRONT PANEL CONTROLS AND CONNECTIONS .......................................................................................11

FIGURE 3 HAND PIECE HOLDER IN HORIZONTAL AND V ERTICAL POSITION......................................................................12

FIGURE 4 INTERNAL COMPONENTS LOCATIONS.......................................................................................................................13

FIGURE 5 INTERNAL COMPONENTS LOCATIONS.......................................................................................................................13

FIGURE 6 INTERNAL COMPONENTS LOCATIONS.......................................................................................................................14

FIGURE 7 PNEUMATIC TUBING DIAGRAM..................................................................................................................................15

FIGURE 8 PNEUMATIC BLOCK DIAGRAM....................................................................................................................................16

FIGURE 9 DISPLAY CONTROL PANEL ..........................................................................................................................................17

FIGURE 10 INTERCONNECT DIAGRAM.........................................................................................................................................18

FIGURE 11 SOLENOID V ALVE MANIFOLD ASSEMBLY..............................................................................................................18

FIGURE 12 TEST CONNECTIONS DIAGRAM.................................................................................................................................31

FIGURE 13 SOLENOID DRIVER CONNECTION LOCATIONS.......................................................................................................31

FIGURE 14 WELCH ALLYN KREATIV AIR ABRASION SYSTEM CONNECTIONS...................................................................33

FIGURE 15 CONNECTION OF AIR ABRASION SYSTEM TO IN-OFFICE AIR SUPPLY.............................................................34

FIGURE 16 CONNECTION OF WELCH ALLYN KREATIV COMPRESSOR SYSTEM ..................................................................34

FIGURE 17 USING BOTTLED/TANKL NITROGEN........................................................................................................................35

FIGURE 18 PNEUMATIC FOOT SWITH ADAPTER SCHEMATIC DIAGRAM..........................................................................36

FIGURE 19 CANISTER POWDER FEED ASSEMBLY COMPONENTS DIAGRAM (170180)........................................................37

FGURE 20 PINCH TUBE V ALVE ASSEMBLY COMPONENTS DIAGRAM (K170179) .................................................................38

FIGURE 21 SOLENOID MANIFOLD ASSEMBLY (K170175).........................................................................................................39

FIGURE 22 AIR IN FILTER ASSEMBLY COMPONENTS DIAGRAM (K170198).........................................................................39

FIGURE 23 AIR OUT FILTER ASSEMBLY COMPONENTS DIAGRAM (K170203).....................................................................40

FIGURE 24 MACH 6 MANIFOLD ASSEMBLY COMPONENTS DIAGRAM (K170202)..............................................................40

FIGURE 25 E XHAUST CATCH ASSEMBLY COMPONENTS DIAGRAM (K170204)....................................................................41

FIGURE 26 PINCH V ALVE REGULATOR ASSEMBLY COMPONENTS DIAGRAM (K170187) ...................................................42

FIGURE 27 SYSTEM REGULATOR ASSEMBLY COMPONENTS DIAGRAM (K170181).............................................................43

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1. General Information

1.1 Introduction

The Welch Allyn Kreativ Mach 6 is a compact, highly reliable, state of the art instrument designed for Air Abrasive Micro Dentistry. They are designed as a means of removing tooth structure and other materials to prepare teeth for restoration, and as an adjunct to the high speed dental handpiece and bur.

Note: Clinical use of the Mach 6 Air abrasion system for procedures not included or suggested in this instruction guide is not advised. Similarly, the Mach 6 system should be only used by dental professionals who have practiced on extracted teeth and who are thoroughly familiar with this manual.

1.2 Purpose of Manual

This manual should be thoroughly studied before installing, using, or performing maintenance on the equipment. Please feel free to call Welch Allyn Kreativ or their representative if you need additional information regarding installation, operation, or service of the instrument.

Information essential to the installation, operation, and routine maintenance of the Mach 6 system manufactured by Welch Allyn Kreativ, is included in this manual. The instructions are written specifically for personnel who have been trained to perform maintenance on the unit.

1.3 Safety Summary

1.3.1 Read This Manual

Prior to operating or servicing the Mach 6.0, this manual must be read and understood. If something is not clear, call the factory for assistance before proceeding. Keep this and other associated manuals for future reference.

1.3.2 Use Proper Power Connections

Use proper wiring and connection methods to satisfy appropriate electrical codes.

1.3.3 Do Not Remove Covers Or Panels

To avoid electrical shock hazard, do not remove covers or panels when power is supplied to the unit. Do not operate the device when the covers or panels are removed.

1.3.4 Shock Hazard

Connect the Mach 6.0 to a properly grounded outlet in accordance with the National Electrical Code. WARNING: Do not under any circumstance remove the ground wire or the ground prong from any power plug. Do

not use extension cords with the Mach 6.0 equipment.

1.3.5 Device Labeling

Do not under any circumstances remove any CAUTION, WARNING, or other descriptive labels from the device.

1.3.6 Other Safety Statements

Other safety statements are included within the manual text and are identified as follows:

• CAUTION: Caution statements identify conditions or practices that could result in equipment or

property damage.

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• WARNING: Warning statements identify conditions or practices that could result in personal injury or

loss of life.

1.3.7 Cautions

The handpiece should be directed precisely at surfaces and tooth structures which are to be modified or removed. The nozzle tip should be placed a few millimeters from the surface and angled toward the area to be removed or

modified. Unlike the high speed handpiece, the Mach 6 nozzle cuts only directly from the end; there is no side cutting.

Do not attempt to service the unit beyond those items described in the maintenance section. Call Welch Allyn Kreativ or their representative for instructions.

Do not substitute non-Welch Allyn Kreativ , materials or accessories. Use of materials or accessories supplied by other manufacturers may result in damage to the unit and will void the factory warranty.

Use only clean dry air. Make sure that your air compressor system utilizes air dryer filter systems and that they are fully operational. Any moisture or oil in the air supply will adversely affect the performance of your Mach 6 system.

When using the Mach 6 system, check to be sure that your air system produces at least 80 psi (550 kPa) at 1.5 cfm (42.5 liter/min).

Sound clinical judgment, good common sense, and proper training are essential to the successful service of the unit in order to provide safe and efficient patient care.

1.3.8 Safety Markings on Labels

On (power: connected to the mains)

1.4 Applications

Alternating current

Protective earth (ground)

Attention, consult accompanying documents

Off (power: disconnection from the mains)

Type B equipment

The Mach 6.0 is designed for simple, reliable, and efficient operation with minimal maintenance. The Welch Allyn Kreativ Mach 6.0 system is designed to deliver a controlled flow of abrasive powder and air mixture through a very precise nozzle. Applications include amalgam removal, cutting, abrading, deburring, peening, and etching of tooth structures and other materials.

990277 Rev. A Page 6 of 46

1.5 Contra-indications

Welch Allyn Kreativ Air Abrasion products are designed for use by and on the order of a dentist. Furthermore, Welch Allyn Kreativ products are not intended to be used outside the device’s specifications or limitations. Results are not guaranteed or warranted if other than approved (Welch Allyn Kreativ) disposable products are used.

1.6 Environmental Considerations

Prior to the installation of the Mach 6.0 air abrasion unit, it will be necessary to provide utilities and create an environment suitable for the trouble-free operation of the equipment.

1.6.1 POWER

All components operate on 100 - 240 VAC 50/60 Hz, single phase power. The use of surge protectors is recommended when possible.

1.6.2 AIR

The Mach 6.0 air abrasion unit requires input air pressure at a minimum of 80 PSI and a maximum of 130 PSI. Air pressure can be delivered to the Mach 6.0 via a main office air compressor, a compact portable compressor, or compressed nitrogen.

1.6.3 Main Office Compressor

The main office compressor should be sized to deliver 80-130 PSI of constant, clean air pressure to the Mach 6.0 unit. The Mach 6.0 unit is equipped with an internal Coalescing Filter which ensures a clean and dry air supply stream. Under extreme environmental humid conditions an additional dryer is recommended to be installed on the air line between the compressor and Operatory Regulator. This will ensure extra protection to the Mach 6.0 unit. If the Operatory does not have the minimum air input requirement, the Mach 6.0 will not perform to the desired specification level and the customer should be informed that auxiliary air supply may be required.

1.6.4 Compressed Nitrogen

Compressed nitrogen can be used to supply the air pressure for the Mach 6.0 unit. There are variously sized tanks available from most local gas companies. The regulator on the nitrogen tank should not exceed 130 PSI.

990277 Rev. A Page 7 of 46

1.7 System Specifications

Power Requirements: 100-127 volt, AC, 50/60Hz, 0.75 A

220-240 volt, AC, 50Hz, 0.35 A

Air Requirements: 80-130 PSI (550-896 kPa) with at least

1.2 cfm (34 l/min) recommended Approximate Size: 10” W x 9” H x 15” D (cm W x 22.9 cm H x 38.1 cm D) Approximate Weight: 12 lbs. (5.5 kg) Environment Limitations: Operational Requirements:

Temperature: 50° F to 104° F (+10° C to 40° C)

Humidity: 30 % to 75 %

Atmospheric pressure range:

10.15 psia ( 70 kPa) to 15.37 psia (106 kPa)

Transport and Storage Requirements: Temperature: -40° F to 122° F (-40° C to 70° C) Humidity: 10 % to 90 % Atmospheric pressure range:

7.25 psia (50 kPa) to 15.37 psia Equipment Classification: The Mach 6 is a Type B device requiring an electrical earth

ground. This device is classified as ordinary with regard to protection against water ingress. The device is designed for continuous operation.

Electrical Fuses: There are no customer serviceable fuses.

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2. Theory of Operation

2.1 Introduction

The Mach 6.0 is an air abrasion system. An external air supply is required to mix abrasive powder and air in a pressurized chamber, which then moves through the nozzle tip of the handpiece. The Front panel control provides a means of adjusting the required air pressure and powder flow.

2.2 Functional Description

When the unit is initially turned on, the microprocessor resets all solenoids. The Particle energy indicators flash while the STAND-BY, ON, LOW, MEDIUM, AND HIGH indicators cycle one time, in that order. When the indicators stop flashing or cycling, the unit is ready to operate. The last settings used will be displayed. The yellow Standby indicator will be turned on.

When the Ready Mode is selected, the system timer is set for ten (10) minutes. The Feed solenoid (SV-6) energizes closing the canister top valve, the Canister solenoid (SV-4) energizes and the Master solenoid (SV-5) opens flushing the filter at the top and the orifice plate at the bottom of the powder canister. After 5 seconds the Canister solenoid (SV-4) closes, the system is pressurized. The Air On LED lights, Air Standby light extinguishes, and the system is ready.

If the hand piece was not in the cradle on power up, and the Footswitch is depressed, the Standby lamp will flash for ½ second indicating the hand piece must be placed in the cradle momentarily. The unit will remain in the “ON” state.

If the hand piece has been in the cradle and is removed, when the foot switch is depressed, the pinch valve is opened by Pinch Valve Solenoid (SV-1). This opens the path for powder flow from the mixing chamber to the nozzle.

When the hand piece is returned to the cradle or if the system is placed into Standby, the Pinch Valve solenoid (SV-

1) closes off the pinch tube and the foot switch is disabled Feed solenoid (SV-6) opens the valve to the top of the canister to relieve system pressure. When the foot switch is released, the Exhaust Purge solenoid (SV-3) opens an exhaust path to stop powder flow. The Master solenoid (SV-5) closes.

The Low, Medium or High Beam Intensity selection can be adjusted to provide optimum powder flow.

Stand-by mode may be selected by a) depressing the Stand-by / On button, or b) inserting the hand piece into the cradle, the unit de-pressurizes. Power can then be cycled to off. After 10 minutes of non-use the unit will automatically go to stand-by.

Safety features built into the Mach 6 unit are:

• Depressurizing when the hand piece is placed into the holder. This prevents accidental discharge of the powder

if the foot switch is depressed.

The instrument should only be powered down with the unit in the Standby Mode.

Please refer to Section 3 for preventive maintenance requirements that will keep the instrument operational.

WARNING: Do not open the top lid of the unit with power turned on!

990277 Rev. A Page 9 of 46

2.3 Connections and Controls (refer to Figure 1 and 2)

2.3.1 DC Power Cord Connector (refer to Figure 1)

The power cord connector is the connection point for the power cord.

2.3.2 Electric Footswitch Connector (refer to Figure 1)

The electric Footswitch is the connection point for the footswitch.

2.3.3 Air In (refer to Figure 1)

The Air Supply is the connection point for the external air source.

2.3.4 Beam Intensity (refer to Figure 2)

The Beam Intensity controls the amount or intensity of abrasive powder in the air stream, affecting the cutting speed. The user should vary this setting (low, medium, or high) to find the best performance.

2.3.5 Air Indicator (refer to Figure 2)

Indicates the status of the air pressure as “On” or “Standby”.

2.3.6 ON/OFF Power Switch (refer to Figure 2)

The power switch is located on the lower left front panel of the Mach 6.0. The switch turns the unit ON or OFF.

2.3.7 Particle Energy Scale and Control (refer to Figure 2)

Indicates the pressure with which the abrasive powder is being delivered. When the light next to a PSI value is initialized that value has been achieved. No intermediate PSI values are indicated. When adjusting the particle energy down, there is a delay in the actual reading. The knob should be adjusted below the desired value then back up until the value stabilizes.

2.3.8 Hand Piece Holder (refer to Figure 2 and 3)

Holds Hand piece when not in use. Hand Piece can be placed horizontally (down) or vertically (up).

2.3.9 Hand Piece Tubing connector (refer to Figure 2)

Hand piece hose connection to the unit.

990277 Rev. A Page 10 of 46

Power In

Air In

Foot Switch

Figure 1 Systems Rear Panel Connections

Beam Intensity

Air Indicator

Main Power

Figure 2 System Front Panel Controls and connections

Particle Energy scale

Particle Energy Control

Hand Piece holder

Hand piece hose

connector

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Figure 3 Hand Piece Holder in horizontal or vertical position

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2.4 Internal Components of the Mach 6.0 (Refer to Figures 4, 5,and 6)

Solenoid Manifold assembly

Air In

Filter

assembly

Figure 4 Internal Components location

Powder Feed

Canister

Pinch Valve

Regulator

Pinch Tube

Valve

Pressure

Regulator

Exhaust

Catch

Figure 5 Internal Components Locations

990277 Rev. A Page 13 of 46

Powder

Canister

Air Out

Filter

Figure 6 Internal Components location

2.4 Pneumatic components

(Refer to Figures 4, 5, and 6)

2.4.1 Solenoid Manifold Assembly (Figure 4)

Houses all system control solenoids that control air flow, powder flow, exhaust and de-pressurization.

2.4.2 Pinch Tube Valve Assembly (Figure 5)

Solenoid

Driver PCA

Houses the pinch tube which allows the powder - air mixture to flow to the handpiece.

2.4.3 Particle Energy Pressure Regulator (Figure 5)

The System Pressure Regulator is the mechanical device which controls the desired amount of air pressure.

2.4.4 Pinch Valve Regulator Assembly (Figure 5)

Adjusted to supply a constant amount of air for closing off the Pinch tube when needed. This is adjusted for 60 PSI.

2.4.5 Powder Canister Air In Filter Assembly (Figure 5)

Consists of a Coalescing and Silica Filters for filtering particulate matter and water vapor from entering the powder canister. Aids in the prevention of powder clogs due to moisture or particulate matter.

2.4.6 Mach 6 Manifold Assembly (Figure 4)

Series of connections for tube routing

2.4.7 Powder Canister Air Out Filter Assembly (Figure 6)

Used to allow air to escape from the top of the canister and keep particles out of the solenoid valves.

2.4.8 Exhaust Catch Assembly (Figure 5)

Used as a method to stop powder flow when the foot switch is released.

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