Aseptico AEU-6000 User manual

SERVICE MANUAL
& PARTS LIST
AEU-6000/AEU-6000-70V
Implant/Endodontic Dental Systems
AEU-6000-70V System

Page i
TABLE OF CONTENTS
General Service Information . . . . . . . . . . . . . . . . . . . . . . . . .1
Inspection & Operation Verification . . . . . . . . . . . . . . . . . . .1
Cleaning & Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ESD Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Disassembly, Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Disassembly, Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Final Test Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
General Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Motor Field Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Handpiece Calibration Error Testing . . . . . . . . . . . . . . . . .12
Power PCB Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Power PCB Testing Points . . . . . . . . . . . . . . . . . . . . . . . .14-15
Electrical Safety Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Reprogramming System Software . . . . . . . . . . . . . . . . . . . .17
Reprogramming System Firmware . . . . . . . . . . . . . . . . .18-19
Sterilization Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Maintenance & Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Changing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Tools List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
AEU-6000/-70V Parts List . . . . . . . . . . . . . . . . . . . . . . . .24-25
Alternate 48VDC Power Supplies . . . . . . . . . . . . . . . . . . . .26
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
P.O. Box 1548 • Woodinville, WA 98072-1548
1-800-426-5913 • 425-487-3157 • Fax: [phone]
email: [email protected] • Internet: www.aseptico.com
To prevent injury to people and damage to
property, please heed relevant warnings and
remarks. They are marked as follows:
WARNING: Serious injury or death may
result if ignored.
CAUTION: Damage to property or the
environment may result if
ignored.
NOTE: Important additional
information and hints.
Persons performing repairs to active electronic circuitry or operat-
ing High Voltage (e.g. HiPot) test equipment must have training or
experience performing similar servicing activities.
WARNING - RISK OF ELECTRIC SHOCK
REQUIRED QUALIFICATIONS OF SERVICE TECHNICIANS:

Page 1
GENERAL SERVICE INFORMATION
This service and parts manual offers technicians informa-
tion and parts lists not available in the AEU-6000 or AEU-
6000-70V Operation and Maintenance Instruction
Manuals. This manual will help you better understand
how the dental units work, thereby reducing service time.
Parts are listed and referenced to callouts in the Parts
Lists, pages 24-26. Use the information in the Parts List
when ordering replacement parts.
Inspection & Operation Verification
To verify that the 6000 units are set up and functioning
properly, refer to the setup instructions below and in their
respective Operation & Maintenance manuals. First, attach
the power cord to the back of the console and plug into a
grounded electrical outlet (see Fig. 1). NOTE: Both 6000
series units are compatible with 115VAC, 60Hz and
230VAC, 50Hz voltages and frequencies.
Connect the motor/cable to the receptacle on the lower
right front of the console
(see Fig. 2). When
attaching the cable to unit,
align the red dot on cable
connector with the arrows
located at top center of
receptacle and bezel, and
gently push the connector
straight in to lock into place.
Remove cord by pushing inward slightly on the strain relief,
then grasping connector body near the red dot and pulling the
connector straight out of receptacle.
Attach an ‘E’ Type 20:1 handpiece to the motor, and
install a bur or drill into the handpiece (see Fig. 3).
Attach the supplied AE-70V2 variable-speed foot control
to the connector located on the rear of the unit (see Fig.
1). The AE-23 Irrigation Tubing Set does not need to be
installed during routine maintenance and troubleshooting
of the console and/or motor. For troubleshooting irrigation
problems relative to the pump and/or irrigation tubing,
refer to General Troubleshooting on page 10. Turn the
power switch on the rear panel of the console to the ‘On’
(-) position. The vacuum fluorescent display should show
the startup screen for a few seconds, then default to the
operating parameters of the last-used preset (or preset #1
if the factory setup was recalled). The startup screen will
display the Aseptico logo and then the software version
onboard your 6000/E unit (see Fig. 4).
Press the “RATIO” Up or Down buttons to select “20:1” on
the display (see Fig. 5). Depress the foot control pedal to
verify that the motor and pump operates. Press the “CAL”
button to calibrate the 6000/-70V handpiece/motor - follow
the menu prompts displayed on the screen (refer to
“OPERATION” section in the Operation Manual for
complete calibration instructions).
Press and hold the “CAL” button for one second to restore
the System’s factory defaults settings (see Fig. 5). Follow
the menu prompts on the screen to recall the factory setup
(refer to “OPERATION/System Setup” section in the
Operation Manual for complete factory recall instructions).
Verify that the “RATIO”, “SPEED”, “TORQUE”, “FLOW”, and
“PRESETS” buttons are functioning properly (see Fig. 5).
Press each button to verify that its displayed values and/or
LEDs change accordingly (refer to “CONTROL PANEL
FUNCTIONS” section in the Operation Manual for complete
descriptions of all key pad buttons).
Figure 1
Power Cord Connector
Foot
Control
Connector
Fuses
Main Power
ON/OFF Switch
Figure 5
Figure 2 Alignment Arrows
Motor
Cable
Strain
Relief
E-TYPE
HANDPIECE MOTOR
Figure 3
Figure 4 (Software
Version
Date)
(Software
Version)
RATIO
CAL
FLOW
SPEED
Motor
Cable
Connector
TORQUE
PRESETS

Page 2
GENERAL SERVICE INFORMATION - Cont’d
Depress each of the buttons on the AE-70V2 foot control to
verify that they control motor direction, turn the pump
On/Off, and step through the torque settings and presets
correctly (see Fig. 6) (refer to “VARIABLE-SPEED FOOT
CONTROL OPERATION” section in the Operation Manual
for complete instructions on setting up and operating the
foot control).
The above procedures describe basic inspection and
verification of the AEU-6000/-70V. If the unit performs
normally during calibration and setup, and all the key pad
buttons function properly, no further testing of the console
is needed. If the unit does not perform as required, further
diagnosis and service of system components is required.
Use the Troubleshooting sections in this manual as a
guide to diagnose problems and perform repairs.
Cleaning and Lubrication
When servicing the AEU-6000/-70V unit, the parts of any
component disassembled should be thoroughly cleaned
and inspected before reassembly. A mild detergent
solution is an effective cleaner on all non-electrical parts.
Abrasive cleaners have the potential to damage surface
finishes and should be avoided. Any wiping should be
done with a soft lint-free cloth.
Electrical parts should be cleaned with an appropriate
electrical parts cleaner or air.
Refer to “STERILIZATION & MAINTENANCE” Sections,
pages 20 & 21, in this manual for additional cleaning
instructions.
ESD PRECAUTIONS
The following electrostatic controls must be used when
working on this unit:
ESD Training and Standards:
Employees handling electronic sub-assemblies and ESD
sensitive components are expected to be trained.
Training should be based on IPC-A-610 or equivalent
ESD standard ANSI/ESD-S-20-20 – Protection of
Electrical and Electronic Parts, Assemblies and
Equipment.
ESD Static Controlled Area:
Areas that are designated for handling and working on
electronic sub-assemblies or their components should be
marked off with signs indicating the area where ESD
controls are to be enforced. These areas are to be kept
clear from persons that are not trained to prevent ESD
damage from occurring.
ESD Environment:
The work area is to be free of all static generating
materials, such as plastic containers, water bottles, plastic
bags, plastic objects, such as plastic pens, heat guns
(unless made for the ESD environment).
ESD Jackets:
Clothing should be non-static generating (cotton).
Static generating clothing (e.g. wool, acrylic, nylon) must
be covered with an ESD jacket that is buttoned closed.
Optional gloves:
Nitrile gloves may be used to cover the hands when
working, but are not required.
Seating:
ESD Chairs should be used in place of static generating
chairs (e.g. modern office seating use static generating
materials).
Storage and packaging:
All circuit boards and components are to be stored on or
in static dissipative or static shielding material, throughout
shipping and storage.
ESD Wrist Strap and Mat Routine Checks:
The wrist strap should be checked daily using an ESD
wrist strap testing station. See chart below.
ESD mats should be checked at least quarterly.
HANDLE (Removable)
VARIABLE OR ON/OFF
CONTROL PEDAL
PRESETS
STEP-THROUGH
PUMP ON/OFF OR
FLOW STEP-THRU
MOTOR
DIRECTION
TORQUE MODE
STEP-THROUGH
Figure 6

Page 3
DISASSEMBLY
1. Turn the main power switch OFF. Unplug Power Cord,
PNs: 840079 (US) or 840078 (EURO), from AC Inlet
Connector. (NOTE: Grasp connector plug at end of
Power Cord when removing cord from Unit – do not
pull on cable.)
2. Remove irrigation bag and irrigation tubing sets (PN:
AE-23) from Unit. Remove Bag Holder Rod (PN:
461541) from Unit by pulling straight up and out of
socket (see Fig. 7). Note alignment of rod pin with
keyway in socket.
3. Disconnect Motor/Cord Assembly (PN: AE-230M-40)
and Foot Control Assembly (PN: AE-70V2) from Unit
(see Fig. 7). NOTE: The Motor/Cord Assembly and
Foot Control Assembly should be returned to Aseptico
if repair services are necessary -- consult Aseptico
Repair Department for more information.
TOP COVER DISASSEMBLY:
4. Remove Motor Cradle (PN: 461561-01) (see Fig. 7).
Turn Unit over and gently lay face down onto padded
surface to prevent scuffing.
5. Using a #2 Phillips screwdriver, remove two screws
(PN: 510663) that attach Motor Cradle Bracket to
Chassis (see Fig. 8). Remove Bracket and set aside
for reassembly later.
6. Locate two screws (PN: 510406) and lock washers
(PN: 510419) that attach Motor Connector Bracket to
Chassis (see Fig. 8). Remove only the front screw
and washer with a #2 Phillips screwdriver. Loosen, but
do not remove, second screw and washer located in
slotted hole.
7. Slide Motor Harness Assembly (PN: 875103) and
Bracket (PN: 461814) backwards in slotted hole so
that Motor Connector disengages from blue bezel in
cover. Lightly tighten mounting screw to secure
Harness/Bracket in place.
8. Locate two screws (PN: 510406), lock washers (PN:
510432), and flat washers (PN: 510431) that mount
Peristaltic Pump Assembly (PN: 330471) to Chassis
(see Fig. 8). Using a #2 Phillips screwdriver, loosen
but do not remove, both screws and washers. Slide
Pump Assembly forward in slotted mounting holes
provided.
9. Using a #2 Phillips screwdriver, remove three short
Plastite®screws (PN: 510650) and lock washers (PN:
510419) located along forward edge of Unit (see Fig.
9). Remove four longer Plastite® screws (PN: 510697)
and lock washers (PN: 510419) that attach Top Cover
subassembly to Chassis.
10. Turn Unit over and position upright on workbench.
Carefully work Top Cover subassembly off Chassis.
(NOTE: To help clear the Cover past the Pump door,
follow these steps: a) Slide Pump forward in slotted
Figure 8
Motor
Cradle
Motor Cradle
Bracket
Motor Cradle
Bracket
Mounting
Screws
= Short Mtg. Screws = Long Mtg. Screws
Figure 9
Pump
Mounting
Hardware
Motor
Connector
Mounting
Hardware
Figure 7
Motor & Cord
Assembly
Motor Cradle
Foot Control
Assembly
Bag Holder Rod

Page 4
mounting holes; b) Carefully lift Cover straight upwards,
until it disengages from Chassis base; c) Push Pump
door release button and hold Door ajar approximately
1/4 inch - do not allow door to fully open; d) With door
ajar, manipulate Cover up and over the rear edge of
door; e) Allow Door to fully open; then, f) Lift Cover
up and off Chassis.) Rest Top Cover on its side, next
to Chassis as shown in Figure 10, taking care not to
kink or sharply twist the flex cables from the Cover’s
Control Panel and Display.
11. Note orientation of red stripe on Display Ribbon
Cable (PN: 870300) with Pin #1 on "Display"
connector ‘J7’, located on PCB Assembly (see Fig.
10). Detach Ribbon Cable from connector ‘J7’.
12. Note orientation of Control Panel flex cable with “Key
Board” connector ‘J11’ on PCB Assembly (see Fig.
10). Detach flex cable from connector ‘J11’.
13. Turn Top Cover subassembly over and lay face down
on protective pad. Remove four plastic spacers (PN:
461727) from Cover if necessary (see Fig. 10). Note
orientation of red stripe on Display Ribbon Cable with
connector ‘CN1’ on Display PCB (see Fig. 11). Detach
Display Ribbon Cable and set aside for reuse later.
14. Use a #2 Phillips screwdriver to remove the two
mounting screws (PN: 510650), split washers (PN:
510010), and flat washers (PN: 510431) from the
Display Support Bracket (PN: 461728). Remove
Bracket and Display subassembly from Cover. Note
that the top edge of the display circuit board is
positioned in the three alignment notches on the
inside top of the display recess.
If disassembly of the Display and Bracket subassembly
is necessary, use a #1 Phillips screwdriver and 3/16"
wrench to remove two mounting screws (PN: 510191),
split washers (PN: 510433), flat washers (PN: 510127),
and nuts (PN: 510434) from Vacuum Fluorescent
Display Assembly (PN: 330558) (see Fig. 11). Carefully
place Display Assembly aside for reuse later. (NOTE:
The Display Assembly is a non serviceable component
of the AEU-6000/-70V System. If not functioning
properly, either replace Display with a new Assembly or
return Display to Aseptico for repairs. When installing a
new Assembly, ensure that the Display header is
properly oriented to Cover cutout (see Fig. 11).
15. The Display Gasket (PN: 461729), which is mounted
under the Display Lens (PN: 461726), uses double-
sided adhesive backing to adhere the Lens to the Top
Cover (see Fig 12). Remove Display Lens from Cover
by pushing outwards on Lens from inside the Cover.
Push firmly with fingers until Lens pops out (take care
not to scratch Lens). Place Lens aside for reassembly
later. Peel old Gasket from face of Display housing
and discard. (NOTE: A new Gasket must be installed
each time the Lens is removed from Cover - do not
reuse an old Gasket.) To reassemble Lens and new
Gasket, remove paper backing from the Gasket and
carefully apply Gasket to back side of Lens, aligning
its outer periphery to the raised edges (see Fig. 12).
DISASSEMBLY - Cont’d
Display Ribbon Cable
Figure 10
(Red Stripe)
J7 “Display” Connector
Control Panel Ribbon Cable
J11 “Key Board”
Connector
Display Ribbon
Cable
Connector
(CN1)
Display Ribbon Cable
Figure 11
Display Bracket
w/Hardware (X2)
Display
Assembly
Figure 12
Display
Lens
Display
Display Gasket w/Liner
Spacer (X4)

Page 5
Then, remove the other plastic liner backing from the face
of the Gasket and press Display Lens onto the front of
the display opening on the top cover. (NOTE: Ensure
that the inside face of Lens is clean and free of dust
before applying to top cover.)
16. Removal of the Control Panel Overlay Assembly (PN:
420769) is not recommended unless absolutely
necessary. If removal is required, carefully peel the
Overlay out of recess in Cover (see Fig. 13a) and
permanently discard entire Overlay Assembly. (NOTE:
Do not reuse an old Overlay Assembly - a detached
Overlay should always be replaced with a brand new
Assembly.) To reinstall new Overlay: 1) Insert flex
cable pigtail through the slotted hole in the Top Cover
(see Fig. 13b); 2) Remove liner from adhesive backing
on new Assembly; 3) Carefully center new Assembly in
recess in Top Cover; and, 4) Press down evenly on
Assembly until firmly adhered to Cover. On the
underside of the Cover, wrap a layer of ESD-safe tape
around the flex cable pigtail, roughly halfway between
the keypad and the connector. This tape holds the two
pigtail layers together.
17. From the inboard side of Cover, use fingers (or pliers)
to pinch together the locking tabs of the Motor Con-
nector Bezel (PN: 461545) (see Fig. 14). Push the
Bezel outward through its hole in Cover. Set Bezel
aside for reuse later. (NOTE: When remounting Bezel,
ensure that the locking tabs fully snap over the edge
of the hole, into the grooves provided on inside of
Cover.)
CHASSIS DISASSEMBLY:
18. Cut and remove the cable tie surrounding the cable
bundle on right-hand side of PCB Assembly (see Fig.
15). Detach Pump Assembly cable connector at 'J1'
("Pump") location on PCB Assembly. Make note of
pin/wire alignments of all connectors before
disconnecting from PCB. Use a #2 Phillips
screwdriver to remove two Pump Assembly mounting
screws (PN: 510406), lockwashers (PN: 510432), and
flat washers (PN: 510431) from bottom of Chassis
(see Fig. 8). Remove Pump Assembly (PN: 330471).
Remove the two Isolation Pads (PN: 461995)
underneath the Pump. (NOTE: The Pump Assembly
is a non-serviceable component of AEU-6000/-70V
System. If not functioning properly, either replace with
new Assembly or return Pump to Aseptico for repairs.)
19. Disconnect all cable and wire connectors from PCB
Assembly (PN: 330559). Make note of each cable’s
routing and connector/pin orientation before
disconnecting from PCB (see Fig. 15). Cut and
remove cable ties as necessary. Pinch the snaps
Slot
In
Cover
Overlay
Flex Cable
Pigtail
Control Panel
Overlay
Assembly
Figure 13a
Figure 13b
Figure 15
Pump
Assy
Pump Cable
Pump Assy Mtg. Hardware (X2)
Cable
Tie
Figure 14
Bezel
Locking Tabs

Page 6
Figure 17
Hex
Nut
White
Alignment
Mark
Motor
Connector
Harness
Round
Nut
together at the tops of the four snap posts that the attach
PCB Assembly. Lift the PCB Assembly off the posts
and set aside for reuse later (see Fig 16) Note the
position of the mylar insulator strip (PN: 461869) on
the bottom of the PCB. Replace strip if torn or
damaged. (NOTE: The PCB Assembly is a non-
serviceable component of the AEU-6000/-70V System.
If not functioning properly, replace with a new
Assembly.)
20. Locate and cut three Cable Ties (PN: 510137) that
attach the Motor Connector Harness to the Chassis
(see Fig. 17). Note the fold in the Harness under the
left front corner of the PCB, which allows the Harness
to “float” over the top of the circuit board.
21. Remove screw (PN: 510406) and lock washer (PN:
510432) from slotted hole in bottom of Chassis that
connect the Motor Connector Harness subassembly to
Chassis (see Fig. 8). Use a ¾" open-ended wrench to
loosen hex nut on the inboard side of Motor Connector
Bracket (PN: 461814) (see Fig. 17). Remove round
connector nut (PN: 461539-08) from outboard side of
Bracket. Remove Motor Harness Assembly (PN:
875103) from Bracket. Set Motor Harness and
Connector Bracket aside for reassembly later. (NOTE:
When reassembling Motor Connector subassembly,
insert Motor Connector from inboard side of Bracket,
outwards through Bracket cutout. Align the flats on
Connector barrel with flats on cutout and ensure white
alignment mark on Connector is positioned at the top.
Apply a drop of white glue (PN: 490142) to the
Connector threads before installing round and hex
nuts. From outboard side of Bracket, thread round nut
up the barrel of Connector by hand until the white
alignment mark becomes visible, with approximately
one thread showing on face of Connector. Tighten hex
nut on the other side of the Bracket to snug Harness
Assembly up against Bracket.)
22. On the 48VDC Power Supply Assembly (PN: 840087),
detach AC Line-In Cable Assembly (PN: 875106) from
connector 'SK1’, and 48V DC Cable Assembly (PN:
875105) from connector 'SK2' (see Fig. 18). Make
note of pin/wire orientation before disconnecting
Cables. Use a #2 Phillips screwdriver to remove three
screws (PN: 510650), lock washers (PN: 510010), and
flat washers (PN: 510587) that attach Power Supply to
Chassis. Remove fourth screw (PN: 510696) and
lockwasher (PN: 510010) from right rear mounting
hole with grounding tab. Remove all ground wire lugs.
(NOTE: When reassembling ground stack, the order
from bottom to top should be circuit board, inlet earth
ground, motor wiring harness ground, split washer,
and screw.) Remove Power Supply and set aside for
reuse later. (NOTE: Refer to page 26 for Alternate
Power Supply configurations and parts.) (NOTE: The
Power Supply Assemblies are non-serviceable
components of AEU-6000/-70V System. If not
functioning properly, replace with new Assembly.)
Figure 16
Snap Posts (X4)
PCB Assy
DISASSEMBLY - Cont’d
Cable
Ties
Fold
Figure 18
Connector ‘SK2’
Power Supply Assy
(See page 26 for Alternate
Power Supply configurations)
48V DC Cable
Connector
‘SK1’
AC Line-In
Cable’
Ground Cable

Page 7
23. Locate and cut the Cable Tie (PN: 510137) that
attaches the AC Line-In Cable (PN: 875106) to the
Chassis. Detach AC Line-In Cable and Ground Cable
Wire (PN: 875085) connectors from wire terminals on
Power Inlet Assembly (PN: 840086) (see Fig. 19).
Make note of wire/terminal orientation and cable loops
through ferrite before removing Cables. (NOTE:
During reassembly, ensure that the black wire of AC
Line-In Cable is attached to the outside terminal on
Power Inlet Assembly.)
24. Use a small screwdriver to detach and remove Fuse
Drawer from Power Inlet Assembly (see Fig. 20a).
Remove two Fuses (PN: 830040) from Fuse Drawer if
necessary. Press in the five locking tabs on inboard
side of Power Inlet Assembly and push Assembly
outward through cutout in Rear Panel (PN: 461725) of
Chassis (see Fig. 20b). Set Power Inlet Assembly
aside for reuse later.
25. On outboard side of Chassis Rear Panel, use pliers to
pinch together the two locking tabs on the sides of the
two Programming Cables (PN: 875057-01) (see Fig.
21). Push cable connectors inward through port
cutouts in Chassis, noting alignment of keyway on
bottom of connectors. Remove Cables and set aside
for reuse later.
26. Use a 13/16" wrench to remove mounting nut on
outboard side of Footswitch Harness Assembly, PN:
875074 (see Fig. 21). (NOTE: Take care to protect the
back panel against scratches when removing nut.)
Push Harness Assembly inward through 'D' shaped
cutout in Chassis. Note top center position of keyway
on threaded connector. Remove Harness Assembly
and set aside for reuse later. (NOTE: If installing a
new Footswitch Harness Assembly, the rubber gasket
that is supplied with the new Assembly is positioned
on the inboard side of Rear Panel. If this gasket is
lost, Flat Washer [PN: 510648] may be substituted.)
Apply a drop of white glue (PN: 490142) to the
connector threads before installing nut. See Fig. 22.
27. Remove Memory Card Dust Cover (PN: 461606) from
Rear Panel of Chassis (see Fig. 20), if necessary.
28. Note location and orientation of the four Cable Tie
Mounts (PN:510206) on the Chassie base. Replace
as necessary, in the same position.
Power Inlet
Assembly
Fuse
Drawer
Locking Tab
(X5)
Figure 20a Figure 20b
Locking
Tabs
Figure 21
Port 1 & Port 2
Programming
Cables
Footswitch
Harness
Mounting Nut
Memory Card
Dust Cover
Ground Cable
Power Inlet
Assembly
(Black Wire To Outside
Terminal)
Figure 19
AC Line-In Cable
Cable Tie
with
Mount
Ferrite
Figure 22
Footswitch Harness
Assembly
Rubber Gasket
Mounting
Nut
‘D’ Shaped
Cutout

Page 8
29. Turn Chassis base (PN: 461728) over to expose four
rubber Bumper Feet (PN: 850069) on bottom side
(see Fig. 23). Replace as necessary.
30. If necessary, replace Serial Number Label (PN:
420295-01) and/or Chassis Label (PN: 420596-07) on
the bottom side of Chassis base. See Fig. 23.
THIS COMPLETES THE DISASSEMBLY OF THE
AEU-6000/-70V SYSTEM.
REASSEMBLY
31. To reassemble the AEU-6000/-70V System, perform
the Disassembly steps 1-30 in the reverse order.
NOTE: Follow these recommended Steps to
reassemble the Top Cover to the Chassis:
a. Prior to attaching Top Cover, loosen the two
Peristaltic Pump Assembly mounting screws.
b. Loosen only the rear mounting screw on the Motor
Connector bracket, then remove the front mounting
screw. Slide the Motor Connector backwards in the
mounting slot and lightly secure it with the rear
screw.
c. Carefully work the Top Cover down over the
Chassis and position in place but do not attach to
Chassis bottom. Ensure the flex cable from the
Control Panel is not sharply bent. Partially open
the pump door to allow the Top Cover to work past
the rear of the pump door. Work the Top Cover all
the way down until it’s properly seated against the
Chassis bottom.
d. Use a #2 Phillips screwdriver to install three 3/8”
screws (PN 510650) with three lock washers (PN
510419), and four longer 1” screws (PN 510697)
and lock washers (PN: 510010), through the
Chassis bottom into the Top Cover, as shown on
Figure 8, page 3.
f. Reposition the Peristaltic Pump frontwards or
backwards until it just clears the Cover at the front
when opened. Tighten the two Pump mounting
screws.
g. Slide the Motor Harness Connector forward until it
protrudes out through the blue bezel in the front of
the Unit. Reinstall the front 3/8” mounting screw
(PN 510406) with lock washer (PN 510432) and
tighten both mounting screws.
h. Open and close the Pump door several times and
verify that the door opens, closes, and latches
smoothly. Readjust Pump position if necessary.
i. Connect Foot Pedal and Motor to the unit. Insert a
length of Pump tubing into the peristaltic pump
(refer to Operator’s Manual for instructions on
setting up Pump/tubing). Verify that the Pump
latches securely.
j. Power AEU-6000/-70V Unit ‘On’.
k. With the “Flow” ‘On/Off’ button set to ‘On’ and the
Pump flow rate set to 100%, depress the Foot
Control and verify the Pump runs.
DISASSEMBLY - Cont’d
Figure 23
Bumper Foot
(X4)
Chassis
Label
Serial No.
Label

Page 9
1.Verify fuse values. Fuses (PN 830040) should be 1.6A
250V SLO-BLO.
2.Check the console for physical imperfections. Verify
that the Foot Switch and Motor connectors are tight by
connecting the relevant cable and attempting to twist
the connector to the left and right by hand.
3. Perform Electrical Safety Tests: Refer to page 16 for
complete instructions on performing the Electrical
Safety Tests on the AEU-6000/-70V units.
4. Connect field programmer AFP-01 to Programming
Port 1 at the rear of the console. Insert memory card
containing Master Code Firmware PN 890041 into the
AFP-01. Turn on the AFP-01 and wait for the
programming process to complete. (Refer to page 18
for complete Master Code Firmware programming
instructions.)
5. Connect field programmer AFP-01 to Programming
Port 2 at the rear of the console. Insert memory card
containing Slave Code Firmware PN 890042 into the
AFP-01. Turn on the AFP-01 and wait for the
programming process to complete. (Refer to page 19
for complete Slave Code Firmware programming
instructions.)
6. Insert System Software memory card PN MC-6000,
containing software PN 890037, into the Memory Card
Port at the rear of the console. Apply power to the
console. Turn the console power switch on and follow
the on-screen prompts to program the console. Verify
that the programming process completed successfully
and that the software version displayed at startup is
correct. (Refer to page 17 for complete System
Software programming instructions.)
7. Verify that the motor drive and calibration systems are
functional:
7.1 Connect motor AE-230M-40 to the console.
7.2 Select the 20:1 handpiece ratio. Press the CAL
button and follow the on-screen prompts to
complete the calibration. Verify that the calibration
completed successfully.
7.3 Select the 8:1 handpiece ratio. Repeat the
calibration process, and verify that the calibration
completes successfully.
8. Connect foot control AE-70V2. Set the motor direction
to forward. Press the foot switch and verify that the
motor runs when the footswitch is depressed and
stops with the footswitch is released. Separately press
each of the four foot control buttons, verifying that the
console beeps when each button is pressed. (Refer to
Operator’s Manual for complete instructions on
installing and using the AE-70V2 foot control.)
9. Change the motor direction to reverse. Press and hold
the foot switch for several seconds, and verify that the
motor runs and that the console audible indicator
beeps consistently.
10.Open and close the pump door several times and
verify that the door opens, closes, and latches
smoothly. Insert a length of pump tubing in the
peristaltic pump and verify that the pump latches
securely. With the Flow ON/OFF button set to ON and
the flow set to 100% depress the footswitch and verify
that the pump runs smoothly.
11. Verify operation and tactile feedback of the keypad
buttons: (Refer to Operator’s Manual for complete
instructions on using the unit’s control panel)
11.1 Press the SPEED UP and SPEED DOWN
buttons, verifying that the display changes with
each press.
11.2 Press the TORQUE UP and TORQUE DOWN
buttons, verifying that the display changes with
each press.
11.3 Press each of the preset buttons and verify that
the display changes and that the LED associated
with each preset button illuminates.
11.4 Press the FWD/REV button repeatedly and verify
that the FWD and REV LEDs illuminate.
11.5 Press the RATIO UP and RATIO DOWN buttons
and verify that the display changes with each
press.
11.6 Set Ratio to 20:1. Press the A-S/MAX button
repeatedly and verify that the A-S and MAX LEDs
illuminate.
11.7 Press the FLOW ON/OFF button repeatedly and
verify that the LED turns on and off. With the
FLOW LED lit, press the FLOW UP and FLOW
DOWN buttons and verify that the flow rate
indication on the display changes.
11.8 Press the blue standby button and verify that the
display goes blank. Press the standby button
again to reactivate the display.
11.9 Turn the console off. Wait five seconds. Press
and hold the CAL button and turn the console on,
holding the CAL button until the scrolling startup
screen passes by and the “Recall Factory Setup”
screen appears. Follow the on-screen prompts to
recall the factory default settings.
11.10 Turn off the console and unplug.
12.Apply Danger Label, PN 420748-01, to the Rear Panel
of the console in the provided recess.
13.Scuff oval recess on front surface of housing with
Scotch-Brite pad to remove gloss from plastic. Wipe
clean with alcohol and soft cloth. When dry, place oval
dome label in recess and press down firmly.
14.Apply Serial Number Label PN 420295-01 and
Chassis Label PN 420596-07 to the recesses on the
underside of the console.
FINAL TEST VERIFICATION

Page 10
Problem:
Console does not light when turned on:
Console lights when turned on, but
handpiece does not turn:
No water flow from pump to handpiece:
Irrigation tube leaks:
Motor slowing down or sluggish:
System functions display incorrectly:
Cannot remove motor/cord from unit:
Correction:
• Check console to power connection.
• If Preset LEDs are blinking, press standby button on
control panel to exiit Sleep Mode.
• Check fuse. If blown, replace with 1.6A/250V
slo-blow fuse.
• Check motor plug connection.
• Check foot pedal connection.
• Depress foot pedal.
• Increase RPM.
• Increase Torque setting
• Check that bur/file/drill is properly seated in the hand-
piece and the collet is closed.
• Check that pump is on and flow level is sufficient.
• Check that water container seal is completely punctured.
• Make sure the irrigation tubing is properly installed in
pump door and flow is in the correct direction.
• Replace worn tube section located under the pump door
with a new section from the extra tube set provided with
the system.
• Check for dirty, under-lubricated handpiece.
• Check if handpiece lubricant is draining into motor. After
lubricating and before autoclaving, stand handpiece on
its base to let excess lubricant drain out.
• Verify that ratio setting matches handpiece ratio.
• Turn power switch Off, wait 5 seconds, then turn back
On to reset.
• Grasp the strain relief directly behind the cord connector
and gently push inward. Then, grasp the connector body
near the red dot and pull the connector straight out of
the receptacle.
GENERAL TROUBLESHOOTING:

Page 11
MOTOR FIELD TESTING
NOTE: AEU-6000/-70V motor testing in the field is
limited to simple manual and visual tests that help to
determine the source of the problem.
1. Motor Rotation Test: This test can be performed
manually using a simple motor-rotation tool that can
be improvised in the field or procured from Aseptico
(PN: AE-43). The tool needs to be able to grasp the
motor’s internal rotor/magnet assembly and rotate it to
determine if the assembly is damaged. Insert tool into
motor tip and engage rotor shaft as shown in Figs.
24A & 24B. Turn tool back and forth to determine if
rotor assembly moves freely (Fig. 24C). If resistance is
felt, return motor/cord assembly to Aseptico for repair.
Figure 24A - Motor Rotation Tool
Figure 24B - Motor Internals
Figure 24C - Rotor Rotation Test
Rotate
Test Tool

Page 12
NOTE: This section provides troubleshooting
procedures for the “Calibration Failed !” error message
which displays if the AEU-6000/-70V motor fails during
the handpiece “Free Run” calibration test (refer to
Operation Manual for complete handpiece calibration
instructions). This information will help determine if the
source of the problem is in the motor, handpiece, or
the unit console.
1. Turn AEU-6000/-70V unit ‘On’. The Startup screen will
appear.
2. Preselect ratio of the handpiece using the Ratio
Up/Down buttons on the console keypad.
3. Press ‘CAL’ button to enter the calibration test. A
prompt will instruct the user to install the handpiece
onto the motor. Insert a file, bur, or drill into the
handpiece. Press “Next”. The System will
automatically run the handpiece through the “Free
Run” test on either increaser or reduction type
handpieces. The message “Free Run In Progress /
Please Wait...” will display
4. If the motor or handpiece is malfunctioning, jammed or
disconnected, the “Calibration Failed !” message will
display. Consult the troubleshooting chart below to
pinpoint the problem.
NOTE: The AEU-6000/-70V power PCB board may be
the source of the problem. For troubleshooting
procedures specific to the PCB board, refer to the PCB
testing chart on page 13. Before replacing PCB board,
try calibrating unit with a new, fully operational motor,
to help isolate the board as the problem.
6. If the motor, handpiece, and console are functioning
properly, the message “Calibration Successful !” will
display.
Figure 25 - Motor/Handpiece Troubleshooting
HANDPIECE CALIBRATION ERROR TESTING

Page 13
POWER PCB TESTING
If the AEU-6000/-70V fails to start properly, use this
flowchart to pinpoint the problem. This flowchart
provides additional troubleshooting procedures for the
unit’s main power printed circuit board (PCB).
NOTE: If the power PCB is replaced, the unit’s firmware
must be reprogrammed (refer to page 18). For
troubleshooting procedures specific to the motor, refer
to the motor testing chart on page 12.
Figure 26 - Power PCB Troubleshooting

Page 14
POWER PCB TESTING POINTS
1. Turn AEU-6000/-70V power switch ‘Off’. Remove
irrigation bag, tubing, and rod. Disconnect motor/cable
and foot control. Disassemble top cover from chassis
(refer to page 3). Place unit upright on work bench to
expose internal Power PCB.
2. 120V (US) or 230V (International) AC Check: This
test verifies that the fuses are good and the proper AC
voltage is being provided to the power PCB circuit.
Connect voltmeter test leads to contacts as indicated in
AC Voltage Ref. ‘A’, Fig. 27. Turn AEU-6000/-70V
power switch ‘On’ .
CAUTION: High voltages present - only qualified
technicians should perform this test. Use extreme
caution to avoid severe electric shock.
If 120V(+/-10V) (US) or 230V(+/-15V) (Internatonal) AC
is not present, check power switch and fuses first, then
if proper voltage still not present, replace Power
Inlet/Fuse Holder assembly.
Turn AEU-6000/-70V power switch ‘Off’ after 120V or
230V AC test is completed.
3. 48V DC Check: This test verifies that proper DC voltage
is being provided to the power PCB circuit. Connect
voltmeter test leads to contacts as indicated in DC
Voltage Reference ‘B’, Fig. 27. Turn AEU-6000/-70V
power switch ‘On’.
CAUTION: High voltages present - only qualified
technicians should perform this test. Use extreme
caution to avoid severe electric shock.
If 48V(+/-1.0V) DC is not present:
a. Disconnect 48VDC Cable from Power PCB
connector ‘J2’.
b. Check 48VDC Cable output from DC Power Supply
for 48VDC(+/-1.0V).
c. If 48VDC(+/-1.0V) Supply output is not present,
replace Power Supply. If 48VDC output is present
from Supply, replace PCB board.
Turn AEU-6000/-70V power switch ‘Off’ after 48VDC
test is completed.
4. 5V DC Check: This test verifies that proper DC
voltage is being provided to the key pad, foot pedal,
flash card, programming ports, and other PCB
components. Connect voltmeter test leads to contacts
as indicated in DC Voltage Reference ‘C’, Fig. 27. Turn
AEU-6000/-70V power switch ‘On’.
CAUTION: High voltages present - only qualified
technicians should perform this test. Use extreme
caution to avoid severe electric shock.
Replace PCB board if 5V(+/-0.2V) DC is not present.
Turn AEU-6000/-70V power switch ‘Off’ after 5VDC test
is completed.
5. 2.5V DC Check: This test verifies that proper DC
voltage is being provided to the motor and other PCB
components. Connect voltmeter test leads to contacts
as indicated in DC Voltage Reference ‘D’, Fig. 27. Turn
AEU-6000/-70V power switch ‘On’.
CAUTION: High voltages present - only qualified
technicians should perform this test. Use extreme
caution to avoid severe electric shock.
Replace PCB board if 2.5V(+/-0.2V) DC is not present.
Turn AEU-6000/-70V power switch ‘Off’ after 2.5VDC
test is completed.
6. 15V DC Check: This test verifies that proper DC
voltage is being provided to the motor and other PCB
components. Connect voltmeter test leads to contacts
as indicated in DC Voltage Reference ‘E’, Fig. 27.
Turn AEU-6000/-70V power switch ‘On’.
CAUTION: High voltages present - only qualified
technicians should perform this test. Use extreme
caution to avoid severe electric shock.
Replace PCB board if 15V(+/-1.0V) DC is not present.
Turn AEU-6000/-70V power switch ‘Off’ after 15VDC
test is completed.
7. 3.3V DC Check: This test verifies that proper DC
voltage is being provided to the Memory Card
Interface Ciruit. Connect voltmeter test leads to
contacts as indicated in DC Voltage Reference ‘F’, Fig.
27. Turn AEU-6000/-70V power switch ‘On’.
CAUTION: High voltages present - only qualified
technicians should perform this test. Use extreme
caution to avoid severe electric shock.
Replace PCB board if 3.3V(+/-0.2V) DC is not present.
Turn AEU-6000/-70V power switch ‘Off’ after 3.3VDC
test is completed.
Dangerous voltages are present during the following
board testing. Severe electric shock can result and
could prove fatal. Only qualified technicians should
perform these tests.
WARNING
IMPORTANT
The Power PCB is a non-serviceable component of
the AEU-6000/-70V Systems. If not functioning
properly the PCB should either be replaced with a
new Assembly or returned to Aseptico for repairs.

Page 15
Figure 27 - AEU-6000/-70V Power PCB Test Points
INTERNATIONAL
AC VOLTAGE:
OR

Page 16
Figure 28
Dangerous voltages are present during the following
Hi-Pot testing. Severe electric shock can result and
could prove fatal. Only qualified technicians should
perform these tests.
WARNING
ELECTRICAL SAFETY TESTS
Whenever repairs on any AEU-6000/-70V unit involves
safety issues, such as electrical malfunctions or
changeout of critical components in the electrical circuit,
i.e., main power board or transformer, it is recommended
that the Hi-Pot and Ground Bond Safety Tests below be
performed after repairs are completed. If the technician
determines that Safety Tests are required, the tests
should consist of three separate tests, typically performed
in tandem via a multimeter and a single Hi-Pot
test/measurement device:
1. Perform Electrical Safety Tests:
1.1 Attach an AE-230M-40 motor to the console.
1.2 Using a multimeter, conduct a ground continuity
test by measuring the resistance between the
Earth Ground Terminal of the Power Inlet and
the E-coupling of the motor (see Fig. 28).
Resistance between the Earth Ground Terminal
and the motor must be less than 2 Ohms.
1.3 Conduct a dielectric withstand test between
mains at the power inlet and the motor housing.
Test is to be performed with the power inlet
switch in the “ON” position and the return lead
of the test equipment connected to the E-
coupling of the motor body (see Fig. 29). Test
parameters are 4250 VDC for one second with
an allowed leakage current of 1.0mA.
IMPORTANT: Any system that fails any of the
above tests must be removed from service and
thoroughly examined, repaired and retested by a
qualified technician.
NOTE: Although Aseptico uses the Associated
Research, Inc. Model 7564SA Tester for the Hipot
tests, alternative equipment with equivalent setup
and testing specifications may be used. Ensure that
the above test parameters are set up correctly
before conducting the tests.
Figure 29

Page 17
Each System has the ability to load software updates
and enhance its functionality, should this be desired. A
card slot, labeled “Memory Card Port”, is provided on
the back of each unit (see Fig. 30). This Port accepts
memory card, PN MC-6000, which is very similar to
those used in common consumer devices. These
cards, available from Aseptico, enable a user to
update software or replace existing software that
might have been accidentally erased or corrupted.
Contact Aseptico for more information on card usage
and availability. To reprogram a unit, follow the Steps
below:
Programming Steps:
1. Turn ‘Off’ the Main Power Switch on the back panel.
2. Grasp the right-hand end of the rubber dust cover for
the Memory Card Port and pry open the cover to
expose the card slot.
3. Insert the new MC-6000 memory card into the slot
with label facing upward (card terminals should face
downward). Carefully and slowly press card inward
until a ‘click’ is felt, then release the card.
4. Turn the Main Power Switch (on the back panel) ‘On’.
5. The Display will show the following message:
• Press the ‘Yes’ key on the Control Panel.
6. The Display will then show the following message:
• Press the ‘Yes’ key on the Control Panel.
7. The Display will show the following message:
• A status bar will indicate the progress of the
programming.
8. When the programming is complete, the Display will
show the following message:
• Press the card inward slightly, then release it to eject it.
When the card is ejected, the System will reset with
normal power-up screen displayed.
9. Remove the memory card and store it in a safe place.
Close the rubber dust cover on the Memory Card
Port.
In the event that the programming procedure is
interrupted, the unit will display the following
message:
Then:
Re-start the programming procedure from Step #1
(Remember to turn main power ‘Off’ before
reprogramming).
REPROGRAMMING SYSTEM SOFTWARE
Figure 30
Memory Card Detected.
Re-program? (Yes / No)
Presets will be erased!
Continue? (Yes / No)
Programming...
Programming successful.
Eject card.
Programming Failed
Console Software Error.
Re-program unit.
MEMORY
CARD
DUST
COVER

Page 18
REPROGRAMMING SYSTEM FIRMWARE
The AEU-6000/-70V Units’ internal components are
controlled by three software microchips. The software in
these chips can be updated or replaced by using the AFP-
01 Field Programmer (see Fig. 31) to upload the new
firmware directly into the microcontrollers. Refer to the
firmware below and its respective programming port when
uploading:
A. Master Code Firmware (Port 1):
6000/-70V: PN 890041
B. Slave Code Firmware (Port 2):
6000/-70V: PN 890042
C. Motor Driver Firmware (J1 Connector):
6000/-70V: PN 890021
Contact Aseptico for availability on the latest firmware.
Follow the appropriate steps below to reprogram the
microcontrollers:
A. Master Code Firmware
1. Turn Off all power to the AEU-6000/-70V Units.
2. Turn Off the programming switch within the AFP-01
Field Programmer (see Fig. 32).
3. Install battery into AFP-01 Field Programmer, as
shown in Figure 32.
4. Install Master Card, PN: 890041 into the card holder
located on Programmer PCB (see Fig. 32).
5. Insert the 4-pin square connector (for an HC08
Microcontroller) into the programming Port-1 on the
back of the Unit, making sure that the connector
latch is properly oriented with the mating connector.
6. Turn On the programming switch within the AFP-01
Programmer.
7. The Green & Red LED’s on the Programmer will
operate in the following sequence when
programming is successful: IMPORTANT: The Red
LED will remain On in the event of improper
programming.
• Green & Red LED’s turn On for approx. one
second.
• Green & Red LED’s turn Off for approx. one
second.
• Green & Red LED’s again turn On for approx. one
second.
• Green & Red LED’s again turn Off for approx. one
second.
• Green LED remains On for about two seconds.
• Green LED flashes On and off during
programming.
• Green LED remains On at the completion of
programming.
8. Turn Off the programming switch within the AFP-01
Programmer and remove the connector from Unit.
Master Code Programming is completed.
Figure 31
Firmware
Cards
AFP-01
Field Programmer
Figure 32
Figure 33
Port-1
9V Battery (Sold Separately)
AEU-6000
Green
LED
Firmware Card
(Master Code)
Port-2
Green
LED On/Off Switch
(Shown in ‘On’ Position)
Firmware Card
(Slave Code)
On/Off Switch
(Shown in ‘On’ Position)