DENTSPLY ProMix 400 Assembly instructions

REPAIR GUIDE
MODEL 400
MODEL 401
MODEL 402
the ProMix
AMALGAMATION UNIT

TABLE OF CONTENTS
SECTION TITLE PAGE
SECTION I: TECHNICAL DETAILS & SPECIFICATIONS
1.1 TECHNICAL DETAILS ............................................................................ 1
1.2 OPERATING ENVIRONMENT ................................................................ 1
1.3 DIMENSIONS ............................................................................................ 1
SECTION II: GLOSSARY OF SYMBOLS
2.0 GLOSSARY OF SYMBOLS .................................................................... 2
SECTION III: SAFETY PRECAUTIONS
3.0 SAFETY PRECAUTIONS ........................................................................ 3
SECTION IV: GENERAL DESCRIPTION
4.0 INTRODUCTION ...................................................................................... 4
SECTION V: INSPECTION, INSTALLATION & OPERATION
5.0 INSTALLATION ........................................................................................ 5
5.1 OPERATION .............................................................................................. 6
SECTION VI: SERVICE AND MAINTENANCE
6.1 SERVICE .................................................................................................... 7
6.2 CLEANING ................................................................................................ 7
SECTION VII: TROUBLESHOOTING GUIDE
7.1 TROUBLE SHOOTING QUICK CHECK ................................................ 7,8
7.2 ELECTRICAL TROUBLE SHOOTING .................................................. 8,13
7.3 MECHANICAL TROUBLE SHOOTING ................................................ 14,15
SECTION VIII: ASSEMBLY & DISASSEMBLY PROCEDURE
8.1 PROMIX DISASSEMBLY ........................................................................ 16,18
COMPONENT LIST: .............................................................................. 19

SECTION I
TECHNICAL DETAILS & SPECIFICATIONS
1.1 Technical Details:
AC INPUT RATING: Model 400 120V, 60Hz, 2.0A
Model 401 230V, 50/60Hz, 1.0A
FUSE RATING: Model 400 F2.0A /250V
Model 401 F1.6A/250V
MOTOR RATING: 115VAC, 60Hz
PRESET MOTOR SPEEDS: Low (Turtle) 3700±200 rpm
High (Rabbit) 4200±200 rpm
IEC EQUIPMENT CLASS: Class I
INSTALLATION CATEGORY II
(OVER VOLTAGE CATEGORY):
POLLUTION DEGREE: 2
OPERATION MODE: Continuous (Under normal usage conditions)*
1.2 Operating Environment:
NOTE: Equipment not suitable for use in the presence of the flamable
anaesthetic mixture with air or with nitrous oxide.
Operating Temperature: 10 to 40C
Relative Humidity: 30 to 75 % noncondensing
Atmospheric Pressure: 700 to 1060 hpa
1.3 Dimensions:
Height: 5 inches (12.7 cm)
Width: 9 inches (22.86 cm)
Length: 9.5 inches (24.13 cm)
Weight: 7 pounds(3.18 Kg)
Power Cord Length: 117.6 inches (300 cm)
* According to ANSI/ADA Standard No. 43-1986: 10 seconds on/110 seconds off (normal usage)
1

SECTION II
GLOSSARY OF SYMBOLS
______ Attention, Consult Accompanying Documents
______ Alternating Current
______ Protective Earth
______ OFF (Power: Disconnection from the Mains)
______ ON (Power: Connection to the Mains)
2

SECTION III
SAFETY PRECAUTIONS
1. Operate the ProMix™only on a hard, flat surface away from countertop edges.
2. The translucent acrylic arm cover/door of the ProMix™has a safety interlock
switch. Do not attempt to override the switch and/or operate the ProMix™with this
door open.
3. Should the ProMix™get damaged in any way, do not attempt to operate the unit
unless thoroughly inspected and serviced by qualified Dentsply Dealer Service
personnel.
4. In cases where a patient or user of the ProMix™has been fitted with an implanted
heart pacemaker and has been cautioned against the use of small electrical
appliances (such as electric shavers, hair dryers, etc.) we recommend that the
ProMix™not be used.
5. DO NOT IMMERSE UNIT, POWER CORD OR PLUG IN WATER.
See Cleaning instructions on page (7).
3

SECTION IV
GENERAL DESCRIPTION
4.0
The microprocessor controlled ProMix™is one of the most advanced amalgam mixer systems
presently available in the dental marketplace.
The ProMix™Amalgamation Unit provides:
a) Two Preset Speeds with an LED indicating the Low speed (3700 rpm) and an LED
indicating the High speed (4200 rpm).
b) Two Memory Locations (M1 and M2) which can be programmed for time and
mixing speed of your two most commonly used amalgam materials (to the
manufacturers specifications).
c) A Timer to set the run cycle to a maximum of 30 seconds in 1 second increments
for both speeds.
d) A Digital Display for convenient viewing of timing functions.
e) A Unique Capsule Holder (arm assembly) which will accommodate a large variety
of today's commonly used capsules (including those with nozzles)
f) A Safety Switch which automatically turns OFF the run cycle should the ProMix™
cover accidentally be opened.
g) A Thermally Protected Motor to prevent any possible damage caused by
overheating.
h) Cycle Interrupt Capability to eliminate amalgam waste should the timer be set
longer than required.
4

5.0 INSTALLATION
NOTE: Upon receiving the ProMix™ system check the packaging and parts for
any damage that may have occurred in transit. If damage is apparent,
please contact your dealer immediately.
Unit Power-up (Initialization):
Plug the detachable power cord into the back of the unit and then to the mains supply.
NOTE: Always use the unit in conjunction with a properly grounded outlet.
Activate the Power Switch on the back of the unit.
Upon the application of AC power, the unit shall always be initialized as follows:
-the Display Board shall read “00”,
-the motor shall be OFF,
- the “LOW” motor speed shall be selected and the “LOW” LED
indicator shall be ON.
NOTE: AC power interrupts and degradation causing improper operating
voltages to the microprocessor shall always result in a microprocessor
master reset and re-Initialization of the unit.
Definition of Terms:
Initialization: is the function performed by the software of the unit after
power up or master reset.
Stand-By: is the condition when the unit is not performing the
amalgamation cycle but has completed the
“initialization” period.
Run: is the condition when the unit is performing the
amalgamation cycle.
5

5.1 OPERATION
The operation of the ProMix™ can be controlled by the LCD display and the seven (7) push
buttons/pads located on the front panel.
Display Board Indicates the set (desired) amalgamation cycle/run time
and counts down to “00” in 1 second intervals during
operation.
“Up” arrow Increments the programmed run time in one second
intervals (to a maximum of 30 seconds).
“Down” arrow Decrements the programmed run time in one second
intervals.
“High” (rabbit) Selects the high amalgamation speed (4200 rpm) and the
associated LED indicator.
“Low” (turtle) Selects the low amalgamation speed (3700 rpm) and the
associated LED indicator.
“Start/Stop” (I/O) Initiates and deactivates the amalgamation cycle.
NOTE: The two (2) “memory” locations are set at the factory
to commonly used settings. To change the settings to
suit individual needs see “Setting Memory Locations”
(page 4).
“M1” (Memory #1) Stores and recalls #1 preprogrammed amalgamation
speed and time, even in the “power OFF” condition.
NOTE: The Memory #1 location is factory set
to 15 seconds at Low speed.
“M2” (Memory #2) Stores and recalls #2 preprogrammed amalgamation
speed and time, even in the “power OFF” condition.
NOTE: The Memory #2 location is factory set
to 20 seconds at High speed.
6

SECTION VI
SERVICE AND MAINTENANCE
6.1 SERVICE
Questions concerning the operation, repair or servicing of this unit should be forwarded to the
nearest Dentsply representative or the service department.
6.2 CLEANING
NOTE: Disconnect the power cord from
the ProMix™unit prior to cleaning.
The ProMix™ Amalgamator Unit may be cleaned with a Sani-Cloth™or a soft cloth
dampened with ProCide™Spray. Do not use other sterilization solutions on the unit.
Remember to reconnect the power cord to the ProMix™unit when cleaning process is
complete.
SECTION VII
TROUBLESHOOTING GUIDE
7.1 TROUBLE SHOOTING QUICK CHECK
NOTE: THIS UNIT HAS CMOS COMPONENTS WHICH
MAY BE SUBJECT TO ELECTROSTATIC
DAMAGE (ESD). WORKSTATION MUST BE
PROPERLY GROUNDED AND THE REPAIR
PERSON SHOULD GROUND THEMSELVES
PRIOR TO HANDLING.
Before opening the unit for servicing, see if the problem can be corrected by checking the
following:
1) Power cord is securely connected into an outlet that supplies the proper voltage
rating, and the outlet has been turned on.
2) The power cord is fully and securely inserted into the A/C receptacle of the power
unit.
3) The ON/OFF power switch at the back of the unit is turned on. (Depressed “I”
position)
If the above checks fails to correct the problem, see the following trouble shooting-guide
for the failure mode and corresponding repair procedure.
7

7.2.1
Display Board does not come on when main switch at the back of the unit is
turned on.
Possible Problem Solution
A. Loose Lead Wires Open unit and check for loose lead wire connections
between the A/C receptacle, main power switch Fig
(1a), and the power supply. See Fig 1b.
B. Blown Fuse Check fuses. See Fig 1b. If open replace with the
same type fuse. See fuse rating section 1.1.
8
Figure 1a Figure 1b
Lead Wires Fuses
Power Supply

C. Power Supply Locate CPU Board (Fig 1d) and disconnect
connector J1 (Fig 1d). Locate power supply (Fig
1c). Measure voltage between the wire connection
marked ac- and ground marked gnd (See Fig 1c).
This voltage should be greater than
7V a.c.. Repeat for the wire connection marked ac+
and gnd. If either is zero or less than 7V a.c.,
replace the power supply.
D. C.P.U. Board Identify C.P.U. board as shown in Fig 1d. Locate
voltage regulator (VR1) see Fig 1e.. Measure
voltage between pin 2(gnd) and 3. If voltage is less
than 4V d.c.. Check voltage between
pin 1 and pin 2 (gnd). If greater than 7V d.c.,
replace C.P.U. board.
E. Display Board If 7.2.1 A to D fail to correct problem replace
display board (Fig 1f).
9
Figure 1c Figure 1d
AC+
GND J1 Connector
CPU Board
AC-
Power Supply
J3

7.2.2
Display Board activates but switches are inactive.
Possible Causes Solutions
A. Power Supply See para 7.2.1 C
B. C.P.U. Board See para 7.2.1.D
C. Display Board If 7.2.2. A and B fail to correct problem replace
Display Board (Fig 1f)
7.2.3
Display Board Up(’) / Down(‘) keys operate properly, but on/off key
activation does not start the unit.
Possible Causes Solution
A. Door switch cable connections Locate power supply (Fig 1c). Check for
(Model 400, 120v) loose or open connections to J3 (Fig 3a). If loose in
connector, press into connector to insure proper
contact. If the problem persists replace door switch
cable assembly.
10
Figure 1e Figure 1f
Door Switch
Display Board
Pin 2
Pin 1 Pin 3
J2 Connector
Voltage Regulator (VRI)

B. Door switch cable connections Locate CPU board (Fig 1d). Check for loose or
(Model 401, 402, 230v) open connections to J2 (Fig 3b). If loose in
connections, press wires into connector to insure
good contact. If the problem persists, replace door
switch cable assembly.
C. Door switch Locate door switch (Fig 1f). On connector at the
end of the cable (see 7.2 3a or 3b) apply ohmmeter
to both connectors and ensure that the switch
functions when the door is opened and closed. If the
problem persists, change the switch.
D. Motor Connections Locate motor wire terminal block (Fig 3a). Check
that connections are secure and that the screws are
tight. If they are secure measure the voltage across
the terminal block while depressing the on/off key.
If this voltage is above 70v a.c., replace motor base
assembly.
E. CPU board If voltage is not above 70 v a.c. replace CPU board.
F. Display Board If the above fails to solve the problem replace the
display board.
11
Figure 3a Figure 3b
Pin 2
Pin 1 Pin 3
J2 Connector
Voltage Regulator (VRI)
Motor Wire
Terminal Block
J3 Connector
Capacitor/Resistor
Connections

7.2.4
Motor speeds up and stops immediately after turned on, All other keys
function properly.
Possible Problem Solution
A. Optical detector board assembly Locate optical detector board (Fig 4a). Check for
broken wires in cable to power supply. If broken or
intermittent, replace optical detector board
assembly.
B. Optical detector If problem still exists clean the inside slot of the
optical detector board assembly.
C. Power supply See para 7.2.1. C
D. CPU board See para 7.2.1. D
E. Display board If all the above does not solve the problem replace
the display board.
12
Figure 4a Figure 5a
Motor Wire
Terminal Block
J3 Connector
Timing Wheel
Optical Dector
Board
Capacitor/Resistor
Connections

7.2.5
Motor speed is inconsistent.
Possible Problem Solution
A. Loose wires Locate power supply (Fig 1c). Check for loose or
broken capacitor/ resistor connections in cable
assembly (Fig 5a). If broken, replace assembly.
B. Optical Detector Refer to 7.2.4. B
C. Timing wheel Locate timing wheel (Fig 4a.). Make sure the timing
wheel has not changed location. This would cause
the wheel to cut the optical board (4a). If this has
happened, change the optical board and realign the
timing wheel.
D. CPU Board If speed is still inconsistent, replace the CPU Board.
7.2.6
Memory buttons MT1 and MT2 does not store the programmed value after
power is off.
Possible Problem Solution
A. CPU board Replace CPU board.
13
Figure 5b Figure 6a
Conical Spring
AB

MECHANICAL FAILURES
7.3.1
Capsule remains locked in arm.
Possible Problem Solution
A. Arm release Locate the arm release mechanism Fig 5b. and
press A and B together repeatedly in the direction
of the arrows.
7.3.2
Unit moves from vibration during operation.
Possible Problem Solution
A. Broken or loose conical springs Open the unit and check the conical springs located
in Fig. 6a. If a spring is broken or loose, replace
motor assembly.
(see assembly/disassembly)
7.3.3
Capsule arm drops and hits the window during operation.
Possible Cause Solution
A. Broken tail spring Locate the tail spring (Fig 6b). Cut tail spring in
half and change. Never reuse tail spring.
14
Figure 6b Figure 6c
Tail Spring Arm Assembly

7.3.4
Arm opens and does not hold capsule.
Possible Cause Solution
ABroken arm Replace arm assembly (Fig 6c). See
assembly/disassembly.
7.3.5
Rubber boot falls off.
Possible Cause Solution
A. Glue bond is broken Glue the boot back to plastic using Loctite Super
bonder 498 (Fig 8.2).
7.3.6
Window makes noise during operation.
Possible Cause Solution
A. Tension of the window has decreased. Locate the tension springs and switch plate
(Fig 6d). Change the tension springs, switch plate
and the window cover.
15
Figure 6d Figure 8.1
Tension Spring Tension Spring
Switch Plate Middle Screw

16
Figure 8.2 Figure 8.3
Assembly and disassembly procedure
(CAUTION: DISCONNECT POWER SOURCE FROM UNIT BEFORE
ATTEMPTING ANY DISASSEMBLY OR REPAIR PROCEDURE)
8.1 ProMix™Disassembly
a. Turn the unit upside down and completely loosen the 4 screws in the bottom half
of the enclosure. (As shown in the Fig 8.1).
b. Remove the small screw in the middle of the unit to release the top cover
(Fig 8.1).
c. Turn the unit right side up while holding the upper and lower halves of the
enclosure. Carefully pull the top cover ahead in a sideward motion while pushing
the arm through the rubber boot as shown in Fig 8.2.
d. Place the top cover beside the unit as shown in Fig 8.3.
8.1.1 Optical Detector Board Removal
a. Disconnect the lead wire assembly connection to the power supply.
b. Unscrew the 4 screws holding the PCB to the motor frame.
c. Take out the circuit board. (see Fig 8.4)
Arm Top Cover
Rubber Boot

17
8.1.2 Power Supply Removal.
Model 400 a. 120v power supply removal. Disconect cable connection to CPU board at
120 Volt J1 and J3 (Fig 1d) Disconnect optical Detector board and door switch
connections at power supply board J2 and J3 (Fig 3a).
Model 401, a. 230v power supply removal. Disconnect cable connection to CPU board
402 J1 (Fig 3b). Disconnect optical detector board at J2.
230 Volt b. Remove power connection at the switch.
c. Remove motor lead connection at J1 blue terminal block.
d. Unscrew the four screws holding the power supply to the metal base.
e. Lift the transformer board up and out.
8.1.3 CPU Board Removal.
Model 400 a. Locate J1 and J2 connectors on the CPU board and disconnect.
120 Volt
Model 401, a. Locate connectors J3 and J1 on the CPU board and disconnect.
402 b. Remove the 4 screws holding the CPU board to Display board.
230 Volt c. Pull the CPU board up to disconnect it from the Display board (Display
board and CPU board are connected by a 24 position board to board
connector).
8.1.4 Display Board Removal.
a. Unscrew the 8 screws holding the display board to top plastic and lift the display
board up and out.
Figure 8.4 Figure 8.5
Timing Wheel
Tail Spring
Optical Dector
Board