Kulzer Cara Scan 4.0 User manual

Quick Start Guide

1Contents
© 2019 Kulzer, LLC
Table of Contents
1Scope of applicability 2
.................................................................................................................................. 21.1 General
.................................................................................................................................. 21.2 EU statement of conformity
2Instruction on using the unit safely 3
.................................................................................................................................. 32.1 Explanation of symbols
.................................................................................................................................. 32.2 Transport damage
.................................................................................................................................. 32.3 Safety information
3Use in accordance with specifications 4
4Scope of delivery/consumables set 5
.................................................................................................................................. 54.1 Scope of delivery
.................................................................................................................................. 54.2 Accessory kit comprising of
5Structure and function 6
.................................................................................................................................. 65.1 Control elements
6Location and Installation 7
.................................................................................................................................. 76.1 Unpacking
.................................................................................................................................. 86.2 Hardware setup
7 Operations 11
.................................................................................................................................. 117.1 Putting into operation
.............................................................................................................................. 12Installation Testing7.1.1
7.1.1.1 Remove Base Plate....................................................................................................... 13
7.1.1.2 Reset Tray Position....................................................................................................... 13
7.1.1.3 Calibrate cara Scan 4.0.................................................................................................. 13
7.1.1.4 Basic Mode Acquisition................................................................................................. 15
8Scanner Basics (Commonly Used Icons)
25
25
9 Beginning a Scan
9.1 Pala Tray Impression Scanning........................................................................................... 19
9.2 Model & Bite Rim Scanning.................................................................................................. 21
9.3 Duplicate Denture Scanning.................................................................................................23
10 Putting Out of Operation
11 System Configuration
17
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2
1Scope of applicability
1.1 General
cara Scan 4.0 is a dental device (USA: medical device) built by Kulzer GmbH, Leipziger
Straße 2, 63450 Hanau (Germany).
This Quick Start Guide applies to:
Order-No
Type Features
Date
66078597
cara Scan 4.0
2018-01
1.2 EU statement of conformity
We, Kulzer GmbH, herewith declare that above mentioned device fulfills the basic safety
requirements of mentioned standards, regulations and directives. In any case of non-
authorized modification, abnormal use or misuse of this device or document Kulzer is not
liable for any injury, risk or malfunction that may occur.
© 2019 Kulzer, LLC

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2Instruction on using the unit safely
2.1 Explanation of symbols
Symbol
Accompanying
word(s)
Explanation
CAUTION
Safety-relevant paragraphs and sections in these
working instructions have been marked with this
symbol
NOTE
Information within the working instructions on the
optimum use of the unit
WARNING
This symbol warns of the dangers of electric voltage
DISCONNECT
FROM MAINS
Danger of electric shock when unit is opened.
Unplug the unit before opening it
2.2 Transport damage
Please check the unit for transport damage and, if necessary, accept the unit with
reserve. Report the eventual damages to the forwarder within 24 hours after receiving
the unit.
CAUTION
Under any circumstances, do not work with a damaged unit.
2.3 Safety information
With these laboratory units the safety concerning the protection of persons, the
environment and the material to be processed mainly depends on the behavior of the
persons operating the unit.
CAUTION
Prior to operation read the cara Scan 4.0 Operating Manual carefully, adhere to the
information provided in order to avoid errors and damage, in particular damage to the
health.
In addition to the information in these working instructions, relevant national laws and
guidelines must be observed for setting up and operating this unit (technical connection
requirements of the electrical supply companies, etc.).
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CAUTION
Connecting cable and plug must be checked for damage prior to operation. If any
damage exists, the unit must not be connected to the mains. A damaged mains
connecting cable may only be replaced by a mains connecting cable of the same type:
· L = 2.5 m long A 10/16 A, 250 V, 90° Schuko plug, IEC 320 C13 connector for European
countries.
· L = 1.8 m long IEC 60320 C13 Femmina / NEMA 5-15 Maschio for USA and North
American countries.
Customer is obliged to ensure proper protective earth supply in electrical installation.
Specification for cara Scan 4.0: 230 V mains socket (3 prong only; phase-neutral ground);
separate fuse 16 A, slow blow.
If not observed risk of electrical shock and serious harm of operator or third parties
cannot be fully avoided.
WARNING
This symbol warns of the dangers of electric voltage. In the case of non-compliance the
result of an electrical shock with all known effects can be death. Removing the scanner
cover this safety symbol is visible on the surface of the main power unit. Works at the
electrical equipment of the unit must only be performed by the authorized Kulzer GmbH
service agents and in the safe condition (voltage cleared). Please observe the safety
instructions when carrying out servicing.
CAUTION
Proper function and safety of the unit are only guaranteed if the required tests,
maintenance and repair work have been performed by Kulzer GmbH service agents or by
personnel adequately trained by Kulzer GmbH. Only permissible original spare parts
must be used. The use of different parts holds unknown risks and must be avoided at
any rate.
3Use in accordance with specifications
The structured light 3D scanner is a laboratory unit for acquiring gypsum or implant
models concerning dental field. The unit is not suitable or intended to acquire any other
type of object, food or pets.
NOTE
· Due to various possible causes for bad models acquisition results, Kulzer GmbH does
not grant any guarantee for such cases.
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4Scope of delivery/consumables set
Check that all components are in perfect condition on delivery of the machine. If you
wish to make a complaint, contact your supplier.
4.1 Scope of delivery
A)
cara Scan 4.0 and cara CAD (1x)
B)
Accessory kit (1x)
4.2 Accessory kit comprising of
A
B
C
D
E
F
G
H
I
K
L
M
A)
Blu Tack® adhesive (1x)
G)
Dongle/USB Stick (1x)
B)
Power cord (1x)
H)
Wi-Fi antenna (1x)
C)
Working plate (1x)
I)
2.5 hexagonal (Allen) tool (1x)
D)
Multidie plate (1x)
K)
Fuse T 5A 250V (2x)
E)
Calibration plate (1x)
L)
cara Scan 4.0 Quick Start Guide
F)
DVI cable (1x)
M)
Dust cover
* This device may not correspond to the illustration above
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5Structure and function
5.1 Control elements
1. Protection cover
2. On/Off switch button
3. Mains AC switch
4. Fuses
5. AC Socket
6. Antenna Port
7. USB 3.0 Ports
8. DVI-I Port
9. Base plate
10. Base plate retention screws
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6Location and Installation
6.1 Unpacking
The cara Scan 4.0 is shipped inside a cardboard box.
1. Open the upper side of the cardboard box at the position where the clamps are
present.
2. Remove first the Accessory kit and afterwards the inner protective parts both on the
right as well as on the left side.
3. Remove the scanner.
4. Remove door protection.
5. Open the front door and check the position of the base plate. If the position is not
horizontal, gently move it by hand until it is roughly aligned with the inner cover.
The perfect base plate position will be achieved later on through the Reset Axis
procedure described in the "Operations" paragraph.
CAUTION
· Do not perform this operation while the scanner is turned on!
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NOTE
· It is suggested to keep the packaging in case you need to ship the scanner for technical
assistance.
6.2 Hardware setup
NOTE
· The scanner must be placed on a solid, rigid and skid-proof surface (laboratory desks,
racks) so that a horizontal safe position is ensured.
· The scanner should not be placed directly in the sun light or close to a spot light
source.
· The scanner should not be placed in a position in which it can come into contact with
liquids or fluid leaks.
· If the scanner is installed in a very dusty environment protect it as much as possible.
When not used always close the front door. In addition a dust cover is provided in
order to secure an optimal protection.
· The room temperature should not be less than 10 °C (50 °F) or more than 40°C
(104°F).
· The humidity should be less than 80 %.
CAUTION
· The table should have a load bearing capacity of at least 40 kg / 88 lbs.
· Take care not to pinch your fingers when placing the scanner on the table.
· Air inlet and outlet openings in the housing of the unit (rear and side surfaces) must
not be covered or blocked. The rear and side of the unit must be at least 100mm /
3.94inch away from the wall to avoid blocking the air outlet of the built-in fan, it
means it is required a free area (w x d: 550 x 550 mm / 21.65 x 21.65 inch).
· The scanner needs to be positioned with easy accessibility to access the main socket
and disconnection from mains is possible, if needed.
· Do not initialize the scanner prior to acclimatization.
· Do not put the device in operation while the dust cover is in place.
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To properly setup the hardware follow the below steps:
1. Connect the wireless mouse and the wireless keyboard (both not included in the
package) using two USB 3.0 ports in the scanner back panel.
2. Connect any end of the DVI-I cable to the vertical scanner DVI-I port and plug the
other end into the monitor (not included in the package) DVI-I port.
3. Connect the scanner and the monitor to AC socket. Mains: 100/240 V (AC), 50/60 Hz,
connect to mains in accordance with local power supply specifications with flexible
mains connecting cable with hot appliance plug and safety plug to a correctly installed
socket with safety contacts. (The monitor mains connecting cable is not provided in
the package).
CAUTION
· Do not use any type of extension cord. Do not use intermediate mobile multiple plugs.
Do not connect the device to any type of emergency backup generator.
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4. Insert the Dongle/USB Stick in a USB 3.0 port.
5. Connect the Wi-Fi Antenna.
NOTE
· If additional hardware is installed it could cause malfunctions to the system. Do not
install additional hardware if not authorized by Kulzer service agents or by personnel
adequately trained by Kulzer GmbH.
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7 Operations
The following pages are to provide basic information and tips which are essential for
successful and error-free working.
7.1 Putting into operation
CAUTION
· Do not operate scanner with dust cover!
1. Turn on the rear mains AC switch.
2. Turn on the scanner using the front operating On/Off button.
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After a few seconds, the projector should light up the rotary table with a cara Scan 4.0
warm up sequence:
When the warm up sequence is finished the scanner will be in idle mode ready for the
operations. The PC monitor will show the standard Windows desktop page.
7.1.1 Installation Testing
NOTE
· Installation testing is required only the first time the scanner is extracted from the
package or moved to another location. During the day by day operations this activity is
not required.
To check if the scanner is working properly, four mandatory steps have to be
performed:
1. Remove the Base Plate.
2. Reset tray position.
3. Calibrate your scanner.
4. Basic Mode Acquisition.
© 2019 Kulzer, LLC

7.1.1.1 Removing the base plate
a. Prior to calibration, please remove the baseplate from inside of the scanner using the Allen
wrench provided in your accessory kit.
b. Unscrew the set-screw in the base plate and set it inside your accessory kit so you don’t lose it.
c. Remove the base plate (it is magnetically connected).
7.1.1.2 Reset Tray Position
a. Your first step prior to calibration is to reset the tray position in the scanner
b. To do so, click on the icon on the scanner toolbar
7.1.1.3 Calibrate cara Scan 4.0
a. Once your tray position is reset, calibrate your scanner.
b. To calibrate, first insert your calibration plate into the scanner. Make sure there is a good
magnetic connection and the calibration plate is secure.
c. Make sure the flat-end of the scanning plate is facing the inside of the scanner as shown below:
d. To begin calibration, click on the three bars in the top left of your screen next to DScan
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e. In the dropdown, click “Calibration.” When you do, the following screen will appear. Click on “Ok”
to begin calibration.
f. Once calibration is completed, you are ready to begin scanning
*Important Note: Anytime you move your scanner from one location to the next, you should
calibrate your scanner before you resume scanning
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7.1.1.4 Basic Mode Acquisition
1. Fix a model on the working plate using Blu-Tack adhesive.
The working plate has a planar reference face: A.
The incisors teeth have to be oriented as in the image below:
A
|
2. Insert the working plate in the scanner, align the flat side of the working plate with
the base plate one. In this way the incisors are to the back of the scanner.
The Basic Mode is a general purpose application used to test the scanner or to acquire a
very simple model. The Basic Mode calls the low level acquisition engine, Lumen, and
moves the model in several pre-defined positions in order to fully cover it from the
cameras and projector point of view. From each position, a points cloud is generated. All
the points clouds are aligned and merged together to create the final mesh; the last
operation is called Finalize.
3. Close the front door.
4. Double click on the cara Scan icon in the desktop .
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in the top left corner of the monitor. The
5. Click the purple arrow button "Scan"
"Basic Mode" dialog box appears.
6. Keep all the parameters by default.
7. Click on the "Scan" button to start the acquisition process. After the first 3 positions
will have been acquired, some points should be visible in the working area.
8. When the "Finalize" button becomes active, click on it to transform the points
into a mesh.
NOTE
· The scanning process can be interrupted in any moment by clicking the red square
button "Stop" , the scanner stops immediately to work and all the data will be
discharged. Use a Reset Axes command to restore the right plate position.
· If the system do not perform the acquisition process correctly, see the paragraph
"Troubleshooting, Error and Causes".
· As soon as scanning cycle has been started, the front door needs to stay closed all the
time. In case door needs to be opened scanning process will be stopped and all data
will be lost.
© 2019 Kulzer, LLC

8. Scanner Basics - Most commonly used icons
a. Assist / Help Icon
You can click on the help icon anytime you need information on particular scanner icons or
functions. To determine what a menu icon does, simply click on the question mark icon and then
move your mouse over the icon in question and left click. This will bring up support document
on using the icon you selected.
b. Edit Shape:
Use the Edit Shape icon to open up the sculpt shape menu to manipulate/edit scanned files to
add/remove distortions, unnecessary bumps or data, fill unnecessary indentations in the
scanned object
Download (Import)
Rectangle Selection
Upload (Export)
Polygon Selection
Trash (Delete)
Lasso Selection
Cursor
Cluster Selection
Brush Selection
Fill Holes
Sculpt Shape – Add: Lets
you add data to a scan (i.e.
fill unnecessary divots or
indentations in your scan)
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Sculpt Remove – Remove:
Lets you remove data from
a scan (i.e. remove
unnecessary bumps or
ridges in your scan)
Sculpt Shape – Smooth:
Lets you smooth/repair
surface areas of your scan
that you don’t want
present on your model
Sculpt Shape – Free Form:
Free form lets you
manipulate existing data
(does not add or remove)
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9. Beginning a Scan – cara Scan 4.0 is intended to scan models and bite rims, impressions
taken with the Pala Tray System, and existing dentures (for copy dentures).
a. Place the model that you want to scan on the scanning plate using Blu Tack adhesive (included in
accessory kit) or modeling clay
b. Make sure the anterior section of your model faces away from the red dot (facing the inside of the
scanner)
c. Insert the scanning plate inside the scanner. Make sure the red dot on the scanning plate lines up
with the red dot inside the scanner.
9.1 Pala Tray Impression Scanning
Open DScan 7.4 or most recent version on desktop
a. Pala Tray Bite Impression
1. Remove the sub-plate from the scanner so the scan plate sits lower in the machine.
2. Place Bite impression onto the scan plate.
3. Click on the solid purple arrow in the upper left corner to begin the scan.
4. On the pop-up window select “Impression”.
a. Leave all settings (options) as default other than mm height.
b. Change to -55mm and press “Scan”.
5. After initial scan, press the white arrow with purple outline and scan will finalize.
6. Fill holes if needed. (not usually necessary with the bite scan as most data will be present)
7. Select “Export” in the upper left corner and save you scan to your desired location. Make sure you identify
the file as “Bite.”
8. Delete the current scan by right clicking on the scan => select all => Trash Can
9. Separate the Pala Bite
a. Attach the posterior section to the upper if it has been cut off with light use of super glue.
b. Attach the posterior sections to the lower impression with light use of super glue.
i. If the line is visible, use only the blue Pala Putty to blend the line.
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