A-dec 1040, 1021, 8000 User manual

Chairs	Overview

A-dec model 1040, 1021 and 8000 chairs are electronically controlled, hydraulically powered dental chairs. Buttons on both the touchpad and 8-button footswitch and actuators on the 8-function footswitch are used to position and program auto-positioning functions into the chair. The hydraulic system is controlled by the electronic control module using relays and solenoidactuated valves.

This section provides information related to locating serial/model numbers, servicing, maintenance, and adjustment of chairs. Detail on how to service chairs and troubleshoot specific problems related to them is presented.

85.0812.00, 2003

CH-1

Chairs	Serial/Model Number Locations

Locating

Serial/Model

Number

The serial/model number tags identify the chair model and manufacture date. The label can be found either on the top surface of a chair’s upper structure (raise the toeboard) or on the righthand side of the upper structure. If you have difficulty locating the serial/model number label, the following example may be helpful.

Serial number label location

Serial number label location

Decade 1021/1011 Chair

Cascade 1040 Chair

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CH-2

Chairs	Manufacture Date

Reading the

Manufacture Date

Different models of the chair can be identified by referring to the “REF” number. Each chair is further identified by its month and year of manufacture.

This example shows how to identify the model and month and year of manufacture of the chair.

Item # Description

1Model number

2The first letter of the serial number indicates the month the product was manufactured; e.g., A is January.

3First digit indicates the year of manufacture.

1

1

	Tele: (44) 1203-350901
DENTAL	REF: 1040		S/N: J167856
CHAIR
MADE IN		!		INPUTS
USA
			120 V -
			10 AMPS MAX
2001			50-60 Hz

DENTAL CHAIR

CAUTION!

C US

®

LISTED 15VJ

LA BEL P/N: 051.515.02 REV L

Serial/Model Number Label

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CH-3

Chairs	Hydraulics

Working with Hydraulics

The hydraulic system consists of the following:

Part	Description
Hydraulic fluid reservoir	The fluid level in the reservoir can be seen through the sides of the reservoir and is serviced via a
	top fill cap.
Hydraulic cylinders	The hydraulic cylinders control the base lift and back functions. Springs and gravity retract the
	rod during base and back down functions.
Motor-driven hydraulic pump	The hydraulic pump and the starter capacitor supply hydraulic fluid from the reservoir, under
	pressure, to the chair lift and tilt hydraulic cylinders for back up and base up functions.
Solenoid/manifold assembly	This assembly gates hydraulic fluid to and from the two cylinders. Depending on the chair
	function called for, the controller selects which solenoid-actuated manifold valves are opened or
	closed. The solenoid/manifold assembly also includes four adjustable needle valves used to
	restrict or divert the flow of hydraulic fluid to and from the lift and tilt cylinders. These valves
	provide the rate of travel adjustment for chair base and back movement.

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CH-4

Chairs	Hydraulic System Flow Diagram

From

motor/pump { start capacitor

Tilt cylinder

Lift cylinder

Solenoid manifold assembly

Hydraulic pump motor

Vent tubes

Pickup tube

MAX

MIN

Hydraulic fluid reservoir (check fluid level with base and back full up)

NOTE: Use only A-dec fluid P/N 61.0197.00.

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CH-5

	Chairs			Hydraulic Manifold
				Before January 1999
	Hydraulic Manifold
	Item #	Part Number	Description
	1	61.1335.00	Solenoid, (8-watt, 100V,
			Yellow wires)
		61.1336.00	Solenoid, (8-watt, 120 V,
			Black wires)
		61.1337.00	Solenoid, (8-watt, 240 V,	6
			Red wires)
	2	035.041.02	O-ring, special pkg 10	3
	3	030.004.02	O-ring, AS568-004 pkg 10
	4	030.010.00	O-ring, AS568-010
			(only on dual-block manifolds)	4
	5	61.0460.00	Flow adjust screw with o-ring
	6	001.002.00	Screw, truss-head slot
				2
				3

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CH-6

Chairs	Hydraulic Manifold

Hydraulic Manifold

	Item #	Part Number	Description
	1	61.1335.01	Solenoid, (8-watt, 100V,
			Yellow wires)
		61.1336.01	Solenoid, (8-watt, 120V,
			Black wires)
		61.1337.01	Solenoid, (8-watt, 240V,
			Red wires)
	2	030.015.02	O-ring, pkg 10
	3	030.004.02	O-ring, AS568-004 pkg 10
	4	61.0460.00	Flow adjust screw with o-ring
	5	002.118.01	Screw, button-head, socket
	6	61.1332.00	Manifold assy, hyd, 100V
		61.1333.00	Manifold assy, hyd, 120V
						6
		61.1334.00	Manifold assy, hyd, 240V

After January 1999

5

4

3

3

1

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CH-7

Chair	Hydraulic Manifold

Removing a

Solenoid

WARNING

The solenoid coils are powered by line voltage (100, 120, or 240V AC). Failure to unplug the chair may result in serious injury from electrical shock.

The following steps will guide you through the removal of a solenoid.

Task	Description	Hydraulic manifold
1	Lower the chair base and back to the	J10
	full down position to depressurize the
	hydraulic system. Remove the motor
	pump cover, then unplug the chair.

2If necessary, remove the two mounting screws that secure the manifold to the hydraulic tray. Rotate the manifold so the solenoids are accessible.

3Using a flat blade screwdriver and a 9/16" wrench, remove the defective solenoid.

4Cut the defective solenoid wires 3" (74mm) from the coil and discard.

5Remove the old o-ring from the solenoid cavity and completely dry the cavity. Replace the o-ring (refer to Solenoid installation instructions for correct o-ring).

O-ring

Poppet

Wire nut

Poppet sleeve

Washer

Coil

ID washer

Retaining nut

Removing a Solenoid

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CH-8

Chair	Hydraulic Manifold

Replacing a

Solenoid

WARNING

The solenoid coils are powered by line voltage (100, 120, or 240V AC). Failure to unplug the chair may result in serious injury from electrical shock.

The following steps will guide you through replacing a solenoid.

Task	Description
1	Install the new solenoid stem and poppet into	Hydraulic manifold
	the manifold and tighten to 35-40 in lb	J10
	(.11085-.2284 Nm). Position the remaining
	solenoid parts on the stem and secure by
	tightening the retaining nut to 25-30 in lb
	(.14275-.1713 Nm).

2Cut the solenoid wires 3" (75 mm) from the coil. Install the stripped wires from the solenoid and the connector housing into a wire nut. Repeat for the remaining wire.

3Using the mounting screws, secure the manifold to the hydraulic tray.

4.Plug in the chair. Test the chair functions to ensure proper operations and that no fluid leakage occurs. Reinstall the motor pump cover.

O-ring

Poppet

Wire nut

Poppet sleeve

Washer

Coil

ID washer

Retaining nut

Replacing a Solenoid

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CH-9

Chairs	Hydraulic Manifold

Adjusting the

Hydraulic Manifold

CAUTION

Do not completely close a speed control valve.

The motor/pump could overheat and become damaged from pumping against a closed valve.

Do not remove retaining screw from the control valves.

The hydraulic manifold incorporates four speed control valves, which restrict or divert the flow of hydraulic fluid to and from the lift and tilt cylinders.

NOTE: The speed control valves are hex drive.

	To adjust...	Do this...
	Base up speed	Turn base up control valve:
		clockwise to decrease speed, or
		counterclockwise to increase speed.
	Base down speed	Turn base down control valve:
		clockwise to decrease speed, or
		counterclockwise to increase speed
	Back up speed	Turn back up control valve
		counterclockwise to decrease speed, or
		clockwise to increase speed.
		NOTE: This is opposite of the other
		three control valves. Turning the back
		up valve counterclockwise too far may
		prevent the back from moving up.
	Back down speed	Turn the back down control valve:
		clockwise to decrease speed, or
		counterclockwise to increase speed.

Base up	Back up
control valve	control valve

Retaining screw

Base down	Back down
control valve	control valve

Adjusting the Hydraulic Manifold

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CH-10

Chairs	Hydraulic Manifold

Correcting

Hydrostatic

Lock

Hydraulic lock occurs based on the following conditions:

•chair base or back is stuck in full up position

•limit switch not activated, or

•down solenoid poppet is unable to open based on excess hydraulic pressure.

Task Description

1Remove the motor/pump cover from the chair.

2Fit a 5/8" wrench to the high pressure outlet port (either lift or tilt, whichever is in hydrostatic lock) of the hydraulic manifold. Hold the port still and use a 9/16" wrench to loosen the hose fitting.

3Place a shop rag around the fitting to absorb the fluid.

4Carefully loosen the fitting counterclockwise until oil begins to leak from the fitting. Retighten the fitting. Operate the down function. A second release of hydraulic fluid may be required.

5Adjust the limit switch that caused the hydrostatic lock (refer to Adjusting the Base Up Limit Switch). In some cases, it may be necessary to remove and replace the limit switch. Adjust the new limit switch as needed. Also ensure that the large gear/actuator is securely installed and not slipping.

6Cycle the chair a couple of times to verify it is no longer in hydrostatic lock.

Tilt cylinder high pressure fitting

Lift cylinder high pressure fitting

Correcting Hydrostatic Lock

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CH-11

Chairs	Electrical System Wiring Diagram

NOTE: If there is no cuspidor, remove

To post box, or jumper from cable and place on board

Radius lift arm connector

To cuspidor						Place jumper
stop switch		LED light				here if there is
						no cuspidor

1 2

0 3

Back positioning	Base positioning
potentiometer	potentiometer

P1	DS8	DS15	AUXILIARY
	P14	P16	OUTPUT POWER
			(2A MAX)
P2	CUSP	STATUS
			L1	N/L2

S1 PRGM

P5
OT	DS3
P
B K
P4
OT	DS5
P
BS

P12

P17

TEST POINTS

			B KUP
			BSUP
			BSDN
			B KDN			BK UP
			PRGM 0
			PRGM 1			DS12
			PRGM 2
			PRGM 3
			EN/DIS TP/FS			BS UP
			FA CT DEFAULT
			B K POT			DS14
			BS POT
			SPARE
			SPARE			BS DN

					DS7
DS1	DS2
				"STATIC SENSITIVE"	BK DN
ON		#1	#2	SETS	DS13
S2		OFF OFF		CUSP/RET
		ON	OFF	LAST POST		K5
1	2	OFF ON		PRGM 3	DS11
PS		DS6	ON	NOT USED		PUMP
P6		ON
B K		DS9			P13
					LOCKOUT
		DS10			DS4
BS

CB1

CB2

Optional duplex 100V and 120V only

Main power from electrical outlet

Ground

MAINS

INPUT POWER

L1 N/L2

P11

P10

N/L2

BK UP

BS UP

BS DN

BK DN

P9

PUMP

PUMP

N/L2

Hydraulic manifold

To hydraulic motor/pump

}

~)

	R73	(220-240V
DS17	DS16
+12V	+5V
BE EPER	R74 R72	(100-120V~)	PART #

Capacitor

Footswitch

Stop plate	Back up limit	Base up limit
limit switches	switch	switch

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CH-12

Chairs	Electrical Systems Service Parts

	Item #	Part Number	Description
	1	61.1332.00	100V, Yellow wires
		61.1333.00	120V, Black wires
		61.1334.00	240V, Red wires
	2	90.1031.00	Capacitor with boot (100-120V)
		90.1034.00	Capacitor with boot (240V)
	3	041.372.00	Positioning potentiometer
	4	61.2065.00	Back up limit switch
	5	044.184.01	Base up limit switch
	6	61.2099.00	Cable assy, tilt switch
			(1040) only
	7	61.3043.00	8-button footswitch
	8	39.1045.00	Chair touchpad
		39.1385.00	Performer touchpad
		39.1090.00	Cascade Master with cuspidor
		39.1090.00	Cascade Master w/o cuspidor

7

8

1 2

0 3

1

6

3

To Replace Circuit Board P/N		Order this kit
											4
	61.2510.00	90.1029.00 (100-120V)															5																			2
61.1214.01
61.1373.01
61.2512.00		90.1029.01(220-240V)
61.1217.01

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CH-13

Chairs	Diagnostic LEDs for the Circuit Board

LEDs

NOTE: Refer to Testing Factory Defaults for more details.

DS3

DS5

DS2

DS1

DS6

DS9

DS10

DS8	DS15
	DS12
	DS14
	DS7
	DS13
	DS11
	DS4
	R73
	R72
	R74
DS17	DS16

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CH-14

		Chairs		Diagnostic LEDs for the Circuit Board
	LED	Description	Information Communicated
	DS1	S2 (red DIP switch) is ON	Switch is ON
	DS2
	DS3	Back Potentiometer LED ON	Back potentiometer is functioning normally when the chair back is moving
	DS4	Handpiece Lockout LED ON	Lockout enabled
	DS5	Base Potentiometer LED ON	Base potentiometer is functioning normally when the chair base is moving
	DS6	Chair Stop Plate Limit Switch LED ON	Chair stop plate limit switch activated
	DS7	Base Down LED	Relay is ON when LED is ON and the function is moving
	DS11	Pump LED
	DS12	Back Up LED
	DS13	Back Down LED
	DS14	Base Up LED
	DS8	Cuspidor Limit Switch LED ON	Cuspidor limit switch activated, or jumper is missing
	DS9	Back Up Limit Switch LED ON	Back Up limit switch activated
	DS10	Base Up Limit Switch LED ON	Base Up limit switch activated
	DS15	Status LED ON	ON:	Normal operation
			OFF:	Microcontroller is not functioning. Verify voltage regulator LEDs
				(DS16 and DS17) are ON. Is the chair plugged in? Circuit breaker tripped?
			Slow Blink:	Check cuspidor (DS8) and stop plate (DS6) limit switch LEDs
			Fast Blink:	Check handpiece lockout (DS4) LED
			Double Blink: A SPARE jumper is in the FACT DEFAULT position
	DS16	5V Regulator LED OFF	1. Power to circuit board is OFF, or
			2. There is a short in the cable to the base or back potentiometer. Disconnect all cables
			except the power cable. Plug the cables in one at a time (the LED will turn ON when the
			problem is fixed).
	DS17	12V Regulator LED OFF	1. Power to circuit board is OFF, or
			2. There is a short in the cable to the status light or limit switch (the LED will turn ON when
			the problem is fixed).

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CH-15

Chairs	Chair Printed Circuit Board (PCB)

Testing and

Programming

the Circuit Board

WARNING

The chair will begin to move automatically during this test; to avoid injury or equipment damage, remove all possible obstructions and maintain a safe distance from the chair. To interrupt the chair cycle, press any button on the touchpad or footswitch, or activate the chair stop plate.

Follow these steps to test and program the chair circuit board.

Task Description

1Insert the SPARE jumper into the FACT DEFAULT location (on P17).

Result: The chair will cycle the base and back movements and automatically reprogram the memory positions to the factory settings

(position 0 to entry/exit; 1 and 2 to the same pre-programmed positions; and 3 to cuspidor/return).

If the circuit board beeps three times, continue with step two.

If the circuit board beeps just once, the chair cycle has been interrupted. Diagnose and correct any errors, then press either circuit breaker for five seconds to restart the cycle (refer to Testing Factory Defaults).

2Move the jumper from the FACT DEFAULT location (on P17) back to the SPARE location.

NOTE: The jumper must be in the SPARE position for normal chair functions and safe operation.

3Press “1” on the touchpad or footswitch, or the green position on the 8-function footswitch.

Result: The chair will move to the operating position.

4Press “0” on the touchpad or footswitch, or the red button on the 8-function footswitch.

Result: The chair will move to the entry/exit position.

NOTE: The chair programmable position buttons can be reprogrammed to the desired positions as specified by the dental team.

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CH-16

Chairs

Tests

Testing Factory Defaults

The table lists conditions and corrective actions for testing the factory defaults for LEDs.

Problem

Action

Factory Default test will not start

If . . .

Then . . .

(LEDs DS15, DS16 and DS17

are Off)

Transformer thermal limiter is open

Wait for transformer to cool off.

Circuit breaker is tripped

Reset circuit breaker (short circuit fault currents

may damage the circuit breaker and prevent it

from resetting).

Factory Default test will not start

If . . .

Then . . .

(LED DS15 is Off; DS16 and DS17

Input voltage is too low or is outside the

Verify input voltage and voltage selection

are ON)

required range

resistors (100-120VAC=R72 and R74)

(220-240VAC=R73).

Microcontroller is not functioning

Replace the circuit board.

Factory Default test will not start

If . . .

Then . . .

(LED DS15 is blinking; DS16 and

Input voltage is too low or is outside the

Verify input voltage and voltage selection

DS17 are ON)

required range

resistors (100-120VAC=R72 and R74)

(220-240VAC=R73).

Microcontroller is not functioning

Replace the circuit board.

85.0812.00, 2003

CH-17

Chairs	Tests
Problem	Action

Factory Default test halts during the BASE UP test and the PCB board beeps one time

Factory Default test halts during the BACK DOWN test and PCB board beeps one time

	If . . .					Then . . .
		Input voltage is too low or is outside the
							Verify input voltage and voltage selection
		required range					resistors (100-120VAC=R72 and
							R74 (220-240VAC=R73).
		Base Up limit switch is activated					Verify switch operation.
		Motor thermal limiter is open, motor is hot					Wait for motor to cool off.
		Motor capacitor is defective					Test capacitor and replace, if needed.
		Base Up solenoid is defective					Test solenoid and replace, if needed.
		Base is in hydrostatic lock					Refer to Correcting Hydrostatic Lock.
		Potentiometer is not changing voltage					Verify potentiometer LED comes ON when base
							is moving.
							Check potentiometer mechanical drive and
							electrical connections.

	If . . .					Then . . .
		Stop plate limit switch is activated
							Verify switch operation.
		Stop plate is jammed					Remove and reinstall the stop plate.
		Back Down solenoid is defective					Test solenoid and replace if needed.
		Back is in hydrostatic lock					Refer to Correcting Hydrostatic Lock.
		Potentiometer is not changing voltage					Verify potentiometer LED is ON when back
							is moving.
							Check potentiometer mechanical drive and
							electrical connections.

85.0812.00, 2003

CH-18

Chairs	Tests
Problem	Action

Factory Default test halts during the BACK UP test

Factory Default test halts during the BASE DOWN test

Chair moves by itself when power is turned ON

	If . . .					Then . . .
		Back up limit switch is activated
							Verify switch operation.
		Back Up solenoid is defective					Test solenoid and replace, if needed.
		Back is in hydrostatic lock					Refer to the Correcting Hydrostatic Lock.
		Potentiometer is not changing voltage					Verify potentiometer LED is ON when back
							is moving.
							Check potentiometer mechanical drive and
							electrical connections.

		If . . .					Then . . .
			Stop plate limit switch is activated					Verify switch operation.
			Base Down solenoid is defective					Test solenoid and replace if needed.
			Base is in hydrostatic lock					Refer to Correcting Hydrostatic Lock.
			Potentiometer is not changing voltage					Verify potentiometer LED is ON when base
								is moving.
								Check potentiometer mechanical drive and
								electrical connections.

	If . . .					Then . . .
		The jumper is in FACT DEFAULT position
							Verify that the jumper is in the
							SPARE position.
		Short circuit in touchpad or footswitch					Unplug the touchpad and footswitch; reset the
							circuit breaker. If the problem isn’t repeated, the
							touchpad or footswitch may have shorted.
		Short circuit on circuit board					Replace the circuit board.

85.0812.00, 2003

CH-19

Chairs	Chair Printed Circuit Board (PCB)

Identifying

New Features

The chart provides information on new features and associated programming on the PCB.

	Feature	Programming
	Raise the chair with the	Plug the chair into an electrical outlet.
	stop plate limit switch	Tap the chair stop plate three times within five seconds and hold on the third tap.
		Result: The chair base will continue to rise as long as the stop plate is held in. This function is
		automatically disabled after five minutes but is re-enabled upon each power up. To reset the
		five-minute timer, depress either circuit breaker until the LEDs turn OFF, then release the
		circuit breaker.
	Enable and disable touchpad	Place the SPARE jumper in the EN/DIS TP/FS position of the Test Points header P17.
	and footswitch buttons	Push the buttons to be Enabled or Disabled (PRGM, PRGM 0, PRGM 1, PRGM 2, PRGM 3).
		Result: One beep indicates the button is disabled. Three beeps indicate the button in enabled.
		Place the SPARE jumper back into the SPARE position of the Test Points header P17.
	Handpiece lockout	Plumb a normally open air-electric switch ( kit P/N 61.1384.00) to the air-coolant tubing (green with
		long white dashes).
		Insert the two position connector from the air-electric switch into P13 Lockout (next to the transformer)
	Diagnostic LEDs	See Diagnostic LEDs for the Circuit Board.
	Test Points Header	Use a SPARE jumper to test the chair manual functions (BKUP, BSUP, BSDN, BKDN).
85.0812.00, 2003		BK POT and BS POT points allow test meter check of potentiometer voltages and	CH-20
		measurement of the analog DC voltage from pin 2 of the potentiometer.