Maquet Betaclassic User manual

111801 / 02 / 03

Betaclassic / Alphaclassic

Maintenance and Mobile O.R. table Repair Instructions

English

MAQUET GmbH + Co. KG · Postfach 2162 · D-76411 Rastatt Telefon (07222) 932-0 ·

1118.0XGB_06

06.2005

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

1118.0XGB_ 06 Page: 1

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

Contents: Page:

General 3

1. Design and functional description 5

Summary of functional parts 5 Transformer, charging unit (1118.02 / 03) 5 Batteries (1118.02 /03) 5

Controller unit A1 and IR-receiver board A4 (1118.03) 6 Corded hand control (1118.03) 6 Override board A2 (1118.03) 6 IR-remote control (1118.03) 6

2. Measurements and tests - electrical, electronic (1118.02) 8

2.1 Transformer T1 primary 8

2.2 Transformer T1 secondary 8

2.3 Charging unit 8

2.4 Batteries 8

2.5 Electric motor 8

3. Measurements and tests - hydraulic 10

3.1 Check of the oil level 10

3.2 System pressure 10

3.3 Hydraulic cylinders 10

3.4 Lowering valve (general), Lowering valve of 1118.01 / 02 12 double check valve (1118.03) 14

3.5 Potentiometer for “0“-positioning (1118.03) 14

3.6 Corded hand control (1118.03) 15

3.7 IR-remote control (1118.03) 15

4. Identification of faults – what to do if... - 16

5. Repair work / instructions for replacement of components 18

5.1 Casings (of the column, of the base- , bellows) 18

5.2 Guiding 20

5.3 Castors with locking lever 22

5.4 Pedal pump (1118.01 / 02) 24

5.5 6/3 directional valve with switch tray (1118.01 / 02) 26

5.6 Lowering valve (1118.01 / 02) 28

5.7 Lowering valve (1118.01 / 02) 30 Double check valve, 5/3-directional valve (1118.03) 30

5.8 Hydraulic cylinders (Height, tilting, trendelenburg) 32

5.9 Hydraulic power unit (1118.02 / 03) 34

5.10 Charging unit, Batteries (1118.02) 36

Charging unit, Batteries (1118.03) 38

5.11 Gas spring (back and leg plate) 40

5.12 Longitudinal shift – Bowden cable ( Type „J“, „K“) 42

5.13 Longitudinal shift – Linear guide ( Type „J“, „K“) 44

5.14 Replacement of gear parts (Spindle, cog wheels) of body elevator (Type „G“, „H“) 46

5.15 Controller unit A1 and IR-Receiver board A4 (1118.03) 50

5.16 Adjustment/setting of the “0“- positioning potentiometer (1118.03) 52

1118.0XGB_ 06 Page: 2

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

General

MAQUET products are to be serviced annually (assuming between 200 and 300 hours in service each year).

Damaged and/or defective components can be replaced by following the instructions given in this manual.

Special tools and equipment will be required for certain repairs.

Maintenance and repair may be carried out only by MAQUET GmbH & Co KG or by service personnel licensed and authorized by MAQUET to do so.

1118.0XGB_ 06 Page: 3

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

1118.0XGB_ 06 Page: 4

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

1. Design and functional description

The main components:

- Transformer (1118.02/03)

- Charging unit, Batteries (1118.02/03)

- DC motor (1118.02/03)

- Hydraulic pump (1118.02/03)

- Pedal pump

- 6/3 directional valve with selector calotte

- Lowering valve

- Hydraulic pressure lines, hydraulic cylinders

- Lowering valve (check valve)

For further information refer to the technical description and to the operating instructions

Description

1118 is a mobile O.R. table that is also available as a electrical-hydraulic version. Actuation of its hydraulic cylinders is selected by means of a selector calotte. A 6/3-channel valve (1) [6 connections, 3 switch positions] is used to control the oil flow. Channels are switched depending on the position of the selector calotte to either extend or reverse the piston rod of the selected cylinder. 2 combined switch&check valves (2) are assigned to the 6/3-channel valves of the tilting and the trendelenburg functions. Channels of these combined switch&check valves are opened or closed by means of the oil flow coming from the 6/3-channel valve. 2 lowering valves (check valves) (2) for tilting and trendelenburg belong to the 6/3 directional valve that are controlled i.e. opened or closed, by means of the oil flow of the 6/3 directional valve. The A and B channels of these lowering valves are closed in quiescent position in order to prevent the piston rod from being pushed back under load. Depending on the position of the selector calotte the functions “tilting” and “trendelenburg” are actuated. In neutral position of the selector calotte the height cylinder is selected. Contrary to the tilting and trendelenburg cylinder, the height cylinder is a single-acting type

To move the table downward the lowering valve (3) must be actuated by means of the separate pedal lever.

- see also the description in the operating instructions.

Transformer and charging unit – only types with electrical option (1118.02)

The O.R. table is supplied with the mains voltage via a 2-conductor cord with a standard inlet-plug and a mains plug. The transformer is equipped with a voltage selector to adapt the O.R. table correctly to the on-site voltage (100...240 V). The primary winding consists of four parts – 2x104 V and 2x12V. To select a voltage of e.g. 230V, all four parts of the winding are connected in series (=232V). The lower limit of voltages that can be selected is achieved in that both the 104V-windings are connected parallel. A temperature fuse (133°C) is integrated in the primary winding. This fuse cannot be replaced i.e. the complete transformer must be replaced if this fuse has blown. The secondary windings provide 2x14V as a supply voltage for the charger board A3. The 2 batteries and the 24V-DC-motor are connected to the charger board A3. These 2 parts are located in the base of the O.R. table. The AC voltages (2x24V) from the transformer are used to produce 2 charging voltages of 13.75V that are regulated separately. Each of these voltages is connected to one battery.

Batterien (1118.02/03)

The batteries used for this O.R. table are maintenance-free lead-gel types. These batteries supply the motor with 24V DC, . 2 batteries with are capacity of 7Ah are sufficient for 1118.02 – batteries with a capacity of 15Ah are used for 1118.03. The period for which the O.R. table can be operated by the batteries depends on the power consumption of the motor and the time for which the motor is actually running. The nominal current consumption of the motor is app. 7A. According to the supplier, the useful lifetime of the batteries is 5-6 years. This is equivalent to 300 cycles of charging/discharging when the batteries are charged weekly.

1118.0XGB_ 06 Page: 5

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

Controller unit A1 and IR- receiver board A4 (type 1118.03 only)

The controller unit A1 is located underneath the black bellows and is covered by a metal protection plate.

The IR receiver board is plugged onto the controller unit A4 as an additional board.

Both IR preamplifiers B1 and B2 are connected to this board.

One of the preamplifiers is located at the head side, the 2

one at the foot side of the column. The receiver board

A4 and the preamplifiers B1/B2 are permanently supplied with a voltage of 5V. Current consumption is very low

i.e. this affects the battery capacity only negligibly.

If more than one O.R. table with IR remote control is used in a surgical department (same floor) each of these

tables and the correspondig remote control must be set to its individual code – see technical description.

2 potentiometers B3/B4 for the “0” positioning and one potentiometer B7 for the height adjustment are connected

to the controller unit A1. Their positions are monitored by the controller unit and functions are carried out

accordingly.

Output voltages of the potentiometers must always be in the range of 0,16V...4,84V.

Corded hand control (type 1118.03 only)

The corded handcontrol consists of 2 housing parts, a PCB with pushbuttons for the functions and an LED for

status indication,

a keypad foil, and a spiral cable with 4 wires (B5, 5V, 0V, Data).

Voltage for the internal circuit is supplied by the connectors 0V

and 5V. B% is used to switch the controller unit A4 ON and OFF.

The line “DATA” is used for bi-directional communication between hand control and controller unit.

Serial signals are sent by the hand control to actuate functions accordingly. The controller unit sends information

to the hand control to actuate the status LEDs accordingly.

To switch the system on, the button “ON” must be pressed.

The status LEDs “battery, mains, ON” are actuated briefly.

After this sequence only the LEDs that indicate the situation

of the O.R. table will be illuminated.

The individual function buttons can now be actuated.

If no function is actuated for a period of 4 min. the controller

unit will be switched off automatically.

Override A2 (type 1118.03 only)

The functions of the override panel correspond to the

functions of the corded hand control. The override panel

can be used as an emergency control if functions of the hand control or the controller unit A4 fail.

Contrary to the hand control the override panel directly

actuates the valve of the desired function. The motor can

directly be actuated by means of the button “ON”, i.e. 2 buttons must be pressed simultaneously – “ON” + the

function button for the movement.

IR remote control (type 1118.03 only)

Contrary to the corded hand control there is no bi-directional

communication with the controller unit.

The LED “battery” indicates the capacity status of the accumulator inside the remote control.

Information on the capacity of the accumulators of the O.R. table is given at the override board.

If no function is actuated within a period of 1,5 min. the controller

Unit will be switched off automatically.

1118.0XGB_ 06 Page: 6

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

Charger unit (0970.2083) 1118

22.5

1118.0XGB_ 06 Page: 7

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

2. Measurements and tests - electrical, electronic

2.1

Measurements at the primary part (1) - transformer T1:

Voltage as per the selector position and the actual mains voltage.

2.2

Measurements at the primary part (2) - transformer T1

2 x 14 ... 15 Volt AC at the plug connectors of the transformer 2 LEDs at the display A§ must be illuminated.

2.3

Charging unit (3):

Connect the O.R. table to the mains supply. Measure the voltage at the batteries.

Voltage ⇒ in the range of 13,6 V ... 13,95 V DC

Otherwise the charger board must be replaced.

Charging current:

The current from the charger board to the batteries depends on the condition of the batteries i.e. information on the condition of the charging unit cannot be obtained from the charging current.

Batteries (5):

Test by means of connecting a light bulb (12 V ca. 45 Watt)

Battery in good condition Weak battery

To be sure about the test result, a weak battery should be charged and tested again. Both batteries should always be replaced together.

2.5

Test of motor M1

Disconnect the plug X3.1 from the charging unit (3), connect an Ampere-meter in between and select a function. Fully press the pump lever and let the cylinder move to its final position. (Max. pressure: 90 bar)

The current consumption must be in the range of 6 ... 7,5 A..

If the current consumption is higher than 8 A defective. Remove the motor and measure the current consumption with no mechanical load.

Motor running without load:

If the current is higher than 0,6 A, replace the motor. If the motor is not found to bedefective → Replace the hydraulic pump. After replacement of the pump, check the current consumption (< 8 A).

Please note: Use of an O.R. table with excessive current consumption for a longer period may entail a failure of the charging unit (3) and other components..

:⇒ bright light for 1...2 min. (good charge/capacity)

:⇒ Light becomes visibly darker after app. 1 min. Voltage drops below 10 V.

, the motor (7) or the hydraulic pump (8) is probably

current max 0,6 Amp.

1118.0XGB_ 06 Page: 8

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

90 bar 1118.01/02

100 bar 1118.03

1118

3.1

3.2

1118.01 / 02

1118.03

3.3

1118.0XGB_ 06 Page: 9

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

3. Measurements and tests - hydraulic

Please note: Before a hydraulic line is opened the concerned cylinder must be free from mechanical load i.e. it must be prevented from sinking down. Move the piston rod to a position in which it is free from load. In most cases this will be the lowermost position of the table movement.

For the height cylinder a distance bar must be used to support the table and prevent it from sinking down. This will also avoid loss of much hydraulic fluid.

3.1 Check of hydraulic fluid level

Adjust the O.R. table to its uppermost position. Adjust the table top to a horizontal position. Move the base casing upward and secure it to the table top. Fluid level should be above the minimum and below the maximum markings at the tank (4).

3.2

System pressure

The nominal system pressure of O.R tables 1118.01 and .02 is 90 bar, - for 1118.03 it is 100 bar. This pressure can be tested at any cylinder as follows: Connect a pressure gauge to the “A”-line of the cylinder and extend the cylinder to its maximum position.

If the system pressure is too low it can be readjusted at the pressure limiter valve “DB 90” (DB 100 for

1118.03). Tolerance: + 5 bar.

If the correct pressure cannot be obtained by adjustment, the DB90/DB100, the pump, or the motor is probably defective (motor test!

3.3 Hydraulic cylinder

Inspect hydraulic cylinders for visible leakages. Test the lowering valve (1118.01 / 02) or check valve (1118.03) (measure without the cylinder).

If the valve is found to be working correctly the cylinder must be replaced.

1118.0XGB_ 06 Page: 10

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118.01/02

1118

1118.03

3.4

1118.0XGB_ 06 Page: 11

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

3.4 Oil tightness of the double check valve (3) or lowering valve (5)

To test oil tightness of the valve (3) or (5) the function in question must be free from mechanical load and supported to prevent it from moving.

For types 1118.01 and 1118.02:

Lowering valve (3)

Remove hydraulic lines “A” and “B” Connect the pressure gauge by means of the measuring adapter included in the tool kit (3111.4913). Actuate the function “tilting” or “ The pressure must rise to a maximum of 90 bar. Release the pedal. The valve (3) must close.

trendelenburg” depends on which valve you check.

Within the following 10 minutes the pressure must not drop below 70 bar

Please note the pressure diagram "Y".

If the pressure suddenly drops at the beginning by app. 10...30 bar and remains constant thereafter, bleed the measuring lines and repeat the measurement.

Lowering valve (5)

Remove the height cylinder

Remove hydraulic line from the cylinder Connect the pressure gauge to the hydraulic line by means of the measuring adapter included in the tool kit (3111.4913). Actuate the function “up” .

The pressure must rise to a maximum of 90 bar. Release the pedal. The valve (5) must close.

Within the following 10 minutes the pressure must not drop below 70 bar

If the pressure suddenly drops at the beginning by app. 10...30 bar and remains constant thereafter, bleed the measuring lines and repeat the measurement.

10 min

1118.01/02

5 10 15 20 min

1118.0XGB_ 06 Page: 12

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

1118.0XGB_ 06 Page: 13

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

1118

Check valve (type 1118.03)

To test oil tightness of the valve (3) the function in question must be free from mechanical load and supported to prevent it from moving. To test oil tightness of the valves (3) the segment in question must be free from mechanical load and secured.

Check valve (3): Disconnect the hydraulic lines A and B of the valve to be tested at the valve block. Close the open ends of the hydraulic lines. Connect the pressure gauge along with the measurement adapter of the hydraulic tool kit (3111.4913). Actuate the function “up” (or “down”) at the hand control.

The pressure must rise to its maximum (100bar). Release the button, the valve (3) must close.

The presssure of 100 bar must not drop below 70 bar within a period of 30 min.

See graph in the pressure diagram "Y"

If the pressure suddenly drops at the beginning by app. 10 bar and remains constant thereafter, bleed the measuring lines and repeat the measurement. This procedure is applicable in the same way for all of the 3 valves.

3.5 Potentiometers for "0"-(Level) adjustment (1118.03 only)

B3/tilting, B4/trendelenburg Supply voltage is 5 Volt – measured at the connected potentiometer between the red and the black

wire

The "0"-position refers to app. 2,5 Volt measured between the

Troubleshooting:

red and the green wire (voltage divider).

- Function moves in the opposite direction when “0”-button is pressed:

→ Possibly red and black wire have been reversed.

- There is a continuous tone when the "0"-button is pressed:

A potentiometer is defective or positioned outside its permitted range (0,15.. 4,8V)

Re-adjust or replace.

1118.03

1118.0XGB_ 06 Page: 14

Wartungs- und Reparaturanleitung Alphaclassic / Betaclassic Maintenance and Repair Instruction

3.6 Corded hand control (1118.03 only)

Functions of the hand control can be simulated by means of the override keypad A2.

If functions can be moved by the override panel but not by hand control, either the hand control or the

controller unit A1 is defective.

Test the functions with another hand control, or with the IR-Tester. If there is

still no movement, the controller unit A1 is defective.

The corded hand control can be tested with the IR tester in the mode Modus „READ DATA-BUS 1132“

Test whether the supply voltage for the hand control (5 Volt) is present.

3.7 IR- remote control (1118.03 only)

Test IR-remote control functions and function of the charging station with the IR tester (mode “1118”)

Check to see that selector switches of the remote control and of the board A4 are set to the same

code.

Test the IR preamplifiers B1/B2 with the IR tester.

If a continuous tone is emitted by the IR transmitter, the code has been altered but not acknowledged.

Maquet Betaclassic User manual

Specifications and Main Features

Frequently Asked Questions

User Manual

English

General

1. Design and functional description

3. Measurements and tests - hydraulic