MAQUET 1132.XX Maintenance and Alphastar Repair Instruction A Ne $i “TS Fd \ i \ BE rath-Stouscirg - rade Core iSpy a 4 suger pomon 2074. Ton orn. WR1132016B ‘ie ha oe dnMAQUET products are subject to maintenance within an annual inlerval (app. 200 .. 300 hours of equipment operation} Damaged or defective parts are fo be replaced as per this maintenance and repair instructions. Repair work may require special too's and mounting devices. Maintenance or repair work is only te bo carried out by MAQUET AG ‘or other service personnel consed by MAQUET Table of contents Generals 4. Design and function sign and function description Transformer, battery charger Batterios,crive unit Controller toard At JR-supplement Cable hand control Override IRetransmritter Override-pump 2 Measurements (tests), elaktrical and elaktronic system 2A Transformer T1 primary 2.2 Transformer T1 secondary 23. Battery charger A3 24 Batteries Gt/G2 25° Motor Mt 2.8 Motor M2 chive unit 2.7 ,0"- Potentiometers B3/B4/B5/86 2.8 Cable hand control 2.9 [Remote control 2.10 Function LOCK/UNLOCK ALPHASTAR 1132_ Page oot 4.01 4.02 41.04 1.08 1.08 1.40 2 201 202 202 202 202 2.04 204 2.06 2.08 2.08 2.10 WR113268, 12.10.2000 Seite/Page: 0.01Maintenance and Repair Instruction ALPHASTAR 1132 3. Measurements (tests), hydraulic system 301 3.1 System pressure 3.02 32 Checking OM level 3.04 3.3 Hydraulic cylinders. 304 3.4 Check valves 3.08 4, Troublosshooting — what to do Hun 401 ‘5 Ropalrwork, repair instructions for hydraulle components: 5.01 5.1 Twin swivel castors 502 5.2 Hand pump 5.04 5.3 Tilting cylinder 5.08, 5.4 Trendelonburg cylinder 5.08 65 Column casing and bellow 5.08 5.6 Chock valve, solenoid vahe 5.08 87 Locking cylinder 8.10 58 Leg plate cylinder 5.12 5:9 Back plate cylinder 5A2 510 Leg plate side arm 514 5.11 Back plate side arm 514 5.12 Hydraulic unit 5.16 5.13 Elevation cylinder 5.18 6, Repalrwork, repair instructions for electrical components. 01 601 Charging board 6.02 602 PCB for dive unit 602 6.02 Control unit At and IR-Decoder Ad 6.02 6.04 Drive unt 6.08 WR113268. 12.10.2000 Seite/Page: 0.021.01 = cron | DetMaintenance and Repair Instruction ALPHASTAR 1132 1_Design and function description The essential components: = transformer 74 = battery charger A3, batteries G1/G2 + DC-motor Mt + hydraulic pump = valve control block + (Movements of table sections) = valve contol block 2 ( Drive unit, LocktUntock) = drive unit incl, Motor M2 and controller board AS = pressure hoses, cylinders. = Controller board A, IR supplement Ad = override functions A2 (handcontrol.Lock/Unlock) + override pump for manual unlocking of castors = hand control box /IR transmitter / foot switch Please refer to the corresponding spare parts ist for the variants used in the existing operating table. WR1132.01GB. 12.10.2000 SeitePage: 1.02at Hysrauay Hyde ni a 1.03 Page co oar 07.05.98 Det:tenance and Repair Instruction ALPHASTAR 1132 Technical description ‘The 1132 model is an electro-hydraulic O.R. table using electrically controled hyeraulic valves. The oil fow is controled by 5/3 directional solenoid valves (1) -(S hydraulic ‘connections, $ positions of switched channels). Depending on the state ofthe control signal of the valve the piston rod (8) ofthe hydraulic cylinder is moved in our ou, or it remains in ts position. “The 5/3 directional solenoid valves operate along with double check valves (2) which ‘are actuated by the oil fow corting from the solenoid valves, As ong as the double check valve is in its rest position the hydraulic ines A and B remain closed to prevent ‘the piston rod from being moved by any extemal mechanical load, Power supoly ofthe O.R, table — transformer and charging ccc! ‘The mains voltage supply ofthe O.R. table is provided by means of a 2-ine cable with fa standard 3-pin connector. Supply cables are available with mains plugs ether according to American or European standard ‘The transformer assembly T1 includes a voltage selector to enable adaptation to the present mains vottage (100...240V). “The primary col ofthe transformer consists of 4 separate windings, 2 of them for 104V ‘each, 2 further for 12 V each, To connect the O.R. table to a mains voltage of e.g. 230V all the windings are switched in series via the voltage selector (232V). The lowest votage setting avallable is achieved by switching the two 104V-windings in parallel circuit. {A thermal protector fuse is integrated inthe primary col If this fuse has blown the transformer must be replaced. The fuse can not be replaced. WR1132.0168 12.10.2000 SoiterPage: 1.0407.05.98 aa wie MAQUETMaintenance and Repair Instruction ALPHASTAR 1132 “The secondary windings ofthe transfomer provide 2x14V which are the supply voltages {forthe charger board A3. The folowing components are connected tothe charger ‘board 3: 2 batteries G1/G2, the 24V-OC motor, solenoid valves of valve block Y1 and the contioller board AS of the drive unit. All these components are located inthe base of the OLR. table. (On the charger board, the output vltages of the transformer (2x14V AC) are converted into separately regulated charging voltages of 13.75 DC for each battery. Batteries G1/G2 ‘The batteries of the O.R. table are maintenance-free lead-acid types. ‘They supply the motors M11 and M2 (i installed) with 24 V DC. 2 batteries of 12 V each and a capcty of 16 Ah are sufficient for this purpose. ‘The period of use until the batterias must be recharged depends on the current drawn by the motors and the actual running operation time of the ‘motors M1/M2. The motor current is app. 7 A. The useful ifetime of the batteries is specified by the manufacturer as 5..6 years. Hence app. 300 cycles of charge/ discharge can be expected during the battery lifetime if they are charged once a week. Controller of drive unit AS and motor M2 ‘The drive units offered as an option for the O.R. table 1132. Its actuated via the buttons .BACKWA." And ,FORW." ofthe cable-connected hand contol, The forward or backward movement ofthe table dtiven by motor M2 is controled by the controller board AS. WRI192,0168 +2.10.2000 SoitePage: 1.06EEE) i SeaMaintanance and Repair Instruction ALPHASTAR 1132 Conivoler board Aj and infrared receiver boar Ad The controller board At is located under the black blows. If IR remote contol is installed an additional receiver board (Ad) is plugged on. Both IR preamplifiers B1, 82 are connected to this board. The IR preamplifiers are located on the column one directed to the leg side the other to the head side. The receiver board Ad and the preampifiers are continuously supplied by the permanent voltage 5Vp. The current consumetion of these components is very low, hence there is only a very smal oss of battery capacity, If there are more than one O.R. table with IR remote controls in the OR. section (on the same floor) it is necessary o assign each table and the IR transmitter ts ‘own IR code (S20 technical description). 4 potentiometers 83/84/86/B6 for the ,zer0-positioning’ of the table top are connected to the controller board At which monitors and evaluates thelr position. The voltage at the output connector ofthe potentiometers must always be within a range of 0.16..4.84V. Two micro switches, $1/82, wired in series, provide a signal to the controller board A‘ (X3.9 Sock) indicating that the O.R. table is locked on the floor. At the same time the 2 ‘green LEDs of the cable connected hand control / override panel A2 are urinated. To set the 4 twin swivel castors out tothe floor the valve UNLOCK" is actuated until the pressure switch P on hydraulic block Y1 is activated at @ pressure of 40 bar and ‘ho controler board receives the signal thatthe O.R. table is now ready to be moved. ‘The 2 red LEDs are iluminated. If the LOCK/UNLOCK slatus ofthe O.R. table cannot be determined by the controller the red and green LEDs show intermittent flashing light WR1132.016B 12.10.2000 Seite/Page: 1.08at ra 07.05.98 Eat oo Pace 1.09Maintenance and Repair Instruction ALPHASTAR 1132 Gable connected hand contro! ‘The hand control box consists of 2 housing pats, a PCB with pushbutton forthe individual functions, LEDS as indicators of the status, a foil keyboard, and a tine spiral cable (85, SV, OV, DATA). Voltage supply ofthe hand contol is provided by the lines OV and SV. ‘The controller A4 is switchod onloff via the tine BS, The line DATA enables @ bistrectonal data transfer between the hand contol andthe controller board of the OR. table. Serial data signals are sent by the hand contol to actuate the desired function, The controler board sends signals to the hand control to contol the status LEDs. ‘To switch on the systom the button ,ON" must be pressed. The status LEDs BATTERY, MAINS, ON, UNLOCKILOGK, and NORMALIREVERSE show a short flashing ight ‘Afr this poriod only the LEDS indicating the current situation remain iturinate. ‘The desired movement buttons can now be pressed. If no button is pressed within a period of 18 seconds the control units switched off ‘automaticaly. The hand contol can be switched off immediately by pressing the button ,OFF’ For further information pease refer tothe brief operating instructions. Override AZ ‘The functions ofthe overide panel are the same as of the hand control. The ables an emergency operation ifthe hand control oF the controller ‘The difference to the hand contol is that valves are actuated directly. The motor is actuated soparaely by the bution ON" hence 2 buttons must always be pressed ‘simutaneously (,ON" + movement button). WR1192.01G8 42.10.2000 SeiterPage: 1.106m tae waouer (1 Sele lela) Ter owt sow wtsoe RaMaintenance and Repair Instruction ALPHASTAR 1132 Infrared remote control There is no bi-directional data transfer as with the cable connected hand contol ‘The LED .Battery" indicates the charge status ofthe accumulators ofthe hand control ‘The charge status of the batteries ofthe O.R. table is indicated by the LED on the OVERRIDE panel ‘The status LOCK/UNLOCK ‘indicated on the OVERRIDE panel as well. ‘As a safely feature there is no possibility provided to actuate the drive unit Via the infrared remote control Manual override pump Ifa failure of the motor Mt or the hydraulic pump occurs this pump can be used 10 release the locking of the O.R, table from the floor. For detalled information please ‘refer tothe ,Technical description’. WR1132.0168 12.10.2000 SeitePage: 1.12Maintenance and Repair Instruction ALPHASTAR 1132 surements (tests), electric and electronic system 2.1, Transformer primary connectors (1):_The voltage corresponds to the setting atthe voltage selector and tothe local power supply 2.2 Transformer secondary connectors (2): 2 soparate outputs of 14 Volt AC each at plug contacts 2.3 Battery charger (3): ‘Connect the O.R. table to the mains supply. Check the charging voltage at each battery. Voltage 136V - 13.95 V6 ‘Sharaing current ‘The charging current depends on the capacity of the batteries so that no information about the Condition ofthe battery charger can be obtained. 24 Batteries (5): ‘Conctet the test (6) using an automotive light bulb (12 V, approx. 45 W) ‘Soed baile; Bright light for 1 to 2 minutes (good charge) Poor battery: Light visibly darker after approx. 1 minute; voltage falls below 10V. Ifa battery seems to be in poor condition, recharge and test it once again to verify the results. ‘Al two batteries should always be replaced at the same timo. WR1132.0168, 12.40.2000 SeiterPage: 2.022.03 Pope eau 07.05.88 Data ate:Maintenance and Repair Instruction ALPHASTAR 1132 25 26 Motor tost (itt) Cone of the cables, Detach the plugs X3.1 at the charging unit (2); insert the ampereme: press any function button and move the function unt its final postion (and the max. pressure ‘of 100ber) is reached, ‘The unit must draw between 6.5 and 7,5 Ampere. f more than 94s drawn, then either the motor (7) or the pump (8) is defective. Remove the motor and measure the power drawn by the separated motor. ‘Whon operating with ne load, the max. admissible value is 0.6 A. Roplace the motor ifthe current i higher. Ifthe motor proves to be OK, then replace the pump. Check the power value again (< BA) after having installed the new pump. ‘Note: Using the operating table over an extended period of time with the rotor drawing an ‘excessive current (> 8A) can damage the battery charger (9) and, in rare cases, even the hand contro unit. Motortest (M2 - drive unit) ‘Adjustment of the limit switch $3 = Switching threshold app. 1mm before the lower end position is reached. Note: If the limit switch $3 is shorted (contact closed) during troubleshooting and the button ,Drive is ‘not pressed within a period of 3 sec. the controller unit will datect this condition as @ fault ‘The OR. table must be switched off the short must be removed and testing can be resumed. Current consumption ofthe drive unit motor (overload protection at 13Amp,) With no mechanical load: 0.4 A Nominal current: 4.9. app. <4A under normal dive condition WR1132.01GB 12,10,2000 SeiterPage: 2.04Maintenance and Repair instruction ALPHASTAR 1132 27 0”-position potentiometers BETiting, B4=Trendelenburg, BS=Back section. BEE Leg pate Voltage supply 5 V, measured when comected between the red and black wires “The 0-posiion corresponds to approx. 2.5 V measured betwen the red and green or the black and green wires (voltage divider), i.e, half ofthe salting range of the potentiometer corresponds to 2.6V. ‘Troubleshooting; When pressing the "0" buttons, the function moves into the opposite direction -> ‘exchange the black and red wires. A continuous acoustic signal is generated when pressing the "0" buttons -> a potentiometer is defective or outside its limit range (0.5 ..4V). > Replacement or adjustment of the potentiometer. Note: ‘An adjustment can be carried out manually by means of a screwdriver or alternatively withthe IR-Tester (see .1132"-mode). The standard adjustments of of FLEX: /REFLEX angle positions can be programmed by means ofthe tester os wel, WR1132.0168 12.10.2000 SeiterPage: 2.06esi "07.05.98 oa at MAQUETMaintenance and Repair Instruction ALPHASTAR 1132 28 29 Control unit and receiver board ‘The functions of the control unit can be simulated by pressing the override buttons A2. If the operating table function is actuated, ether the controller board A1 or the hand control is defective. Try another hand controViR-transmiter, Ifthe OR. table dogs stil not respond the controler board is. defective. Functions of the hand control box or ofthe foot switch can be tested by means of the IR-Tester within the mode ,READ DATA BUS 1132" : Test the 5V-supply of the hand contra! box. IR remote contro! “Test the IR transmitter and charging station using the IR tester ~ mode 1132" ‘Check equal settings of the selector ewitches (6/7) of boards (28). Test the IR recelveripreamp. 81/82 by means ofthe IR tester. Test the range of transmission ofthe IR transmitter by means of the IR tester modus IR detect VV" or .IR detect ASIC, Ifthe IR transmitter emits a continuous tone when a function is actuated, the IR code has been set but not acknowledged ~ see technical description. WR1132.016B 12.10.2000 Seite/Page: 2.0834/52 2.09 Emer 07.05.98 Daw. (MigteliseJaintenance and Repair instruction ALPHASTAR 1132 2.10. Function LOCK/UNLOCK ‘The LEDs of the pushbuttons LOCK/UNLOCK indicate the current status of the O.R. table. ‘The iluinated LED ,UNLOCK indicates thatthe castors ate posiioned towards the floor, mmicroswitches $1 and 82 are not activated (open) and the contact ofthe pressure switch UNLOCK is closed. ‘Switching threshold ofthe pressure switch: app. 40 bar. Flashing light of both LEDs LOCK/UNLOCK indicates that the status is pending, Le. the OLR. table is being switched from LOCK to UNLOCK or in reverse order. Flashing light of both LEDs can also indicate that one of the microswitches has not opened though the castors are fully set out onto the floor. WR1132.016B 12.10.2000 Seite/Page: 2.10