Maintenance and Repair Instructions ALPHAMAQUET 1150

1150.01XX

Maitenance and OR column

Repair instructions

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Maintenance and Repair Instructions ALPHAMAQUET 1150

General

Assuming an operating time of about 100 hours per year, the ALPHAMAQUET 1150
operating table system will require maintenance annually.

Damaged or defective components can be replaced by following the directions given in

these Repair Instructions.

Special tools and equipment will be needed to carry out repair work and to replace
component groups.

Consequently these types of repairs can be effected only by the factory customer service or
by an authorized representative with a field service department.

Please refer to the appropriate instructions for maintenance and repair work to be carried
out at the series 1150.XX operating table tops and the series 1140.XX trolleys.

IR-Tester will be used for adjusting the drive units, see also Operating manual of the IR-Tester
Adjustment of the IR-Code at the IR-transmitter and the control board also the voltage
selection see Technical Description and Operating manuals 1150

Important: The following assembly procedures will be described once only:

Removing and reattaching the column casing (see Item 1.1)

Removing and reattaching the controller unit cover (see Item 1.2)
Removing and reattaching the battery cover casing (see Item 1.3)

Note also the links and tips to service informations about OR-System 1150

Contents Page

Generals 0.01 -

1. Repair works 1150 columns 1.01 -

1.1 Column casing 1.02

1.2 Controller unit cover 1.04
1.3 Battery case (for Version C only) 1.04
1.4 Sealing profiles (for Version C only) 1.04
1.5 Linear drive (M1/M2/M3) 1.06
1.6 Geared motors (M1/M2/M3) 1.08
1.7 Height adjustment drive 1.10
1.8 Geared motor M4 1.12
1.9 Pulse counter (M1/2/3/4) 1.14

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Page

1.10 Motor mount with center guide 1.16

1.11 Fitted keys 1.18
1.12 Guiding cradle with Hall-sensor 1.18
1.13 Column controller unit 1.20
1.14 Microcontroller chips 1.22
1.15 Contact module 1.24
1.16 Infrared preamplifier and equipment socket 1.24
1.17 Batteries and monitoring boards 1.26
1.18 Override key board 1.28
1.19 Hand control unit 1.28
1.20 Eccentric shaft, brake buffer (with flush-mounted base plate) 1.30
1.21 O-ring and hollow O-ring (version with flush-mounted base plate) 1.30
1.22 Eccentric shaft, brake buffers (with surface-mounted base plate) 1.32
1.23 Surface mounted base plate 1.32
1.24 Charge voltage regulator 1.34

2. Maintenance tasks 2.01 –

3. Troubleshooting 3.01 –

3.1 Take-over problems, locking system 3.01

3.2 Poor charge capacity of accumulators of mobile O.R. columns 3.04
3.3 Unintended unlocking brake levers of O.R. table columns 3.05

4. Appendix 4.01 –

4.1 Survey of relevant service informations 4.01

4.2 Operating media 4.02

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Maintenance and Repair Instructions ALPHAMAQUET 1150

1. Repair work 1150 columns

1.1 Column casing

The column casing comprises the boot (1) and the three-section, telescoping casing (2) made of
stainless steel.
(Upper section 2a; center section 2b; lower section 2c)

Removal

Raise the operating table column to its highest position (basic stroke plus additional stroke).
Detach the lower fasteners for the bellows; remove two screws (3) at either side.
Grasp the right and left halves of the upper casing section (2a) and spread them apart; allow the
center section (2b) to slide downward. Grasp the right and left halves of the center section (2b) and
spread them apart.
The bellows (1) can be slid upward to give access for service work at the universal joint adjustment
components.
Remove four screws (6). Grasp the right and left halves of the lower section (2c) and spread them
apart.

For Version C only

Remove the base cover at both sides (see Item 1.3).

Disconnect the batteries (4) at the charge regulator (5) and remove the batteries.
Remove four screws (6). Grasp the right and left halves of the lower casing section (2c) and spread
them apart. (Remove only that half of the cover without the socket.)
Remove the potential equalization cable (7) and the charging socket (8) and then remove the two
halves of the cover.

Assemble in reverse order.

Note: When assembling the two halves of the cover, ensure that the snap fasteners seat properly.

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1.2 Controller unit cover

Remove one screw (1) and remove the socket case. Unscrew the four screws (3) and lift off the
controller unit cover (4) together with the contact module (5). Disconnect the plug connector (6) at
the column controller unit.
Assemble in reverse order.

Note: Lubricate the four fastening threads for the screws (3) with silicone grease.
Pay attention to the routing of the cables ¼ Crimping hazard.

1.3 Battery case (for Version C only)

Remove two screws (7) each and slide off the battery case (8/9) in the longitudinal direction.
Assemble in reverse order.

Note: Although the battery case sections are identical in shape,

they are not interchangeable ¼ battery indicator (LED).
Ensure that the sealing profiles are properly seated.

1.4 Sealing profiles (for Version C only)

Remove the battery case (see Item 1.3).

Remove the four screws (10) and lift off the sealing profiles (11).
Use the screws (10) to attach one each sealing profile (12/13) between the battery casing sections
(8/9) and the cross-covers (14/15).
Assemble in reverse order.

Note: Old version with O-ring ¼ Replace with sealing profiles.

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1.5 Linear drive (M1/M2/M3)

The linear drives M1/M2/M3 are identical in design. The cover (1) for drive M1, with the threaded
cable fittings, is rotated through 90° for mounting.
To replace the M2 and/or M3 linear drive it will first be necessary to remove the hose clamp (2) and
to loosen the retainer plate for the coiled cord and/or the terminal strip.
The corresponding conductors for the geared motor (3) and the pulse transmitter (4) are to be
detached from terminal strip X7.
Remove the retaining rings (5) at the upper bearing pins (6). Support the head plate to keep it from
dropping (e.g. by placing wooden blocks under the guiding cradles).
Drive out the bearing pins (6). Retract the drive using a 12-Volt battery.
Remove the retaining rings (7) at the lower bearing pin (8).
Secure the drive to keep it from dropping (being aware that the drive is quite heavy) and drive out
the lower bearing pins. Lower the linear drive to remove it.
Assemble in reverse order.
See the wiring diagram for information on the connections.

Note: Note the step-down ratio for the geared motor.

note modification of 1150 see also service info no. 235
Turn the hose clamps at M2 and M3 out as far as possible.
The retainer plate, the X7 terminal strip and the coiled cord should be turned inward as
far as possible and should be in firm contact with the cast metal case.
All the drives for the operating table column will have to be readjusted with the IR tester
to eliminate the danger of damage (see Operating instruction IR-Tester).

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1.6 Geared motors (M1/M2/M3)

Remove the linear drive (see Item 1.5).

Loosen the threaded cable fittings (1/2) and remove the multiple seals (3).
Lift off the cover (4) being careful not to place the conductors under tension.

Note: Mark the installation position and orientation of the geared motor.
Mark the position of the cover.

Remove six screws (5) at the lower section of the housing. Rotate the motor so that the connecting
link (6) in the roller chain (7) is located between the two sprockets. Open the connecting link (6) and
remove the roller chain (7). Remove the retaining ring (8) and the sprocket (9).
Remove four screws (10). The geared motor (11) can now be lifted out of the guide tube.

Assemble in reverse order.

Note: The four screws (10) are to be coated with Loctite 243 and torqued down to 8Nm.

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1.7 Height adjustment drive

Remove the keep-off plates (1) in Versions A and B.

Remove the cable cover (2) inside the column casing.
Position the assembly frame (3) or trolley 1009.94 together with its adapter on the column. Remove
four screws (4). Activate the ”Lower column” function. The column will raise itself, being carried by
the mounting frame, and will lift the base housing by a maximum of 8 to 10 cm.

Note: When working with Version C, detach the two leads for the battery indicator.
Ensure that no voltage is present (detach batteries, remove fuses).

Detach the voltage supply at the X6 terminal strip and set up a direct supply (48 V DC) to terminal
strip X6. Do not pass the cable through the housing.
Move the column and mounting frame to the side and, by activating the two function buttons for
”Raise column + R” set it down on two wooden blocks (5). Move the height adjustment drive,
including the supplementary stroke, to the highest position. Use the IR test transmitter to move M4
downward far enough that the guiding cradles (6) are supported on the mounting frame and/or the
adapter (3).
Remove six mounting screws (7) at the supporting plate (8) from the guide piston. Use the IR test
transmitter to move M4 about 10 cm downward. Reposition the mounting frame with the upper
column section so that the stationary column housing can be laid on its side.
Remove the retaining ring (9) and shims. Unscrew six screws (10) and the remove the cover (11).
Remove four screws (12) at the housing. Disconnect six motor and pulse counter cables from the X6
terminal strip.
Pull the height adjustment drive unit (spindle, spindle nut, motor and chain housing) downward to
remove it.
Assemble in reverse order.
See the wiring diagram for information on the connections.

Note: Note the step-down ratio for the geared motor.

note modification of 1150 see also service info no. 235
Insert shims as required at the retaining ring (9) and pay attention to the cable routing.
Be careful when aligning the upper column section with the lower column section.
All the column’s drives will have to be readjusted with the IR tester .
The six screws (7) are to be coated with Loctite 243 and torqued down to 25 Nm.
Do not fix the wires of the counter with the wires of the motor M4!

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Maintenance and Repair Instructions ALPHAMAQUET 1150

1.8 Geared motor M4

Remove the height adjustment drive (see Item 1.7).

Note: Mark the installation position of the geared motor.

Mark the position of the cover.

Loosen the threaded cable fittings (1/2) and remove the multiple seal (3).
Lift off the cover (4), being careful not to subject the leads to tension or strain.
Remove the retaining ring. Remove four screws (6) and the geared motor (7) by applying pressure
to the shaft (do not tap or strike due to the danger of damaging the unit), press it upward, out of the
guide tube. Remove four screws (8) at the noise insulation sleeve (9) and pull off the insulating
sleeve. Assemble in reverse order.

Note: Apply Loctite 243 to the four screws (6) and torque them down to 4 Nm.
Apply Loctite 243 to the four screws (8) and torque them down to 8 Nm.
Do not fix the wires of the counter with the wires of the motor M4!

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1.9 Pulse counter (M1/2/3/4)

Remove the geared motor (see Item 1.6 and/or 1.8).

Remove two screws (1). Replace the pulse counter.

Note: Position the pulse counter (2) so that the sensors (3/4) do not touch the magnetic
ring (5) but so that the clearance does not exceed 0.5 mm.
Observe correct positioning for the spacer sleeves (6).
Do not fix the wires of the counter with the wires of the motor M4!

Functional test:
The pulse counter can be operated at a voltage of 12 to 15 V DC.
A 12-volt battery will suffice for test purposes.

With the unit installed:

Connect “+” of supply voltage to terminal 1, “-“ to terminal 3; apply operating voltage to the motor.
Use a multimeter to measure the voltage between terminals 3 and 2 (for sensor 3).
The measured voltage should correspond to about the half of the supply voltage.
Repeat the test between terminals 3 and 4 (for sensor 4).

Unit dismounted:
Connect “+” of supply voltage to terminal 1, “-“ to terminal 3. Use a multimeter to measure the
voltage between terminals 3 and 2 (for sensor 3). Apply alternately the N and S poles of a magnet to
the sensor. The voltage measurement should change between 0 volts and the level of the supply
voltage applied to terminals 1 and 3.
Repeat the test between terminals 3 and 4 (for sensor 4).

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Maintenance and Repair Instructions ALPHAMAQUET 1150

1.10 Motor mount with center guide

Remove the casing carrier frame (1) and move it downward.

Move the operating table column to its highest position (including the additional stroke length).
Remove the keep-off plates from stationary versions.
Position the mounting frame with its adapter and use the IR test transmitter in the adjustment mode
to lower M4 far enough that the guiding cradles (2/3) rest on the mounting frame.
Remove five screws (4) at the supporting plate (5).

Note: Only loosen the sixth screw (6); do not remove it.

Unscrew the two screws (7) at the universal joint and use an M8 screw to pull out the guide bolts (8).
Remove the retaining rings (9) and the lower bearing bolts (10) of linear drives M1/2/3. Retract the
linear drives using the IR test transmitter in the adjustment mode. Detach the six conductors for the
M1 from terminal strip X7. Remove the retaining ring (11) at the upper bearing bolt (12) for M1.
Support the drive to keep it from dropping (be aware that the drive is quite heavy!). Drive out the
upper bearing bolt and lay the linear drive aside.
Use the IR test transmitter in the adjustment mode to lower drive M4 by about 5 to 6 cm.
Slide the upper section together with the mounting frame to the side
(toward the height adjustment drive).
Stabilize the supporting plate (5) to keep it from dropping (be aware that it is quite heavy!), remove
the sixth screw (6) and lift out the supporting plate with the center guide.
Assemble in reverse order.
See the wiring diagram for information on the connections.

Note: All the column’s drives will have to be readjusted using the IR tester.
During assembly the six screws (4/6) are to be coated with Loctite 243 and torqued
down to 25 Nm.

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Maintenance and Repair Instructions ALPHAMAQUET 1150

1.11 Fitted keys

Remove the M3 linear drive (see Item 1.5).

Remove two screws (1) and lift off the fixation plate (2).
Ensure that none of the cup washers can fall down.
Remove the cup washers (3) and pull out the fitted key (4).
Assemble in reverse order.
See the wiring diagram for information on the connections.

Note: Insert the cup washers (3) as indicated in the drawing.

Grub screws (5) are to be torqued down to 6 Nm (adjustment force for the fitted key)
and secured with the lock nuts (6).

1.12 Guiding cradle with Hall-sensor

Insert 2 magnets into the guiding cradles in order to simulate the presence of a table top for the
column controller unit. Move the ”tilt” function into its limit position. If this is not possible (due to a
defective sensor), then use the IR test transmitter in the adjustment mode to set up this
configuration.
Remove three screws (7) and disconnect the hall-sensor leads from the column control unit. Detach
the boot from the mounting angle (8) and loosen three screws (9). Pull out the conductors and
replace the guiding cradle (10). Assemble in reverse order.
See the wiring diagram for information on the connections.
Put a distance plate under each guiding cradle
Note modification set 3113.0474 with test instruction and service info no. 237

Function test:
Place a person on the table top ( out of the middle), test the take-over function again. Apply force to the
trendelenburg adjustment device in upward direction
Pull the foot-end of the table top in an upward direction. Keep the force and actuate the tilting function.
Check to see that the tilting function is carried out correctly. The upper edge of the locking catch must be
in touch with the guide bracket as long as the table top is pulled upward.
For more detailed info see trouble shooting point 3 “take-over problems”
New versions are marked at lower side of guiding cradles.

Note:
A guiding cradle and the hall-sensor can only be replaced together
since the sensor is glued-in.
The screws (7) are to be coated with Loctite 243 and torqued down to 40 Nm.

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1.13 Column controller unit

Wait until the column controller unit has switched itself off (about 6 seconds after the last actuation
of a button). Detach the jumper (1) and detach the plug connector (2) (voltage supply).
Depress any function-control button on the IR transmitter until the signal transducer has discharged
the capacitors. Wait another 5 minutes (dissipation of residual charge in the capacitors).
Detach the rest of the plug connectors.

Note: When detaching the plug connectors at the column controls, take care to pull them out
straight and not at an angle.

Remove four screws (3) and replace the complete column control unit.
Whenever column control units are replaced, the microcomputers should be left in the defective unit.
New column control units are always fitted with new microcomputers.
Assemble in reverse order. Note also service info no. 236 and 237.
See the wiring diagram for information on the connections.

Note:
Functions may be activated also by IR-Tester only after the jumper (1) has been
connected as the unit could otherwise be damaged.
All the column’s drives will have to be readjusted using the IR tester.
See operating instruction IR-Tester.

Adjustment of IR system code ( see also Technical description 1150)

The two rotary encoding switches are marked on the circuit board with the letters HB = High Byte
and LB = Low Byte. The HB encoding switch (6) is used to set the left-hand character in the system
code; the LB encoding switch (7) corresponds to the right-hand character in the system code.
Set the rotary encoding switches (6/7) to the desired position and use the IR transmitter to switch on
the column controller unit. When the LED (5) lights, press button (4) to acknowledge the system
code just set.

Note: The code specified here is to be used at only one IR receiver within any surgical area
(floor) and must correspond to the system code label affixed to the column.
255 different code combinations are available for use.
Never set up an IR receiver to respond to system code 0-0.

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Adjustment potentiometer (column control unit)

An intermittent signal will sound as soon as the batteries have been discharged to about 30%
of full capacity.
The threshold at which this warning signal is given can be adjusted by means of
the potentiometer (5) on the column controller board.
The basic setting is for 45° to the left. ( Position 7.30 o’clock)

Note: Modification „Total discharge protection for batteries“

1.14 Microcontroller chips

Note: Proper tools must always be used when working on the electronics and in particular
when replacing the microcomputers.
1. To remove use Puller tool and ESD wrist strap
2. To plug-in use Vacuum pipette and ESD wrist strap

Wait until the column controller unit has switched itself off
(about 6 seconds after the last actuation of a function).
Remove the wire jumper (1) and detach the plug connector (2) (voltage supply).
Depress and hold any function-control button on the IR transmitter until the signal transducer has
discharged the capacitors. Wait another 3 minutes (dissipation of residual charge in the capacitors).
Detach the rest of the plug connectors.

Note: When detaching the plug connectors at the column controller, take care to pull them out
straight and not at an angle.

Remove four screwed bolts (3). Lift off the upper circuit board (4). Use the puller tool to lift out the
microcontrollers. Use the vacuum pipette to install the new microcomputers in the correct position.
Position the circuit board (4) over the screwed bolts and press downward into the connector
contacts. Affix the upper circuit board with the four screwed bolts (3).

Note: Position the microcontrollers correctly when installing (slanted surfaces matching)
(5) Central controller
(6) Motor controller (tilt/slope controller)
(7) Monitoring controller
All the column’s drives will have to be readjusted using the IR tester .
See operating instruction IR-Tester

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1.15 Contact module

Remove the cable strap (1). Remove the six nuts (2) and replace the contact module together with
its protective foil.
Assemble in reverse order.

Note: Fill the groove for the O-ring with silicone grease.
Ensure that the O-ring is seated correctly.
Apply Loctite Type 243 to the six nuts (2) and torque them down to 2.2 Nm.
Pay attention to cable routing when positioning the cover ¼ Crimping hazard.
The protective foil must in all cases be glued in place over the contact module.

1.16 Infrared preamplifier and equipment socket

Remove two screws (4) and the cable guide (5). Loosen the screw (6) and detach the appropriate
plug at the column control unit.
Use a screwdriver (blade 2.5 mm wide) to depress the spring contacts in the plug and pull out the
conductors.
Partially dismantle the cable bunch and pull the conductors out through the guide sleeve.

IR preamplifier:
Unscrew the two screws (7) and then remove the retainer strip (8) and the spacer ring (9).
Change out the infrared preamplifier.

Socket for handcontrol:

Unscrew the nut (10) and replace the socket (11) with the hinged cover (12).

Assemble in reverse order.

See the wiring diagram for information on the connections.

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1.17 Batteries and monitoring boards

Disconnect the batteries (1) at the charge regulator board (2). Apply a 45-watt load
(e.g. a 12 V, 45 W automotive lamp) to the 12-volt battery while measuring the voltage.
(in the mobile version there are six 2-volt batteries (4x) connected in series = 12 V)

Good battery: Bright light for five minutes (good charge)

Bad battery: The light dims noticeably after about a minute.
The measured voltage drops below 11 V (low charge or bad battery).

If a defective battery is indicated, then the test should be repeated as a precautionary measure.
In the mobile version both the batteries which are connected in series must always be replaced
together. Assemble in reverse order. See the wiring diagram for information on the connections.

Description of the function of monitoring boards

There is a monitoring circuit on each of the boards A10 and A11 which monitors the voltage of
2 battery packs during the process of discharging.
The threshold is adjusted to 5.4 V for each 6V branch.
As soon as 3 cells of a battery pack are discharged to the threshold of 5.4V, all motor
functions are cut off. In addition there are signals indicating that re-charging is necessary:
an acoustic signal and a flashing yellow LED (5).
The column remains in this condition until it is connected to the mains supply via the
mobile transformer unit for re-charging of the batteries.
The functions of the O.R. column can be actuated again as soon as it is connected to
transformer unit and the mains supply (locking is inactivated).
During the charging process the green LED (4) is illuminated.
If there is no mains supply, or a defective wire within the charging cable, or a blown
fuse in the transformer unit the LED (4) remains dark and the locking function –
if activated by low battery voltage – is not reset.

Functional test of the monitoring circuit

There are triangle markings on the boards A10 / A11 each pointing towards 2 pins of an IC or
towards connections of 2 resistors. If a pair of such pins is shorted while a column function
is actuated a failure of one battery is simulated. The protection circuit is activated.
There is a delay time of 2..3 seconds before the circuit responds.
The activated function locking can be reset by connecting the column to the mobile
transformer unit.
As long as the transformer unit is connected the green LED (4) must be illuminated.

Warning:

Always ensure not to reverse the polarity Irreversible damage may result.
see also “modification total discharge protection 3113.3249” with function test
and service information no. 235, 239, 241, 243
see trouble shooting point. 3 , poor capacity of the batteries
see also adjusting of charging voltage regulator point 1.24

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1.18 Override key board

Remove upper column casing. First the half without Override (7).
Remove the other half carefully until you can reach the plug (8) of the Override.
Remove the casing with the Override .
Unscrew six nuts (9).
Assemble in reverse order.
Put grease Molykote 111 between Override and casing.
Torque down with 0,3 Nm!

1.19 Hand control unit

The retaining clip (2) is attached with two screws (3) which pass through a fixation disc
into the rear part of the housing.
The coiled cord with plug (4) can be replaced. Loosen the threaded cable fitting (5)
and rotate to remove. Use a micro screwdriver to depress the locking catch (6) of the plug
element and pull out the cable.
Assemble in reverse order.
See service information no. 243 “new hand controls”

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1.20 Eccentric shaft, brake buffer (version with flush-mounted base plate)

Remove the keep-off plates. Attach the mounting frame with the adapter to the column.
Remove the six cover screws (1) and the six fixation screws (2).
Lower the column until the base plate is lifted by 10 to 15 cm
(paying attention to the length of the cable).
The brake buffers (3) can be pulled downward, out of the base plate, from underneath.
Remove the screw (4) and cover plate (5). Remove the screw (6) and cover plate (7)
with the locking lever (8) and stop sleeve (9).
Pull the eccentric shaft (10) out of the adapter (11).

Assemble in reverse order.

Note:
The locking lever (8) must be mounted at the left side of the column!
The locking lever (8) must be mounted on the eccentric shaft in such a way
that locking of column rotation is achieved by rotating the lever clockwise.
Adjustment see also service information no. 241 “short tappets”
There must be about 1 cm of play when the lever is in the released position.

1.21 O-ring and hollow O-ring (version with flush-mounted base plate)

Remove the column casing (see Item 1.1).

Pass the O-ring and/or hollow O-ring over the shaft and lay it on the base plate.
Use the mounting frame to lift the column (see Item 1.20).
Support the base plate (12) and base plate ring (13) to keep them from dropping
(be aware that they are quite heavy!). Remove four screws (14).
Replace the O-ring and/or hollow O-ring.

Assemble in reverse order.

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1.22 Eccentric shaft, brake buffers (version with surface-mounted base plate)

Unscrew two screws (1) and remove the locking lever housing (2).
Replace the brake buffers with intermediate plate (3).

Note: The braking surface and brake buffers must be kept absolutely free of grease.

Unscrew the screw (4) and remove the cover plate (5) with the locking lever (6).
Replace the eccentric shaft (7).
Assemble in reverse order.

Note: The locking lever (6) must be mounted on the eccentric shaft in such a way that locking
of column rotation is achieved by rotating the lever clockwise.
There must be about 1cm of play when the lever is in the released position.
See also service information no. 241, 243 “short tappets” spacers

1.23 Surface-mounted base plate (version with surface-mounted base plate)

Remove the brake buffer (3) (see Item 1.22).

Remove four screws (8) and use two longer M4-screws (about 20 mm long) to lift the closure
cover (9). Use the threaded holes (10) for this purpose.
These threaded holes are not present in older models and it may be necessary to break
the cover to remove it.
Remove the 154 balls (11). Lift the rotating plate (12) off the fixed plate (13).
If the operating table column is mounted on the rotating plate (12), then the keep-off plates
will have to be removed and the mounting frame must be positioned to the column.
Use the height adjustment drive to lift the column off the fixed plate (13).
Clean and re-lubricate the base plate.
Assemble in reverse order.

Note: Use Stucarit sealing gel to seal the closure cover (9).

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View with installed HAWKER batteries

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1.24 Charge voltage regulator

Located in an external transformer case for the stationary version.

In the base of the mobile version.

Each charge regulator (1) is responsible assigned one 12-volt battery unit.
Power is supplied by 14 V AC transformer outputs via bridge-connected rectifiers.
The peak input voltage of the charge regulators is about 20 V DC.
The output voltage of each charge regulator (measured at battery terminals) must be 14,99DC.
See also service information no. 241

Disconnect and replace the charge regulator.

Assemble in reverse order.
See the wiring diagram for information on the connections.

Adjustment of the charge voltage regulators:

Increase the charging voltage to 14,99 V at each (4x) charger board:
Connect the interconnection cable from the mobile transformer unit 1150.81 to the column.
Connect the power supply cord to the line voltage.
Connect the 12kW-load resistor at A10: terminals 2 – 5 and measure the actual charging voltage of
A2 at A10 terminals 2 – 5.
Increase the charging voltage of the correspondent charger board A2 to 14,99 V by turning
the screw of the trimmer into the clockwise direction until the 14,99 V are reached.
The tolerance of the charging voltage should be: U = 14,99 V DC +/-0,05 V
Mark the capacitor C2 with the „14,99 V“ label.
Disconnect the 12 kW-load resistor.
Repeat this procedure for the charger boards A3, A4 and A5. The correspondent terminals for the
connection of the load resistor are:
A3: A10: terminals 8 – 11, A4: A11: terminals 8 – 11,
A5: A11: terminals 2 - 5
Attach the new battery packs with the velcro straps.
Connect the new 12 V battery packs at A10 and A11 as shown below.

Note: Before replacing the charge controller (1) it is first necessary to remove all power from
the supply line.
Never reverse the polarity ¼ Irreversible damage may result.
see also “modification total discharge protection 3113.3249” with function test.
And service informations 235, 239, 241 and 243.

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14 V AC 14 V AC + output to the 2nd PCB

14 VAC 14 VAC - output Battery 1 Battery 2

Input Input to the controller - + - +

Battery connectors are wired in the same order for both PCBs.

AC-inputs from PCB 1 + output to the controller

+ Voltage coming from PCB 1 – routed to the Minus-Input of this board

- for series wiring of the batteries

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1.25 Charging regulator boards

Mobile versions have 2 charging regulator boards (as shown) in the base.
Voltage supply is provided by 4 separate transformer windings (14V each), i.e. there are 8
wires routed from the charging socket to the inputs of the charging regulator boards.
There are 2 separate voltage regulator circuits on each board. Each board is used to supply 2
batteries with the charging voltages. (14,4V for each battery).

Additional functions of the charging regulator boards:

- Discharge protection:
If the voltage of a battery drops below 10,8V, the supply voltage for the motors will be cut off in
order to prevent the batteries from further discharge.

- Total power-off (battery protection) during longer periods of storage:

If the batteries are not charged for a period of 9 days i.e. the mains supply voltage (mobile
transformer unit) is not connected to the column, the batteries will be fully separated from the
charger boards by means of a relay. Operation of the column can only be obtained again in that
the column is connected to the mains supply via the transformer unit. Provided that there is still
sufficient battery capacity it will be sufficient to provide the connection for a short time

Replacement of a charging regulator board:

Disconnect all the cables from the PCB. Caution! At first disconnect the batteries – ensure that
cables of the batteries are not shorted!
Assemble in reverse order – please observe the order when connecting the cables!
Connect all cables except the batteries!
Connect the mobile transformer unit 1150.81X0 to the column.
Connect the transformer unit to the mains supply.
The batteries can now be connected to the charger boards.

Reason for this order of connection:

If the batteries are connected at first this will entail very high currents (coming from the batteries)
rushing into the big capacitors on the PCB. This may lead to destruction of electronic
components.

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2. Maintenance tasks

2.1 1150 operating table columns

‰ 1. General visual inspection

‰ 2. Check hand control unit, connector cable condition and functions
‰ 3. Check infrared transmitter condition and functions
‰ 4. Check charging generator
‰ stat 5. General visual inspection of the stationary transformer unit
‰ mob 6. General visual inspection of the mobile transformer unit and connector lcables
‰ stat 7. Check cable attachment and fastening elements
‰ 8. Check charge voltage regulators and batteries
‰ 9. Check all the movements with the table top in place (observing operating noises)
‰ 10. Check the "0" position and limit positions of adjustments
‰ 11. Check Hall-effect sensor functioning
‰ 12. Check the condition of the bellows and proper seating
‰ 13. Remove the controller cover and column casing, clean and align the casing parts
‰ 14. Visual check of cable routing to the IR receivers and sockets
‰ 15. Check plug connectors for proper seating (column control unit)
‰ mob 16. Remove and clean base cover
‰ 17. Visual inspection of cable routing in the column area
‰ stat 18. Check for unrestricted rotation and mechanical limit stops
‰ stat 19. Check the locking elements
‰ stat 20. Loosen the base plate ring (flush-mounted base plate)
‰ stat 21. Remove locking lever with housing and brake buffers (surface-mounted base plate)
‰ stat 22. Remove cover plate and balls (surface-mounted base plate)
‰ 23. Raise the column using the mounting frame
‰ mob 24. Visual inspection of the bottom surface and rubber buffers
‰ stat 25. Check the filling material below the base plate (in so far as this is possible)
‰ stat 26. Check the screw anchors
‰ stat 27. Visual inspection of the cables in the rotating area
‰ stat 28. Check the sealing of the cable outlets (flush-mounted base plate)
‰ stat 29. Check, clean and lubricate the cam shaft (flush-mounted base plate)
‰ stat 30. Check, clean and lubricate the brake buffers (flush-mounted base plate)
‰ stat 31. Check the brake buffers, disk and buffer surfaces (surface-mounted base plate)
‰ stat 32. Clean and re-lubricate the base plate
‰ stat 33. Check the base plate for damage (ball running grooves, brake buffer surface)
‰ stat 34. Check, lubricate and insert sealing rings (flush-mounted base plate)
‰ stat 35. Check the mechanical stop screws
‰ stat 36. Lower the column and mount the base plate ring (flush-mounted base plate)
‰ stat 37. Lower the column, insert the balls. Mount brake assembly (surface-mounted base plate)
‰ stat 38. Check for proper rotation and locking
‰ 39. Check to see that the stop bolts are tightly seated
‰ 40. Check the stop grooves; glue stop bolts in place (where stop bolts are loose)
‰ 41. Clean and re-lubricate the guide cylinder
‰ 42. Examine and readjust the fitted keys of the elevation guide
‰ 43. Examine and readjust the fitted keys of the central guide
‰ 44. Check the fixation screws at the supporting plate
‰ 45. Mount the casing components

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2.2 1150 surgical table tops

‰ 1. General visual inspection

‰ 2. Functional check of motions
‰ 3. Check condition and function of the guide element and locking buffers
‰ 4. Degrease the sliding surface at the guide element
‰ 5. Functional check of motions with mechanical load (observing operating noises)
‰ 6. Check "0" position and limit positions
‰ 7. Remove padding
‰ 8. Remove controller unit cover
‰ 9. Check plug connectors for proper seating (table-top controller unit)
‰ 10. Visual inspection of cable routing
‰ 11. Check condition and tension of the toothed belt
‰ 12. Mount controller unit cover
‰ 13. Check functioning of toothed element and adjustment (upper back)
‰ 14. Check table top extension (upper back)
‰ 15. Check functioning and clamping force of the eccentric levers
‰ 16. Check fixation of the side rails
‰ 17. Check functioning and seating of the leg plate locking
‰ 18. Check clamping force of the leg plate joints (when released and when engaged)
‰ 19. Clean and lubricate the guide rods
‰ 20. Lubricate the longitudinal shift gearing, if necessary (grease gun)
‰ 21. Reinstall padding

2.3 Series 1150 operating table trolleys

‰ 1. General visual inspection

‰ 2. Check mechanical switch-over for column transfer and readjust if necessary
‰ 3. Check distance (383 mm) at the trolley fork
‰ 4. Check condition of plastic guides
‰ 5. Check swivel and fixed castors and the locking unit
‰ 6. Check trendelenburg adjustment and remote adjustment shaft (1140.61/62 )
‰ 7. Clean and lubricate sliding elements
‰ 8. Check hydraulic height adjustment and hydraulic fluid level (1140.62 )

2.4 General for series 1150 (columns / table tops / trolleys)

‰ 1. Recording of the condition of the floor (if not yet done)

‰ 2. Read out and record status
‰ 3. Read out and record counter readings for the motor controller
‰ 4. Readjust motors if necessary
‰ 5. General functional check
‰ 6. Check automatic return to ”0” position (from all directions)
‰ 7. Check adjustment functions with mechanical load
‰ 8. Check transfer and locking functions
‰ 9. Conduct electrical safety inspection as per VDE 0751

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3. Troubleshooting

3.1 Take-over problems, locking system

3.1.1 Take-over of table top without patient load. (force in upward direction applied to trendelenburg
adjustment device).

Take-over function ok? yes / no

3.1.2. Measure the remaining distance between the locking catch and the guide bracket.

Measured distance:
Side where the adjustment
device is located.

Measured distance:
Opposite side:

3.1.3. trendelenburg adjustment device).

Take-over function ok? yes/ no

3.1.4. Measure the remaining distance between the locking catch and the guide bracket.

Measured distance:
Side where the adjustment
device is located.

Measured distance:
Opposite side:

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3.1.5. Place a person on the table top, test the take-over function again. Apply force to the trendelenburg
adjustment device in upward direction

Take-over function ok? yes / no

3.1.6. Test the take-over function again. Apply the force in downward direction

Take-over function ok? yes / no

3.1.7 Ensure that the controller unit of the column is switched off (LED with battery symbol must be off).
No patient load on the table. Pull the foot-end of the table top in an upward direction. Keep the force
and actuate the tilting function. Check to see that the tilting function is carried out correctly. The
upper edge of the locking catch must be in touch with the guide bracket as long as the table top is
pulled upward.

Signal of failure? yes/ no

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3.1.8 Ensure that the controller unit of the column is switched off (LED with battery symbol must be off).
No patient load on the table. Pull the head-end of the table top in an upward direction. Keep the
force and actuate the tilting function. Check to see that the tilting function is carried out correctly.
The upper edge of the locking catch must be in touch with the guide bracket as long as the table top
is pulled upward.

Signal of failure? yes / no

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3.2 Poor charge capacity of accumulators of mobile O.R. table columns 1150.01C

Several measures have been introduced in the past in order to achieve an improvement
(see former service information issues).
The following is a summary of the measures taken, the serial numbers of columns at which they were
introduced, and a short checklist for troubleshooting.

How to proceed when a customer complains about insufficient capacity:

- The O.R. table column must be equipped with a total discharge protection board
(columns 1150.01C0 with serial No. 548 or higher: installed during manufacturing).
New type of socket for the charging unit (4 pins, 4 holes) and new interconnecting cable in order to provide
improved protection against incorrect plugging-in.

- Long version of heatsink sheet (7204.9554, Serial No. 728 and higher: installed during manufacturing)
underneath the charger boards in the base made of stainless steel.
(1150.01C0, Serial No. 616 and higher: installed during manufacturing) for better dissipation of heat.

- „Hawker“-Batteries must be used. (1150.01C0, Serial No. 788 and higher: installed during manufacturing)
Holes in the base must be sealed (1150.01C0, Serial No. 795 and higher: sealed during manufacturing)

- Charging voltage setting of the regulator boards in the base must be adjusted to 14,99 V (formerly 14,4 V)
See also Service information 241, (1150.01C0, Serial No. 1003 and higher: done during manufacturing)

- Mobile charging units 1150.81 of the columns must be checked for correct voltages of all the 4 pairs of
output cables.

- Customers should always have as many charging units as columns.

3.2.1 Complaint of customer: „column is suddenly switched off without the warning signal „insufficient charge“
(slow interval tone, flashing LED in the base):

Before replacement of batteries or other components the cause of the failure must be determined.
Proceed as follows:

a) There is one interconnecting wire (orange) coming from each discharge protection board (A10, A11)
and connected to Terminal X3 in the column. Disconnect one of these wires, charge the batteries of the
column for a short time and check the movement function.This procedure enables you to determine
which of the protection boards is sending the signal “defective battery”.

b) After the board sending the signal is determined the batteries assigned to the boards should be
interchanged in order to find out whether the failure is caused by a defective protection board or a defective
battery.

- If protection boards are found to work correctly check the batteries. Probably there is one of the 6 V
branches that has dropped below 5.4 V. This causes the cut-off by the controller unit (total discharge
protection).

- If the failure is found to be caused by one of the protection boards (A10, A11) the board must be replaced.
Boards of columns with serial No. 800 or higher are covered by a protection coating (moisture)
If a defective board has no such coating both boards should be replaced. At the same time when the
coated boards were introduced also the holes in the base were sealed – see service information 239.

3.2.2 Complaint of customer: column signals “insufficient capacity” after a short period of operation (slow
interval tone)
This signal is not caused by the protection boards A10 or A11 but the controller unit. The supply voltage of
48 V is monitored during operation of the column and the signal tone is emitted when it drops below a
certain value.
In general batteries should be charged for a period of 12...15 h. Inform the customer by phone before the
service technician is on site. If this is still not sufficient the batteries must tested and replaced if necessary.

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3.3 Unintended unlocking brake levers of O.R. table columns 1150.01A0

In the course of modification 77302A, another tappet which is 1.5mm shorter has been introduced.
(Short version of tappet No. 5009.5964). This version of tappet can be identified by an additional groove.
To rectify the problem of unintended unlocking this new tappet should be used.
These new types of tappets are enclosed to the installation parts of O.R. column 1150.01A0.
An additional note has been added to the drawing
“Do not lubricate the contact surfaces of tappet/eccentric shaft“.
Please strictly observe this instruction!”

The eccentric shaft has been marked as shown below in order to indicate the locking position in which the
eccentric shaft should be positioned when the locking lever is actuated.
The marking dot corresponds to the “highest” position of the eccentric shaft.
In lock position the marking dot should be almost in lowest position (6 o’clock position).

For 1150.01B with surface mounted base plate you have to use two inlay sheets with different thickness

Order No. Name of part Used for product: Order No. for
For “short version” „standard version”
5009.5964 Brake buffer „short“ 1150.01A0 / A1 5008.8844
(with built-in base plate)
7205.0124 Inlay sheet „thin“ (1mm) 1150.01B0 / B1 7204.8974 (2mm)
(on the buffer)

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4. Appendix

4.1 Survey of relevant service informations:

Nr. 235 Modification of 1150 system 20.10.1998

Nr. 236 Control boards with adjusted IR diods 14.05.1999
Nr. 237 New software „ heavy patients“ 27.10.1999
Column stopps 3cm before lowermost position
Nr. 241 Adjusting of the charger board, 14,99 Volt 1150.01C0 06.04.2000
„short“ tappets for built-in base plate
Nr. 243 IR transmitters with “amnesia“ (loss of programmed data) 08.08.2000
Poor charge capacity of accumulators of mobile columns
Modified version of guide brackets ( take-over problems)
New generation of O.R. table columns 1150.01X1, new hand controls
Preventive Charging of accumulators of columns and IR transmitters
„short“ tappets ( survey of 1150, 1140 and 1120)
Installation of a column 1150.01A as replacement for an 1120
Nr.244 Additional isolating of the batteries for mobile columns 01.12.2000
New PTC in the mobile charging unit 1150.81A0 from ser.no. 105

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4.2 Operating media

Item. No. Designation Package Used at

3821.0080 Microlube GL 261 1 kg tin Column

3112.6379 Aral UB HL 3 1 kg tin Base plate (balls)
3822.0160 Molykote 111 100 g tube Corrosion protection
3822.0180 Molykote 111 1 kg tin Corrosion protection
5822.0040 Molykote DX 1 kg tin Sliding surfaces (longit. shift)
3822.0150 Klüberplex BE 31-502 1 kg tin Table top
3822.0130 Rivolta SKD 3000 0.32 dm³ spray can Washable version
3713.0190 Stucarit 309 Sealing gel
3711.0680 Loctite Type 5331 Thread sealant (waterproof)
3711.0320 Loctite Type 243 Threadlocker (blue)
3711.0610 Loctite Type 270 Threadlocker (green)
3711.0490 Loctite Type 638 Threadlocker (green)

4.3 Tools, aids

9900.0434 Mounting frame „new“ for 1150,1140

1009.9400 Mounting frame “old” for 1120
3150.7209 Mounting frame adapter for 1009.94
9900.0353 IR-Tester
Wooden strip 20 x 40 x 200 mm, two each
Cable, 2 x 1.5 mm² conductors, approx. 2 meters long
0112.0274 Removal tool for microcomputers
0112.0264 ESD – wrist strap
0112.0254 Vacuum - pipette
Spring balance 10-400N
Torque wrench for 2,2/4/6/8/25/40/70/120 Nm

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