Skytron ELITE Series Maintenance Manual
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Skytron ELITE Series Maintenance Manual

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ELITE SERIES SURGICAL TABLES
MAINTENANCE MANUAL
MODEL ELITE 3500 AND 3500B
REV 6/05
Page 69

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  • Page 1 ELITE SERIES SURGICAL TABLES MAINTENANCE MANUAL MODEL ELITE 3500 AND 3500B REV 6/05 Page 69...

  • Page 3: Table Of Contents

    SECTION IV ELECTRICAL SYSTEM ........................26 4-1. General ..............................26 4-2. Components .............................. 26 4-3. Battery Model Components ......................... 26 Although current at time of publication, SKYTRON's policy of continuous development makes this manual subject to change without notice. REV 6/05 Page 63...
  • Page 4 TABLE OF CONTENTS (cont.) SECTION V ELECTRICAL SYSTEM TROUBLESHOOTING ................28 5-1. Troubleshooting Notes ..........................28 5-2. Main Switch ..............................28 5-3. Pendant Control ............................29 5-4. Relay Box ..............................30 5-5. Solenoids ..............................32 5-6. Motor/Pump Assembly ..........................33 5-7.
  • Page 5 3500 Series Surgical Table Specifications 9-1/2" 18-1/2" 25" 23" TOP VIEW 60˚ 79" 21-3/4" 6" 19-3/4" 90˚ 26-45"* 6" 8-1/2" 40-1/2" 19" SIDE VIEW END VIEW Electrical Specifications Power requirements 120 VAC, 60Hz, 450 Watts Current Leakage Less than 100 micro amps Power Cord 15 feet w/hospital grade connector (removeable on battery model)
  • Page 6 EQUIPMENT LABELS AND SPECIFICATIONS FUSE TYPE 10 AMP, FAST ACTING (FA) INDICATES DANGEROUS VOLTAGE, 120 V, 60 Hz CLASS I DEFIBRILLATION PROOF, TYPE B EQUIPMENT- IPX4 RATED. INTERNALLY POWERED EQUIPMENT TYPE B EQUIPMENT PROTECTIVE GROUNDING. IN ORDER TO ENSURE PROPER GROUNDING RELIABILITY, THIS TABLE MUST BE CONNECTED TO A PROPERLY GROUNDED HOSPITAL GRADE OUTLET.

  • Page 7: Section I Hydraulic System

    SECTION I HYDRAULIC SYSTEM 1-1. General Electro-Hydraulic System hand-held push button pendant control. The power requirements for the table are 120 VAC, 5 amp, 60 The hydraulic system (with the exception of the hydraulic cylinders and hoses) is contained within the base of the table.

  • Page 8: Component Operation

    b. Pressure Relief Valve a. Oil Reservoir - Main oil supply. Approximately two quarts. This device provides an alternate oil path when the hydraulic cylinders reach the end of their stroke b. Motor/Pump Assembly - A positive displace- and the pump continues to run. If this path were not ment gear type pump provides the necessary oil provided, the pump motor would stall because the pressure and volume.

  • Page 9: Mini-Valves

    The main component of the valve is an adjustable The speed controls are always located in the return spring loaded plunger that is pushed off from its oil circuit. This prevents uncontrolled movement of seat by the oil pressure. The oil then flows back into the piston in the slave cylinder due to one side of the the reservoir.

  • Page 10: Mini-Valve Right Port Activated

    e. Mini-Valve Right Port Activated f. Mini-Valve Left Port Activated (See figure 1-6) (See figure 1-7.) Slave Cylinder Piston Moves to Left Slave Cylinder Piston Moves to Right Right Mini-Valve Port is Supply Line Left Mini-Valve Port is Supply Line Left Mini-Valve Port is Return Line Right Mini-Valve Port is Return Line INLET...

  • Page 11: Hydraulic Cylinders (Slave Cylinders)

    g. Hydraulic Cylinders (Slave Cylinders) O-RING O-RING There are several different types of hydraulic cylin- ders used in the table that activate the control functions. With the exception of the elevation and brake cylinders, all operate basically the same PISTON way.
  • Page 12 The cylinder is set in the center of the elevation main column. The two stage cylinder is elevated by the driven force of the oil pressure. When lowering, the oil that is accumulated in the cylinder is returned to the oil reservoir through the mini-valve due to the table top weight.

  • Page 13: Elevation Cylinder Return Circuit

    h. Elevation Cylinder Return Circuit i. Brake System A three-way (single check valve type) mini-valve The brake system consists of the following compo- controls both the elevation and return circuits. The nents: (figure 1-16) elevation circuit operation within the mini-valve is identical to the operation of the four-way valves 1.

  • Page 14: Emergency Brake Release

    When activated, the return hydraulic circuit oper- 1. The brakes will release slowly- depending ates similar to the elevation cylinder return circuit. on how loose the valve is, this could take anywhere Return springs inside the single action brake cylin- from a few minutes to several hours.

  • Page 15: Hydraulic Adjustments

    1-3. Hydraulic Adjustments c. Pressure Relief Valve a. Fluid Level. The pressure relief valve is adjusted by turning the The fluid level should be approximately 1/2" below adjustment nut until the desired pressure is reached. the filler hole or gasket surface. If additional fluid is needed, remove the filler vent cap with a phillips To adjust: screwdriver and add fluid through this opening...
  • Page 16 A pressure gauge should be used to set the speed One speed control adjusts one direction of a of the back section, trendelenburg and flex control particular function and the opposite speed control functions. adjusts the other direction. They are adjustable by using a small straight blade screwdriver and To adjust: turning the adjustment screw clockwise to de-...

  • Page 17: Section Ii Mechanical Table Adjustments

    SECTION II MECHANICAL TABLE ADJUSTMENTS 2-1. Back Section Gear Mesh Adjustment Any twisting or flexing of the back section as it The gear mesh is adjusted by the use of an eccen- approaches the stalled position indicates that one tric cam. This cam moves the gear teeth closer of the cylinders is not reaching its fully extended together to eliminate gear lash.

  • Page 18: Slide And Kidney Lift Cylinders

    To adjust: 2-3. Slide Roller Adjustment Loosen the cam locking set screws located on the The pivot pins on the slide rollers are eccentric bottom of the cylinder mounting plates inside the cams. The rollers can be adjusted if required to table side frames.

  • Page 19: Section Iii Hydraulic Troubleshooting

    SECTION III HYDRAULIC TROUBLESHOOTING 3-1. Precautions Once the problem has been determined, concen- Before attempting to troubleshoot any hydraulic trate on that particular hydraulic circuit or control problem on the table, please read through the pre- function. cautions and notes below. Listed below are the hydraulic components that are common with all hydraulic circuits.

  • Page 20: Elevation Diagnosis Chart

    3-3. ELEVATION DIAGNOSIS CHART Problem Reason Table will not elevate properly Pressure Relief Valve Not Set Properly Low on Oil Spool Valve Not Centered or Adjusted Properly Defective Pump Defective Mini-Valve Defective Solenoid or Wiring Defective Relay Box or Pendant Control Table will not descend properly Incorrect Speed Adjustment Bad Check Valve...

  • Page 21: Trendelenburg Diagnosis Chart

    3-4. TRENDELENBURG DIAGNOSIS CHART Problem Reason Trendelenburg function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly Bad Check Valves Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Defective Solenoid or Wiring Defective Relay Box or Pendant Control Trendelenburg function chatters or loses position Defective or Dirty Check Valve...

  • Page 22: Lateral Tilt Diagnosis Chart

    3-5. LATERAL TILT DIAGNOSIS CHART Problem Reason Lateral tilt function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly Bad Check Valves Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Defective Solenoid Defective Relay Box or Pendant Control Lateral tilt function chatters or loses position Defective or Dirty Check Valves...

  • Page 23: Back Section Diagnosis Chart

    3-6. BACK SECTION DIAGNOSIS CHART Problem Reason Back Section function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly Bad Check Valves Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Defective Solenoid or Wiring Defective Relay Box or Pendant Control Back Section function chatters or loses position Defective or Dirty Check Valves...

  • Page 24: Flex System Diagnosis Chart

    3-7. FLEX SYSTEM DIAGNOSIS CHART Problem Reason Back Section or Trendelenburg function moves Incorrect Speed Adjustment (Trendelenburg, Back improperly Section or Flex - check with gauge) Spool Valve Not Centered or Adjusted Properly Bad Check Valves IMPORTANT Low on Oil Pinched Hose If Flex System does not function prop- Defective Mini-Valve...

  • Page 25: Leg Section Diagnosis Chart

    3-8. LEG SECTION DIAGNOSIS CHART Problem Reason Leg function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly Bad Check Valves Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Defective Solenoid or Wiring Defective Relay Box or Pendant Control Leg function chatters or loses position Defective or Dirty Check Valves...

  • Page 26: Kidney Lift Diagnosis Chart

    3-9. KIDNEY LIFT DIAGNOSIS CHART Problem Reason Kidney Lift moves improperly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly Bad Check Valve Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Defective Solenoid or Wiring Defective Relay Box or Pendant Control Kidney Lift chatters or loses position Defective or Dirty Check Valve...

  • Page 27: Slide Diagnosis Chart

    3-10. SLIDE DIAGNOSIS CHART Problem Reason Slide function moves improperly Incorrect Speed Adjustment Spool Valve Not Centered or Adjusted Properly Bad Check Valves Low on Oil Pinched Hose Defective Mini-Valve Pressure Relief Valve Not Set Properly Defective Solenoid or Wiring Defective Relay Box or Pendant Control Slide function chatters or loses position Defective or Dirty Check Valve...

  • Page 28: Brake Circuit Diagnosis Chart

    3-11. BRAKE CIRCUIT DIAGNOSIS CHART Problem Reason Brakes will not set properly Emergency Brake Release Valve Open or Defec- tive Spool Valve Not Centered or Adjusted Properly Bad Check Valve NOTE Low on Oil If brakes have been released with the Pressure Relief Valve Not Set Properly Emergency Brake Release Valve, Pinched Hose...

  • Page 29: Flexible Hose Identification And Placement

    3-12. Flexible Hose Identification and Place- ment The flexible hydraulic hoses used in the table are number coded to aid in the correct placement of the hoses from the plumbing terminal to their respec- tive hydraulic cylinders. Figure 3-10 shows the correct placement of the flexible hydraulic hoses and their respective number codes.

  • Page 30: Kidney Lift System

    3-13. Kidney Lift System 3. Open the bypass valve by loosening the The Kidney Lift cylinders are connected in series screw in the bottom of the valve and activate so that both cylinders operate simultaneously. "KIDNEY UP". Hydraulic fluid fills cavity "A" and pushes the piston into cavity "B".

  • Page 31: Cylinder Adjustment

    b. Cylinder Adjustment - If either of the kidney lift cylinders reaches the end of the down stroke 5. Repeat steps 3 and 4 as needed to remove before the other one, an adjustment is needed. Use any remaining air in the system. the following procedure to adjust the system.

  • Page 32: Section Iv Electrical System

    SECTION IV ELECTRICAL SYSTEM 4-2. Components 4-1. General Refer to figure 4-1 for the relationship of the elec- The complete electrical system (with the excep- trical components. tion of the hand-held pendant control and the return circuit micro-switches) is contained within the base a.
  • Page 33 3500 Figure 4-1. 3500 Electrical Circuit Block Diagram Page 27...

  • Page 34: Section V Electrical System Troubleshooting

    3500 SECTION V ELECTRICAL SYSTEM TROUBLESHOOTING 5-1. Troubleshooting Notes The basic operation of each component will be 2. Disconnect connector CN4 from the relay defined along with a drawing and explanation on box. See figure 5-1. Leave all other connectors how to check it out.

  • Page 35: Pendant Control

    3500 b. Test Results If you do not receive the correct voltage measure- 1. Unplug the pendant control from the base of ment, the problem would have to be in the wires, the table. You will be checking the cord side main switch, fuses, or power cord.

  • Page 36: Relay Box

    3500 d. Test Results: b. Test Results: If you do not receive the correct voltage reading, If you do not receive continuity between any of the the wiring or connector pins may be faulty. Discon- pins, either the micro-switch in the Pendant Control nect connector CN8 from the relay box and using is defective or a wire is broken.
  • Page 37 3500 d. Test Results: a. Relay Box Input Connector CN4 If you do not receive the correct meter readings, the 1. Plug the power cord into the 120 VAC power relay box or wiring is defective. If the correct supply (wall receptacle) and turn the main switch readings are obtained, this part of the relay box is ON.

  • Page 38: Solenoids

    3500 f. Test Results: b. Step #1 1. Plug the table cord into the wall receptacle If you do not receive the correct meter readings, the relay box or wiring is defective and should be and turn main switch ON. replaced.

  • Page 39: Motor/Pump Assembly

    3500 e. Test Results: 5-6. Motor/Pump Assembly If the solenoid does not check out with the meter, The electric motor is a capacitor start type with a it is more than likely defective and must be re- rating of 120 VAC, 200 watts. The field windings placed.
  • Page 40 3500 c. Test Results: a. Motor/Pump Test If you do not receive the correct meter readings, the The following tests will check the voltage applied to problem could be in the wires, connectors, relay the motor and the resistance of the motor field box, or main switch (refer to appropriate section for windings.

  • Page 41: Return-To-Level Micro-Switches

    3500 The kidney lift has a back section-up inhibit switch 3. Use the R x 1 scale of the ohmmeter and to prevent the table back section from damaging measure the resistance between the pins located the kidney lift when the lift is raised. The back in the pump connector CN15.

  • Page 42: Return/Inhibit System Troubleshooting

    3500 The micro-switches operate on low voltage, and cover on the top of the elevation column. Connector control the function circuits (pump/motor and ap- CN2 plugs into the relay box and is the most propriate solenoid valves) when activated by the convenient location to make circuit continuity pendant control RETURN button.
  • Page 43 3500 WHITE NS-1 LIGHT BLUE CN-2 BLUE NS-2 TS-1 NS-1. Trendelenburg NS-2. Reverse Trendelenburg Test at pins 1 & 14 Test at pins 2 & 14 Table Switch Meter Table Switch Meter Position Position Reading Position Position Reading Level Open Infinity Level Open...
  • Page 44 3500 NS-6 RED/WHITE PINK TS-1 PINK CN-2 TS-1 NS-5 NOTE When CN-2 is disconnected, BACK- DOWN function will not operate. NS-5. Back Section Down NS-6. Back Section Up Test at pins 5 & 13 Test at pins 6 & 13 Table Switch Meter...
  • Page 45 3500 NOTES SLIDE function will not operate when CN-2 is disconnected. BLACK BLACK/WHITE PINK CN-2 TS-2 CS-2 CS-1 CS-1. Leg Down 45˚ Inhibit CS-2. Back Down Inhibit Test at pins 9 & 13 Test at pins 10 & 13 Table Switch Meter Table...
  • Page 46 3500 CS-4. Slide Inhibit Test at pins 8 & 13 Table Switch Meter Position Position Reading Level Open Infinity Leg Dn Closed more than 45° When Leg Section is more than 45° below horizontal, CS-4 will not allow Top to Slide toward head. Figure 5-20.
  • Page 47 3500 b. Switch Adjustment. If proper readings are not obtained during test or if 3. To adjust the Leg Section switches, remove table does not properly return to level, use the seat section top, loosen the two phillips head screws following procedure to adjust the switches.

  • Page 48: Section Vi -3500B- Battery Model, Electrical Troubleshooting

    3500B SECTION VI -3500B- BATTERY MODEL, ELECTRICAL TROUBLESHOOTING 6-3. Main Switch 6-1. General The main power supply, 120 VAC, 60 HZ, comes The battery table components operate on 24VDC. in through the power cord and through the main The internal charging system also incorporates the switch.
  • Page 49 3500B SOLENOID COIL 24VDC PENDANT CONTROL MINI-VALVES AUXILIARY CONNECTOR CN14 CN13 RELAY BOX RETURN CIRCUIT AUXILIARY CN2A SWITCHES CN10 CN2B BATTERIES CHARGER BOX CAPACITOR PUMP SWITCH-OVER RELAY CN16 CN15 22 VAC FROM TRANSFORMER 120 VAC TO TRANSFORMER CN51 FUSE CHARGER 15AMP CN12 CN13...

  • Page 50: Batteries

    3500B 4. Continue to press the TABLE UP button on Check the continuity from the power cord connec- the pendant control so that the pump motor contin- tor ICN1, through the fuses, switch and wiring to ues to run and using a DC voltmeter, check the connector CN12.
  • Page 51 3500B BROWN 4. Meter should read 26.5 ±1VDC if charger is operating. If batteries are fully charged there will be under 5 volts at pins 5 and 6. d. Test Results Figure 6-5. Connector CN13 Test If you do not receive the correct readings, the b.

  • Page 52: Switch-Over Relay

    3500B 6-6. Switch-Over Relay a. Switch-Over Relay in OFF Position NOTE The Switch-Over Relay supplies the 24 volt input The battery charging circuit is only op- power from either the BATTERY or AC120V oper- erational when the table is in the AC120V ating modes to the relay box for table operation.

  • Page 53: Pendant Control

    Pendant Base Conn. Pend. Conn. Base Conn. Pend. Conn. Control or the Relay Box. Contact SKYTRON if all tests performed indicate that the problem is located in the Pendant Control. Figure 6-11. Pendant Control Cord Test Page 47...

  • Page 54: Auxiliary Switches

    3500B 6-8. Auxiliary Switches The following tests will determine if the auxiliary switches are functioning properly. Figure 6-14. Auxiliary Switch Test a. Switch Test 6-9. Relay Box Disconnect connector CN3 at the Relay Box and The power supply is directly connected to the relay using an ohmmeter check for continuity at the contacts.
  • Page 55 3500B a. Checking Relay Box Input Power d. Checking Output to Solenoids 1. Connect power cord to table. Plug the power This test checks the voltage that is used to cord into the 120VAC supply (wall receptacle). energize the solenoids. Disconnect connector CN4, leave all other con- nectors connected.

  • Page 56: Main Wire Harness Continuity Test

    The output to the Pendant Control can not be tested without specialized equipment. If all tests have been conducted and it appears that the Relay Box CN15 OR CN16 is faulty, contact SKYTRON. NOTE The Relay Box connectors CN7 (Pen- dant Control), and CN8 (Auxiliary Base Connector), are interchangeable.

  • Page 57: Solenoids

    3500B 6-11. Solenoids Use a DC voltmeter and measure the voltage across the 2 pin connector. Pin 1(+), and The solenoids are energized by 24 volt potential pin 2(-). Meter should read approximately 24-28 that is controlled by the relay box. volts.

  • Page 58: Motor/Pump Assembly

    3500B d. Test #2 CN15 The solenoid can be checked out using an ohm- meter R x 1 scale. 1. Measure the resistance between the two Figure 6-21. Motor Input Voltage pin connector in question as shown in figure 6-20. Connector must be disconnected.

  • Page 59: Return-To-Level Micro-Switches

    3500B 2. The meter should read 1 to 2 ohms at room The slide function has inhibit switches to prevent temperature. damage to the back and leg sections. If the back 3. Measure the resistance between either pin section is below horizontal the top will not slide and ground.

  • Page 60: Return/Inhibit System Troubleshooting

    3500B 6-14. Return/Inhibit System Troubleshooting a. Switch Test If a problem is suspected in the return circuits, Turn Main Power ON, lock the table brakes, and disconnect the connector CN10 from the Relay place the table top sections in a level position with Box to eliminate the circuits.
  • Page 61 3500B WHITE NS-1 LIGHT BLUE CN-10 BLUE NS-2 TS-1 NS-1. Trendelenburg NS-2. Reverse Trendelenburg Test at pins 1 & 15 Test at pins 2 & 15 Table Switch Meter Table Switch Meter Position Position Reading Position Position Reading Level Open Infinity Level Open...
  • Page 62 3500B NS-6 RED/WHITE PINK TS-1 PINK CN-10 TS-1 NS-5 NOTE When CN-10 is disconnected, BACK- DOWN function will not operate. NS-5. Back Section Down NS-6. Back Section Up Test at pins 5 & 15 Test at pins 6 & 15 Table Switch Meter...
  • Page 63 3500B NOTES SLIDE function will not operate when CN-10 is disconnected. BLACK BLACK/WHITE PURPLE CN-10 TS-2 CS-2 CS-1 CS-1. Leg Down 45˚ Inhibit CS-2. Back Down Inhibit Test at pins 9 & 15 Test at pins 10 & 15 Table Switch Meter Table...
  • Page 64 3500B CS-4 BROWN/WHITE GREY CN-10 TS-2 CS-4. Slide Inhibit Test at pins 8 & 15 Table Switch Meter Position Position Reading Level Open Infinity Leg Dn Closed more than 45˚ When Leg Section is more than 45˚ below horizontal, CS-4 will not allow Top to Slide toward head.
  • Page 65 3500B b. Switch Adjustment. 3. To adjust the Leg Section switches, remove If proper readings are not obtained during test or if seat section top, loosen the two phillips head screws table does not properly return to level, use the following procedure to adjust the switches.

  • Page 66: Section Vii -3500B- Battery Model, Electrical System Adjustments

    SECTION VII ELECTRICAL SYSTEM ADJUSTMENTS 7-1. Relay Box Adjustments a. Brake Release Timer The Relay Box contains variable resistors for ad- The Brake Release Timer is set for about 7 sec- justing the operating timers for the BRAKE SET onds and is controlled by the variable resistor VR1 on the relay box circuit board.
  • Page 67 VR-4 VR-3 VR-1 VR-2 CN-2A CN-1 CN-2B Figure 7-2. Relay Box Adjustments Model 3500B Page 61...
  • Page 69 RELAY BOX HOSPITAL GRADE PLUG MNPC-32 F1, FH1 MNPC-33B + C1 #RL-22 AC115V #RL-22 RL-23 RL-24 PB10SU 60Hz F2, FH2 AC115V 200W #RL-21 60Hz CN15 #RL-41 TRA1 #RL-42 #RL-42 #RL-23 #RL-41 RL-21 180V 75µ F #RL-1 RL-1 SV-1 CN-21 #RL-2 RL-2 #RL-29 SV-2...
  • Page 70 MNPC-68 MNPC-70 #RL-1 SV-1 CN21 ELEV. RL-1 #RL-2 SV-2 CN22 #RL-3 RL-2 SV-3 CN23 15 14 13 12 11 10 VDD OSC C2 C3 SP1 2 #RL-4 TREND. RL-3 SV-4 TC9149 CN24 HP1 2 3 4 5 6 #RL-5 #RL-25 RL-4 1 2 3 4 5 6 7 8...
  • Page 72 5000 36th Street S.E. • Grand Rapids, MI 49512 1.800.SKYTRON • 1.616.957.0500 • FAX 1.616.957.5053 Page 68...

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