ITO CO., LTD. Printed on July 21st, 2011
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Rev.1 May 21st, 2012
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Rev.1 May 21st, 2012
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Rev.1 May 21st, 2012
About Test Mode (1) Activativation of the TEST mode (i) Switch on power while holding down both the A and D k eys. (The buzzer will sound to indicate Note: To clear the test mode, turn off the power.
(2) Functions The test test mode provides the following following functions: functions: Remarks
Function
Allows testing of each key involved in unit operations. Testing a key function should display the corresponding indication on the LCD screen. Keys that can be checked: "A"" B"" C"" D ""E ""F ""G"" H"" I ""START ""PAUSE ""STOP"" ▲"" ▼" * Use the ”OK” key to go to the next step of the function mode.
Key
Check the LCD for abnormal conditions and to confirm that the screen is clean and clear. The following pattern is displayed: (Press the ”OK” key to change patterns.) Totally lit (White) Totally extinguished (Blue) Blue lattice White lattice Fine lines in four directions.
LCD
This function is used to adjust or evaluate traction force. Select traction force with the ”p ” and "q ” keys and initiate traction with the ”START ”key. While traction is underway, stop with the ”STOP” key. Clear over current errors with the ”STOP” key.
The following traction modes are available: (i) DA Ctl mode (Fixed motion using hard coding under D/A control only): ”5 kg”” 50 kg”” 90 kg” (ii) Normal mode (Same standard traction as with actual unit): ”5 kg”” 50 kg”” 90 kg” (iii) Cur Test test mode (Standard traction; no over over current detection in NCD): NCD): ”120 kg NCD”” 120 kg ”
Traction
Operation time This function indicates cumulative power-on and traction times. indication This function is used to initialize one of the four items below. Select an item with the ”p ” or ”q ” keys and initialize by holding down the ”OK” key for at least three seconds. Initialization (i) All parameters (except traction force calibration data) (ii) Cumulative power-on time (iii) Cumulative traction time *(iv) All of items (i) through (iii) above, including traction force calibration data. Inhibited for field Traction force Enables calibration to improve calibration force accuracy (see Adjusting the main unit). calibration
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Rev.1 May 21st, 2012
Power Supply Rated Power Consumption Type of medical equipment Dimension Weight of the main unit Input/output of main unit Length of traction rope Operating section
110 / 115 / 120 VAC 50Hz/60Hz Worldwide Model 220 / 230 / 240 VAC 50Hz/60Hz 75VA + 15% or less Type of protection : Class 1, Type B, Pharmaceutical Low : Class II, MDD : Class IIa, FDA : Class II 170mm(H)(incl. protrusions) x 260mm(W) x 330mm(D) Approximately 12kg Patient switch connector x 1 AC inlet x 1 1.6m (extensible length) Vinyl coated wire rope Power switch (rocker switch x 1on rear panel) ON/OFF operation of main power supply The following functions are executed when the keys are activated along the function window displayed on the LCD.
Front panel: Function keys (x10) / Ten keys Rear panel: LCD controler / Force unit selector / Language selector
Parameter setting function (i) Traction mode selecting, (ii) High force setting, (iii) Low force setting, (iv) Hold time setting, (v) Hold time setting, (vi) Rest time setting, (vii) Traction speed setting, (viii) Treat time setting Program setting function (i) Registration of programs, (ii) Launch of program Configuration setting function (i) 18-kg check ON/OFF, (ii) LCD brightness regulation, (iv) Kg/lbs selection , (v) Selection of language for screen display, (vi) Traction force calibration
START key (membrane switch x 1) STOP key (membrane switch x 1) Clear key (membrane switch x 1)
Traction start Traction stop Clear the entered parameters
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Display section
LCD: 121x 92mm, 320 x 240 dots
10 languages supported Traction accuracy: 1kg: -0/+2 kg, 2-20 kg: ±2 kg, 21-50 kg: ±2.5kg, 51-90kg: ±3kg (selectable in 1 kg steps)
High force range: 1 - 90kg (1 - 198lbs) Low force range: 0 - 89 kg (0 - 197 lbs)
[Pulling time for 0 to 90 kg] Standard speed; 15 second, 1/2; 30 s, 1/4; 60 s, 1/6; 90 s, 1/8; 120 s
Traction speed: Standard, 1/2 or 1/3 Traction output section
Traction hold time: 0 - 99 seconds Traction Rest time: 0 - 99 seconds Treatment time range: Intermittent = 1- 99 min., Static = 1- 99 min. Traction modes: 8 modes
Selectable in 1-sec steps Selectable in 1-sec steps Selectable step by step (setting below 1 kg/step not permitted) Selectable in 1-sec steps
Program memory: 20 memories Traction force detection section
Traction force sensor (potentiometer x 1)
Traction force is detected
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Rev.1 May 21st, 2012
Display section
LCD: 121x 92mm, 320 x 240 dots
10 languages supported Traction accuracy: 1kg: -0/+2 kg, 2-20 kg: ±2 kg, 21-50 kg: ±2.5kg, 51-90kg: ±3kg (selectable in 1 kg steps)
High force range: 1 - 90kg (1 - 198lbs) Low force range: 0 - 89 kg (0 - 197 lbs)
[Pulling time for 0 to 90 kg] Standard speed; 15 second, 1/2; 30 s, 1/4; 60 s, 1/6; 90 s, 1/8; 120 s
Traction speed: Standard, 1/2 or 1/3 Traction output section
Traction hold time: 0 - 99 seconds Traction Rest time: 0 - 99 seconds Treatment time range: Intermittent = 1- 99 min., Static = 1- 99 min. Traction modes: 8 modes
Selectable in 1-sec steps Selectable in 1-sec steps Selectable step by step (setting below 1 kg/step not permitted) Selectable in 1-sec steps
Program memory: 20 memories Traction force detection section
Traction force sensor (potentiometer x 1)
Traction force is detected
Rev.1 May 21st, 2012
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The treatment is promptly ceased, traction force is decreased to zero and E2 error is displayed when the switch is pressed. , direction, stops truction force to zero and E3 error
Remote patient switch manipulated by patient Traction force abnormality detection
If wire breakage is detected in the load cell, traction is interrupted (E3) Traction is interrupted, and E2 is displayed.
Sensor wire breakage detection Safety functions
Interruption of traction with patient switch System check >18-kg check
Executed when power is turned on and when Warning is issued when traction force is set to more Uses CPU's built-in WDT.
Monitoring for CPU malfunction OK key (membrane switch x 1)
To confirm selected parameters
Traction force calibration function
Factory Calibration
Control signal data from tractions performed at 5 kg, 50 kg, and 90 kg are stored in the EEP memory and linear approximation is applied.
Timer function
Max. 99 min.
Selectable from 1 to 99 min. in 1-min. steps.
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Rev.1 May 21st, 2012
The treatment is promptly ceased, traction force is decreased to zero and E2 error is displayed when the switch is pressed. , direction, stops truction force to zero and E3 error
Remote patient switch manipulated by patient Traction force abnormality detection
If wire breakage is detected in the load cell, traction is interrupted (E3) Traction is interrupted, and E2 is displayed.
Sensor wire breakage detection Safety functions
Interruption of traction with patient switch System check >18-kg check
Executed when power is turned on and when Warning is issued when traction force is set to more Uses CPU's built-in WDT.
Monitoring for CPU malfunction OK key (membrane switch x 1)
To confirm selected parameters
Traction force calibration function
Factory Calibration
Control signal data from tractions performed at 5 kg, 50 kg, and 90 kg are stored in the EEP memory and linear approximation is applied.
Timer function
Max. 99 min.
Selectable from 1 to 99 min. in 1-min. steps.
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program function
Freely programmable: 10 categories
Buzzer function
Separately excited piezo-electric buzzer (φ20)
Error detection function
Error E1 Error E2 Error E3 : just initial system check Error E3 : 30 second after motor on with no traction force.
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Rev.1 May 21st, 2012
The user can save or load settings freely. Buzzer beeps in constant intensity when an active or an inactive key is pressed, when traction ends, or when an error is issued. Traction force is decreased. Recalibration is required. Disconnection of the patient cable or activation of the patient switch was detected. Defect of the panel switch, the sensor wiring or the CPU board was detected. Improper situation occurred with Wave washer, Pinion hexagon socket screw or the Motor.
Rev.1 May 21st, 2012
program function
Freely programmable: 10 categories
Buzzer function
Separately excited piezo-electric buzzer (φ20)
Error detection function
Error E1 Error E2 Error E3 : just initial system check Error E3 : 30 second after motor on with no traction force.
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The user can save or load settings freely. Buzzer beeps in constant intensity when an active or an inactive key is pressed, when traction ends, or when an error is issued. Traction force is decreased. Recalibration is required. Disconnection of the patient cable or activation of the patient switch was detected. Defect of the panel switch, the sensor wiring or the CPU board was detected. Improper situation occurred with Wave washer, Pinion hexagon socket screw or the Motor.
Rev.1 May 21st, 2012
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Rev.1 May 21st, 2012
Force
LCD
Safety
kg /lbs
Red
Yel
Org Red
Brn Grn
CN52 1
CN53 1
3
2 3
P1: 5V P4: 12V P7: GRD
Grn Yel
Pur
P.S.
7 CN55 1
4
Red 12V Blu 15V Yel 25V
PC2 IC54 -24V Reg
IC53 5V Reg
IC52 12V Reg
IC51 12V Reg
IC8,10,11,12,14,15 CN3 CN1 1
12
CN4(LCD) 1
Blk
12
8
Brn
Gry Wht Limit
Red 9
LCD Inverte r
Noise Filter
10V
CN54 1
1
CN56 1
4
Wht
P4 : 5V P5 : 0V P11: -24V (LCD) Panel Switch Board
2
REC51 17v Reg
AC Inlet
L.Blue
Blk
Blk Red
P3-P4:≒1７V Pink DC The solenoid does not pull the idling gear lever in full stroke until the motor rotates.
M
LCD Module
Rev.1 May 21st, 2012
8
CN5 L.. BLU
3,4,
AC 220v BRN REC2 AC 16v
4
1
Check point 1
M Froward Rotation
User SW 1
3 4
(GND) CN55/Pin7&8
SSR1
5 1
7
BLK RED
RL1-1(make) 1
IC2
3
+12v
9
SSR2 4 Reverse Rotation (GND) CN55/Pin7&8
Low
2
WHT
CN56 Froward Low Reverse Low
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Rev.1 May 21st, 2012
CN5 L.. BLU
3,4,
AC 220v BRN REC2 AC 16v
1
Check point 1
M User SW
1
4
Froward Rotation 3 SSR1
4 (GND) CN55/Pin7&8
5 1
BLK RED
7
RL1-1(make) 1
IC2
3
+12v
9
SSR2 4 Reverse Rotation (GND) CN55/Pin7&8
WHT
2
Low
CN56 Froward Low Reverse Low
Rev.1 May 21st, 2012
9
4
AC 12v
REC51 1
3 If not, REC1 is faulty.
C51
4
2 To TR51(K)
REC52 AC 15v
4
CN54
Check point 4
Check point 2
Solenoide
PC51 1
1
4
3
TR51 Check point 3
(GND) CN55/Pin7&8 1
IC52
RL1-1(make)
3
To REC1(-)
REC53 REC52 REC51
+
(GND) CN55/Pin7&8
REC51
7v
1
2
10
4
3
Rev.1 May 21st, 2012
4
AC 12v
REC51 1
3 If not, REC1 is faulty.
C51
4
2 To TR51(K)
REC52 AC 15v
Solenoide
PC51 1
1
4
CN54
Check point 4
Check point 2
4
3
TR51 Check point 3
(GND) CN55/Pin7&8 1
IC52
RL1-1(make)
To REC1(-)
3
REC53 REC52 REC51
+
(GND) CN55/Pin7&8
REC51
7v
1
4
2
3
Rev.1 May 21st, 2012
10
REC3 AC 25v
4
1
+35v
3
IC54 1
(GND) CN55/Pin7&8 AC 16v
1
4
+22.5v 1
IC52 2
REC2 (GND) CN55/Pin7&8 1
IC51
CN4
Check point 5
2
11 VEE:LCDPS (GND) CN55/Pin7&8
+12v 1
Check point 6 IC53 (GND) CN55/Pin7&8
2
(GND) CN55/Pin7&8
4
Check point 7
+12v
To LCD 12 BackLight
(GND) CN55/Pin7&8
5
LCD DATA IC19 LCD Control
11
VDD:LogicPS
VSS:LogicGND
10 9 VSS:LogicGND 8 7 3 CL2:DataCapture 2 CL1:DataLatch 1 FLM:ScanStart
Rev.1 May 21st, 2012
REC3 AC 25v
4
1
+35v
3
IC54 1
(GND) CN55/Pin7&8 AC 16v
1
4
+22.5v 1
IC52 2
REC2 (GND) CN55/Pin7&8 1
IC51
CN4
Check point 5
2
11 VEE:LCDPS (GND) CN55/Pin7&8 Check point 6 IC53
+12v 1
(GND) CN55/Pin7&8
2
(GND) CN55/Pin7&8
4
Check point 7
+12v
5
LCD DATA IC19 LCD Control
Check the continuity of
No
Yes
Step 2
Change the
Measure the secondary
No.1 card P1-2 = AC 12V P3-4 = AC 16V No
VSS:LogicGND
10 9 VSS:LogicGND 8 7 3 CL2:DataCapture 2 CL1:DataLatch 1 FLM:ScanStart
Rev.1 May 21st, 2012
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The power cord is OK.
To LCD 12 BackLight
(GND) CN55/Pin7&8
Step 1
VDD:LogicPS
Step 1
Check the continuity of
The power cord is OK.
No
Yes
Step 2
Change the
Measure the secondary
No.1 card P1-2 = AC 12V P3-4 = AC 16V No Yes Change T1 or
Step 3
Measure the voltages of 5V, 7V, 12V, -24V
5V : CN2-3/CN3-7 7V : CN4-3/4 12V: CN3(LCDINV)-1/2
No
Chang IC3(5V) or IC2(12V), IC1(12V), IC4(-24V),
Yes
Power supply is
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Rev.1 May 21st, 2012
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Rev.1 May 21st, 2012
No LCD display
Step 1
Adjust the LCD control knob located on the
Character became readable.
Yes
No LCD is OK. Step 2
Measure +12V for LCD inverter.
+12V : CN3-1/2
No
Yes Change IC12 or Step 3
Measure +5V, -24V for LCD module
+5 : CN4(LCD)-4 0V : CN4(LCD)-5
No
Yes Change IC3(5V), IC4(-24V), or Step 3
Change LCD inverter
No LCD lights up Yes Change LCD Change LCD inverter, Inverter harnesses
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Rev.1 May 21st, 2012
Step 1
Turn power on, start 5kg traction and
Yes
The wire rope is pulled out smoothly.
The wire winding mechanism is returned to normal.
No Go to Troubleshooting (4)
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Rev.1 May 21st, 2012
Step 1
Turn power off. Pull out the wire rope in full length by hand, then slowly
Yes
The rope is smoothly pulled into the unit. No
Step ２
Rope winding mechanism is working normal.
Check the wire rope path.
Yes
The wire rope is off the track.. No
Step ３
Go to Troubleshooting (6)
Check the wire
The wire rope is entangled, surface is
Yes
No
Change the wire rope.
Change the mechanical assembly.
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Rev.1 May 21st, 2012
Step 1
Turn the power off.
Yes
The wire rope is pulled out properly.
Go to Troubleshooting (4)
No
Step 2
Check the wire rope path.
Yes
The wire rope is off the track.. No
Step 3
Go to Troubleshooting (6)
Check the gear block.
The relay puley is separated from the
Yes
No
Go to Troubleshooting (4)
Go to Troubleshooting (7)
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Rev.1 May 21st, 2012
Step 1
Turn power off. Check the puley, the 1st & 2nd rollers, the
Yes
The pulley and the rollers rotate
Go to Troubleshooting (4)
No Change the pulley or the rollers.
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Rev.1 May 21st, 2012
The idling gear is not
Check the electromagnetic solenoid.
The planger is released.
Yes
No Check the gear lever.
Measure the solenoid driving voltage.
The idle gear is separated from the 0V : Pin3 - Pin4 of CN4.
Yes No
No Measure the status of solonoid driving.
Yes
Change the mechanical assy.
Change the wire assembly or the
Change the solenoid.
Yes High : Pin1 of IC23 Change IC23, PC1, or TR1. Change No.1 card.
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Rev.1 May 21st, 2012
Perform "2-2 Easy Calibration" on page 4 of the service manual.
E1 error is
No
Yes System is returned to normal.
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Rev.1 May 21st, 2012
Connect the patient switch properly to CN3.
E2 error is
Yes
No System is returned to normal.
Replace the
E2 error is
Yes
No System is returned to normal.
Check +12V
Yes +12V: CN3-P3/P7 No Change PC2 or No.1 card.
Check IC2
Yes +12V: IC2 OUT/GND No Change RL1 Change IC2 or
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Rev.1 May 21st, 2012
Check the traction sensor
The sensor circuit is disconnected.
Yes
No Connect the sensor hurness
Change the sensor wire. No E3 error is No
E3 error is
Yes Yes Complete
Complete
Change the potentiometer.
E3 error is No
Yes
Complete
Change No.1
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Rev.1 May 21st, 2012
Check the rope.
Yes Rope is cut. No
Change the Rope.
Check the gears.
Gears are ground
Yes
No
Change the Gear along the section 3-6 on page 18 of the Service Manual_TM-300.
Check the inner hurness of the motor..
The hurness is properly connected.
Yes
No
E3 is cancelled Yes
No
Complete
Connects the hurness. Change the No E3 is cancelled Yes
E3 is cancelled Yes
Change the No1 card.
Complete
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Rev.1 May 21st, 2012
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Rev.1 May 21st, 2012
(1) Press "A" key and "D" key simultaneously then turn power switch on. (2) Initial check window is displayed and initial check is start. (3) The system enters test mode with beep sound generated by CPU. (4) The initial check operation finally opens key check window then wait next key input. (5) Press "OK" key 9 times to display "Initialization function" window. (6) Select "Parameters" with ▲ and ▼ keys. (7) Press "OK" key more than 3 second to initialize selected item. (8) Turn power off.
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Rev.1 May 21st, 2012
Step 1 Step 2 Step 3
Turn the pully ９０゜to the right. (See Fig. 1) Pull the pulley out from the upper panel, then put the pulley on the left side of the unit. (See Fig.1, Fig.2 and Phto2) Untie the rope from the snap hook. (Fig. 3)
Fig 2
Fig 1
Photo
Fig 3 Photo 2 Step 4 Step 5 Step 6
Remove the six screws on the botom of the upper cover. (See Fig.4) Pull out the upper cover and place it on the left side of the unit. (See Fig.5 & Photo 3) Tentatively tie the rope on the snap hook. (See Photo 3)
Total six screws
Fig 4
Fig 5 Tie the loop clutch with
Photo 3
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Rev.1 May 21st, 2012
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Rev.1 May 21st, 2012
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Rev.1 May 21st, 2012
1 Remove the ro e holder b removin the three screws. Lock the wheel ear 2 Pull the most wire ro e out from the drum. RopeHolder
Fig 1
3 Rotate the drum to the an le where two socket screws are visible. (4) Lock the wheel gear by putting the I shaped tool between the wheel gear and the idler gear.
I shaped gear locking tool
Wheel gear
Hexagon Fig 2
Photo 1
(5) Push the rope into the drum until the rope taile comes out from the oposit side See Fig 3. (6) Cut the rope tail off and take the rope out from the mechanism.
Fig 3
Fig 4
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Photo 2
Rev.1 May 21st, 2012
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Rev.1 May 21st, 2012
(1) Check the contents of the wire rope kit. Wire rope with a hook Stop ring I shaped tool Hexagon wrench key (1.5mm) Fig. 1
(2) Bend the rope taile to the direction of its natural curl at the 35mm from the rope See Fig. 2 (3) Pass the rope taile through the drum hole. See Fig.3 and Fig. 4. Hole entrance
Fig. 2
Fig. 3
Hole entrance
Fig. 4
(3) Attach the stop ring at the end of the rope and narrow the slit of the ring by using ra
pliers.
Stop ring Fig. 5
Slit Fig. 6
(4) Pull the rope out at the drum entrancerope hole firmly until the stop ring is caught at the drum hole, just under the two screws on the other side of the drum. Two screws
Stop ring
Fig.7
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Rev.1 May 21st, 2012
io
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Rev.1 May 21st, 2012
Recovery method from unexpected drum release by slipping out of the drum locking jig between the wheel gear and the relay gear during the rope replacement. (1) Rotate the wheel gear clockwise 19 turns and lock the gear with the drum locking jig. Then continue the rope replacement.
Count the drum revolution number by using the rope hole Rotate the wheel gear in clockwise.
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Rev.1 May 21st, 2012
Step 1
Disconnect the harnesses from CN1, CN2, CN3, CN4, CN5, CN6. Disconnect the harnesses from the LCD inverter and the LCD.
CN
CN
CN CN
CN Step 2
CN
Take the grounding harness from the No.1 card and upper cover. (See Photo 1)
Step 3
Disconnect the two harnesses comming from the membrane board.
Step 4
Remove the six (6) nuts from the No.1 card.
Harness of LCD Step 5
Take off the No.1 card gently from the upper cover.
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Rev.1 May 21st, 2012
Regular calibration
Please see the Regular Calibration (2) in the case that the system displays E1 error immediately after power on and cannot enter the parameter setting window.
(3) Calibration procedure Step 1 Press "START" key to open the "Set parameters" window. Step 2
Press "STOP", "3", "6" and "9" keys simultaneously for five seconds so that "5Kg Calibration" windo opens on the LCD.
Step 3
Keep pressing "8" key to increase traction force up to 5kg +/-0.1kg on the force gauge. If the traction is exceeded 5kg, press "2" key until the traction becomes 3kg, then increase the tension to 5kg by pressing "8" key.
Step 4
Press "5" key to save the setting.
Step 5
Increase the traction up to 50kg +/-0.2kg in the same manner as Step 3.
Step 6
Save the setting by pressing "5" key.
Step 7
Increase the traction up to 90kg +/-0.2kg in the same manner as Step 3.
Step 8
Save the setting by pressing "5" key.
Step 9
Confirm that "Calibration is complete" is displayed on the LCD and all mechanical mevemnet is ceased.
Step 10 Power off the device. Step 11 Turn Power on of the device then confirm that E1 error is not displayed on the LCD.
Regular calibration (2) In the case that the system displays E1 error immediately after power and cannot enter the parameter setting window. (3) Calibration procedure Step 1 Press "START" key to open the "Set parameters" window. Step 2
Press "STOP", "3", "6" and "9" keys simultaneously for five so that "5Kg Calibration" windo opens on the LCD screen.
Step 3
Keep pressing "8" key to increase traction force up to 5kg +/-0. on the force gauge. If the traction is exceeded 5kg, press "2" key until the traction becomes 3kg, then increase the tension to 5kg by pressing "8" key.
Step 4
Press "5" key to save the setting.
Step 5
Increase the traction up to 50kg +/-0.2kg in the same manner Step 3.
Step 6
Save the setting by pressing "5" key.
Step 7
Increase the traction up to 90kg +/-0.2kg in the same manner Step 3.
Step 8
Save the setting by pressing "5" key.
Step 9
Confirm that "Calibration is complete" is displayed on the LC all mechanical mevemnet is ceased.
Step 10 Power off the device. Step 11 Turn Power on of the device then confirm that E1 error is not displayed on the LCD.
on
1kg
s
s
nd
The spring must withstand 120kg.
Fix TM-400 on the bed with four bolts. The table must withstand 120kg pulling
