Mettler Traction 4000 Maintenance Manual
Contents
1. 5 19 c el rs E L EN nm tb amp m x cm x a ac 4 Pea N l ganana DA nen 213 og D S 4 E ZEN c E vik gt 9t c HVO8 T108LNOJI YOLOW 173 CONTROL BOARD 1 MOTOR TOTS 9515 962 52 ety 292 D i 2 Je men SZIH rd o 5 5 sto AN T lt FH pA a G a AN EI d a nO 6 ecru e US m LL 2 C zza 978 ref I 92H I 4 ved E sau a D p LJ 464 EG sa een zzs am D Tf D Jr 5 CON KEYPAD 4 mo mm Do gt NA or lt ea 20 MTD 4000 Maintenance Manual Rev _7 15 11 4 3 Motor Control Board Silkscreen aci Part No Name of Material Troubleshooting ASY3324X 4000CE Motor Control Board E 2 E 3 E4 E 5 E6 E 8 E A Failure of power ASY3323X ME4000 Motor Control Board No output Mettler Electronics Corp Rev _7 15 11 4 4 A D Board Silkscreen Top Part No Name of Material Troubleshooting ASY2900X 4000 A D Board E 7 E 8 4 5 A D Board Silkscreen Bottom 22 MTD 4000 Maintenance Manual Rev _7 15 11 sec2. 4000 Mettler Traction Decompression Maintenance Manual Distributed by 2 LECTRONICSO corp 1333 S Claudina Street Anaheim California 92805 U S A Call toll free 800 854 9305 Tel 1 714 533 2221 FAX 1 714 635 7539 http www mettlerelectronics com Email mail mettlerelectronics com IR9 63 Rev F 7 15 11 Copyright O 2010 2011 by Mettler Electronics Corp Anaheim CA Mettler Electronics Corp Rev _7 15 11 MTD 4000 Maintenance Manual Rev _7 15 11 Table of Contents Section Title Page List of Figures 4 Limited Warranty 5 1 Introduction T 1 1 The Manual T 1 2 The MTD 4000 T 1 3 Precautions T 1 4 Labels 8 1 5 Calibration and Maintenance Schedule 8 1 6 Tools and Fixtures for Maintenance 8 Specifications 11 Configuration and System Chart 13 3 1 MTD 4000 Configuration 13 3 2 MTD 4000 Disassembly Diagram 13 3 3 Mechanical Structure 14 3 4 Printed Circuit Board Placements 14 9 5 15 3 6 Assembly Parts 16 Il Assembly Parts II 17 4 Drawings and Diagrams 19 4 1 Main Board Silkscreen Top 19 4 2 Main Board Silkscreen Bottom 20 4 3 Motor Control Board Silkscreen Top 21 4 4 A D Board Silkscreen Top 22 4 5 A D Board Silkscreen Bottom 22 5 Troubleshooting Guide 23 5 1 Simple Troubleshooting 24 5 2 Complete Troubleshooting 26 5 3 Simple Miscellaneous Troubleshooting 31 5 4 Complete Miscellaneous Troubleshooting 32 Replacement
3. HOLD 20 0 75Kg REST 10 0 75Kg HOLD Kg REST Kg HOLD 30 1 5Kg gt REST 20 0 75Kg HOLD Kg REST Kg HOLD 40 1 5Kg gt REST 30 1 5Kg HOLD Kg REST Kg HOLD 50 1 5Kg REST 40 1 5Kg HOLD Kg REST Kg HOLD 60 2Kg gt REST 50 1 5Kg HOLD Kg REST Kg HOLD 70 2Kg gt REST 60 2Kg HOLD Kg REST Kg HOLD 80 2Kg gt REST 70 2Kg HOLD Kg REST Kg HOLD 90 2Kg gt REST 80 2Kg HOLD Kg REST Kg VU m s O D D ect 5 O et UD lt O D gt Oo 3 5 O D 5 Q eg 2 Imperial System HOLD 22 2Ibs gt REST 4 2lbs HOLD lbs REST lbs HOLD 110 3Ibs gt REST 66 3Ibs HOLD lbs REST lbs HOLD 198 4lbs REST 132 4lbs HOLD lbs REST lbs Supervisor Inspector RWO9021602 DD Mettler Electronics Corp Rev _7 15 11 Manufactured in Taiwan by ZMI Electronics Limited ZMI Electronics Limited is a participant in Good Manufacturing Practices and is qualified as an ISO 9001 and ISO 13485 supplier Notified Body Det Norske Veritas Certification AS Veritasveien 1 1322 HOVIK Norway 0434 56
4. Use the rotary dial to adjust REST value to the recorded RELEASE value on the Appendix Annual Calibration Table If the values already match please go to next step Press SET button to save This point is calibrated Press START button to check the real PULL force If the real PULL force on the force meter does not match the HOLD PULL value within tolerance please repeat annual calibration from step one of this section until acceptable Press START button to check the real RELEASE force If the real RELEASE force on the force meter does not match the REST value within tolerance please repeat annual calibration from step one of this section until acceptable Press STOP button to complete saving If the PULL and RELEASE calibration points are within tolerance see Test Range Spec on Annual Calibration Table and you wish to calibrate another point press the SPEED button and go back to step one of section 7 2 1 If you are done with the Annual Calibration press the STOP button again to release tension on the cable Note To adjust the value in kg the REST value can match the value on force meter However to adjust the value in Ib the REST value may experience increased tolerance error depending on force meter sensitivity MTD 4000 Maintenance Manual Rev _7 15 11 7 4 Calibrate the Next Point 1 Press SPEED button to go back the main calibration menu Use the rotary dial to adjust the next calibration point Fol
5. misuse or neglect of the Product voids this warranty Except as specifically set forth above Mettler Electronics Corp makes no warranties express or implied including without limitation any implied warranty of merchantability or fitness for a particular purpose with respect to the Product If any implied warranties apply as a matter of law they are limited in duration to one year Mettler Electronics Corp shall not be liable for any indirect special consequential or incidental damages resulting from any defect in or use of the Product Any legal action brought by the buyer relating to this warranty must be commenced within one year from the date any claim arises and must be brought only in the state or federal courts located in Orange County California some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to the buyer This warranty gives the buyer specific legal rights and the buyer may also have other rights which vary from state to state Mettler Electronics Corp Rev _7 15 11 MTD 4000 Maintenance Manual Rev _7 15 11 Section 1 Introduction 1 1 The Manual This manual is intended to aid qualified biomedical engineers and technicians in testing servicing and repairing MTD 4000 s It contains an equipment description operating procedures theory of operation test pr
6. 1 0 4416 216 2 46 11016 3 112 19816 Alb Supervisor Inspector 93 Mettler Electronics Corp Rev _7 15 11 F 9 Force Test Main Board S N Device S N Date O 110V E s Voltage 5507 O Vibration Test Before n a Ll Vibration Test After n a X Origin Traction Kg Initial traction force hooking on the force meter before start Origin Traction Check 0 6 1 25Kg The initial traction force must locate in range of 0 6 1 25kg h Test Range and Specification for Metric System Metric Tolerance 1 0 20 Kg 0 75 Kg 2 21 50 Kg 1 5 Kg 3 51 90 Kg 2 Kg Metric kg Test kg Metric kg Test kg Metric kg Test kg Metric kg Test kg Setting Recording System Recording System Recording Setting Recording Ju pnscsj J gt Supervisor Inspector RW09021603A Note The numbers with grey area are for the test of non calibration points 54 MTD 4000 Maintenance Manual Rev _7 15 11 Quality Acceptance Checklist Main Board S N Device S N Date Voltage Q 110V 1220V Force meter No Testitem Note _ PT _ 4 Pulling Speed Test factory only I T1 O D o et 1 D et O N lt o et D 3 5 m 2 T Oo h 5 O ct 5 HOLD 5 0 75Kg gt REST 2 0 75Kg HOLD Kg REST Kg HOLD 10 0 75Kg REST 5 0 75Kg HOLD Kg REST Kg
7. 17 6 24 2 30 8 37 4 44 0 50 6 57 2 63 8 70 4 77 0 83 6 90 2 96 8 103 4 110 116 123 129 136 143 149 156 162 169 176 182 189 195 Note The end points 2kg 4lbs and 90kg 198Ibs cannot be calibrated manually for safety reasons Note All other points in between can be manually calibrated 1 Turn the force meter and press the button 2 Connect the traction cable hook to the fixed force meter as shown below Note The angle of traction cable must be close to a normal therapy situation nearly 90 x20 Note The force meter should be calibrated regularly o On the MTD4000 traction system press and hold the SET button and turn on the system ON switch is in the back by the power cord Continue to hold the button for 3 sec until the screen displays 0 Set the Units on the traction system to the same as the force meter both in Kilograms or both in Pounds To change the Units press the START button and use the SET button to switch between kg and Ibs Press STOP to save Units selection Turn the rotary dial to F 3 mode Press the START button to enter F 3 mode The ACTUAL display will show CAL Press the STOP button to begin the annual calibration the REST display will show the first calibration point 5kg 11 0 Ibs 7 2 Test amp Record the Values Press the SET button and use the rotary dial to select the point to be calibrated Note Please use Appendix Annu
8. ANYMORE 3 Connect the traction cable to the hook of force meter 4 Press and hold SET button and turn on the system 5 Turn the dial to F 4 mode and press button The system will display LSF Limit Switch Function and touch the limit switch and start beeping 6 Please press the button System will return to about 88kg and pull again until touching the limit switch Check the value on the force meter The range X must be between 94 X 97kg If the force limit is in range and the displays of HOLD and REST show the value between 1 to 4094 corresponding A D value press the button to save the limit value The system will release the force automatically Rotate the rotary dial to F 6 and press button to check the saving value in kg is within the range Restart the system and run the automatic calibration procedure If the force limit is out of the range press and hold the button to release the force and adjust the placement of limit switch through the following procedure a On the Limit Switch assembly clean the threadlocker adhesive from the heads of the screws holding the bracket in place Loosen the two screws using a 2mm hex Allen key and move the switch and its mounting bracket back towards the edge of the plate b Run the F 4 mode again c Push the limit switch forward to lightly touch the mechanical drive until the system beeps It is in 004 Mettler Electronics Corp Rev F_ 7 15 11 the right position f
9. Corp Rev _7 15 11 1 4 Labels Each medical device must be uniquely identified for traceability and device history This is accomplished with serial numbered labels unique to each device Product labels provide performance data and must remain on the device at all times Preserve label integrity during repair and servicing when actions such as removing access covers could cause label damage Please include model and serial numbers when requesting service assistance from the factory including serial number of printed circuit board assembly as applicable 1 5 Calibration and Maintenance Schedule Device Calibration Period Timing To ensure the output force is correct MTD 4000 traction device needs to be regularly calibrated every 1 year or every time while the maintenance is done Please refer to the Section 7 for device calibration Cable Replacement Period Timing The traction cable shall be replaced every 2 years for maintenance Please refer to the Section 8 for cable replacement The MTD 4000 must be recalibrated after cable replacement 1 6 Tools and Fixtures for Maintenance General Tools tem Name Specification Open end Torque orque Hex Wrench No 1 5 2 2 5 3 4 5 Range 6 60 Kg Torque Socket EI No 10 Torque Range 6 60 Kg Philip Torque TEE Standard Type Torque Range 6 60 Kg 5 Piers a ul Holding cutting and bending the parts egree 6 Tweezers Normal Tw
10. gt Mettler s QC gt Rest the setting gt END Replacement Parts Traction Cable Procedure F 5 auto calibration gt F 9 Force Test gt F 3 if necessary gt Burn in gt Mettler s QC gt Rest the settting gt END Procedure Replacement Parts Clutch Module Drive Gear Procedure F 9 Force Test gt 3 if necessary gt F A Burn in gt Mettler s QC gt F 7 Rest the setting gt END Procedre8 Replacement Parts Motor Procedure F 8 traction speed test gt adjust the VR on the SSR if necessary gt double check 8 traction speed test gt Burn in gt Mettlers QC gt Rest the setting gt END 52 MTD 4000 Maintenance Manual Rev _7 15 11 Appendix Annual Calibration Table Worksheet Nr Date I Device S N Unit Setting O kg L1 Ib Software Version Original Tension kg Origin Tension Range Check 0 6 1 25 kg Original Tension lbs Origin Tension Range Check 1 3 2 76 Ibs Record the value Record the value Check Record the value Record the value Chec before calibration after calibration before calibration after calibration k run ROS pun PO sovo ng m TES se Joafsla m mee Joe m x Test Range and Specification for Metric System 1 0 20Kg 0 75kg 2 21 50kg 1 5kg 3 51 90kg 2kg x Test Range and Specification for Imperial System
11. make sure the harness cable is properly connected Step2 Press START Check the solenoid valve is acting pull release If yes jump to Step4 Step3 If not please replace solenoid valve If problem still occurs please replace motor control board Re run Step2 Step4 Press START Check the clutch module is in mesh If yes end the process Step5 If not please replace clutch module Re run Step2 MTD 4000 Maintenance Manual Rev _7 15 11 E 3 Micro switch of clutch is damaged Step1 Open outer casing Step2 Press STOP Check the clutch module is touching micro switch If yes jump to Step4 Step3 If not please replace clutch module Re run Step2 Step4 Check motor is stopping action while clutch module touching micro switch If yes end the During treatment Press STOP clutch module touching micro switch Replace clutch module Replace micro switch When touching micro Replace motor ich owen ee P control board process Replace main Step If not please replace micro board switch Run step2 If the problem still occurs please replace motor control board E 4 Emergency switch patient safety switch has been pressed Replace Step1 Make sure the emergency stop a emergency switch is properly connected Check switch cable the error is occurring when it is pressed If
12. yes end the process Step2 If not please replace emergency Ib Hue vene switch cable Check again If the problem still occurs please replace motor control board error occurring in pressing emergency switch cable E 5 Pull strength reached limit Replace limit N 3 switch system staying on the Step1 Restart the system If the problem is still occurring run Step2 Step2 Check system is staying on the output status If yes run Step4 Yes Step3 If not please replace limit switch Check again If the problem is still occurring please replace motor control board Step4 Check the error is occurring in output status Replace motor control board No Reinstall the a placement of limit Is error occurring in touching limit switch switch touching limit switch If yes end the process Step5 If not please reinstall the placement Vas of limit switch Run Step4 Mettler Electronics Corp Rev _7 15 11 E 6 Force Meter communication NG connected and the connection cable is not broken E 7 LTC1400 A D Converter no signal or NG Replace signal transmission cable Replace A D board Replace main board E 8 Sudden and abnormal pull strength Restart system Is erre still occurring If yes run 2 2 Run automatic calibratio
13. Axle Fixed Set Screws from the cable cylinder Upper Casing Baffle Plate Output Pulley Axle Fixed Screw Cable Cylinder e Remove the nut from the end of the Traction Cable where it is installed in the Cable Cylinder Remove the cable from the cylinder f Unscrew and loosen the three main Cable Retaining Plates see below using a 3mm Hex Allen Key 42 MTD 4000 Maintenance Manual Rev _7 15 11 h The detachment sequence of the Traction Cable from the pulley is as follows Step 1 Detach one C shape Retaining Ring a from Output Pulley Axle b and remove the Output Pulley Axle b from Output Pulley and hub c amp d 2 Remove the Output Pulley from the hub and remove the old Traction cable After removing please confirm all items are located and nothing is missing Mettler Electronics Corp Rev _7 15 11 Items Confirmation Output Pulley Output Pulley Axle amp 0 b Step 1 2 2 b Step 2 3 a C shape Retaining Ring Traction Cable and Hook 8 2 Traction Cable Installation a Before re assembly please confirm all items are located and nothing is missing Step 1 Place a new Traction Cable e in the Output Pulley c amp d as shown Step 2 Insert the Output Pulley Axle through Output Pulley and hub Install a C shape Retaining Ring to secure the Output Pulley Axle Items Confirmation Output Pulley Output Pulley Axle step 1 St
14. Parts 35 Annual Calibration Procedure 37 7 1 Start the Annual Calibration 37 7 2 Test amp Record the Values 37 res Adjust amp Save the Calibration 38 7 4 Calibrate the Next Point 39 8 Traction Cable Replacement 41 8 1 Traction Cable Disassembly 41 8 2 Traction Cable Installation 44 9 Factory Mode and Repair Procedure 49 9 1 Factory Mode Setting 49 9 2 Repair Procedure with Factory Modes 51 Appendix Annual Calibration Table 53 F 9 Force Test 54 Quality Acceptance Checklist 55 CE Declaration 56 7 Mettler Electronics Corp Rev _7 15 11 MTD 4000 Maintenance Manual Rev _7 15 11 Limited Warranty The MTD 4000 generating unit is warranted against defects in materials and workmanship for a period of two years from date of purchase During the applicable warranty period Mettler Electronics Corp will at its discretion either repair or replace the Product without charge for these types of defects For service under this warranty the Product must be returned by the buyer within the applicable warranty period to Mettler Electronics Corp Shipping charges to and from Mettler Electronics Corp under this warranty must be paid by the buyer The buyer must also include a copy of the sales receipt or other proof of the date of purchase If the Product is returned without proof of the date of purchase it will be serviced as an out of warranty product at Mettler Electronics Corp s prevailing service rates Alteration
15. Step1 Assemble the Cable Hook Step2 Assemble the Assistant Step3 Fixed by two C shape and Cable Sheave Sheave and its axis retaining rings Q Step4 Pass the Cable through the Step5 Connect all terminals and connectors Assemble the Rear Casing Upper Casing Main Board Motor Control Board placed and Bilateral Casings placed and Mechanical Drive to the inner cable cylinder Mettler Electronics Corp Rev _7 15 11 18 MTD 4000 Maintenance Manual Rev _7 15 11 section 4 Drawing and Diagrams 4 1 Main Board Silkscreen Top E Se N h NT FI LL al Hl e REST U Mi FI LED20 FORCE Ko H 1 U 10 DRE U 14 0 Me LED 1 I FI U e a f FI HCM I E I kt I py FI lo lo LED12 CON Jf y gt me u REST TIME HOLD TIME TREATMENT TIME Part No Name of Material Troubleshooting ASY2910X 4000 Main Board E 1 E 6 E 7 E 8 E 9 E A 7 bar display LED module NG Switch button or LED display doesn t work No output or abnormal output No Buzzer or Alarm Music Mettler Electronics Corp Rev _7 15 11 4 2 Main Board Silkscreen Bottom
16. Step2 Run Auto calibration 30 MTD 4000 Maintenance Manual Rev _7 15 11 E E Display parameter error Restart the system Step1 Restart the system to remove the error code 5 3 Simple Miscellaneous Troubleshooting 4 Problem Possible Cause Solution gt Replace fuse AC power cord NG Replace AC power cord 1 Check and make sure power cord and transformer are properly connected 2 Replace Transformer if necessary Failure to power ON Transformer NG Main board NG Replace main board Traction cable NG Replace traction cable 1 Check for damages to the mechanical driving parts in motor 2 Replace motor control board if necessary Mechanical damages 02 No output 1 Replace A D board first Circuit NG 2 Replace motor control board if the problem is not solved after solution 1 Wrong parameter of Calibrate the unit If the problem continues Abnormal output pulling force contact the manufacturer Replace main board Unit is in operation or Switch or button will work normally once unit releasing force operation or releasing force Check and make sure if harness cable is Membrane switch NG properly connected 2 Replace membrane switch if necessary Encoder NG Replace Main Board if necessary 7 bars display LED NG Replace Main Board if necessary 7 bars display LED 7 bars display LED Replace Main Board if necessary module NG Peer module NG Main control c
17. _7 15 11 2 Prepare the Traction Force Test Report RW09021603A for recording the traction force 3 Press and hold SET button and restart the system Press both OUTPUT MODE and SPEED buttons and rotate the rotary dial to the F 9 mode Hang on the traction cable on the hook of force meter Record the initial tension between 0 6 1 25 kg Press START to run the force test mode and record the validated values of each segment on the test report 4 When finish the ACTUAL display will show End and system will beep 5 Restart again Do not press SET button 6 Please confirm all initial settings are correct Factory Mode F A Burn in Test Each device is recommended to run the Burn Test after any repair The system will automatically output the traction force from low to high for several times Once the system causes any error the test will be interrupted Technicians or Engineers shall eliminate the error first and then restart the Burn Test until the test is complete Please follow the procedure 1 Press and hold SET button and restart the system Press both OUTPUT MODE and SPEED buttons and rotate the rotary dial to the F A mode 2 Press START button to start the Burn Test Each test will take 46 minutes Once the test finishes the system will return to the default status 3 Turn off the system and wait for 2 seconds Restart again and check the system is normal or not Factory Mode F b Final force test for
18. al Calibration Table for recording and saving Mettler Electronics Corp Rev _7 15 11 NO QD O N 0 gt kom 38 Se e t 10 START gt A o d U START STOP HS STOP Press the START button The PULL LED will light The traction system will PULL to calibration point value Record the PULL value from the force meter on the Appendix Annual Calibration Table Press the START button again The RELEASE LED will light The traction system will RELEASE to calibration point value Record the RELEASE value from the force meter on the Appendix Annual Calibration Table Press the STOP button The measurement for the calibration point is complete If the PULL and RELEASE calibration points are within tolerance see Test Range Spec on Annual Calibration Table and you wish to calibrate another point press the SPEED button and go back to step one of this section Otherwise go to the next section 7 3 to adjust If you are done with the Annual Calibration press the STOP button again to release tension on the cable djust amp Save the Calibration Press the HOLD button The HOLD LED will light Use the rotary dial to adjust HOLD PULL value to the recorded PULL value on the Appendix Annual Calibration Table If the values already match please go to next step Press REST button The REST LED will light
19. check again If problem still exists replace main board and check again If problem still exists replace motor and check again Step6 Check the traction cable is drawn back while motor acting If yes please adjust speed of motor through SSR If the speed of motor is still too slow due to motor aging please replace motor and end the process Step7 not please check the clutch module and Drive Gear Replace them if necessary and then run Step6 again Note If the other gearings are broken please contact manufacturer directly E b Auto Calibration Error s the unit of force meter set in Kg Set the unit in Kg Step1 Confirm the unit force meter that set in kg If yes end the process Step2 If no set the unit in Kg and try again E C VR failure Try tdrn off and on first if problem still occur che the VR piece is connected with Aechanical drive Connect the VR piece to the mechanical drive and firmly screw it Step1 Try to turn off and on first if problem still occurs check the VR piece is connected with mechanical drive If yes end the process Step2 If no please connect the VR piece to the mechanical drive and firmly screw it E d EEPROM failure Replace the CPU and burn the irmware a problem still DIEASE replace the main haaraA Step1 Replace the CPU and burn the firmware in if the problem still occurs please replace the main board
20. duction Gear ar Clutch Module Pivot Rod Mechanical Drive Limit Switch gt olenoid valve A D Board Drive Gear Cable Cylinder Micro Switch 3 4 Printed Circuit Board Placements Main Board Upper Casing Motor Control Board Rear Casing MTD 4000 Maintenance Manual Rev _7 15 11 3 5 System Chart AC 110 220 S0Hz 60Hz Electronic Part Mechanical Part tja Output Failure of Power i ps Abnormal Output Motor Speed Control LowiMonnalHigh Motor Direct Control Motor Driver Motor ON OFF Control I E A y Clutch OM OFF Contra Clutch Magnet Vinding E 2 EZ Reduction Motor Control Board Een ea Turn wheel Micro Switch E 3 Solenoid Valve RS 252 arinad ONC Limit Switch E 2 1 E SFI Interface E 5 Fvl Signal T ission eine Clutch E 4 Displacement Sensor E 7 E 8 Board Mechanical Part Main Board This system chart provides a comprehensive concept of system control logic and fast troubleshooting The 27561 traction system consists of two main parts electronics and mechanical The electronics part includes main board motor control board and A D board The main board controls all peripheral I O as a control center of traction system The motor control board receives the control signals from main board and simultaneously supplies th
21. e driving power to the AC motor The A D board is used to detect the displacement of gearing and gives feedbacks to the main board The mechanical part not only receives the driving power from motor control board and brings a displacement change to A D board but also provides special components for error detections In addition this system chart also gives an index of fast troubleshooting Technicians and mechanics can fast and easily search for the corresponding problems and solutions PPP Bwitch huttan doesn t work ques T bar Display LED Module NG LED Display doesn t work I 1 i i Mo Buzzer or Alarm Music i I I Patient Mettler Electronics Corp Rev _7 15 11 3 6 Assembly Parts Step1 Assemble the mechanical drive Step2 Place the mechanical drive transformer and limit switch on the base plate and install the A D Board on the side of mechanical drive Step3 Fix the lateral plate and partition plate and Step4 Install the Traction Rope Axis to the lateral then install the motor with reduction gear and plate Mount the Micro Switch Pivot Rod mount the cluch module on the lateral plate Solenoid Valve and Drive Gear on the lateral plate and then connect all with clutch module to be a mesh system Step5 Install and fix the other lateral plate and upper plate with ball bearing module black circle 16 MTD 4000 Maintenance Manual Rev _7 15 11 3 Assembly Parts II
22. ected Replace control panel membrane if necessary Step2 If problem still exists please replace main board Step1 Replace main board if necessary Step1 Replace main board if necessary Step1 Replace Speaker or main board if necessary Mettler Electronics Corp Rev _7 15 11 34 MTD 4000 Maintenance Manual Rev _7 15 11 Section 6 Replacement Parts PartNo Description are Motor Control Boars AO Amen are Motor Control ovas 3 OA1 13 Motor 110V E10753 03 L 150mm 8 pin p 3 96 mm 110 1 14 Motor 220 E10753 04 L 150mm 8 pin p 3 96 mm VH 220 Drap T 1 15 Fuse 1A 250V UTE001 4000CE ES FB1 22 Fuse 2A 250V ME4000 EJ me Qr5 17 Signal Transmission Cable 2a between main board and Motor control board 3 pin connector TD1 14 Signal Transmission Cable 2b between main board and Motor control board 10 pin connector Mettler Electronics Corp Rev _7 15 11 36 MTD 4000 Maintenance Manual Rev _7 15 11 Section Annual Calibration Procedure 7 1 Start the Annual Calibration The annual calibration function is designed to allow technicians to manually calibrate the traction system The following points should be calibrated kg 5 8 11 14 17 20 23 26 29 32 35 38 41 44 47 50 53 56 59 62 65 68 71 74 77 80 83 86 89 Ibs 11 0
23. eezers Picking up and manipulating the small parts Threaded fastener 7 Thread locker Gel between 1 4 and 3 4 Removable medium strength thread locker 1 Loctite 243 Cable Tie 1oO0mm x 2 5 mm Ties are used to bundle wires cables and tubing together 9 TappingToo M4orothersize Cleaning the remaining thread lockergel Calibration Tools tem Model Description ALGOL HF 100 Load bearing shall be over 100 kg Provided with RS 232 transmission interface Electronics Force signal Acquisition Point Meter ALGOL HF 100 RS 232 Transmission Interface MTD 4000 Maintenance Manual Rev _7 15 11 Force Nieter The transmission line between force meter and 2 ner PD3 0149 traction is provided and designed by ZMI please Transmission Cable contact manufacturer if needed The fixture shall be able to bear over 100 kg load to ensure stability during calibration Mettler has its own designed fixture please contact manufacturer if needed 3 Traction Fixture OTH 05 03 Mettler Electronics Corp Rev _7 15 11 10 MTD 4000 Maintenance Manual Rev _7 15 11 section 2 Specifications Power Supply Power Consumption Fuse Maximum Output Force Output Force Tolerance Traction Speed Hold Rest Period Treatment Time Treatment Mode Security System Display Patient Safety Switch Electromagnet
24. em still occurs please contact Mettler Electronics for repair service Contact Mettler Electronics for repair service Restart the unit to remove the error If the problem still occurs please contact Mettler Electronics for repair service If the Simple Troubleshooting cannot solve the problem please refer to the Complete Troubleshooting Mettler Electronics Corp Rev _7 15 11 5 2 Complete Troubleshooting E 1 EEPROM calibration data is wrong Check the Calibration Status QD Follow the right Replace the instructions and redo a MCU auto calibration Mainboard E 2 Solenoid valve is damaged Replace solenoid valve Press START Is solenoid valve acting pull release Replace motor control board Replace main Press START Replace clutch Is clutch module in module mesh 26 Step1 Check the Calibration Status first Pull LED 1 Stage Release LED 2 Stage 1 1 The limit switch didn t locate in the range 93 5 96 kg please readjust the position 1 22 Data sorting is wrong 1 3 Transmission Error 2 Stage Data Comparison with 2 12 Data sorting is wrong 2 2 Transmission Error 2 3 MCU Error Step2 For 1 2 1 3 2 1 and 2 2 please redo the auto calibration For 2 3 please replace the MCU and burn the firmware in and try again Step1 Open outer casing
25. end of Traction Cable completely back into the Cable Cylinder Firmly screw the two Axle Fixed Set Screws using a 2mm hex Allen key Replace and screw the Baffle Plate onto the Mechanical Structure 46 MTD 4000 Maintenance Manual Rev _7 15 11 Axle Fixed Screw Cable Cylinder Upper Casing Baffle Plate Output Pulley g Put the Upper Casing back in place and connect the three Connectors shown 1 2 and 3 and re fasten the two cables with Cable Ties Then grab the Traction Hook remove the Screwdriver from Drive Gear and let the Cable Cylinder slowly draw the Traction Cable back onto the cylinder track Upper Casing Drive Gear Screwdriver Connectors Cable Ties h Reinstalling the Upper Casing gt Install all screws from arrow 3 to arrow 1 See Section 7 for recalibration 48 Mettler Electronics Corp Rev _7 15 11 Lateral Casing Lateral Frame Upper Casing Part Number Traction Cable OCP0150X x 1 C shape Retaining Ring x 2 if necessary Tools No 2 Hexagon Wrench Philips and Flat Head Screwdriver Hexagon wrench 13 mm 90 Pliers MTD 4000 Maintenance Manual Rev _7 15 11 Section 9 Factory Mode and Repair Procedure 9 1 Factory Mode Setting Factory Mode F 0 UNIT ADJUSTMENT This mode provides user to exchange the system unit from either metric or imperial types 1 Press and hold SET button and restart the system The system will enter into the F 0 mode Press START and p
26. ep 2 OO C shape Retaining Ring Traction Cable and Hook b Note In case the drive gear is loose without any torque the internal spring needs to be rewound Please turn the Drive Gear counter clockwise about 11 revolutions as shown by arrow 1 Use a Screwdriver to fix the Drive Gear as indicated by arrow 2 Screwdriver Drive Gear 44 MTD 4000 Maintenance Manual Rev _7 15 11 c Pass the Traction Cable through the Ball bearing and the Upper Casing and into the blue part see lower right diagram Wind it around as shown following the direction through the three main Pulleys and up to the Cable Cylinder d Adjust the two smaller pulley retainers by rotating them against their respective vertical mounting blocks and the cable The bow of the new cable will resist the retainer from being pushed against the pulley wheel due to its initial rigidity and thus provides the proper location for the retainers Please make sure the cable is properly in the groove of pulleys Use a 13mm open end wrench to tighten the pulley retainer nuts On the large horizontal pulley install a new U Shaped bracket per section 3 of these Modification Instructions Note There is a minor interference during pulley rotation caused by the cable friction This is normal F o Put down toits support f Retainerl 5 Mettler Electronics Corp Rev _7 15 11 f Pull the
27. ic Compatibility Medical Device Classification CE Marking Operation Temperature Humidity Storage Temperature Humidity Dimension Net Weight 110V 120V 50 60Hz 220V 240V 50 60Hz 100 W Max 2 0 A 250 Vx 2 Slow Blow 1 0 A 250 Vx 2 Slow Blow 90 Kg 198 Ib 2 20 kg 0 75 kg 4 44 Ib 2 Ib 21 50 kg 1 5 kg 45 110 Ib 3 Ib 51 90 kg 2 0 kg 111 198 Ib 4 Ib FAST NORMAL SLOW 1 99 Seconds 1 99 minutes Continuous Intermittent Error Code E1 EE Yellow Green Digital LED Display 2 Pin connector push button normally close IEC 60601 1 2 Class as per MDD 93 42 EEC Annex IX CE 0434 0 40 C 90 RH under 20 60 C 90 RH under L 14 2 x W 12 2 x T 9 32 pounds Mettler Electronics Corp Rev _7 15 11 12 MTD 4000 Maintenance Manual Rev _7 15 11 Section 3 Configuration and System Chart 3 1 MTD 4000 Configuration Traction Cable Hook Emergency Cable Connector 3 RS232 Connector Power ON OFF Switch Fa p Power Cord Connector Output Pulley Lateral Casing Lateral Casing Rotary Dial Control Panel Speaker Output 3 2 MTD 4000 Disassembly Diagram Upper Casing Rear Casing F i al nn 3 n ili P ut 1 Casing 5 0 GF w Mechanical Structure Right Casing 13 Mettler Electronics Corp Rev _7 15 11 3 3 Mechanical Structure Motor Re
28. ircuit Main control circuit NG Replace Main Board if necessary Replace Main Board if necessary Board if necessary LED module NG Replace Main Board if necessary Replace Speaker if necessary No alarm music Replace Main Board if necessary Switch or button does not work No buzzer or alarm music 1 Mettler Electronics Corp Rev _7 15 11 5 4 Complete Miscellaneous Troubleshooting 01 Failure to power on Does power switch light on Replace power cord Replace fuse Replace signal transmission cable between main board a motor control board nd Replace motor control board Replace main board Replace transformer 32 Is motor acting Is traction cable drawn back Is traction cable broken Replace clutch module Replace driven gear Replace other gearing Replace signal transmission cable between main board and motor control board Replace motor control board Replace main board Replace motor Replace traction cable Step1 Make sure the power switch lights on If yes run Step3 Step2 If not please check POWER CORD and FUSE and then replace them if necessary Step3 Check the display works out If yes end the process Step4 If not please check the signal transm
29. ission cable between main board and motor control board motor control bard main board and transformer and then replace them if necessary Run Step3 and check again Step1 Check to see if the motor is acting If yes run step3 Step2 if not check the signal transmission cable between main board and motor control board motor control board main board and motor Replace them if necessary Run Step1 again Step3 Check to see if the traction cable is drawn back If yes end the process Step4 If not check to see if the traction cable is broken If yes replace the traction cable and then run Step3 again If not run Step5 Step5 Check the clutch module Drive Gear and other gearing Replace them if necessary 03 Abnormal output Calibrate the system Replace main board 04 Failure of switch or button Replace control panel membrane Replace main board 05 7 bars display LED module NG Replace main board T 06 LED display does not work Replace main board T 07 No buzzer or alarm music Replace speaker Replace main board MTD 4000 Maintenance Manual Rev F 7 15 11 Step1 Run automatic calibration and check the output If the problem continues run Step2 Step2 Replace main board and run Step1 again Step1 Check and make sure if harness cable is properly conn
30. ive use of surface mount circuitry Any attempt at replacing a surface mount component may result in damage to the board Replace entire circuit board assemblies only 3 For maximum safety plug the MTD 4000 into a grounded wall outlet of proper voltage only or use the optional battery Follow general safety practices for medical electronic equipment 4 The MTD 4000 requires AC 110V 120V 50 60Hz primary power other voltages available DISCONNECT THE LINE SUPPLY CORD PRIOR TO DISASSEMBLY OF THE UNIT FOR SERVICE Line supply voltage is present on primary components exposed by removing the back cover 5 Use calibrated test equipment in good working order 6 USEOF CONTROLS OR ADJUSTMENTS OR PERFORMANCE OF PROCEDURES OTHER THAN THOSE SPECIFIED IN THIS MANUAL AND IN THE MTD 4000 INSTRUCTION MANUAL MAY RESULT IN HAZARDOUS EXPOSURE TO ELECTRICITY 7 not operate the MTD 4000 in close proximity to operating shortwave or microwave diathermies 8 Replace line fuses with specified type and rating only to avoid risk of fire or other damage 9 Do not operate the controls with pointed objects such as pencils pens or tools 10 Make sure all connectors are tight with all pins making good contact when reassembling the unit after service 11 Asa prescription device the MTD 4000 may be sold only to or on the order of a physician physical therapist or other practitioner licensed by the state in which he she practices Mettler Electronics
31. low 7 1 to 7 3 until all calibration points in Appendix Annual Calibration Table have been completed Press SPEED button at anytime to return to the main calibration menu 3 Note Incomplete calibration procedures may not be saved Mettler Electronics Corp Rev _7 15 11 40 MTD 4000 Maintenance Manual Rev _7 15 11 section 8 Traction Cable Replacement 8 1 Traction Cable Disassembly a Check the condition of traction cable by touching and visually inspecting If necessary please replace the traction cable ME 40002 b Remove screws from the two lateral casings the lateral frames and the upper casing at locations 1 2 and 3 shown below Turn the Output Pulley wheel to face the right side of the unit Then fully extend the cable by removing the output pulley from the Upper Casing Pull out he 1 a 11 vi 11 1 1 Lateral Casing Lateral Frame Upper Casing b 1 After fully extending the cable insert a screwdriver through a hole the drive gear to fix it in place Open the upper casing Remove the cable ties securing the electrical cables Then disconnect the three connectors from locations 1 2 and 3 as indicated below Mettler Electronics Corp Rev _7 15 11 Drive gear Screwdriver Upper casing Fri Cable ties Connectors d Lay aside the Upper Casing and Output Pulley Unscrew and remove the Baffle Plate Use 2 hex Allen key to remove the
32. metric system After each repair or maintenance the device shall run the FQC procedure either using the designate criteria or factory criteria This function F b is one of the tests in the procedure of factory FQC In the form RW09021602 when using F b system will automatically run the setting force in metric system Note Except the factory modes F1 F2 F6 F7 the other factory modes need to run together with the fixture and designate force meter 9 2 Repair procedure with factory modes Procedure Replacement PCBs A D Board Main Board Procedure 5 auto calibration gt 9 Force Test gt F 3 if necessary gt Mettler s QC gt Rest the setting SEND Procedure2 Replacement Parts Micro Switch Fuse Transformer Solenoid Valve Speaker Cables A D cable Signal Cables Procedure Mettler s QC gt 7 Rest the setting gt END Procedre3 Replacement PCBs Motor Control Board Procedure F 8 traction speed test gt adjust the VR on the SSR if necessary gt double check F 8 traction speed test gt Mettlers QC gt Rest the setting gt END Procedure4 Replacement Parts Limit Switch 51 Mettler Electronics Corp Rev _7 15 11 Procedure F 4 limit force check gt F 6 Read A D value gt END Procedure5 Software upgrade Procedure After installing the new firmware gt Procedure 4 gt 5 auto calibration gt Force Test gt F 3 if necessary
33. n error still occurring Step1 Make sure the force meter is properly connected and its Replace motor control board transmission cable is not broken Replace main board And then check the error is still occurring not end the process Step2 If yes please replace the motor control board run Step1 again If error is still occurring Please replace main board Step1 Check and make sure the signal transmission cable is properly connected If the problem is still occurring run Step2 Step2 Replace A D Board check again If the problem is still occurring run Step3 Step3 Replace main board end the process Replace signal E Replace main board transmission cable d Replace motor b Replace A D board Ri Step1 Press STOP or restart system to remove error code Check error is still occurring If yes run Step2 If not end the process Step2 Run automatic calibration Check error is still occurring If not end the process Step3 If yes try to replace signal transmission cable first and then check again If problem still exists try to replace A D board If problem still exists replace main board and motor control board until problem solved 28 MTD 4000 Maintenance Manual Rev _7 15 11 E 9 EEPRON non calibration data is wrong Replace main Step1 Press STOP or restart the system
34. ocedures specifications and troubleshooting tips For additional assistance you may contact our service department toll free 800 854 9305 or outside the continental US 1 714 533 2221 The email address for the service department is service mettlerelectronics com This manual is current as of its publication Mettler Electronics Corp may however make improvements as required To receive manual changes send your name and address to Mettler Electronics Corp Service Manual Changes 1333 S Claudina Street Anaheim CA 92805 1 2 The MTD 4000 The MTD 4000 is a Traction Decompression system distributed by Mettler Electronics Corp The microprocessor controlled MTD 4000 provides cervical or lumbar traction by exerting therapeutic pulling forces on the patient s body with enhanced reliability and ease of use The MTD 4000 system is an easy to use device that offers static and intermittent traction with user definable hold rest and treatment times It gently pulls the cervical spine or lumbar spine in opposite directions to draw the soft tissue around the cervical or lumbar joints and separate the distance between bone sections of the vertebra 1 3 Precautions 1 The MTD 4000 operates with high voltages Servicing should be performed by qualified electronics technicians or the unit should be returned to the factory for service 2 The internal circuit boards are not designed to be serviced at the component level because of the extens
35. on and press the stop button to remove error code A sudden strength in exceed 3 kg and maintained for over 1 second No calibration data has been Press the STOP button to remove improperly saved error code m Check and make sure the signal Signal transmission cable is not SR transmission cable is properly properly connected connected LTC1400 damaged Replace A D board if necessary non calibration data is wrong 24 Detect motor performance Auto Calibration Error VR failure EEPROM failure Display parameter error MTD 4000 Maintenance Manual Rev F 7 15 11 Pulling or releasing takes longer than the default time 50 seconds This will happen if the patient is incorrectly strapped where traction forces cannot reach the setting value Strap too loose Patient s body is not positioned appropriately on the table Motor non conformance Unit detection for force meter in auto calibration The unit between system and force meter not set in kg VR Variable Resistance failure EEPROM data saving failure or EEPROM end of product life Turn off Check table mechanism Re strap patient Make sure the patient s body is appropriately positioned Turn on and try again Contact Mettler Electronics for repair service Turn off the system Unhook the traction cable and let it retract completely into the system Turn on the system and the error will be reset If the probl
36. or limit switch Tighten the screw the two screws of limit switch Press STOP button d Pease repeat step 5 to step 6 until the force limit is right set If the force limit is in range please run the auto calibration directly 7 Put some threadlocker adhesive on the screws where the screw heads meet the bracket The operation is complete Factory Mode F 5 Automatic Calibration This function is to provide an automatic calibration for the device maintenance and annual calibration The calibrated data is according to the measurement of designate force meter The sequences of automatic calibration are from minimum to maximum force and then from maximum to minimum force Please refer to section 5 1 for the procedure Note Please refer to the procedure of AUTOMATIC CALIBRATION in the Service DVD for more detail Factory Mode F 6 Read the A D value of Load cell at Limit Force Software Protection After each automatic calibration system will automatically record the A D value of load cell at the limit force This function is read only for factory test The system will activate this software protection based on the recording A D value when the system output exceeds the limit force Factory Mode F 7 Reset to Default Setting For each parts repair technician shall run the F 7 mode to reset the system to the default setting Please follow the procedure 1 Press and hold SET button and restart the system Press both OUTPUT MODE and SPEED bu
37. ress SET to switch the unit Ib kg Press STOP to save the setting and restart again 2 Switch the unit of force meter a Press MODE button to select the function UNIT by pressing PRINT button b Press MEMO button to enter into the setting mode Set the UNIT to LB by pressing PRINT button and press MODE to confirm Factory Mode F 1 MIDI Selection 1 Press and hold SET button and restart the system Turn the rotary dial to F 1 mode 2 Press START button to confirm and then turn the rotary dial to choose MIDI music 3 Press START button again to save the setting 4 Press STOP button to leave the status Factory Mode F 2 MIDI Volume Level 1 Press and hold SET button and restart the system Turn the rotary dial to F 2 mode Press START button to confirm and then turn the rotary dial to adjust MIDI volume 3 Press START button again to save the setting 4 Press STOP button to leave the status Factory Mode F 3 Manual Calibration This function is to calibrate the unit manually Please refer to the Section 7 for its procedure Factory Mode F 4 Force Limit Setting Hardware Protection This function is to help technician to set the position of limit switch for hardware protection at limit force Please follow the procedure 1 Set the device on the fixture and connect the RS 232 transmission cable with force meter 2 Turn on the force meter and press the Du button NO NEED TO PRESS PEAK TRACK BUTTON
38. tion 5 Troubleshooting Guide PRE TASKS OF REPAIR the technicians or engineers must receive the training for device installation and casing detachment Except the external parts all internal parts need to do these two procedures Please refer to the first category Casing of service DVD ERROR EXAMINATION this service manual provides a table for quick troubleshooting and a detailed procedure for complete troubleshooting The technicians or engineers are able to examine the causes of error and try to fix it SEVICE DVD the technicians or engineers shall follow the procedures of replacement in the service DVD and fix the parts according to the material list in the section 3 The table of content of DVD Casing 1 Device Installation 2 Case Detachment PCBs 1 Main Board 2 Motor Control Board 3 A D Board Parts 1 Clutch Module 2 Solenoid Valve 3 Micro Switch 4 Limit Switch 5 Drive Gear 6 Motor 7 Fuse 8 Speaker 9 Transformer 1 A D Cable 2 Signal Cables Calibration 1 Automatic Calibration Traction Cable Replacement 1 Disassembling the Output Pulley 2 Removing the Traction Cable 3 Installing the Traction Cable AUTO CALIBRATION once the part replacements are finished the technicians or engineers can do the initial pretest to check the status of device And then please run the auto calibration and observe the results until the calibration is finished QC AND RECORD Each repair has
39. to board remove error code Step2 Check the error 1 still occurring If not end the process Step3 If yes please replace main board and then run Step2 again Is error still occurring after restarting system E A Motor performance detection Yes Replace traction cable Is traction cable broken No mm mm mm s Replace signal transmission cable Replace main board between main board i Press START No and motor control board Is motor acting i b Replace motor control d Replace motor i board Yes Replace clutch module When motor acting traction cable drawn back No b Replace drive gear Replace other gearing eee ee rere Adjust speed of motor through SSR b Replace motor 9 Mettler Electronics Corp Rev _7 15 11 Step1 Restart the system Check error is still occurring If not end the process Step2 If yes please check the traction cable is broken If not run Step4 Step3 If it is broken please replace traction cable and then run Step2 again Step4 Press START check motor is acting If yes run Step6 Step5 If not make sure the signal transmission cable between main board and motor control board is not broken and well connected If problem still exists replace the motor control board and
40. to proceed the easy QC and check all functions The QC report must be filed for the purpose of regular device traceability If necessary please send back the copy to the manufacturer for further analysis Please refer to the Appendix Mettler Electronics Corp Rev _7 15 11 5 1 Simple Troubleshooting Did not implement calibration or the EEPROM saved data was wrong or E 1 calibration data is Calibrate the unit wrong Did not test limit switch function or the limit strength data was wrong Check and make sure the harness Solenoid valve is The valve is broken or improperly cable is properly connected damaged connected Replace Solenoid valve if necessary E 3 Micro switch of Micro switch has no signal or is Replace the micro switch if clutch is damaged damaged necessary Check and make sure the Emergency switch is pressed emergency stop switch is properly E tch removed or improperly connected connected Press STOP to remove mergency switc Eror code 4 the patient safety switch has been Emergency stop switch damaged Replace the patient safety switch pressed Emergency control circuit NG Replace motor control board Pull strength 4 1 Reset the device es ult limit ARE 2 Calibrate the unit 1 Press STOP to remove error Force meter is not properly connected code communication NG jor wrongly set up 2 Check and make sure load cell is E 6 properly connected Check cable connecti
41. ttons and rotate the rotary dial to the F 7 mode 2 Press START button and then press SPEED button The system will display E 9 error message and recall the default setting at the same time 3 Restart the system Do not press SET button 4 Please confirm the initial setting is correct The monitor will show below Timer 15 min OUTPUT MODE intermittent SPEED Normal HOLD 5sec HOLD 10 kg REST 5 sec REST 5 ACTUAL 0 kg Factory Mode F 8 TRACTION SPEED CONTROL 1 Press and hold SET button and restart the system Press both OUTPUT MODE and SPEED buttons and rotate the rotary dial to the F 8 mode Press START button to enter into the traction speed mode 2 Press SPEED button set the speed to Fast Normal Slow Press START button The system will automatically run the test arise the traction force up to 90 kg 1kg 3 Please confirm the time is less than the setting value 10 20 30 seconds Speed Testing Force Note Please refer to the procedure of MOTOR CONTROL BOARD in the Service DVD Factory Mode F 9 Traction Force Test 1 Confirm the unit of force meter a Press MODE button and select the Unit function by pressing PRINT b Press MEMO button and set the unit to KG by pressing PRINT and press MODE button to confirm c Remove the traction cable from the hook of force meter and press ZERO to zero the value Please confirm the LCD shows 0 00 KG 50 MTD 4000 Maintenance Manual Rev
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