TM-300Service Manual ITO CO., LTD. Printed on July 21st, 2011 TM-300 Repair Information Menu 1. Specification & Circuit Concept Index Specification Function Circuit Diagram Spare Parts Trouble Shooting Inspection Procedure Error Messages 2. Assembly / Disassembly Rope replacement Upper cover replacement Upper Cover Motor Wheel gear Drum No.1 card Rev.1 1 May 21st, 2012 TM-300 Table of Contents Contents Page 1 Repair Information Menu 1 2 Table of Contents 2 3 Function 3 4 Specification 4 5 Spare Parts 7 6 Circuit Diagram 8 7 +B Lines 9 8 Troubleshooting 12 9 Error Messages 19 10 Clear EEPROM 24 11 Removing Cover 25 12 Rope Replacement 26 13 No.1 Card 29 2 Rev.1 May 21st, 2012 TM-300 Function About Test Mode (1) Activativation of the TEST mode (i) Switch on power while holding down both the A and D keys. (The buzzer will sound to indicate Note: To clear the test mode, turn off the power. (2) Functions The test mode provides the following functions: Function Remarks Allows testing of each key involved in unit operations. Testing a key function should display the corresponding indication on the LCD screen. Key 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. 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.) LCD Totally lit (White) Totally extinguished (Blue) Blue lattice White lattice Fine lines in four directions. 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: Traction (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 current detection in NCD): ”120 kg NCD”” 120 kg ” 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 service. Enables calibration to improve calibration force accuracy (see Adjusting the main unit). calibration Rev.1 3 May 21st, 2012 (viii) Treat time setting Rear panel: LCD controler / Force unit selector / Language selector Program setting function (i) Registration of programs. MDD : Class IIa. Parameter setting function (i) Traction mode selecting. protrusions) x 260mm(W) x 330mm(D) Weight of the main unit Approximately 12kg Patient switch connector x 1 Input/output of main unit AC inlet x 1 Length of traction rope 1. (vi) Traction force calibration START key (membrane switch x 1) Traction start STOP key (membrane switch x 1) Traction stop Clear key (membrane switch x 1) Clear the entered parameters Rev. (v) Selection of language for screen display. (ii) High force setting. (iv) Kg/lbs selection . 2012 . (iv) Hold time setting. (v) Hold Front panel: time setting. TM-300 Specification (1) ITEM SPECIFICATION FUNCTION and OTHERS 110 / 115 / 120 VAC 50Hz/60Hz Power Supply Worldwide Model 220 / 230 / 240 VAC 50Hz/60Hz Rated Power Consumption 75VA + 15% or less Type of medical equipment Type of protection : Class 1.6m (extensible length) Vinyl coated wire rope Operating section 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. (vi) Rest time setting. (ii) LCD brightness regulation. Pharmaceutical Low : Class II. (vii) Traction speed Function keys (x10) / Ten keys setting.1 4 May 21st. Type B. FDA : Class II Dimension 170mm(H)(incl. (ii) Launch of program Configuration setting function (i) 18-kg check ON/OFF. (iii) Low force setting. 2012 .99 seconds Selectable in 1-sec steps Selectable step by step (setting below 1 kg/step not Treatment time range: Intermittent = 1. 1/4. 30 s. Static = 1.5kg.197 lbs) 51-90kg: ±3kg (selectable in 1 kg steps) [Pulling time for 0 to 90 kg] Standard speed. 1/2 or 1/3 second.99 seconds Selectable in 1-sec steps Traction Rest time: 0 . 21-50 kg: ±2. 1/2. permitted) Traction modes: 8 modes Selectable in 1-sec steps Program memory: 20 memories Traction force detection Traction force sensor (potentiometer x 1) Traction force is detected section Rev.89 kg (0 .198lbs) 1kg: -0/+2 kg. 1/6.99 min.99 min. 1/8.1 5 May 21st. 320 x 240 dots 10 languages supported Traction accuracy: High force range: 1 . 2-20 kg: ±2 kg. 120 s Traction output section Traction hold time: 0 .90kg (1 . 90 s. 15 Traction speed: Standard. Low force range: 0 . TM-300 Specification (2) ITEM SPECIFICATION FUNCTION and OTHERS Display section LCD: 121x 92mm.. 60 s. If wire breakage is detected in the load cell. Rev. and 90 kg are stored in the EEP memory and Factory Calibration function linear approximation is applied. in 1-min. and E2 is displayed. traction Sensor wire breakage detection is interrupted (E3) Safety functions Traction is interrupted. stops truction force to zero and E3 error is displayed. built-in WDT. Traction force calibration 50 kg. If the sensor detects 100 kg. 99 min. motor turns reverse Traction force abnormality detection direction.1 5 May 21st. Interruption of traction with patient switch System check Executed when power is turned on and when >18-kg check traction is issued Warning started. traction force is Remote patient switch manipulated by patient decreased to zero and E2 error is displayed when the switch is pressed. Timer function Max. Selectable from 1 to 99 min. CPU's Monitoring for CPU malfunction OK key (membrane switch x 1) To confirm selected parameters Control signal data from tractions performed at 5 kg. steps.when traction force is set to more than 18 Uses kg. TM-300 Specification (2) ITEM SPECIFICATION FUNCTION and OTHERS The treatment is promptly ceased. 2012 . TM-300 Specification (3) ITEM SPECIFICATION FUNCTION and OTHERS program function Freely programmable: 10 categories The user can save or load settings freely. 2012 . Buzzer beeps in constant intensity when an active Buzzer function Separately excited piezo-electric buzzer (φ20) or an inactive key is pressed. or when an error is issued. Recalibration is Error detection function Error E1 required. the sensor wiring or the Error E3 : just initial system check CPU board was detected. Traction force is decreased. Defect of the panel switch. Pinion hexagon socket screw or the Motor. Rev. Error E3 : 30 second after motor on with no traction force. when traction ends. Improper situation occurred with Wave washer.1 6 May 21st. Disconnection of the patient cable or activation of Error E2 the patient switch was detected. 2012 . 1 PCB Assembly (E) 210406 2 PCB Assembly (China) 210410 3 LCD module 07181 4 LCD backlight inverter 210516 5 Membrane board 170502 6 Rope Holding Assembly 01614 7 Power switch 140151 8 Fook spring 15902 9 Pulley Assembly 010621 10 Mechanism (240V) 01634 11 Mechanism (230V) 010806 12 Mechanism (120V) 010805 13 Mechanism (120V) UL 010822 14 Rope Assembly 400112 15 Gear-fastener 150959 16 Potentiometer Rev.1 7 May 21st. TM-300 Spare Parts No. Name Part No. 10. TM-300 Circuit Diagram Force LCD Safety kg /lbs Red P1: 5V P4: 12V P7: GRD Yel Brn Org Grn Grn Red Yel Pur P.Blue 1 12V PC2 Blu Noise IC54 IC53 IC52 IC51 15V Filter -24V 5V 12V 12V REC51 Yel Reg Reg Reg Reg 17v Reg 25V 8 Brn CN54 10V IC8.14. 2012 .12.S. Panel Switch Board LCD Module Rev.1 8 May 21st.11. CN52 1 CN53 1 AC Inlet 3 2 3 4 7 CN55 Red L.15 2 1 Gry 1 CN3 Wht CN1 CN4(LCD) Blk Red Limit 1 12 1 12 9 CN56 1 4 P3-P4:≒1７V Wht Pink P4 : 5V Blk Blk P5 : 0V Red DC P11: -24V (LCD) LCD Inverte The solenoid does not pull the idling gear r M lever in full stroke until the motor rotates. 1 9 May 21st..5v CN55/Pin7&8 RL1-1(make) +12v 3 1 IC2 1 SSR2 9 WHT 2 2 4 Reverse Rotation (GND) Low CN56 CN55/Pin7&8 Froward Low Reverse Low Rev.4. BLU 3. AC 220v BRN 1 Check point 1 M REC2 +12v Froward User SW 5 AC 16v 4 1 Rotation 3 1 BLK SSR1 7 RED 4 2 (GND) +22. TM-300 +B Line for Motor Drive Power Supply for Traction Motor CN5 L. 2012 . TM-300 +B Line for Solenoid Drive Power Supply for Solenoide REC51 Check point 4 CN54 Check point 2 +17v AC 12v 4 1 3 If not.1 10 May 21st. C51 15-16v 2 4 Solenoid Solenoide To PC51 On REC52 TR51(K) 3 4 AC 15v 4 1 1 +22. REC1 is faulty. 2012 .5v TR51 (GND) Check point 3 Low CN55/Pin7&8 RL1-1(make) To +12v REC1(-) IC52 1 3 REC53 2 REC52 REC51 . (GND) Low + CN55/Pin7&8 REC51 7v 1 4 2 3 Rev. 5v +12v 4 4 IC52 IC53 VDD:LogicPS 1 1 REC2 2 (GND) 2 (GND) CN55/Pin7&8 CN55/Pin7&8 (GND) To LCD CN55/Pin7&8 +12v Check point 7 +12v 12 BackLight IC51 1 2 (GND) CN55/Pin7&8 5 VSS:LogicGND 10 9 LCD DATA VSS:LogicGND 8 IC19 7 3 CL2:DataCapture LCD Control 2 CL1:DataLatch 1 FLM:ScanStart Rev. 2012 . TM-300 +B Line for LCD Drive Power Supply for Display REC3 CN4 Check point 5 AC 25v +35v 3 2 -24v 1 4 IC54 11 VEE:LCDPS 1 (GND) (GND) CN55/Pin7&8 CN55/Pin7&8 Check point 6 +5v AC 16v 1 +22.1 11 May 21st. Rev. IC1(12V). Power supply is IC4(-24V).1 12 May 21st. 7V. TM-300 Troubleshooting (1) No Power Step 1 Check the continuity of The power cord is No OK.1 card P1-2 = AC 12V P3-4 = AC 16V No Yes Change T1 or Measure the voltages Step 3 of 5V. 2012 . 12V. -24V 5V : CN2-3/CN3-7 7V : CN4-3/4 12V: CN3(LCDINV)-1/2 No Chang Yes IC3(5V) or IC2(12V). Yes Change the Measure Step 2 the secondary No. 1 12 May 21st. Rev. 2012 . No +12V : CN3-1/2 Yes Change IC12 or Measure +5V. TM-300 Troubleshooting (2) No LCD display Adjust the LCD control Step 1 knob located on the Character became Yes readable. Step 2 Measure +12V for LCD inverter. 2012 .1 13 May 21st. or Step 3 Change LCD inverter No LCD lights up Yes Change LCD Change LCD inverter. No LCD is OK. -24V for Step 3 LCD module +5 : CN4(LCD)-4 No 0V : CN4(LCD)-5 Yes Change IC3(5V). IC4(-24V). Inverter harnesses Rev. Turn power on.1 14 May 21st. Troubleshooting (4) Rev. TM-300 Troubleshooting (3) Wire winding stops on the way. 2012 . No The wire winding mechanism is Go to returned to normal. Step 1 start 5kg traction and The wire rope is Yes pulled out smoothly. The wire rope is off Yes the track. Rev. then slowly The rope is smoothly Yes pulled into the unit. Pull out the wire Step 1 rope in full length by hand. No Rope winding mechanism is Check the wire working normal.1 15 May 21st. TM-300 Troubleshooting (4) Wire rope is not properly wound Turn power off. Change the mechanical assembly. surface is No Change the wire rope.. Step ２ rope path. 2012 . No Go to Troubleshooting (6) Step ３ Check the wire The wire rope is Yes entangled. The wire rope is off Yes the track. The wire rope is Yes pulled out properly. TM-300 Troubleshooting (5) Wire rope cannot be pulled out Turn the power Step 1 off. 2012 .1 16 May 21st. No Go to Troubleshooting (4) Check the wire Step 2 rope path.. No Go to Troubleshooting (6) Check the gear Step 3 block. The relay puley is Yes separated from the No Go to Troubleshooting (4) Go to Troubleshooting (7) Rev. the 1st & 2nd rollers. TM-300 Troubleshooting (6) Wire is off the track.1 17 May 21st. Rev. the The pulley and the Yes rollers rotate No Go to Troubleshooting (4) Change the pulley or the rollers. Turn power off. 2012 . Step 1 Check the puley. Change the solenoid. Rev. The idle gear is Yes separated from the Yes 0V : Pin3 .Pin4 of CN4. Measure the solenoid driving voltage. No Check the gear lever. Yes The planger is released.1 card.1 18 May 21st. TM-300 Troubleshooting (7) The idling gear is not Check the electromagnetic solenoid. Yes High : Pin1 of IC23 Change IC23. Change No. Change the No mechanical assy. No Change the wire assembly or the Measure the status of solonoid driving. 2012 . PC1. or TR1. No E1 error is Yes System is returned to normal.1 19 May 21st. TM-300 Error Messages (1) E1 error Perform "2-2 Easy Calibration" on page 4 of the service manual. 2012 . Rev. 1 20 May 21st. Yes E2 error is No System is returned Check +12V to normal. 2012 . E2 error is Yes No System is returned Replace the to normal.1 Check IC2 card. TM-300 Error Messages (2) E2 error Connect the patient switch properly to CN3. Yes +12V: CN3-P3/P7 No Change PC2 or No. Yes +12V: IC2 OUT/GND No Change RL1 Change IC2 or Rev. 1 21 May 21st. Yes E3 error is No Complete Change No.1 Rev. TM-300 Error Messages (3-1) E3 error: Just after initial system check. 2012 . Check the traction sensor The sensor circuit Yes is disconnected. No Connect the sensor hurness Change the sensor wire. No E3 error is Yes E3 error is Yes No Complete Complete Change the potentiometer. . No Change the Rope. Yes Rope is cut. Change the No E3 is cancelled E3 is cancelled Yes Yes Change the No1 card. Check the gears. of the Service Manual_TM-300. Yes Gears are ground No Change the Gear Check the inner along the section hurness of the 3-6 on page 18 motor. The hurness is properly Yes No E3 is cancelled connected. TM-300 Error Messages (3-2) E3 error: After 30 second of Check the rope.1 22 May 21st. Yes No Connects the Complete hurness. Complete Rev. 2012 . 2012 .1 22 May 21st. Rev. 1 24 May 21st. (3) The system enters test mode with beep sound generated by CPU. (5) Press "OK" key 9 times to display "Initialization function" window. (2) Initial check window is displayed and initial check is start. Warning! Do not select "All Items" initialization at step (6) at any occasion in the field. Rev. since this item erases all data including calibration data which is necessary to work the unit linearly. TM-300 Initialization of Parameters Note: Initialization of the parameters must be performed only when "Error 3" is displayed on LCD. (7) Press "OK" key more than 3 second to initialize selected item. The "All Items" is reserved for factory use only. (4) The initial check operation finally opens key check window then wait next key input. (1) Press "A" key and "D" key simultaneously then turn power switch on. (6) Select "Parameters" with ▲ and ▼ keys. (8) Turn power off. 2012 . 1) Step 2 Pull the pulley out from the upper panel. 2012 . (See Fig.1. (See Photo 3) Total six screws Fig 4 Fig 5 Tie the loop clutch with Photo 3 Rev.4) Step 5 Pull out the upper cover and place it on the left side of the unit. (See Fig. (See Fig. (See Fig. then put the pulley on the left side of the unit. TM-300 Assambly / Disassembly 1. Removement of The Upper Cover Step 1 Turn the pully ９０゜to the right. Fig.5 & Photo 3) Step 6 Tentatively tie the rope on the snap hook. (Fig. 3) Photo Fig 1 Fig 2 Fig 3 Photo 2 Step 4 Remove the six screws on the botom of the upper cover.1 25 May 21st.2 and Phto2) Step 3 Untie the rope from the snap hook. Rev.1 25 May 21st. 2012 . 2012 .5 & Photo 3) Rev.1 25 May 21st. 1 26 May 21st. (6) Cut the rope tail off and take the rope out from the mechanism. RopeHolder Fig 1 (3) Rotate the drum to the angle 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. 2012 . Lock the wheel gear (2) Pull the most wire rope out from the drum. ※ I shaped gear t Wheel gear locking tool 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. Fig 3 Fig 4 Photo 2 Rev. TM-300 Rope Replacement (1) <Removement of the rope> (1) Remove the rope holder by removing the three screws. 1 26 May 21st. 2012 . Rev. Wire rope with a hook Stop ring I shaped tool Hexagon wrench key (1. 2 (3) Pass the rope taile through the drum hole. 4. 2012 . Two screws Stop ring Fig. Hole Hole entrance entrance Fig. 5 Fig.3 and Fig.1 27 May 21st. See Fig.5mm) Fig. 2 Fig. 1 (2) Bend the rope taile to the direction of its natural curl at the 35mm from the rope See Fig. just under the two screws on the other side of the drum. 3 Fig. TM-300 Rope Replacement (2) <Installation of the rope> (1) Check the contents of the wire rope kit. Stop ring Slit Fig. 4 (3) Attach the stop ring at the end of the rope and narrow the slit of the ring by using radio pliers. 6 (4) Pull the rope out at the drum entrancerope hole firmly until the stop ring is caught at the drum hole.7 Rev. 2012 .by using radio Rev.1 27 May 21st. (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. TM-300 Rope Replacement (3) 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. 2012 . Rev.1 28 May 21st. Disconnect the harnesses from the LCD inverter and the LCD. CN4.1 card. CN3. CN2.1 29 May 21st. CN6. 2012 .1 card replacement 1) Replacing the No. Rev. Harness of LCD Step 5 Take off the No. Connectors & Harnesses CN CN Motor LCD Membrane SW Power supply LCD inverter CN CN Solenoid LCD back light Sensor CN CN Limit SW Safety SW Step 2 Take the grounding harness from the No. TM-300 No.1 card. Step 1 Disconnect the harnesses from CN1. (See Photo 1) Step 3 Disconnect the two harnesses comming from the membrane board.1 card and upper cover.1 card gently from the upper cover. CN5. Step 4 Remove the six (6) nuts from the No. then increase the tension to 5kg by pressing "8" key. press "2" key until the traction becomes 3kg. Step 9 Confirm that "Calibration is complete" is displayed on the LCD and all mechanical mevemnet is ceased. Step 8 Save the setting by pressing "5" key. Step 6 Save the setting by pressing "5" key. "6" and "9" keys simultaneously for five seconds so that "5Kg Calibration" windo opens on the LCD. Step 10 Power off the device. Step 5 Increase the traction up to 50kg +/-0. Step 2 Press "STOP".1kg on the force gauge. If the traction is exceeded 5kg. (3) Calibration procedure Step 1 Press "START" key to open the "Set parameters" window. Step 4 Press "5" key to save the setting. . Step 3 Keep pressing "8" key to increase traction force up to 5kg +/-0. TM-300 Calibration 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". Step 7 Increase the traction up to 90kg +/-0. Step 11 Turn Power on of the device then confirm that E1 error is not displayed on the LCD.2kg in the same manner as Step 3.2kg in the same manner as Step 3. Step 5 Increase the traction up to 50kg +/-0. Step 11 Turn Power on of the device then confirm that E1 error is not displayed on the LCD.2kg in the same manner as Step 3. (3) Calibration procedure Step 1 Press "START" key to open the "Set parameters" window. Step 10 Power off the device. Step 7 Increase the traction up to 90kg +/-0. Step 8 Save the setting by pressing "5" key. then increase the tension to 5kg by pressing "8" key. "3".2kg in the same manner as Step 3. Step 9 Confirm that "Calibration is complete" is displayed on the LC and all mechanical mevemnet is ceased. . If the traction is exceeded 5kg. "6" and "9" keys simultaneously for five so that "5Kg Calibration" windo opens on the LCD screen. press "2" key until the traction becomes 3kg. Step 3 Keep pressing "8" key to increase traction force up to 5kg +/-0. Step 4 Press "5" key to save the setting. TM-300 Regular Calibration (2) Regular calibration (2) In the case that the system displays E1 error immediately after power on and cannot enter the parameter setting window. Step 6 Save the setting by pressing "5" key. Step 2 Press "STOP".1kg on the force gauge. 1kg e traction e manner as e manner as on the LC and rror is not .fter power on o 5kg +/-0. Strain gauge able to measure more than 120kg. To Test Bed(2) Fix TM-400 on the bed with four bolts. TM-400 Test Bed The spring must withstand 120kg. The table must withstand 120kg pulling . TM-400 Test Bed Strain gauge measurable more than 120kg. . Strain meter connected with the strain gauge.
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