a-dec
1021, 1011 Decade and 1040 Cascade Service Manual 2003
Service Manual
64 Pages
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Page 1
Chairs
Overview A-dec model 1040, 1021 and 8000 chairs are electronically controlled, hydraulically powered dental chairs. Buttons on both the touchpad and 8-button footswitch and actuators on the 8-function footswitch are used to position and program auto-positioning functions into the chair. The hydraulic system is controlled by the electronic control module using relays and solenoidactuated valves. This section provides information related to locating serial/model numbers, servicing, maintenance, and adjustment of chairs. Detail on how to service chairs and troubleshoot specific problems related to them is presented.
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CH-1
Chairs Locating Serial/Model Number
Serial/Model Number Locations The serial/model number tags identify the chair model and manufacture date. The label can be found either on the top surface of a chair’s upper structure (raise the toeboard) or on the righthand side of the upper structure. If you have difficulty locating the serial/model number label, the following example may be helpful.
Serial number label location Serial number label location
Decade 1021/1011 Chair
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Cascade 1040 Chair
CH-2
Chairs Reading the Manufacture Date
Manufacture Date Different models of the chair can be identified by referring to the “REF” number. Each chair is further identified by its month and year of manufacture. This example shows how to identify the model and month and year of manufacture of the chair.
2601 CRESTVIEW DRIVE NEWBERG, OREGON 97132 USA
1
Designated EU Representative: A-dec Dental U.K., Ltd. Austin House, 11 Liberty Way, Attleborough Fields, Nuneaton, Warwickshire, England CV 116RZ Tele: (44) 1203-350901
2
®
1
Item #
Description
1
Model number
2
The first letter of the serial number indicates the month the product was manufactured; e.g., A is January.
3
First digit indicates the year of manufacture.
DENTAL CHAIR
S/N: J167856
REF: 1040
MADE IN USA
2001
INPUTS 120 V 10 AMPS MAX 50-60 Hz
! DENTAL CHAIR
CAUTION! C
®
US
LISTED 15VJ LA BEL P/N: 051.515.02 REV L
Serial/Model Number Label
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CH-3
Chairs Working with Hydraulics
Hydraulics The hydraulic system consists of the following:
Part
Description
Hydraulic fluid reservoir
The fluid level in the reservoir can be seen through the sides of the reservoir and is serviced via a top fill cap.
Hydraulic cylinders
The hydraulic cylinders control the base lift and back functions. Springs and gravity retract the rod during base and back down functions.
Motor-driven hydraulic pump
The hydraulic pump and the starter capacitor supply hydraulic fluid from the reservoir, under pressure, to the chair lift and tilt hydraulic cylinders for back up and base up functions.
Solenoid/manifold assembly
This assembly gates hydraulic fluid to and from the two cylinders. Depending on the chair function called for, the controller selects which solenoid-actuated manifold valves are opened or closed. The solenoid/manifold assembly also includes four adjustable needle valves used to restrict or divert the flow of hydraulic fluid to and from the lift and tilt cylinders. These valves provide the rate of travel adjustment for chair base and back movement.
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CH-4
Chairs From motor/pump start capacitor
Hydraulic System Flow Diagram
{ Tilt cylinder
Vent tubes
Lift cylinder Solenoid manifold assembly
Pickup tube
MAX MIN
Hydraulic pump motor
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Hydraulic fluid reservoir (check fluid level with base and back full up)
NOTE:
Use only A-dec fluid P/N 61.0197.00.
CH-5
Chairs
Hydraulic Manifold Before January 1999
Hydraulic Manifold Item # 1
Part Number
Description
61.1335.00
Solenoid, (8-watt, 100V, Yellow wires) Solenoid, (8-watt, 120 V, Black wires) Solenoid, (8-watt, 240 V, Red wires)
61.1336.00 61.1337.00 2
035.041.02
O-ring, special pkg 10
3
030.004.02
O-ring, AS568-004 pkg 10
4
030.010.00
O-ring, AS568-010 (only on dual-block manifolds)
5
61.0460.00
Flow adjust screw with o-ring
6
001.002.00
Screw, truss-head slot
6
5
3
3
4
2
3 1
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CH-6
Chairs
Hydraulic Manifold After January 1999
Hydraulic Manifold Item # 1
Part Number
Description
61.1335.01
Solenoid, (8-watt, 100V, Yellow wires) Solenoid, (8-watt, 120V, Black wires) Solenoid, (8-watt, 240V, Red wires)
61.1336.01 61.1337.01 2
030.015.02
O-ring, pkg 10
3
030.004.02
O-ring, AS568-004 pkg 10
4
61.0460.00
Flow adjust screw with o-ring
5
002.118.01
Screw, button-head, socket
6
61.1332.00 61.1333.00 61.1334.00
Manifold assy, hyd, 100V Manifold assy, hyd, 120V Manifold assy, hyd, 240V
5 4 3
6
2
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3
1
CH-7
Chair Removing a Solenoid WARNING The solenoid coils are powered by line voltage (100, 120, or 240V AC). Failure to unplug the chair may result in serious injury from electrical shock.
Hydraulic Manifold The following steps will guide you through the removal of a solenoid. Task
Description
1
Lower the chair base and back to the full down position to depressurize the hydraulic system. Remove the motor pump cover, then unplug the chair.
2
If necessary, remove the two mounting screws that secure the manifold to the hydraulic tray. Rotate the manifold so the solenoids are accessible.
3
Using a flat blade screwdriver and a 9/16" wrench, remove the defective solenoid.
Hydraulic manifold J10
O-ring
4
5
Poppet Wire nut Poppet sleeve
Cut the defective solenoid wires 3" (74mm) from the coil and discard.
Washer Coil
Remove the old o-ring from the solenoid cavity and completely dry the cavity. Replace the o-ring (refer to Solenoid installation instructions for correct o-ring).
ID washer Retaining nut
Removing a Solenoid
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CH-8
Chair Replacing a Solenoid WARNING The solenoid coils are powered by line voltage (100, 120, or 240V AC). Failure to unplug the chair may result in serious injury from electrical shock.
Hydraulic Manifold The following steps will guide you through replacing a solenoid. Task
Description
1
Install the new solenoid stem and poppet into the manifold and tighten to 35-40 in lb (.11085-.2284 Nm). Position the remaining solenoid parts on the stem and secure by tightening the retaining nut to 25-30 in lb (.14275-.1713 Nm).
2
3
Hydraulic manifold J10
Cut the solenoid wires 3" (75 mm) from the coil. Install the stripped wires from the solenoid and the connector housing into a wire nut. Repeat for the remaining wire. Using the mounting screws, secure the manifold to the hydraulic tray.
O-ring Poppet Wire nut Poppet sleeve
4.
Plug in the chair. Test the chair functions to ensure proper operations and that no fluid leakage occurs. Reinstall the motor pump cover.
Washer Coil ID washer Retaining nut
Replacing a Solenoid
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CH-9
Chairs Adjusting the Hydraulic Manifold
Hydraulic Manifold The hydraulic manifold incorporates four speed control valves, which restrict or divert the flow of hydraulic fluid to and from the lift and tilt cylinders. NOTE:
The speed control valves are hex drive.
To adjust...
Do this...
Base up speed
Turn base up control valve: clockwise to decrease speed, or counterclockwise to increase speed.
Base down speed
Turn base down control valve: clockwise to decrease speed, or counterclockwise to increase speed
Back up speed
Turn back up control valve counterclockwise to decrease speed, or clockwise to increase speed. NOTE: This is opposite of the other three control valves. Turning the back up valve counterclockwise too far may prevent the back from moving up.
CAUTION Do not completely close a speed control valve. The motor/pump could overheat and become damaged from pumping against a closed valve. Do not remove retaining screw from the control valves.
Back down speed
Turn the back down control valve: clockwise to decrease speed, or counterclockwise to increase speed.
Base up control valve
Back up control valve
Retaining screw
Base down control valve
Back down control valve
Adjusting the Hydraulic Manifold
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CH-10
Chairs Correcting Hydrostatic Lock
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Hydraulic Manifold Hydraulic lock occurs based on the following conditions: •
chair base or back is stuck in full up position
•
limit switch not activated, or
•
down solenoid poppet is unable to open based on excess hydraulic pressure.
Task
Description
1
Remove the motor/pump cover from the chair.
2
Fit a 5/8" wrench to the high pressure outlet port (either lift or tilt, whichever is in hydrostatic lock) of the hydraulic manifold. Hold the port still and use a 9/16" wrench to loosen the hose fitting.
3
Place a shop rag around the fitting to absorb the fluid.
4
Carefully loosen the fitting counterclockwise until oil begins to leak from the fitting. Retighten the fitting. Operate the down function. A second release of hydraulic fluid may be required.
5
Adjust the limit switch that caused the hydrostatic lock (refer to Adjusting the Base Up Limit Switch). In some cases, it may be necessary to remove and replace the limit switch. Adjust the new limit switch as needed. Also ensure that the large gear/actuator is securely installed and not slipping.
6
Cycle the chair a couple of times to verify it is no longer in hydrostatic lock.
Tilt cylinder high pressure fitting
Lift cylinder high pressure fitting
Correcting Hydrostatic Lock
CH-11
Chairs
Electrical System Wiring Diagram NOTE:
To post box, or Radius lift arm connector To cuspidor stop switch
If there is no cuspidor, remove jumper from cable and place on board Place jumper here if there is no cuspidor
LED light
Optional duplex 100V and 120V only
Main power from electrical outlet
P2
PRGM
B KUP BSUP BSDN B KDN PRGM 0 PRGM 1 PRGM 2 PRGM 3 EN/DIS TP/FS FA CT DEFAULT B K POT BS POT SPARE SPARE
Hydraulic manifold
DS3
B K POT
P10
BK UP DS12
N/L2 BK UP
BS UP DS14
BS UP
To hydraulic motor/pump
BS DN
BS DN
DS2
BK DN
"STATIC SENSITIVE"
P9 PUMP N/L2 PUMP
K5 PUMP
DS11
DS6
P13
LOCKOUT DS4
DS16
R72
PART #
+5V
R74
BE EPER
}
(220-240V~)
R73 DS17 +12V
(100-120V~)
2
DS13
DS9
1
#1 #2 SETS OFF OFF CUSP/RET ON OFF LAST POST OFF ON PRGM 3 ON ON NOT USED
DS10
ON
P6
3
P11
BK DN DS1
S2
2
MAINS INPUT POWER L1 N/L2
DS7
BS B K SP
0
DS5
BS POT
P4
1
AUXILIARY OUTPUT POWER (2A MAX) L1 N/L2
P17 TEST POINTS
P5
Base positioning potentiometer
DS15
P16 STATUS
P12
S1
Back positioning potentiometer
DS8
P14 CUSP
CB2
P1
CB1
Ground
Capacitor
Footswitch Stop plate limit switches
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Back up limit switch
Base up limit switch
CH-12
Chairs Item #
Electrical Systems Service Parts
Part Number
Description
61.1332.00 61.1333.00 61.1334.00
100V, Yellow wires 120V, Black wires 240V, Red wires
2
90.1031.00 90.1034.00
Capacitor with boot (100-120V) Capacitor with boot (240V)
3
041.372.00
Positioning potentiometer
4
61.2065.00
Back up limit switch
5
044.184.01
Base up limit switch
6
61.2099.00
Cable assy, tilt switch (1040) only
7
61.3043.00
8-button footswitch
8
39.1045.00 39.1385.00 39.1090.00 39.1090.00
Chair touchpad Performer touchpad Cascade Master with cuspidor Cascade Master w/o cuspidor
1
8 1
2
0
3
1
6 3
7
To Replace Circuit Board P/N
Order this kit
61.2510.00 61.1214.01 61.1373.01
90.1029.00 (100-120V)
61.2512.00 61.1217.01
90.1029.01(220-240V)
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4
5
2
CH-13
Chairs
Diagnostic LEDs for the Circuit Board
LEDs NOTE:
DS8
Refer to Testing Factory Defaults for more details.
DS15
DS12
DS3
DS14
DS5
DS7
DS2 DS1
DS13 DS6
DS11
DS9
DS4
DS10 R73 R72 R74
DS17 85.0812.00, 2003
DS16 CH-14
Chairs
Diagnostic LEDs for the Circuit Board
LED
Description
Information Communicated
DS1 DS2
S2 (red DIP switch) is ON
Switch is ON
DS3
Back Potentiometer LED ON
Back potentiometer is functioning normally when the chair back is moving
DS4
Handpiece Lockout LED ON
Lockout enabled
DS5
Base Potentiometer LED ON
Base potentiometer is functioning normally when the chair base is moving
DS6
Chair Stop Plate Limit Switch LED ON
Chair stop plate limit switch activated
DS7 DS11 DS12 DS13 DS14
Base Down LED Pump LED Back Up LED Back Down LED Base Up LED
Relay is ON when LED is ON and the function is moving
DS8
Cuspidor Limit Switch LED ON
Cuspidor limit switch activated, or jumper is missing
DS9
Back Up Limit Switch LED ON
Back Up limit switch activated
DS10
Base Up Limit Switch LED ON
Base Up limit switch activated
DS15
Status LED ON
ON: OFF:
DS16
5V Regulator LED OFF
1. Power to circuit board is OFF, or 2. There is a short in the cable to the base or back potentiometer. Disconnect all cables except the power cable. Plug the cables in one at a time (the LED will turn ON when the problem is fixed).
DS17
12V Regulator LED OFF
1. Power to circuit board is OFF, or
Normal operation Microcontroller is not functioning. Verify voltage regulator LEDs (DS16 and DS17) are ON. Is the chair plugged in? Circuit breaker tripped? Slow Blink: Check cuspidor (DS8) and stop plate (DS6) limit switch LEDs Fast Blink: Check handpiece lockout (DS4) LED Double Blink: A SPARE jumper is in the FACT DEFAULT position
2. There is a short in the cable to the status light or limit switch (the LED will turn ON when the problem is fixed).
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CH-15
Chairs Testing and Programming the Circuit Board
Chair Printed Circuit Board (PCB) Follow these steps to test and program the chair circuit board. Task
Description
1
Insert the SPARE jumper into the FACT DEFAULT location (on P17). Result: The chair will cycle the base and back movements and automatically reprogram the memory positions to the factory settings (position 0 to entry/exit; 1 and 2 to the same pre-programmed positions; and 3 to cuspidor/return).
WARNING The chair will begin to move automatically during this test; to avoid injury or equipment damage, remove all possible obstructions and maintain a safe distance from the chair. To interrupt the chair cycle, press any button on the touchpad or footswitch, or activate the chair stop plate.
If the circuit board beeps three times, continue with step two. If the circuit board beeps just once, the chair cycle has been interrupted. Diagnose and correct any errors, then press either circuit breaker for five seconds to restart the cycle (refer to Testing Factory Defaults). 2
Move the jumper from the FACT DEFAULT location (on P17) back to the SPARE location. NOTE:
3
The jumper must be in the SPARE position for normal chair functions and safe operation.
Press “1” on the touchpad or footswitch, or the green position on the 8-function footswitch. Result: The chair will move to the operating position.
4
Press “0” on the touchpad or footswitch, or the red button on the 8-function footswitch. Result: The chair will move to the entry/exit position. NOTE:
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The chair programmable position buttons can be reprogrammed to the desired positions as specified by the dental team.
CH-16
Chairs Testing Factory Defaults
Tests The table lists conditions and corrective actions for testing the factory defaults for LEDs.
Problem Factory Default test will not start (LEDs DS15, DS16 and DS17 are Off)
Factory Default test will not start (LED DS15 is Off; DS16 and DS17 are ON)
Factory Default test will not start (LED DS15 is blinking; DS16 and DS17 are ON)
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Action If . . .
Then . . .
Transformer thermal limiter is open
Wait for transformer to cool off.
Circuit breaker is tripped
Reset circuit breaker (short circuit fault currents may damage the circuit breaker and prevent it from resetting).
If . . .
Then . . .
Input voltage is too low or is outside the required range
Verify input voltage and voltage selection resistors (100-120VAC=R72 and R74) (220-240VAC=R73).
Microcontroller is not functioning
Replace the circuit board.
If . . .
Then . . .
Input voltage is too low or is outside the required range
Verify input voltage and voltage selection resistors (100-120VAC=R72 and R74) (220-240VAC=R73).
Microcontroller is not functioning
Replace the circuit board.
CH-17
Chairs
Tests
Problem Factory Default test halts during the BASE UP test and the PCB board beeps one time
Action If . . .
Then . . .
Input voltage is too low or is outside the required range
Verify input voltage and voltage selection resistors (100-120VAC=R72 and R74 (220-240VAC=R73).
Base Up limit switch is activated
Verify switch operation.
Motor thermal limiter is open, motor is hot
Wait for motor to cool off.
Motor capacitor is defective
Test capacitor and replace, if needed.
Base Up solenoid is defective
Test solenoid and replace, if needed.
Base is in hydrostatic lock
Refer to Correcting Hydrostatic Lock.
Potentiometer is not changing voltage
Verify potentiometer LED comes ON when base is moving. Check potentiometer mechanical drive and electrical connections.
Factory Default test halts during the BACK DOWN test and PCB board beeps one time
If . . .
Then . . .
Stop plate limit switch is activated
Verify switch operation.
Stop plate is jammed
Remove and reinstall the stop plate.
Back Down solenoid is defective
Test solenoid and replace if needed.
Back is in hydrostatic lock
Refer to Correcting Hydrostatic Lock.
Potentiometer is not changing voltage
Verify potentiometer LED is ON when back is moving. Check potentiometer mechanical drive and electrical connections.
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CH-18
Chairs
Tests
Problem Factory Default test halts during the BACK UP test
Action If . . .
Then . . .
Back up limit switch is activated
Verify switch operation.
Back Up solenoid is defective
Test solenoid and replace, if needed.
Back is in hydrostatic lock
Refer to the Correcting Hydrostatic Lock.
Potentiometer is not changing voltage
Verify potentiometer LED is ON when back is moving. Check potentiometer mechanical drive and electrical connections.
Factory Default test halts during the BASE DOWN test
If . . .
Then . . .
Stop plate limit switch is activated
Verify switch operation.
Base Down solenoid is defective
Test solenoid and replace if needed.
Base is in hydrostatic lock
Refer to Correcting Hydrostatic Lock.
Potentiometer is not changing voltage
Verify potentiometer LED is ON when base is moving. Check potentiometer mechanical drive and electrical connections.
Chair moves by itself when power is turned ON
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If . . .
Then . . .
The jumper is in FACT DEFAULT position
Verify that the jumper is in the SPARE position.
Short circuit in touchpad or footswitch
Unplug the touchpad and footswitch; reset the circuit breaker. If the problem isn’t repeated, the touchpad or footswitch may have shorted.
Short circuit on circuit board
Replace the circuit board. CH-19
Chairs Identifying New Features
Chair Printed Circuit Board (PCB) The chart provides information on new features and associated programming on the PCB.
Feature
Raise the chair with the stop plate limit switch
Programming Plug the chair into an electrical outlet. Tap the chair stop plate three times within five seconds and hold on the third tap. Result:
Enable and disable touchpad and footswitch buttons
The chair base will continue to rise as long as the stop plate is held in. This function is automatically disabled after five minutes but is re-enabled upon each power up. To reset the five-minute timer, depress either circuit breaker until the LEDs turn OFF, then release the circuit breaker.
Place the SPARE jumper in the EN/DIS TP/FS position of the Test Points header P17. Push the buttons to be Enabled or Disabled (PRGM, PRGM 0, PRGM 1, PRGM 2, PRGM 3). Result:
One beep indicates the button is disabled. Three beeps indicate the button in enabled.
Place the SPARE jumper back into the SPARE position of the Test Points header P17.
Handpiece lockout
Plumb a normally open air-electric switch ( kit P/N 61.1384.00) to the air-coolant tubing (green with long white dashes). Insert the two position connector from the air-electric switch into P13 Lockout (next to the transformer)
Diagnostic LEDs
See Diagnostic LEDs for the Circuit Board.
Test Points Header
Use a SPARE jumper to test the chair manual functions (BKUP, BSUP, BSDN, BKDN).
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BK POT and BS POT points allow test meter check of potentiometer voltages and measurement of the analog DC voltage from pin 2 of the potentiometer.
CH-20