Retractable Arm Customer Maintenance Manual

Retractable Arm
Maintenance Manual
P/N RA1403MM Feb 2009

General Information
Abstract This Maintenance Manual (P/N RA1403MM) provides references information

and procedures for using the Retractable Arm.
Manufacturer and Manufacturer: European Representative:

European
Varian Medical Systems, Inc. Ltd. Varian Medical Systems UK Ltd.
Representative
3100 Hansen Way, Bldg. 4A Gatwick Road, Crawley
Palo Alto, CA 94304-1030, U.S.A. West Sussex RH10 9RG
United Kingdom
Notice Information in this document is subject to change without notice and does not
represent a commitment on the part of Varian. Varian is not liable for errors
contained in this document or for incidental or consequential damages in
connection with the furnishing or use of this material.
This document contains proprietary information protected by copyright. No part
of this document may be reproduced, translated, or transmitted without the
express written permission of Varian Medical Systems, Inc.
FDA 21 CFR 820 Varian Medical Systems, Oncology Systems products are designed and
Quality System manufactured in accordance with the requirements specified within this federal
Regulations (CGMPs) regulation.
ISO 13485 Varian Medical Systems, Oncology Systems products are designed and
manufactured in accordance with the requirements specified ISO 13485 quality
systems standards.
CE Varian Medical Systems, Oncology Systems products meet the requirements of

Council Directive MDD 93/42/EEC.
HIPAA Varian’s products and services are specifically designed to include features that
help our customers comply with the Health Insurance Portability and
Accountability Act of 1996 (HIPAA). The software application uses a secure
login process, requiring a user name and password, that supports role-based
access. Users are assigned to groups, each with certain access rights, which
may include the ability to edit and add data or may limit access to data. When a
user adds or modifies data within the database, a record is maintained of the
data that was changed, the users ID and the date and time the changes were
made. This establishes an audit trail that can be examined by authorized system
administrators.
ii Retractable Arm Maintenance Manual, RA1403MM

General Information
Trademarks ARIA®, VARiS Vision®, Clinac®, Eclipse®, Varian® and VMS® are registered
trademarks
ARIA™, VARiS Vision™, Eclipse™ and PortalVision™ are trademarks of Varian
Medical Systems, Inc.
Microsoft®, Windows NT® and Windows® are registered trademarks of
Microsoft Corporation.
All other trademarks or registered trademark are the property of their respective
owners.
Contacting Support If you have access to the Varian Intranet, you can download additional Varian
internal documents from the PSE Web.
To order additional hardcopies of documents, call your local office administrator
If you cannot find the required information in this document nor on the PSE
Web, please contact the appropriate service listed below.
Web
PSE Website http://pse.oscs.varian.com
North America
National Technical Support (NTS), telephone support 800-455-3351
NTS Hardware Support oscs-nts-h@oscs.varian.com
PSE pse_support@oscs.varian.com
Europe
European telephone support +41 41-749-8700
Eclipse & CadPlan support tps.os@varian.com
ARIA, VARiS Vision & technical support varis.os@varian.com
Brachy Help brachyhelp@varian.com
PSE iLab in Switzerland pse.ilab@varian.com
PSE Crawley pseuk@varian.com
Updates For updates to this document, please contact PSE Milpitas/PSE Las Vegas/
PSE Crawley/PSE iLab in Switzerland
Copyright© 2009 Varian Medical Systems Inc., Oncology Systems

All rights reserved. Edited in Switzerland.
Retractable Arm Maintenance Manual, RA1403MM iii

General Information
Document History
1.4.03 Jan 20, 09 Section 3.1.2 updated due CAPA-580, added pictures to section SET
3.2.1. Added pn for motors to section 6.7, corrected various typos
1.4.02 Apr. 22, 08 Added Motor assembly friction performance test MCA
Based on Hazard Analysis Report CP-00085
Converted in a new template
1.4.01 Feb. 3, 99 Updated to Word 97 and new document standard DA
1.4.00 Sept. 30, 97 Small changes in 6.4 RF
1.3.00 May. 05, 97 Included 2.2, minor changes RF
1.2.00 Dec. 22, 94 Section 3.1.2 Shoulder bearing holder check added / RF
Section 6.6.3.3. Hand retract switch angle changed from 2.2 to 2.6
degrees / Section 7. added
1.1.00 Jun. 28, 94 Section 3.4.6 Motion Enable Bar added, PS
minor changes, doc. converted to WinWord 6.0
1.0.00 Nov. 17, 93 Initial Version RF
iv Retractable Arm Maintenance Manual, RA1403MM

Contents
Contents
Distribution and Approval List ......................................................................................... i

Contents ............................................................................................................................ v
1 General...................................................................................................................... 1
2 Spare parts and Maintenance equipment .............................................................. 2
2.1 Special tools, test equipment and supplies.................................................................................2
2.2 How to order Spare parts............................................................................................................2
3 Preventive Maintenance .......................................................................................... 3

3.1 Inspection....................................................................................................................................4
3.1.1 Visual Inspection .........................................................................................................4
3.1.2 Fasteners.....................................................................................................................4
3.1.3 Check gear belts..........................................................................................................6
3.2 Cleaning ......................................................................................................................................6
3.2.1 Cassette cover.............................................................................................................6
3.2.2 Linear Drives and Hand Mechanism ...........................................................................6
3.2.3 Drive Chains ................................................................................................................7
3.2.4 External painted surfaces ............................................................................................7
3.2.5 Handpendant and Charging Station ............................................................................7
3.3 Lubrication/Rust Prevention........................................................................................................7
3.4 Safety Checks.............................................................................................................................8
3.4.1 Emergency Off.............................................................................................................8
3.4.2 Collision Interlock ........................................................................................................8
3.4.3 Collision Override ........................................................................................................8
3.4.4 Movement Channel Two (MCH2)................................................................................9
3.4.5 Enable Supervision......................................................................................................9
3.4.6 Motion Enable Bar .....................................................................................................10
3.4.7 U Arm Motor Assembly Friction Check .....................................................................10
4 Performance Tests................................................................................................. 11
4.1 Stability and Backlash Check....................................................................................................11
4.2 Calibration Check......................................................................................................................11
4.3 Accuracy Check ........................................................................................................................11
5 Interlock Diagnosis ................................................................................................ 12

5.1 Software Interlock Indication List ..............................................................................................12
5.2 Hardware Logic Trip..................................................................................................................12
5.3 Fuse List....................................................................................................................................12
6 Removal, Replacement, and Adjustment Procedures ........................................ 13

6.1 Handpendant ............................................................................................................................13
6.1.1 Battery replacement ..................................................................................................13
6.2 Driver PCB Replacement..........................................................................................................13
6.3 Shaft Encoders and Gear Box Replacement............................................................................13
6.3.1 S-joint Encoder (E571) Replacement........................................................................13
6.3.2 E-joint Encoder (E581) Replacement........................................................................14
6.3.3 Lateral Motion Encoder (E591) Replacement ...........................................................14
6.4 Encoder Adjustments................................................................................................................14
6.4.1 Purpose .....................................................................................................................14
6.4.2 Preparation ................................................................................................................15
6.4.3 Shoulder joint Encoder (E571) Adjustment ...............................................................15
6.4.4 Elbow joint Encoder (E581) Adjustment....................................................................15
6.4.5 Lateral Motion Encoder (E591) Adjustment ..............................................................16
Retractable Arm Maintenance Manual, RA1403MM v

Contents
6.5 Overload Clutch Resetting ....................................................................................................... 16

6.6 Switches Adjustment Procedures ............................................................................................ 16
6.6.1 U Arm Switch ............................................................................................................ 16
6.6.2 F Arm Switch............................................................................................................. 16
6.6.3 Hand Switches .......................................................................................................... 17
6.7 Replacement of Linear Actuators and Lateral Motor ............................................................... 17
6.7.1 Disconnecting and Securing the U- and F Arms ...................................................... 17
6.7.2 Replacement of the Hand Motor............................................................................... 18
6.7.3 Replacement of the U Arm Motor ............................................................................. 18
6.7.4 Replacement of the F Arm Motor.............................................................................. 19
6.7.5 Replacement of the Lateral Motor ............................................................................ 19
6.7.6 To release a motor after it got stuck ......................................................................... 20
7 Abbreviations..........................................................................................................21
7.1 General Abbreviations.............................................................................................................. 21
7.2 Control Rack LED Description ................................................................................................. 21
7.3 Signal Abbreviations ................................................................................................................ 22
vi Retractable Arm Maintenance Manual, RA1403MM

General
1 General
WARNING: Uninformed or careless maintenance of the R Arm can result in poor
performance; damage to the R Arm or its components, its associated Clinac,
or other property; serious bodily injury; and death. All persons who operate
or service the R Arm must read, understand, and be thoroughly familiar with
the information in Section 2, Emergency and Safety, of the Clinac manual, as
well as warnings and cautions contained elsewhere, and take precautions to
protect themselves and other persons from injury and from damaging the
equipment.
Persons who perform any maintenance on the equipment must be familiar with the R Arm
Operator Manual.
If not specially mentioned the Pos. numbers in this manual refer to the assembly drawings and
parts list in the Data Book.
This section provides information for general maintenance, preventive maintenance,

performance tests, adjustment procedures, and removal and replacement of components:
• Section 2 identifies recommended tools, test equipment, and supplies.
• Section 3 describes preventive maintenance procedures, including cleaning and lubrication.
• Section 4 contains performance tests.
• Section 5 contains information for interlock diagnosis.
• Section 6 contains removal, replacement, and required adjustment procedures.
• Section 7 contains lists with abbreviations used in the R Arm documentation.
Retractable Arm Maintenance Manual, RA1403MM 1 of 22

Spare parts and Maintenance equipment
2 Spare parts and Maintenance

equipment
2.1 Special tools, test equipment and supplies
The following table lists the special tools, test equipment and supplies recommended to perform
the maintenance and test procedures in this section:
• Metric open ended spanners
• Metric Allen key (ball type preferred) 2/2.5/3/4/5/6/8/10 mm
• English Allen key 0.05
• Various screw drivers
• Loctite 242
• Red marking sealer
• Light machine oil
• Tool kit (included in delivery)
• Allen keys 2,5 / 3 / 5 / 6 mm
• C spanner
• Open ring spanner 19 mm
2.2 How to order Spare parts

For ordering spare parts, the Part No. of the required part respectively assembly shall be used.
The Part numbers for electrical and mechanical parts can be found in the PV Data Book.
For parts where no direct Part No. is available, the parts list or schematic number plus the
position or component number can be used.
2 of 22 Retractable Arm Maintenance Manual, RA1403MM

Preventive Maintenance
3 Preventive Maintenance
This section contains procedures that can help to ensure that the equipment is ready for use
when needed. The preventive maintenance procedures, performed periodically, include visual
inspection, checking fasteners for tightness, cleaning und lubrication, and adjustments. Refer to
the following table for the Preventive Maintenance Schedule:
Maintenance Action Frequency

Inspection
3.1.1 Visual Inspection Semiannually
3.1.2 Major fasteners Semiannually
3.1.3 Gear belts Annually
Cleaning
3.2.1 Cassette cover Semiannually
3.2.2 Linear actuator tubes and Hand mechanism Semiannually-apply light
machine oil after cleaning
3.2.3 Drive chains Semiannually
3.2.4 External painted surfaces Semiannually
3.2.5 Handpendant and charging station Semiannually
Lubrication/Rust Prevention
3.3 Check and lubrication (where required) Semiannually
Safety Checks
3.4.1 Emergency off Semiannually
3.4.2 Collision interlock Daily
3.4.3 Collision override Weekly
3.4.4 Movement Channel 2 and Standstill Supervision Annually
3.4.5 Enable Supervision Annually
3.4.6 Motion Enable Bar Check Monthly
3.4.7 U Arm Motor Assembly Friction Check Semiannually
Performance tests
4.1 Positioning and Backlash Semiannually
4.2 Calibration Check Daily
4.3 Accuracy Check Semiannually
Varian recommends to keep records of the performed maintenance and checks.

3.1 Inspection
The R Arm should be inspected regularly to be sure that dirt and foreign objects do not
accumulate and impair performance. Use the following procedure:
3.1.1 Visual Inspection

Inspect surfaces of the slide ways (linear actuator tubes and lateral roller bearing slide way) and
lateral gear rack. All bearing surfaces should be smooth, clean, and free of scoring, rust, and
foreign objects; they should be covered with a thin film of light machine oil.
Check for smooth motions, no excessive noise, no striking between Cassette, Arms and
Covers.
3.1.2 Fasteners
WARNING: Under normal operation, nuts, bolts and other fasteners can loosen due to
vibration. This could lead to accessories or machine components moving or
falling, resulting in injuries to patients or technical personnel. Check major
fasteners for tightness at least semiannually. If fasteners became loose,
apply Loctite 242 and retighten them. The Assembly Drawings contain torque
requirements for fasteners used in the R Arm.
CAUTION: Do not ensure tightness by tightening the major fasteners. This breaks the
existing Loctite bond and could allow the fasteners to become loose. Also,
over tightening could over torque the fastener or its threaded hole, causing it
to fail. Instead, check to see if any major fastener can be loosened easily by
hand. If a major fastener has become loose, remove it, apply Loctite 242, and
retighten the fastener.
Some fasteners are secured in the factory by Loctite. In general, any fastener on the R Arm that
has been removed for Maintenance and that is not regularly removed or is not secured with a
lock washer, should be secured with Loctite 242.
Fasteners to be checked:
Item Where ? What to do ?

Hand Motor Check that the safety latches Pos. 107 (Assembly drawings) of
A U Arm Motor the clevis are mounted and its screws Pos. 147 are securely
F Arm Motor fastened (torque 2.9 Nm).
Hand Motor Verify that both setscrews Pos. 190 are tighten. Do not apply
B U Arm Motor Loctite to Pos. 190.
F Arm Motor
U Arm Motor Check that the counter nut on the threaded bolt is screwed
C F Arm Motor against the connection head and both sealer marks are ok (the
connection head is the piece which connects the electro cylinder
via the pivot pin to the clevis).
U Arm Motor Check that no gab exists between the threaded bolt and the
D F Arm Motor electro cylinders drive tube.
Cont. next page.

Cont. from previous page.
Hand Motor Check that the cylinder clamp bolts Pos. 3 and 4 of the three Electro
E U Arm Motor cylinder assemblies are centered and the sealer mark is ok.
F Arm Motor
Shoulder Bearing left Check that the shoulder bearing holders Pos.13 and 14 are securely
F and right tightened by the screws Pos. 161 to the cast chassis ( M12 screws with
10 mm Allen head, torque 83 Nm ).
Hand Motor U Arm Motor F Arm Motor
B B B
A A A
C C D
Cylinder Clamps (3x) Shoulder Bearing left Shoulder Bearing right
E F F

3.1.3 Check gear belts

Inspect the edges of the Gear Belts. Check for damages by wearing out.
For gear box replacement see Section 6.3.
Single gear belts should only be replaced by Varian Service.
3.2 Cleaning
WARNING: Water and cleaning agents that enter the internal workings of the R Arm and
associated equipment could cause short circuiting, resulting in damage to
equipment and possible serious bodily injury. Before cleaning the R Arm ,
turn off all electrical power. Wipe off any spills and dry surfaces as
thoroughly as possible before turning on power.
CAUTION: Jamming, switch power off when cleaning moving parts like arms!
3.2.1 Cassette cover

Clean the cover by using a cloth dipped into a solution of soap and water or a mild spray
cleaner for ordinary dirt and grime. For removing sticky or oil-based substances, use isopropyl
alcohol.
3.2.2 Linear Drives and Hand Mechanism

Remove the side covers and the cover for the Hand mechanism.
Remove dust and dirt accumulated on the linear actuator tubes and on the Hand mechanism
components using a clean dry cloth and a mild spray cleaner. Remove foreign objects from the
ways, rack and actuator tubes. Lubricate actuator tubes and lateral bearing ways with a thin film
of light machine oil immediately after cleaning.
CAUTION: The linear actuator tubes and the lateral bearing ways are made of unpainted
steel and will rust if left unlubricated, especially if they have come into
contact with skin oils. Avoid touching the ways. Never use strong cleaners
on these components. Never leave these components unlubricated for more
than an hour. Light rust does not affect function, but degrades the
appearance and is difficult to remove.

3.2.3 Drive Chains

• Remove the U Arm’s left Collision Cover Pos. 62 with Freedrive screws and Cover Plate
Pos. 110 with screws Pos. 148. Use Allen key to get access to the Hand chain in the U Arm.
• Remove the U Arm's right Collision Cover Pos. 63 with Freedrive screws Pos. 173 and the
Cover Plate Pos. 109 with the screws Pos. 148. Use Allen key 3 mm to get access to the
Elbow chain.
• Remove the F Arm's left Cover Plate Pos. 73 by removing the screws Pos. 176. Use Allen
key 2,5 mm to get access to the Hand chain in the F Arm.
• To get access to the shoulder axis remove the cover Pos. 25 with the two Freedrive screws.
• To get access to the elbow axis remove the two covers Pos. 37 and 38 by unscrewing its
Freedrive screws.
• To get access to the hand axis remove the two covers Pos. 74 and 75 by removing its
Freedrive screws.
• Remove dust and dirt accumulated on the chains and chain tighteners. Using a clean dry
cloths. Remove foreign objects from the chains tighteners and axis. Lubricate axis, chains
and tighteners with a thin film of light machine oil immediately after cleaning.
3.2.4 External painted surfaces

Remove dust or dirt accumulated on external painted surfaces by using a damp cloth that has
been dipped into a solution of soap and water, or by using a mild spray cleaner. Remove oil-
based substances using isopropyl alcohol. Use care to prevent any liquid from getting inside the
internal mechanisms and possibly causing rusting.
3.2.5 Handpendant and Charging Station
WARNING: Take care not to allow any liquids to enter the protective plastic housing of
the hand pendant as corrosion and short circuiting can result in damage to
the pendant or possible malfunction of the couch that could lead to serious
bodily injury.
Remove accumulated dust or dirt from the hand pendant cable by using a cloth dipped into a
solution of soap and water. For removing sticky or oil-based substances use isopropyl alcohol.
To clean the hand pendant use a damp cloth.
Clean contacts on Hand Pendant and Charging Station with alcohol.
Do not touch the contacts with fingers. Never use anything that could scratch the contact
surface.
3.3 Lubrication/Rust Prevention

Certain unpainted parts of the R Arm should be lubricated periodically to prevent rust. These
parts include the chains, lateral ways and the linear actuator tubes (refer to section 3.2.2 and
3.2.3).
Other than this no lubrication or greasing is required on the R Arm.

3.4 Safety Checks

3.4.1 Emergency Off
If installed on a Varian Clinac:
• Switch on the Clinac, then press any Emergency off Button
Check on R Arm Control Rack Front Panel if all LED's are off!
If installed on another than a Varian Clinac:
• Press any Emergency off Button while moving the arm in the position control mode.
Check that the arm immediately starts breaking!
NOTE: If the power is switched off during R Arm motion, recalibration is necessary.
3.4.2 Collision Interlock

• Move the R Arm laterally:
While moving press one of the U Arm side cover. The buzzer must sound and the motion
must stop. Collision interlock will be displayed on the pendant.
• Move the Couch lift:
• Move the Gantry rotation:
• Press the other U Arm side cover:
Listen for the buzzer and check the Pendant Display for Collision interlock.
• Press the Hand mechanism cover:
• Press the Cassette cover:
• Press the Top Collision Bar:
3.4.3 Collision Override

While pressing against one of the U Arms side cover, push the Clinac touchguard button at the
Clinac collimator (on older Clinacs press one of the override buttons at the Retractable Arm)
and check:
• That the couch lift is re-enabled
• That R Arm lateral can be moved at slow speed

3.4.4 Movement Channel Two (MCH2)

Move Arm Drive in single motor mode (Mode, P3/P1, P1, P1, P1/P2) by the thumb wheel at full
speed and during motion remove Jumper J3 (pin) on the Enable PCB.
U Arm Drive (vertical thumb wheel)

Check that: Trip LED lits
U En LED goes off
Arm starts breaking immediately
F Arm Drive (longitudinal thumb wheel)
F En LED goes off
To get access to J3, remove the Control Rack Front Panel.
Calibration is required after these tests if they are not performed at full speed.
Note: The Control Rack contains electronic parts which are sensitive to Electro Static
Discharge. Use appropriate measures.
3.4.5 Enable Supervision

Move Lateral Drive by the lateral thumb wheel and remove Jumper J4 on the Enable PCB.

3.4.6 Motion Enable Bar

The motion enable bar check differs for the Infrared Handpendant and the Hard Wired
Handpendant. The check has to be performed monthly.
WARNING: If the following check is not performed and therefore a failure relating to the
Motion Enable Bars is not detected, the R Arm could move in specific
positions without human action.
The possibility of such a scenario is extremely remote possible, because
several circumstances must occur. That means, during one bar is set to
enable all the time (failure), the other bar must be pressed by mistake and a
setup command must be given.
The consequences to the patient or operator could be in minor shock or
minor injury.
Check Infrared Handpendant

• Display of the handpendant is inactive. Press the left Motion Enable Bar of the handpendant.
→ Display still inactive.
• Release both Motion Enable Bars. Display of the handpendant is inactive. Press the right
Motion Enable Bar of the handpendant. → Display still inactive.
• Press both Motion Enable Bars. → Display will be activated.
• Release both Motion Enable Bars. After ca. 10 seconds the display will be deactivated.
Check Hard Wired Handpendant
• Switch the main power of the R Arm on (if already on , switch off and after ca. 10 seconds on
again).
• Display of the handpendant is inactive. Press the left Motion Enable Bar of the handpendant.
→ Display still inactive.
• Release both Motion Enable Bars. Display of the handpendant is inactive. Press the right
Motion Enable Bar of the handpendant. → Display still inactive.
• Press both Motion Enable Bars. → Display will be activated.
• Release both Motion Enable Bars. After ca. 10 seconds the display will be deactivated.
3.4.7 U Arm Motor Assembly Friction Check

Rotate the Gantry to “head – down” position and move the arm out to position (lvert/long/lat)
-40/0/0 cm.
Mark the shaft on the side with a waterproof pen, this will allow counting the revolution from that
shaft. Initiate a rotation of the U Arm motor shaft by turning in clockwise direction. Release the
hand from the shaft after performing this kick off and monitor the mark on the U Arm Motor
shaft. It has to stop within half a turn.
Perform these steps in the same manner for arm position (-80/0/0).
If the Retractable Arm doesn’t stop within half a turn on either height, the U Arm Motor
Assembly has to be replaced. Please contact Varian Service accordingly.

Performance Tests
4 Performance Tests
The tests described in this section are listed in the recommended order of execution. One or
more performance tests may be used as an aid in troubleshooting and as a validation test
following completion of repairs to make sure that the R Arm works properly.
4.1 Stability and Backlash Check

Position the R Arm at (long/lat/vert) 0/0/-30 cm with Gantry at 12 o'clock. Rotate the Gantry to 6
o'clock and do not correct the R Arm position.
Measure the longitudinal and vertical position of the chamber by the front pointer.
The vertical displacement should be less than 30 mm.
The longitudinal displacement should be less than 15 mm.
4.2 Calibration Check

Move the following positions (long/lat/vert) and measure with the mechanical front pointer or the
cross hairs the position of the center of the chamber surface Gantry at 12 o'clock.
• At 0/0/-20 cm Check for less than 3 mm difference
• At 0/0/-50 cm Check for less than 3 mm difference
(For daily check: At 0/0/-20 cm only, check for less than 5 mm difference but without removing
the cassette cover).
4.3 Accuracy Check

Position the R Arm to a displayed position of (long/lat/vert) 0/0/-20 cm.
Move the Gantry to the various positions and measure the long., the lat., and the vert.
displacement between the mechanical front pointer ( or the cross hairs ) and the center of the
chamber surface. Always reposition the R Arm, so the display shows 0/0/-20 cm.
Gantry 12 o'clock check for accuracy inside sphere with 5 mm radius.

Interlock Diagnosis
5 Interlock Diagnosis
5.1 Software Interlock Indication List
See operators manual Folder Utilities.
5.2 Hardware Logic Trip

The red Trip LED on the front panel of the R Arm Control Rack indicates a H/W Trip.
This happens if:
• The system gets a CPU enable but no HW Enable.
• At U Motor or F Motor is a voltage but its driver gets no enable.
• A CPU time out occurs.
• CPU activates emergency stop.
Resetting: Clear all Handpendant interlocks than press the Trip Reset Button at the Control
Rack Front Panel.
WARNING: Interlocks always indicate a problem in the system and must not be cleared
routinely, a careful investigation is necessary. At least the calibration must
be rechecked.
5.3 Fuse List

Name Value Location
Primary Mains Contactor 1A on Transformer Assembly
Secondary 3-ph. Supply Fuses FU 1/2/3 6,3 x 32 mm, 10 A on PSU PCB
Logic Supply Fuse FU 5 5 x 20 mm, 1 A on PSU PCB
Driver Supply Fuse FU 4 5 x 20 mm, 1 A on PSU PCB
Hand Drive Fuse FU 2 5 x 20 mm, 4 A on H+L Driver PCB
Lateral Drive Fuse FU 1 5 x 20 mm, 2,5 A on H+L Driver PCB
F Driver Input 6,3 x 20 mm, 10 A on F Driver PCB
U Driver Input 6,3 x 20 mm, 10 A on U Driver PCB
NOTE: All of the above mentioned PCB's contain electronic parts which are sensitive to
Electro Static Discharge. You must use appropriate measures to ensure no
damage to such part can happen.

Removal, Replacement, and Adjustment Procedures
6 Removal, Replacement, and

Adjustment Procedures
WARNING: Do not attempt maintenance on an R Arm that is inoperative due to a collision
or if there is any other reason to suspect structural damage. A damaged
R Arm could collapse and cause serious injury. Contact your Varian service
representative. If the overload clutch has tripped contact Varian service for
inspection and resetting.
6.1 Handpendant
6.1.1 Battery replacement
To replace the battery, refer to drawing B3 00234 Handpendant Assy. Remove the four
screws Pos. 18 on the top and the two screws Pos. 17 on the bottom side of the enclosure-
bottom Pos. 16. Lift the enclosure-bottom carefully and remove the cable from the PCB-Charge
Pos. 14. Unplug the connector of the battery and remove it. Insert the battery and pay attention
that the plug is connected correctly. Reconnect the plug to the PCB-Charge Pos. 14 and fit the
enclosure-bottom Pos. 16 to the enclosure-top Pos. 1. Be careful, do not damage the cable. Do
not tight the screws to heavy. Check that actuating the enable bar switches the Pendant on.
Releasing the enable bars switches the power off after a several seconds time delay.
6.2 Driver PCB Replacement

WARNING: For safety reasons each driver has its own current limit set by the motor
modules. The F Arm motor modules must only be used on the F Arm Drivers
PCB. The U Arm motor modules must only be used on the U Arm Driver PCB.
Be aware that interchanging them reduces the safety of the system.
6.3 Shaft Encoders and Gear Box Replacement

6.3.1 S-joint Encoder (E571) Replacement
To get access remove the "side cover right".
To remove the encoder, untight the grabscrew on the encoder shaft (2 mm Allenkey) and
remove the encoder.
From the old encoder remove the metal slot plate Pos. 17 by unscrewing the three screws Pos.
148 M4x6 (3 mm Allenkey).
Mount the metal plate to the new encoder.
Place the encoder shaft back into the axis of the gear box.
The encoder has to be held in place by the pin in gearbox through the slot in the metal plate.
The metal plate must be placed so that the encoder connector is pointing to about 11 o'clock
when locking from the right hand side towards the R Arm.

6.3.2 E-joint Encoder (E581) Replacement

To get access to the encoder remove the "side cover left" and move the U Arm to horizontal.
Then remove the collision cover left Pos. 62 by removing the two Freedrive screws Pos. 173.
Also remove the cover Pos. 110 by the three screws Pos. 146 M4x12 (3mm Allen key).
Remove the aluminum cover of the U Arm at the elbow left side Pos. 38 by the two Freedrive
screws Pos. 174.
Through the whole underneath that cover you get access to the gear box spanner screw,
untight that screw (4 mm Allenkey) (this screw is for tightening the first tooth belt, between
elbow axis and gear box).
Then remove the two screws M8x12 underneath the U Arm (5 mm Allen key) which hold the
gearbox in place. Remove the gear box.
Untight the screw which holds the encoder shaft (2 mm Allenkey) on the gearbox axis.
Change the metal slot plate Pos. 42 to the new encoder (2,5 mm Allen key) three screws, make
sure the slot has the same orientation.
Mount the new encoder. The cable must point towards the elbow. Mount the gearbox back into
the R Arm keep the screws loose. Slightly tight the first tooth belt with the spanner screw. Then
fix with counternut and tight the gear box screws M8x12.
6.3.3 Lateral Motion Encoder (E591) Replacement

To get access to the "Lateral Drive Assembly" remove the cassette cover together with the
cassette. (Note: Before unplugging the Cassette connection, switch the PV Acquisition Station
off).
Remove the two screws Pos. 155 (M6x16) use 5 mm Allen key. Remove the Lateral Drive
Assembly. Unscrew the encoder by loosening two and removing the third of the screws Pos.
145 which are holding the encoder via the washers Pos. 198. Change the coq wheel Pos. 102
and the adjustment knob Pos. 100 to the new encoder (use 0,05 inch Allen key).
Mount and connect the new encoder to the Lateral Drive Assy.
Mount the assy: The motor pinion must not have any play to the Lateral Gear Rack, while the
encoder must have a little (very little) play.
6.4 Encoder Adjustments

6.4.1 Purpose
The R Arm has 3 encoders, for lateral motion of the cassette tray, S-joint and E-joint rotations.
Each encoder delivers one pulse (called "zero pulse") per revolution. When this pulse is
delivered, the correspondent LED on the remote control PCB B561 lights on. Note that the
pulse is quite short and you have to turn slowly the encoder axis in order to find the right
position when the light goes on. It is important that each encoder is adjusted so that this pulse is
delivered for a special position of R Arms and cassette tray. This procedure has to be
performed for example when an encoder is replaced.

6.4.2 Preparation
• For S-joint axis encoder only, remove the axis cover on the top of R Arm.
• For E-joint axis encoder only, remove the collision and cover plates on left side of the U Arm.
Remove also the plastic cap that closes the hole designed to reach the encoder axis screw
(top of the U Arm).
• For lateral motion encoder only, remove the cassette collision cover and the cassette itself
from the cassette tray.
• Move the R Arm to the retracted position.
• The F Arm, U Arm and cassette tray must be vertical. Check with a spirit level and adjust if
necessary using emergency buttons. The cassette tray must be centered laterally in relation
to the R Arms.
6.4.3 Shoulder joint Encoder (E571) Adjustment

• Loosen the grubscrew of the encoder axis pinion use 2 mm Allen key.
NOTE: If the screw cannot be reached when the R Arm is retracted, the S-joint axis cog
wheel Pos.40 has to be turned until the screw is visible. To get access to the
screw: Remove the Shoulder axis cover Pos. 25, then loosen the S-joint axis
locking screw Pos. 151 (M5x16) use 4 mm Allen key, turn the cog wheel until the
grub screw is accessible, and tighten the locking screw Pos. 151 .
• Turn slowly the encoder axis until the LED LD7L on the remote control PCB B561 lits.
• Tighten the screw of the encoder axis pinion.
• Recheck correct adjustment.
6.4.4 Elbow joint Encoder (E581) Adjustment

• Loosen the grubscrew of the encoder axis pinion through the hole on top of the U Arm (use 2
mm Allen key).
NOTE: If the screw cannot be reached when the R Arm is retracted, the E-joint axis cog
wheel Pos 41 has to be turned until the screw is visible. Loosen the coq on the
Elbow axis by untightening the screw Pos. 159 (M10x20) in its center with an 8 mm
Allen key. Retighten it after adjusting.

• Turn slowly the encoder axis until the LED LD6U on the remote control PCB B561 lights on.
• Mount back the plastic cap, the cover plate and the collision cover plate.
• Recheck correct adjustment.
6.4.5 Lateral Motion Encoder (E591) Adjustment

• Loosen the grub screw Pos 186 of the encoder axis coq wheel Pos. 102 (use 0.05 inch
Allen key)
NOTE: If the screw cannot be reached when the cassette tray is vertical, the encoder axis
pinion has to be turned first as following:
• Loosen the two screws Pos. 155 (M6x16) that hold the lateral drive assembly in
place (it is not necessary to remove the screws).
• Pull the assembly away from the gear rack to disengage the gear.
• Turn the encoder axis until the screw is visible.
• Tighten the two screws that hold the assembly in place. The motor axis should
have no play, while the encoder axis should have a little bit play.
• Turn the encoder axis by the knob Pos. 100 until the LED LD5L on the remote control PCB
B561 lights on.
6.5 Overload Clutch Resetting

A force, which is high enough to activate the Elbow joint overload clutch, could do severe
damage to various drive parts. It needs a careful inspection of these parts. Therefore this
inspection and replacement of such parts must be done only by Varian Service.
Varian Service will also reset and seal the Overload Detection System.
6.6 Switches Adjustment Procedures

6.6.1 U Arm Switch
The U Arm switch enables, via the CPU, the proper zero pulse of the Shoulder encoder to be
read by the motion controller.
It must be adjusted, on its holder Pos. 22, so that the switch is made 2° to 5° before the U Arm
is retracted (fully vertical).
Check that the switch is activated not just at the end of the ramp at the activator Pos. 57. On the
other hand you have to check that the switch lever has at least 0,1 mm clearance even when
the R Arm passed the vertical position. Use a 5,5 mm spanner.
6.6.2 F Arm Switch

The F Arm switch enables, via the CPU, the proper zero pulse of the Elbow Encoder to be read
by the motion controller.

It must be adjusted, on its holder Pos. 18, so that the switch is made 2° to 5° before the F Arm
is retracted (fully vertical). Check that the switch is activated not just at the end of the ramp at
the activator Pos. 48.
On the other hand you have to check that the switch lever has at least 0,1 mm clearance even
when the R Arm passed the vertical position. Use a 5,5 mm spanner.
6.6.3 Hand Switches

The hand switches are positioning the Hand in the Vertical and the Horizontal position. They are
directly responsible for the proper hand positioning.
• The Hand out switch must be positioned on the Holder Pos. 15 so that the switch is activated
by one ramp of the activator Pos. 52. The switch must be made with the Hand mechanism
(cassette mounted, Gantry 12 o'clock) at 88,7° (+/- 0,1°) that's 1,3° before horizontal.
• To check the Switch point, give short movement pulses by the emergency buttons and listen
for the contact to snap.
The switch has to be made not just at end of the ramp but the switch lever needs at least 0,1
mm clearance even when you move to the motors mechanical end stop. Use a 5,5 mm
spanner.
• The Hand retract switch must be positioned on the Holder Pos. 15 so that the switch is
activated by the other ramp of the activator Pos. 52. The switch must be made with the Hand
mechanism (Gantry at 12 o'clock) at 2,6° (+/- 0,3°) before vertical.
6.7 Replacement of Linear Actuators and Lateral

Motor
WARNING: Removal and replacement of these components are not required for routine
maintenance. Damage to the equipment or injury to personnel may result if
they are not properly handled. Do not attempt to repair these components.
These activities are more complex than they appear and should be attempted
only by trained Varian Service representatives.
6.7.1 Disconnecting and Securing the U- and F Arms

See Operation Manual: Emergency and Safety.

6.7.2 Replacement of the Hand Motor

Remove the left R Arm fiber glass side cover.
Rotate the Gantry to 9 o'clock.
Remove the Safety Latch Pos. 107 of the Hand clevis Pos. 34 by removing the two screws Pos.
147 (M4x8) use 3 mm Allen key. Untight (do not remove) the two grab screws Pos. 190 in the
front of the hand devise Pos. 34 use 2,5 mm Allen key. Remove the Pin Pos. 47.
Untight the Cylinder Clamp Bolt Pos. 3 at the Hand Motors Bottom End. Use two 5 mm Allen
keys. Push the Clamp bolt out from the side where you loosened the screw. Mount the motor
(B200075) by remounting the components in the reversed order.
NOTE: The Cylinder Clamp bolt must be centered and both screw must be firmly tightened
and marked with sealer. See also Note 2 on Assembly drawings.
WARNING: The proper mounting of the Safety latch pos. 147 and the Cylinder Clamp Bolt
Pos. 3 are absolutely necessary to ensure the safety of the system.
6.7.3 Replacement of the U Arm Motor

Remove the left R Arm fibre glass side cover.
Remove the Safety Latch Pos. 107 of the U Arm clevis by removing the two screws Pos. 147
(M4x8) use 3 mm Allen key. Untight (do not remove) the two grab screws Pos. 190 in the front
of the U Arm devise use 2,5 mm Allen key. Remove the Pivot Pin Pos. 53.
Untight the Cylinder Clamp Bolt Pos. 4 at the U Arm Motors Bottom End. Use two 5 mm Allen
The connection Head at the Top of the Electro cylinder is part of the motor
assembly (connecting the motor assy to the devise via the Pivot Pin).
The connection head and its counter nut are glued to the Electro cylinder's
thread. It must be marked with sealer, If the Connection head has been
disassembled from the rest of the electron cylinder. The motor assembly
must not be used for treatment anymore.

6.7.4 Replacement of the F Arm Motor

Remove the right R Arm fiber glass side cover.
Remove the Safety Latch Pos. 107 of the F Arm clevis Pos. 32 by removing the two screws
Pos. 147 (M4x8) use 3 mm Allen key. Untight (do not remove) the two grab screws Pos. 190 in
the front of the F Arm devise Pos. 32 use 2,5 mm Allen key. Remove the Pin Pos. 53.
Untight the Cylinder Clamp Bolt Pos. 4 at the F Arm Motors Bottom End. Use two 5 mm Allen
The connection Head at the Top of the Electro cylinder is part of the motor
assembly (connecting the motor assy to the devise via the Pivot Pin).
The connection head and its counter nut are glued to the Electro cylinder's
thread. It must be marked with sealer, if the Connection head has been
disassembled from the rest of the electron cylinder. The motor assembly
must not be used for treatment anymore.
6.7.5 Replacement of the Lateral Motor

To get access to the "Lateral Drive Assembly" remove the cassette cover together with the
cassette.
NOTE: Before unplugging the Cassette connection plug, switch off the PV acquisition
station).
Remove the two screws Pos. 155 (M6x16) use 5 mm Allen key. Remove the Lateral Drive
Assembly. Unscrew the motor from the Assy. plate by its three holder screws.
Mount the new motor to the assy. plate.
Mount the assy: The motor pinion must not have any play to the Lateral gear rack, while the
encoder must have a little (very little) play.

6.7.6 To release a motor after it got stuck

For Hand motor or U Arm Motor, remove the R Arm left side fiber glass cover and rotate the
gantry to 9 o'clock.
For the F Arm motor, remove the R Arm right side cover and rotate the gantry to 3 o'clock (see
also operators manual Figure 7).
Remove the Safety Latch Pos. 107 of the clevis of the stuck motor by removing the two screws
Pos. 147 (M4x8) use 3 mm Allen key.
Untight (do not remove) the two grub screws Pos. 190. Use 2,5 mm Allen key.
Remove the pivot pin which frees the motor assembly.
Rotate the top end of the motor assembly at least one half turn and reassemble the parts again.
WARNING: The proper screwing of the pivot pin by the safety latch is very important to
the safety of the R Arm.
Always recalibrate the R Arm after part replacements and readjustments as described in the
Operation Manual.

Abbreviations
7 Abbreviations
7.1 General Abbreviations
A selection of abbreviations which are used in the R Arm documentation.
CPU Central Processing Unit PCB

LED Light Emitting Diode
PCB Printed Circuit Board
PIXDMC Digital Motion Controller PCB
PSU Power Supply Unit
7.2 Control Rack LED Description

Short description of some LED’s at the Front Panel of the Control Rack.
Trip A Hardware supervision trip has been activated

MCH2 Movement Channel Two is enabled
Overload The elbow joints Overload detection system is activated
Em Mov The Emergency Movement switch on the Remote Control PCB is in
the Emergency Movement Control position
Em Stop LED is on if the CPU sends no Emergency Stop command
Interl LED is on if no collision Interlock devices is detecting a collision
F En F Arm drive is enabled
U En U Arm drive is enabled
Prp Com A Proper movement Command has been recognized by the CPU

Abbreviations
7.3 Signal Abbreviations

A list of signal abbreviations in the R Arm Databook
AGND Analogue Ground

ARM EN NON CL Arm Enable Non Clinac ( used for other than Varian Linacs )
CONTR. SYS READY Control System Ready
DGND Digital Ground
EM. M BLOCK Emergency Movement Block
EXT. CONT. EN External Control Enable
F ref. F Arm Reference Voltage ( analogue speed and direction signal )
L PWM Lateral Pulse With Modulation
MCH2 Movement Cannel Two
N CL. EM. OFF Non Clinac Emergency Off ( used for other than Varian Linacs )
OVERL. Overload ( elbow joint overload detection system )
PEND EN Pendant Enable
PRP.COM Proper Movement Command Recognized
PRP.COM EN Proper Movement Command Recognized is Enabling
PWGND Power Ground ( Ground for Power Drives )
RXDA Read Data interface A (RS 232)
RXDB Read Data interface B (RS 232)
RX+A Read Data interface A (RS 485)
RX+B Read Data interface B (RS 485)
SW F RET Switch F Arm Retracted
SW H OUT Switch Hand Out
SW H RET Switch Hand Retracted
SW U RET Switch U Arm Retracted
TXDA Transmit Data interface A (RS 232)
TXDB Transmit Data interface B (RS 232)
TX+A Transmit Data interface A (RS 485)
TX+B Transmit Data interface B (RS 485)
U ref U Arm Reference Voltage ( analogue speed and direction signal )
Z.P.F. Zero Pulse F Arm
Z.P.L Zero Pulse Lateral
Z.P.U Zero Pulse U Arm

Contents
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Retractable Arm

P/N RA1403MM Feb 2009

Abstract This Maintenance Manual (P/N RA1403MM) provides references information

Manufacturer and Manufacturer: European Representative:

CE Varian Medical Systems, Oncology Systems products meet the requirements of

ii Retractable Arm Maintenance Manual, RA1403MM

Copyright© 2009 Varian Medical Systems Inc., Oncology Systems

Retractable Arm Maintenance Manual, RA1403MM iii

iv Retractable Arm Maintenance Manual, RA1403MM

Distribution and Approval List ......................................................................................... i

3 Preventive Maintenance .......................................................................................... 3

5 Interlock Diagnosis ................................................................................................ 12

6 Removal, Replacement, and Adjustment Procedures ........................................ 13

Retractable Arm Maintenance Manual, RA1403MM v

6.5 Overload Clutch Resetting ....................................................................................................... 16

vi Retractable Arm Maintenance Manual, RA1403MM

This section provides information for general maintenance, preventive maintenance,

Retractable Arm Maintenance Manual, RA1403MM 1 of 22

2 Spare parts and Maintenance

2.2 How to order Spare parts

2 of 22 Retractable Arm Maintenance Manual, RA1403MM

Maintenance Action Frequency

Varian recommends to keep records of the performed maintenance and checks.

Retractable Arm Maintenance Manual, RA1403MM 3 of 22

3.1.1 Visual Inspection

Item Where ? What to do ?

Cont. next page.

4 of 22 Retractable Arm Maintenance Manual, RA1403MM

Cont. from previous page.

Hand Motor U Arm Motor F Arm Motor

Cylinder Clamps (3x) Shoulder Bearing left Shoulder Bearing right

Retractable Arm Maintenance Manual, RA1403MM 5 of 22

3.1.3 Check gear belts

3.2.1 Cassette cover

3.2.2 Linear Drives and Hand Mechanism

6 of 22 Retractable Arm Maintenance Manual, RA1403MM

3.2.3 Drive Chains

3.2.4 External painted surfaces

3.2.5 Handpendant and Charging Station

3.3 Lubrication/Rust Prevention

Retractable Arm Maintenance Manual, RA1403MM 7 of 22

3.4 Safety Checks

3.4.2 Collision Interlock

3.4.3 Collision Override

8 of 22 Retractable Arm Maintenance Manual, RA1403MM

3.4.4 Movement Channel Two (MCH2)

U Arm Drive (vertical thumb wheel)

3.4.5 Enable Supervision

Retractable Arm Maintenance Manual, RA1403MM 9 of 22

3.4.6 Motion Enable Bar

Check Infrared Handpendant

3.4.7 U Arm Motor Assembly Friction Check

10 of 22 Retractable Arm Maintenance Manual, RA1403MM

4.1 Stability and Backlash Check

4.2 Calibration Check

4.3 Accuracy Check

Retractable Arm Maintenance Manual, RA1403MM 11 of 22

5.2 Hardware Logic Trip

5.3 Fuse List

12 of 22 Retractable Arm Maintenance Manual, RA1403MM

6 Removal, Replacement, and

6.2 Driver PCB Replacement

6.3 Shaft Encoders and Gear Box Replacement

Retractable Arm Maintenance Manual, RA1403MM 13 of 22