2030 OPTIFLEX 2
®
SERVICE MANUAL
Models:
2030
(Serial Numbers- 5000 and above)
2060
(Serial Numbers- 5000 and above)
ISO 9001/ISO 13485 CERTIFIED
TABLE of CONTENTS
OptiFlex® 2030 & 2060
Forword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1- Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
1.1 Precautionary Symbol Definitions . . . . . . . . . . . . . . . .2
1.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2- Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3- Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
4- Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
6- Removal & Replacement Procedures . . . . . . . . . . . .12-17
8-Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19
9- Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-23
©2002 Encore Medical Corporation or its affiliates, Austin, Texas, USA. Any use of editorial, pictorial or layout composition of this publication without express written consent from
the Chattanooga Group of Encore Medical, L.P. is strictly prohibited. This publication was written, illustrated and prepared for print by the Chattanooga Group of Encore Medical, L.P.
FOREWORD
OptiFlex® 2030 & 2060
Read, understand and follow the Safety Precautions and information contained in this manual.
This manual contains the necessary safety, and field service information for those Field Service Technicians, approved by
Chattanooga Group, to perform field service on the OptiFlex CPM Models 2030 and 2060 units.
At the time of publication, the information contained herein was current and up to date. However, due to continual
technological improvements and increased clinical knowledge in the field of electrotherapy, as well as Chattanooga Group’s
policy of continual improvement, Chattanooga Group reserves the right to make periodic changes and improvements to their
equipment and documentation without any obligation on the part of Chattanooga Group.
It is the sole responsibility for field technicians to stay informed and trained in the latest technology utilized in the OptiFlex
CPM Models 2030 and 2060 units by Chattanooga Group from time to time, as significant improvements are incorporated,
Service Bulletins will be produced and made available on our web site (www.chattgroup.com) in lieu of reprinting a complete
manual prematurely. These Service Bulletins will provide updated service information and technology improvements to the
OptiFlex CPM Models 2030 and 2060 for use by approved service technicians.
“Approved Service Technician” Definitions;
1. Level I-
Those Field Service Technicians that have successfully completed the minimal training required by Chattanooga
Group, in basic service techniques.
2. Level II-
Those Field Service Technicians that have successfully completed Level I Training as well as Level II training as
required to perform specific troubleshooting and repair techniques and procedures.
3. Level III- Those Field Service Technicians that have successfully completed Levels I & II Training as well as Level III
Advanced Training as required to perform all necessary Troubleshooting and Repair techniques. The Technician
having successfully completed the three levels of training and coupled with experience should have the ability to
train other technicians in Level I and Level II Training with the necessary Training Materials from Chattanooga
Group.
4. Temporary-
Chattanooga Group, at its discretion and based on known experience of the technician, may grant a
“Temporary Approval” to a field technician for particular troubleshooting and repair of a specific unit requiring
immediate attention. This “Temporary Approval” in no fashion acknowledges the training level of a technician
as defined above. This “Temporary Approval” is utilized only in unique situations for a specific unit for a
specific service technique only and is documented as such.
Due to the complex nature of the technology utilized by Chattanooga Group, the recommended troubleshooting techniques are
to determine “Bad Board” and board replacement only. No board component level troubleshooting is recommended nor will
information or parts be supplied by Chattanooga Group. Any board component level troubleshooting performed will be at sole
risk and liability of the Service Technician performing such troubleshooting techniques.
This equipment is to be sold and used only under the prescription and supervision of a licensed medical practitioner.
This equipment is to be serviced only by an “Approved Service Technician”.
For Additional Service Contact:
Chattanooga Group
CPM Support Department
Toll Free: 1-866-266-0026
Outside USA: +1-423-870-7200
1
SAFETY PRECAUTIONS
OptiFlex® 2030 & 2060
Precautionary Symbol Definitions
The precautionary instructions found throughout this
manual are indicated by specific symbols.
Understand these symbols and their definitions before
operating or servicing this equipment. The definitions of
these symbols are as follows:
Safety Precautions
Read, understand and follow all safety precautions
found in this manual. Below are general safety
precautions that must be read and understood before
attempting any service techniques on these units.
Throughout this manual specific safety precautions will
be found. Read, understand and follow all safety
precautions.
! CAUTION
! CAUTION
A. CAUTION
• Read this manual before assembling or using OptiFlex.
• Only use OptiFlex on solid, flat surfaces.
• Extreme caution should be taken when in use around
children.
• Use OptiFlex only as described in this manual.
• Keep hair, loose clothing, fingers and all parts of body
away from moving parts of OptiFlex.
• DO NOT use OptiFlex outdoors or on wet surfaces.
• Materials may become flammable or combustible if
exposed to a source of ignition.
• Disconnect electrical supply before servicing or
cleaning. Failure to do so could result in electrical
shock or personal injury.
• DO NOT use OptiFlex while smoking or around
open flame.
• Exercise caution when using accessories and auxiliary
devices such as muscle stimulators, ColPaCs and
other modalities.
• Turn power off before unplugging.
• Unplug the power supply by grasping the plug not
the cord.
• Damage may occur to OptiFlex if not transported and
stored between 0° and 140°F (-18° to 60°C).
• Unplug power supply when not in use.
• DO NOT use if cord or plug is damaged.
• Use extra care when touching metal of OptiFlex after
exposure to cold or heat.
• DO NOT handle any electrical apparatus with wet
hands.
• Condensation could result and damage OptiFlex if unit
is subjected to periods of low temperatures followed by
periods of high temperatures.
• DO NOT use on unstable surfaces or liquid filled
devices such as water mattresses or flotation pads.
Text with a “CAUTION” indicator will explain possible
Safety infractions that could have the potential to
cause minor to moderate injury or damage to
equipment.
!
WARNING
B. WARNING
Text with a “WARNING” indicator will explain possible
Safety infractions that will potentially cause serious
injury and equipment damage.
! DANGER
C. DANGER
Text with a “DANGER” indicator will explain possible
Safety infractions that are imminently hazardous
situations that would result in death or serious injury.
D. EXPLOSION HAZARD
Do not use this equipment in the presence of
flammable anesthetics. This symbol is also
prominently displayed on the serial number plate of
the unit.
E. NOTE:
Throughout this manual “NOTE” may be found.
The Notes are helpful information to aid in the
particular area or function being described.
2
SAFETY PRECAUTIONS
OptiFlex® 2030 & 2060
Safety Precautions Continued
!
DANGER
CAUTION
• Explosion hazard if used in the presence of
flammable anesthetics. The warning symbol for
this hazard is prominently displayed on the serial
number plate.
• OptiFlex has been designed for maximum protection
against the exposure of urinary incontinence.
Precautionary measures should still be taken, when
any type of liquid comes in contact with an electrical
apparatus.
• OptiFlex is made from high impact materials. However,
structural failure or hidden damage can be caused by
shock, impact or dropping the unit. Use care when
transporting and storing unit to avoid equipment
damage.
• To isolate the unit from the power source, disconnect
the power cord at the wall outlet.
• OptiFlex should only be used after the operator has
thoroughly read and understands the User Manual.
• Rapid increases in ROM can cause complications.
• OptiFlex is not to be used in the presence of flammable
anesthetic mixture with air or with oxygen or
nitrous oxide.
!
• Exercise caution when using accessories and auxiliary
devices such as muscle stimulators, ColPaCs and
other modalities. Route lead wires, hoses, tubes, etc
away from the working mechanism of the OptiFlex to
help prevent damage to the Optiflex and any other
modality used with it.
• Unconscious patients or patients under heavy
influence of medication must be constantly attended
and monitored while the OptiFlex is in use.
• The OptiFlex unit must be completely visible at all
times during use. Never cover the unit with bedding or
any other means of concealment while in operation.
• If the OptiFlex is used in conjunction with the optional
OptiFlex “T” trolley, make certain the OptiFlex unit is
resting on the mattress of the bed and the OptiFlex “T”
is suspended with no weight on the casters to prevent
possible movement of the unit and or possible injury
to patient.
• OptiFlex is a prescription device used under the
supervision of or by the order of a physician or other
licensed healthcare provider.
WARNING
• Make certain that the unit is electrically grounded by
connecting only to a grounded electrical service
receptacle conforming to the applicable national and
local electrical codes.
• Keep hair, loose clothing, loose bedding, fingers and
toes away from the hinge components of the unit.
• Do not use the OptiFlex outdoors, on wet or gel filled
surfaces. Use only on firm, flat, stable level surfaces to
ensure stability of the unit while in operation.
• Materials of the unit may become flammable or
combustible if exposed to a source of ignition.
• Heat generated within the pendant may cause ignition
of the pendant if wrapped in bedding or other materials.
• DO NOT use OptiFlex while smoking or around open
flame.
• OptiFlex has been designed for maximum protection
against the exposure of urinary incontinence.
Precautionary measures should still be taken when any
type of liquid comes in contact with an electrical
apparatus.
• Always turn off and unplug unit from electrical source
before servicing or cleaning. Failure to do so could
result in electrical shock or personal injury.
• Handle the unit only when unit is dry and hands are dry
to prevent electrical shock.
• Do not use the OptiFlex as a toy.
3
THEORY of OPERATION
OptiFlex® 2030 & 2060
2.1 Overview
The OptiFlex 2030 & 2060 CPM products are comprised of two PC Board assemblies housed within the head section of
the unit along with the Motor and Gearbox Assembly. These components are linked to a Pendant via a cable connection
that provides the operator access for set up and operation of the unit. The basic components of the OptiFlex CPM units
are Frame Base, Motor and Gearbox Assembly, Power Transformer, Motor Control Board, Power Supply Circuit,
Adjustable Femur Bar, Adjustable Foot Plate and User Interface (Pendant). The units are designed for patient use only
with the Patient Softgoods Kit (Part Number 20533). This single patient use softgoods kit is designed specifically for the
OptiFlex 2030 & 2060 CPM units and provides proper installation and support to the patient during therapy.See Figure 2.1.
If necessary, two units may be used simultaneously for patients that have been prescribed dual therapy by a licensed
professional. If two units are prescribed for use simultaneously, use with the optional bed mount to secure the units in
position during therapy.
*PATIENT
SOFTGOODS KIT
PART NUMBER 20533
FLEXION ANGLE
POTENTIOMETER
ADJUSTABLE
FEMUR BAR
ADJUSTABLE
TIBIAL TUBES
ADJUSTABLE
FOOT REST
FRAME
BASE
UNIT
HEAD
USER INTERFACE
(PENDANT)
*Single Patient Use
FIGURE 2.1
4
NOMENCLATURE
OptiFlex® 2030 & 2060
3.1 OptiFlex Familiarization
The nomenclature graphics below, Figure 3.1, indicate the
general locations of the major components of the OptiFlex
CPM unit.
ADJUSTABLE
FOOT REST
FOOT REST
PIVOT
ADJUSTMENT
Know the components and their functions before performing
any operation of or service to the OptiFlex 2030 or 2060
CPM unit.
TIBIAL
ADJUSTMENT
KNOB
FLEXION ANGLE
POTENTIOMETER
(KNEE POT)
FEMUR BAR
ADJUSTMENT
SCALE
UNIT
HEAD
FRAME
BASE
USER INTERFACE
(PENDANT)
SEE PAGE 6
ADJUSTABLE
FEMUR BAR
DRIVE BELT
AND GEARS
MOTOR & GEARBOX
ASSEMBLY
MAIN
PC BOARD
MOTOR
CONTROL
BOARD
Power Supply not illustrated.
FIGURE 3.1
5
NOMENCLATURE
OptiFlex® 2030 & 2060
3.2 OptiFlex Pendant Familiarization
The Pendant nomenclature graphics below, Figure 3.2,
indicate the location and functions of the OptiFlex CPM
Pendant (user interface).
Know the components and their functions before performing
any operation of or service to the OptiFlex 2030 or 2060
CPM unit.
OSCILLATION ZONE™
Carriage will oscillate three times between the
flexion angle and 10° less than the flexion angle.
FAST BACK™
Carriage will slow down within
15° of the flexion angle.
*PROGRESSIVE ROM™
Unit will automatically increase the programmed flexion
angle by 1° every hour up to a maximum of 5° per day.
MODE
Used with Fast Back, Oscillation
Zone and Progressive ROM*
UP ARROW
RESET
Allows user to increase treatment parameters.
Clear previous treatment
settings and completed cycles
EXTENSION
Displays the extension angle.
DOWN ARROW
Allows user to decrease treatment parameters.
FLEXION
Displays the flexion angle.
COMFORT ZONE™
Temporarily decreases the flexion ROM* when
discomfort is experienced.
SPEED
Displays the speed of operation.
EMERGENCY START/STOP
EXTENSION/FLEXION DELAY
Start or Stop Treatment
Allows user to program carriage to stop at both the
extension and flexion angle for the time programmed.
*Range Of Motion
FIGURE 3.2
6
SPECIFICATIONS
OptiFlex® 2030 & 2060
MODEL 2030
Input:
120 VAC~50/60 Hz, 40 Watts
Weight:
28 Lbs. (13 kg)
Length:
37 in. (94 cm)
Operation
Knee Flexion ROM Limit:
120°
Knee Extension Limit:
-10° Hyper Extension
Knee Speed Range :
30°/min. to 150°/min. Nominal
Maximum Patient Weight:
350 Lbs. (159kg.)
Calf Length Range:
(knee joint to sole of foot)
10 to 23.5 in. (25.4 to 59.7 cm)
Thigh Length Range:
(hip joint to knee joint)
12 to 19 in. (30.5 to 48.3 cm)
Transportation and Storage
Unit should be transported and stored within the following conditions:
Temperature:
0° - 140°F (32° - 60°C)
Humidity:
0 - 75% Relative Humidity
MODEL 2060 (International)
Input:
230 VAC~50/60 Hz, 40 Watts
Weight:
28 Lbs. (13 kg)
Length:
37 in. (94 cm)
Operation
Knee Flexion ROM Limit:
120°
Knee Extension Limit:
10° Hyper Extension
Knee Speed Range :
30°/min. to 150°/min. Nominal
Maximum Patient Weight:
350 Lbs. (159kg.)
Calf Length Range:
(knee joint to sole of foot)
10 to 23.5 in. (25.4 to 59.7 cm)
Thigh Length Range:
(hip joint to knee joint)
12 to 19 in. (30.5 to 48.3 cm)
Transportation and Storage
Unit should be transported and stored within the following conditions:
Temperature:
0° - 140°F (32° - 60°C)
Humidity:
0 - 75% Relative Humidity
7
TROUBLESHOOTING
OptiFlex® 2030 & 2060
5.1 OptiFlex Software Error Messages
A. The information provided below is intended to
aid in troubleshooting Software Error Messages
of the OptiFlex Units to “Board Level” only. No
component level troubleshooting information is
ERROR MESSAGE
or will be provided by Chattanooga Group for
field troubleshooting of board components.
B. Once a particular PCB has been determined as
bad, replace the suspected board.
PROBABLE CAUSE
POSSIBLE REMEDY
RAM Test Failed
Pendant
Replace Pendant
Checksum Test Failed
Pendant
Replace Pendant
(2) Motor Failure
1. Carriage Angle <-15°
2. Carriage Angle >125°
Replace Pendant
Adjust or replace knee pot.
(3) Motor Failure
Motor Speed Counter
Make certain Femur Adjustment knobs are tight.
Carriage Obstruction,
Treatment Stopped
1. Motor Overcurrent
2. Carriage Stuck or in Bind
Calibrate unit. Should calibration not clear the problem,
send unit to factory for service.
Pendant is not Connected
1. Loop Around
2. DAC Speed Out
Connect Pedant to unit. If this does not correct the
problem, replace pendant
(2) Failure
RTC 3V Battery (A/D Pendant)
Replace pendant battery. If this does not correct
problem, replace pendant.
(3) Failure
Monitor 8V (A/D Pendant)
Cable
(4) Failure
Monitor 24V (A/D SPI)
Cable, knee pot, main PCB
(5) Failure
Monitor 5V (A/D SPI)
Cable
Stuck Button
Sticky Deposits
Remove and clean button pads, inspect switch lands. If
this does not correct problem, replace pendant.
8
TROUBLESHOOTING
OptiFlex® 2030 & 2060
5.2 OptiFlex System Testing
A. General
1. The following information is intended to aid in
troubleshooting the major components of the
OptiFlex Units to “Board Level” only. These
tests are OEM standard testing procedures and
methods used at the factory before shipment of
any OptiFlex unit.
2. Due to the complex nature of the technology
utilized by Chattanooga Group, the recommended
troubleshooting techniques are to determine “Bad
Board” and board replacement only. No board
component level troubleshooting is recommended
nor will information or parts be supplied by
Chattanooga Group. Any board component level
troubleshooting performed will be at sole risk and
liability of the Service Technician performing such
troubleshooting techniques.
3. Once a particular PC Board has been determined
as bad, replace the board only with Chattanooga
Group OEM replacement parts and hardware.
B. Special Tools, Fixtures & Materials Required
1. Certain tests require the use of special Tools
and/or Fixtures. These will be listed at the
particular test where they are required. Testing
with any other special tool or fixture other than
those stated could give erroneous readings or
test results. Always perform the tests exactly as
stated to ensure accurate results.
2. Standard test equipment settings will be listed for
each test performed to aid in performing the test
to OEM standards and ensure proper readings.
3. The troubleshooting and repair of the OptiFlex
units, should be performed only by authorized
technicians trained and certified by Chattanooga
Group.
C. Equipment Required
1. Digital Multimeter
2. Dielectric Withstand (Hi-Pot) and ground
resistance tester.
3. Milliohm Meter.
NOTE:
Adjust Dielectric Withstand tester to indicate fault with
120k Ohm Load across the output when at specified test
voltage.
!
CAUTION
The following tool, lubrication and locking compound
requirements are critical to the component removal and
replacement of the OptiFlex.
All hardware,bolts, nuts and screws, used to assemble the
OptiFlex are SAE Standard. Due to the size of these
components no metric equivalent is available. Therefore,
it will be necessary to obtain the proper size tools for
removal and replacement of certain components.
The lubricants and locking componds listed below are
crucial in the assembly of certain components to ensure
patient safety and efficient operation of the unit. Use only
the recommended products listed or an approved
equivalent possessing the same properties and qualities.
5. Required SAE Tools
#1 Phillips Screwdriver
#2 Phillips Screwdriver
Preset and calibrated, 5 inch pound “T”-Handle
Torque Wrench with 1/4” square drive and 5/64”
straight hex key socket.
Preset and calibrated, 10 inch pound “T”-Handle
Torque Wrench with 1/4” square drive and 9/64”
straight hex key socket.
5/16” Socket Driver
3/32” Allen Wrench
6. Required Lubricants
Molykote 33 Grease (Light Pink) by Dow Corning.
MolyGraph Grease (Black) by Sta-Lube.
7. Required Locking Compound and Primer
Type N Primer by Loctite
Loctite 222 (Purple)
Loctite 242 (Blue)
Loctite 262 (Red)
Loctite 609 (Green)
8. Inclinometer, Protractor or Goniometer accurate
to 1°.
9. Certified, calibrated Stop Watch.
NOTE:
The tool, lubricant and locking compound requirements will
be listed at the respective removal and replacement
procedures throughout this manual.
9
TROUBLESHOOTING
OptiFlex® 2030 & 2060
5.3 Visual Inspection
A. General
Visually inspect the OptiFlex unit. A visual inspection
can, to an experienced Technician, indicate possible
abuse of the unit and/or internal problems.
5.4 Ground Resistance Test
A. Voltage Specifications
Model 2030 . . . . . Input: 120 VAC~50/60 Hz, 40 Watts
Model 2060 . . . . Input: 230 VAC~50/60 Hz, 40 Watts
B. Specification
Maximum Acceptable Resistance: 500 milliohms
C. Equipment Required
Milliohm Meter
D. Test
Place unit on level work surface.
Place one meter probe on the ground prong of power
supply and the other to any exposed metal or screw .
on the unit. See Figure 5.1.
FIGURE 5.2
5.6 Flexion Angle & Calibration Test
Spec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90° ± 2°
A. Equipment Required
Inclinometer, Protractor or Goniometer accurate to 1°
B. Test
Place unit on level work surface.
Plug unit transformer into grounded wall outlet with .
appropriate voltage. See Specifications on page 7.
Connect Pendant to Unit and turn unit power ON.
Press and hold the Extension button. While holding
the Extension button down, press the Down arrow
until -10 is displayed on the Pendant. See Figure 5.3.
Press and hold the Flexion button. While holding the .
Flexion button down, press the Up arrow until 120 is .
displayed on the Pendant. See Figure 5.4.
FIGURE 5.1
5.5 Leakage Tests
Test Voltage Spec . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000V
Conduct all necessary leakage tests as required per
“Chapter 7 Electrical Equipment” of the 1999, or later,
edition of the NFPA (National Fire Protection
Association) “Health Care Facilities” standards.
See Figure 5.2.
!
FIGURE 5.3
FIGURE 5.4
FIGURE 5.5
Press and hold the Speed button. While holding the
Speed button down press the Up or Down arrow
button until 90 is displayed on the Pendant. See
Figure 5.5.
Press the Emergency Start/Stop button on the
Pendant. When the number on the Pendant display
reads 90, press the Emergency Start/Stop button to
stop movement of the unit.
WARNING
UNIT FAILING DIELECTRIC WITHSTAND AND/OR LEAKAGE
TESTS COULD INDICATE SERIOUS INTERNAL SYSTEM
PROBLEMS.
DO NOT PLACE UNIT BACK INTO SERVICE! SEND UNIT TO
FACTORY FOR REPAIR! DO NOT ATTEMPT TO REPAIR IN
THE FIELD!
10
TROUBLESHOOTING
OptiFlex® 2030 & 2060
B. Test
Place unit on a level work surface.
Plug unit power supply into grounded wall outlet
with appropriate voltage. See Specifications on
page 7.
Connect Pendant to Unit and turn unit power ON.
Press the Emergency Start/Stop button to start
the unit.
Disconnect the Pendant from the unit while moving.
Unit should stop.
Using the Inclinometer or Protractor measure the
angle of the flexion of the unit. Compare to Spec. See
Figure 5.6.
FIGURE 5.6
NOTE:
In Figure 5.6, a Digital Inclinometer is used to measure each
side and the two numbers are added together.
5.7 Travel Speed Test
Spec. . . . . . . . . . . . . . . . . . . 0° to 90° in 65 Seconds ±8%
A. Equipment Required
Calibrated Stop Watch
B. Test
Set unit up as described in the “Flexion Angle Test”
Press the Emergency Start/Stop button and start the
Stop Watch when the Pendant reads 0. The unit
should move from 0° to 90° within the specification
listed above.
Repeat and record results three times. Record
the average.
5.8 Emergency Start/Stop Function Test
Spec.. . . . . . . . . . . . Unit Start or Stop upon pushing button
A. Equipment Required
OptiFlex® with Pendant
B. Test
Place unit on a level work surface.
Plug unit power supply into grounded wall outlet with
appropriate voltage. See Specifications on page 7.
Connect Pendant to Unit and turn unit power ON.
Press the Emergency Start/Stop button to start and
stop the unit. Repeat several times.
5.9 Pendant Disconnect Test
Spec. . . . .Unit Stops immediately upon Pendant disconnect
A. Equipment Required
OptiFlex with Pendant
11
REMOVAL & REPLACEMENT
OptiFlex® 2030 & 2060
6.1 Cover Removal & Replacement
!
NOTE:
Retain both parts of the push rivets for re-installation.
B. Rear Access Cover
Remove the 6 Male Push Rivets from the Blue Rear
Access Cover by hand. See Figure 6.3.
WARNING
UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE
ATTEMPTING ANY REMOVAL OR REPLACEMENT
PROCEDURES TO PREVENT ELECTRICAL SHOCK.
A. Motor Cover Removal
Remove the 11 Male Push Rivets from the Blue
Motor Cover by hand. See Figure 6.1
REMOVE THE 6
MALE PUSH RIVETS
FIGURE 6.3
Remove the 6 Female Push Rivets from the Blue
Front Access Cover by hand. See Figure 6.4.
REMOVE THE 11
MALE PUSH RIVETS
FIGURE 6.1
Remove the 11 Female Push Rivets from the Blue
Motor Cover by hand. See Figure 6.2.
REMOVE THE 6 FEMALE
PUSH RIVETS
FIGURE 6.4
C. Replacement Component Part Numbers
Push Rivet (Male & Female Components). . . . . J6004
Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . .J2007
Front Access Cover. . . . . . . . . . . . . . . . . . . . . . J2005
REMOVE THE 11 FEMALE
PUSH RIVETS
FIGURE 6.2
Lift up and rotate the Blue Motor Cover toward the
carrying handle of the unit. Then slide the cover
over the carrying handle to completely remove from
the unit.
D. Replacement
Replace both covers in reverse order of removal.
12
REMOVAL & REPLACEMENT
OptiFlex® 2030 & 2060
6.2 Main PC Board Removal & Replacement
A. Tools Required
#2 Phillips Screwdriver
!
NOTE:
The Main PC Board is permanently mounted to the
aluminum mounting bracket.
D. Replacement Component Part Numbers
Main PC Board Assembly. . . . . . . . . . . . . . . . . .J6043
E. Main PC Board Replacement
Replace in reverse order. When connecting
harnesses, each harness will only connect to their
respective locations on the board.
6.3 Motor PC Board Removal & Replacement
A. Tools Required
#2 Phillips Screwdriver
B. Motor Cover Removal
Remove Motor Cover. Refer to “6.1. Cover Removal &
Replacement”.
C. Motor PC Board Removal
Disconnect the three wiring harnesses from the
Motor PC Board. See Figure 6.7.
WARNING
UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE
ATTEMPTING ANY REMOVAL OR REPLACEMENT
PROCEDURES TO PREVENT ELECTRICAL SHOCK.
B. Motor Cover Removal
Remove Motor Cover. Refer to “6.1. Cover Removal &
Replacement”.
C. Main PC Board Removal
Disconnect the six wiring harnesses from the main
board. See Figure 6.5.
REMOVE THE 6
HARNESSES FROM BOARD
FIGURE 6.5
Using the #2 Phillips Screwdriver, remove the two
mounting screws securing the Main PC Board
Assembly to the unit. See Figure 6.6.
REMOVE THE 3
HARNESSES FROM BOARD
FIGURE 6.7
NOTE:
Memory for Calibration and Model Number are stored on
the Main PC Board. Calibration and verification of Model
Number will be necessary if the Main PC Board is replaced.
To determine Model Number, turn unit on and press the Up
and Down arrows simultaneously. If “OPTIFLEX I” is
displayed on pendant, it will be necessary to put unit in the
Calibration Mode. See Page 16.
With unit in Calibration Mode, press the “Mode” button.
The pendant display should change from “OPTIFLEX I” to
“OPTIFLEX II”. Unit is now ready for Calibration.
REMOVE THE 2
BOARD MOUNTING SCREWS
FIGURE 6.6
13
REMOVAL & REPLACEMENT
OptiFlex® 2030 & 2060
Using the #2 Phillips Screwdriver, remove the two
mounting screws securing the Motor PC Board
Assembly to the unit. See Figure 6.8.
LOOSEN THREE MOTOR
MOUNTING SCREWS
FIGURE 6.9
Rotate the motor toward the center of the unit to
loosen the tension from the belt. Tighten the one
Motor Mounting Screw in the upper left hand corner.
Remove the old belt from the pulleys.
D. Drive Belt Replacement Part Number
Motor Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . J2000
E. Drive Belt Replacement
Replace Drive Belt in reverse order.
Rotate motor by hand applying tension to the belt.
Make certain the belt is seated into the pulley teeth.
Torque Motor Mounting Screws using the Preset 10
inch-pound “T”-Handle Torque Wrench with 9/64”
straight hex key socket.
6.4 Motor Removal & Replacement
REMOVE MOUNTING
SCREWS FROM
BOTTOM OF BOARD
MOUNTING BRACKET
FIGURE 6.8
D. Replacement Component Part Numbers
Motor PC Board Assembly. . . . . . . . . . . . . . . . .J6010
E. Motor PC Board Replacement
Replace in reverse order. When connecting
harnesses, each harness will only connect to their
respective locations on the board.
!
WARNING
UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE
ATTEMPTING ANY REMOVAL OR REPLACEMENT
PROCEDURES TO PREVENT ELECTRICAL SHOCK.
!
WARNING
UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE
ATTEMPTING ANY REMOVAL OR REPLACEMENT
PROCEDURES TO PREVENT ELECTRICAL SHOCK.
6.3 Drive Belt Removal & Replacement
A. Tools Required
#2 Phillips Screwdriver
9/64” Allen Wrench
Preset 10 inch-pound “T”-Handle Torque Wrench
B. Motor Cover Removal
Remove Motor Cover. Refer to “6.1. Cover Removal &
Replacement”.
C. Belt Removal
Loosen the three Motor Mounting Screws. See
Figure 6.9.
A. Tools Required
11/32” Open End Wrench
#2 Phillips Screwdriver
5/64” Allen Wrench
9/64” Allen Wrench
3/32” Allen Wrench
Preset 10 inch-pound “T”-Handle Torque Wrench
Preset 5 inch-pound “T”-Handle Torque Wrench
Type N locking compound primer
Loctite 222 (Purple) or approved equivalent
Molykote or approved equivalent grease
14
REMOVAL & REPLACEMENT
OptiFlex® 2030 & 2060
B. Motor Cover Removal
Remove Motor Cover. Refer to “6.1. Cover Removal &
Replacement”.
C. Motor PC Board Removal
Remove Motor PC Board. Refer to “6.3 Motor PC
Board Removal & Replacement”.
D. Motor Removal
Loosen three motor mounting screws. Rotate
motor to release belt tension and remove belt. See
Figure 6.10.
Remove the three motor mounting screws using the
9/64” Allen Wrench and remove motor from unit. See
Figure 6.12.
REMOVE THREE MOTOR
MOUNTING SCREWS
FIGURE 6.12
E. Replacement Component Part Numbers
Motor and Gearbox Assembly. . . . . .40101 and 40100
F. Motor Replacement
Position the motor in the unit with ribbon cable
up. Install the three Motor Mounting Screws and
Nylon Lock Nuts. Do not completely tighten.
Position the pulley onto the motor shaft. Make
certain the set screw hole is aligned with the flat
area of the shaft.
Push the pulley onto the shaft until the face of the
pulley collar is flush with the end of motor shaft.
Prime the pulley set screw with the Type N primer
and apply the Loctite 222 or approved equivalent per
the manufacturer’s instructions to the threads of the
set screw.
Install the set screw until seated against motor shaft
and then torque using the Preset 5 inch-pound “T”Handle Torque Wrench with 5/64” straight hex
key socket.
Rotate motor and place belt onto both pulleys. Rotate
motor in the opposite direction until belt is tight.
Tighten the three motor mounting screws and torque
using the Preset 10 inch-pound “T”-Handle Torque
Wrench with 9/64” straight hex key socket.
Replace the Motor PC Board. Refer to “6.3 Motor PC
Board Removal & Replacement”.
Replace Motor Cover. Refer to “6.1. Cover Removal &
Replacement”.
LOOSEN THREE MOTOR
MOUNTING SCREWS
FIGURE 6.10
Using the 5/64” Allen Wrench, remove the set screw
from the motor pulley. See Figure 6.11.
REMOVE PULLEY
SET SCREW
FIGURE 6.11
Remove Pulley from shaft.
NOTE:
It may be necessary to use a gear puller in removing the
pulley.
15
REMOVAL & REPLACEMENT
OptiFlex® 2030 & 2060
7.1 Potentiometer (Knee Pot) Removal & Replacement
Removal and replacement of the Potentiometer (Knee
Pot) can be accomplished with the followng procedures.
A. Tools Required
#2 Phillps Screwdriver
Calibrated and certified Protractor with 1° accuracy
or other angle measuring device that is calibrated
with 1° accuracy.
Sharp tipped tool for removal of potentiometer decal
3/32” Allen Wrench
Preset 5 inch-pound “T”-Handle Torque Wrench
B. Potentiomenter Decal and Cover Removal
Using a tool with a sharp tip (pocket knife) carefully
remove the decal from the potentiometer cover. See
Figure 7.1.
C. Pre-Calibration Procedure
Operate the unit until the carriage is at zero on the
pendant.
Enter the “Calibration Mode” of the Pendant by
pressing and holding the “Comfort Zone”
button.
While holding the “Comfort Zone” button press the
following buttons in the sequence listed.
1. Progressive ROM
2. Fast Back
3. O-Zone
4. Mode
5. Release the “Comfort Zone” button. “Calibration
Mode OptiFlex II” should be diplayed at the bottom
of the Pendant display window. See Figure 7.3.
CAREFULLY REMOVE
DECAL
FIGURE 7.3
Place the calibrated Protractor with 1° accuracy
across the carriage and press the Up and Down
arrow on the Pendant until the protractor reads zero.
See Figure 7.4.
FIGURE 7.4
FIGURE 7.1
NOTE:
Be careful not to damage decal as it will be used for reinstallation after the calibration procedure is complete.
Using the #2 Phillps Screwdriver, remove the three
potentiometer cover mounting screws. See
Figure 7.2.
PLACE PROTRACTOR ACROSS THESE
TWO SURFACES AND ADJUST
UNTIL PROTRACTOR READS ZERO
REMOVE THE THREE
MOUNTING SCREWS
FIGURE 7.2
16
REMOVAL & REPLACEMENT
OptiFlex® 2030 & 2060
With the 3/32” Allen Wrench loosen the two set
screws retaining the potentiometer in position. See
Figure 7.5.
PLACE PROTRACTOR ACROSS THESE
TWO SURFACES AND ADJUST
UNTIL PROTRACTOR READS 90°
LOOSEN SET SCREWS
RETAINING POTENTIOMETER
IN POSITION
FIGURE 7.7
After verification of angle is 90° with protractor,
press the Flexion button.
Turn power to unit off.
Unit is now calibrated.
Reinstall the potentiometer cover and decal.
FIGURE 7.5
Rotate the potentiometer by hand until the “>0<”
symbol is visible in the Pendant display. See
Figure 7.6.
ROTATE POTENTIOMETER
BY HAND
>O<
SYMBOL
FIGURE 7.6
Tighten and torque the two set screws securing the
potentiometer in position. Torque these screws using
the Preset 5 inch-pound “T”-Handle Torque Wrench.
Press the Extension button.
Press the Up arrow button until the carriage is at 90°.
Use the protractor to gage the 90° position. See
Figure 7.7.
17
CALIBRATION
OptiFlex® 2030 & 2060
8.1 Annual Calibration Procedures
The OptiFlex CPM unit should be calibrated annually
using the following procedures.
A. Tools Required
Calibrated and certified Protractor with 1° accuracy
or other angle measuring device that is calibrated
with 1° accuracy.
PLACE PROTRACTOR ACROSS THESE
TWO SURFACES AND ADJUST
UNTIL PROTRACTOR READS ZERO
B. Calibration Procedure
Operate the unit until the carriage is at zero on the
pendant.
Enter the “Calibration Mode” of the Pendant by
pressing and holding the “Comfort Zone”
button.
While holding the “Comfort Zone” button press the
following buttons in the sequence listed.
1. Progressive ROM
2. Fast Back
3. O-Zone
4. Mode
5. Release the “Comfort Zone” button. “Calibration
Mode OptiFlex II” should be diplayed at the bottom
of the Pendant display window. See Figure 8.1.
FIGURE 8.2
To set “Zero”, press the Extension button.
The >0< will be replaced by two arrows
pointing left.
Use the arrow up button to move carriage to 90°.
When Carriage reaches 90° the >0< should be
visible.
Verify the carriage is at 90° with the calibrated
protractor or other measuring device. Once 90° is
verified, press the Flexion button.
Press the Start/Stop button. Unit
is now calibrated.
FIGURE 8.1
Place the calibrated Protractor with 1° accuracy
across the carriage and press the Up and Down
arrow on the Pendant until the protractor reads zero.
See Figure 8.2.
18
MAINTENANCE / CALIBRATION RECORD
19
OptiFlex® 2030 & 2060
REPLACEMENT PARTS
OptiFlex® 2030 & 2060
With Femur Bar
91
29
48
25
81
47
24
46
1
49
19
31
32
53
14
56
30
57
38
26
27
61
36
6
50
40
52
55
15
17
50
44
54
34
41
22
59
38
62
39
63
42
43
12
20
2
18
28
10
15
16
9
76
5
71
8
45
51
23
74
64
37
13
21
72
65
67
69
3
70
81
21
4
58
73
68
11
78
77
79
80
60
33
75
7
66
35
20
45
REPLACEMENT PARTS
OptiFlex® 2030 & 2060
With Femur Bar
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
J6028
J1072
40100
40101
J2003
J6035
J2008
J2007
J1025
J2005
J2006
J1063
J6010
87898
J6044
J1055
J2004
J6008
J1067
J6009
71319
J6034
J6020
J1014
J1022
J1026
J1011
J1034
J1032
J1030
J1036
J2014
J1058
J2013
J1057
J1041
J1075
J6023
J6022
J6003
J6002
BUSHING, NYLON 5/16” OD
BUSHING, NYLON 3/8” OD
MOTOR, BRUSHLESS
GEARBOX
EXTRUSION
PIN, COTTER
COVER, REAR BOTTOM
COVER, REAR TOP
WIPER
COVER, FRONT TOP
COVER, FRONT BOTTOM
FEMUR BAR CATCH
PCB MOTOR CONTROL
SPLIT PIN, .125” X 3/4”
WASHER, .252 X .62 X .06 Thk
PIN, TRUNION
ACME ROD
BEARING, FLANGE
VELCRO HOOK
BEARING, ROLLER
SCREW, 6-32 X 1/4”
WASHER, FLAT BEARING
ROD END, PLATED
FEMUR SUB ASSEMBLY
THIGH S/A
FEMUR HINGE LF
CALF S/A
SLIDER
FEMUR LINKAGE
FEMUR HINGE RT
FOOT ROD S/A
FOOT PLATE
PAD, FRONT
FOOT PLATE, FORMED
PAD, REAR
PIN, POT PIVOT
BASE, FRONT S/A
SPLIT PIN, 1/16” X 9/16”
TUBE, POT PIN
SERVO MOUNT CLEAT
SCREW, #4-40
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
21
J1003
J6024
J1071
J1068
J1061
J6007
65991
J6012
62066
J6052
60396
J6011
J6025
J6029
J6027
J6006
68964
J6001
J6004
J6005
J6051
J1050
J6040
J6000
66058
J6043
J6048
21733
J2022
J6056
J6053
J6042
J2023
70099
J2000
J2001
J2002
J2009
70105
53973
J6065
COVER, POT
SCREW, POT MOUNT, #6-32
PIN, FOOT ROTATION
VELCRO LOOP
SLEEVE, CARRIAGE PIVOT
SCREW, PIVOT, 1/4”-28 X 5/8”
TUBE PLUG
KNOB, MALE 1/4”-20
SCREW, 1/4”-20 X 5/8”
SCREW, 1/4”-20 X 1”
SCREW, #10-32 X 1/4”
KNOB, FEMALE
BOLT, STOVE
SPACER, NYLON FOOT PLATE
RIVET, FEMUR HINGE
WASHER, .312”ID X 1”OD X .06
FOAM, HANDLE GRIP
BEARING, SPLIT FLANGE TRUN
NYLON SNAP RIVET
BEARING, SPLIT FLANGE PIVOT
SNAP RING
DECAL, POT
CABLE, KNEE POT
SCREW, SELF TAP #10-24
RIVET
PCB, MAIN
SCREW, 8-32 X 2” SOCKET HD
NUT, #8-32 ESNA
PENDANT S/A
POWER SUPPLY (120V UNIT)
POWER SUPPLY (220V UNIT)
MOTOR CONTROLLER CABLE
CABLE, PENDANT RECEPTICAL
SCREW, #6-32 X 3/8”
DRIVE BELT
PULLEY, BALL SCREW
PULLEY, MOTOR
BASE, REAR S/A
WASHER #10 FLAT
SCREW, #10 X 1/2” PAN TEK
RIGHT ANGLE STRAIN RELIEF
REPLACEMENT PARTS
OptiFlex® 2030 & 2060
Without Femur Bar
91
29
48
25
81
47
38
46
1
49
19
31
32
53
14
56
30
57
38
26
27
61
83
36
6
50
62
39
40
52
55
15
22
59
17
50
44
54
34
41
63
42
43
12
20
2
18
28
10
15
16
9
76
5
71
8
45
85
74
84
82
64
13
21
72
65
67
69
3
70
81
21
4
58
73
68
11
78
77
79
80
60
33
75
7
66
35
22
45
REPLACEMENT PARTS
OptiFlex® 2030 & 2060
Without Femur Bar
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
25
26
27
28
29
30
31
32
33
34
35
36
38
39
40
41
42
43
44
45
J6028
J1072
40100
40101
J2003
J6035
J2008
J2007
J1025
J2005
J2006
J1063
J6010
87898
J6044
J1055
J2004
J6008
J1067
J6009
71319
J6034
J1022
J1026
J1011
J1034
J1032
J1030
J1036
J2014
J1058
J2013
J1057
J1041
J6023
J6022
J6003
J6002
J1003
J6024
J1071
J1068
BUSHING, NYLON 5/16” OD
BUSHING, NYLON 3/8” OD
MOTOR, BRUSHLESS
GEARBOX
EXTRUSION
PIN, COTTER
COVER, REAR BOTTOM
COVER, REAR TOP
WIPER
COVER, FRONT TOP
COVER, FRONT BOTTOM
FEMUR BAR CATCH
PCB MOTOR CONTROL
SPLIT PIN, .125” X 3/4”
WASHER, .252 X .62 X .06 Thk
PIN, TRUNION
ACME ROD
BEARING, FLANGE
VELCRO HOOK
BEARING, ROLLER
SCREW, 6-32 X 1/4”
WASHER, FLAT BEARING
THIGH S/A
FEMUR HINGE LF
CALF S/A
SLIDER
FEMUR LINKAGE
FEMUR HINGE RT
FOOT ROD S/A
FOOT PLATE
PAD, FRONT
FOOT PLATE, FORMED
PAD, REAR
PIN, POT PIVOT
SPLIT PIN, 1/16” X 9/16”
TUBE, POT PIN
SERVO MOUNT CLEAT
SCREW, #4-40
COVER, POT
SCREW, POT MOUNT, #6-32
PIN, FOOT ROTATION
VELCRO LOOP
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
23
J1061
J6007
65991
J6012
62066
J6052
60396
J6011
J6025
J6029
J6027
J6006
68964
J6001
J6004
J6005
J6051
J1050
J6040
J6000
66058
J6043
J6048
21733
J2022
J6056
J6053
J6042
J2023
70099
J2000
J2001
J2002
J2009
70105
53973
J6065
J1089
J1084
J1085
54931
SLEEVE, CARRIAGE PIVOT
SCREW, PIVOT, 1/4”-28 X 5/8”
TUBE PLUG
KNOB, MALE 1/4”-20
SCREW, 1/4”-20 X 5/8”
SCREW, 1/4”-20 X 1”
SCREW, #10-32 X 1/4”
KNOB, FEMALE
BOLT, STOVE
SPACER, NYLON FOOT PLATE
RIVET, FEMUR HINGE
WASHER, .312”ID X 1”OD X .06
FOAM, HANDLE GRIP
BEARING, SPLIT FLANGE TRUN
NYLON SNAP RIVET
BEARING, SPLIT FLANGE PIVOT
SNAP RING
DECAL, POT
CABLE, KNEE POT
SCREW, SELF TAP #10-24
RIVET
PCB, MAIN
SCREW, 8-32 X 2” SOCKET HD
NUT, #8-32 ESNA
PENDANT S/A
POWER SUPPLY (120V UNIT)
POWER SUPPLY (220V UNIT)
MOTOR CONTROLLER CABLE
CABLE, PENDANT RECEPTICAL
SCREW, #6-32 X 3/8”
DRIVE BELT
PULLEY, BALL SCREW
PULLEY, MOTOR
BASE, REAR S/A
WASHER #10 FLAT
SCREW, #10 X 1/2” PAN TEK
RIGHT ANGLE STRAIN RELIEF
CLEVIS PIN 1/4” X 1” X 3/8” SS
WELDMENT, TUBE
WELDMENT, BASE FRAME
PIN, SPLIT 3/32” X 5/8” PLT
ISO 9001/ISO 13485 CERTIFIED
4717 Adams Road
P.O. Box 489
Hixson, TN 37343 U.S.A.
1-423-870-2281
1-800-592-7329 U.S.A.
1-800-361-6661 CANADA
+ 1-423-870-2046 OUTSIDE U.S.A. FAX
www.chattgroup.com
Part Number: 20696A
© 2002 Encore Medical
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