Intelect Adanced Service Manual

Intelect Adanced Service Manual
Moving
Rehabilitation
Forward™
MODEL – 2738
TRANSPORT COMBO
THERAPY SYSTEM
TABLE OF CONTENTS
FOREWORD............................................................. 1
1- SAFETY PRECAUTIONS..................................2-4
1.1 Precautionary Symbol Definitions............................. 2
1.2 Safety Precautions ....................................................... 2
2- THEORY OF OPERATION................................... 5
2.1 Overview........................................................................ 5
2.2 Power Supply Circuit.................................................... 5
2.3 Control Board................................................................ 5
2.4
Stim Boards.................................................................... 5
2.5
Ultrasound Board and Applicator ............................ 5
2.6
User Interface and Accessories.................................. 5
2.7 NIMH Battery (Optional).............................................. 5
3- NOMENCLATURE............................................6-8
3.1 Components and Controls.......................................... 6
3.2 Hardware and Software Symbol Definitions........... 7
4- SPECIFICATIONS.......................................... 9-13
4.1 Intelect Transport Combo System............................. 9
4.2
Intelect Transport Electrotherapy Waveform
Specifications...................................................................10
4.3
Intelect Transport Combo Ultrasound
Specifications...................................................................13
5- TROUBLESHOOTING................................. 14-28
5.1
Intelect Transport Combo Error Messages............14
5.2 Intelect Transport Combo System Testing.............16
5.3 Electrical Safety...........................................................17
5.4 Leakage Tests...............................................................17
5.5 Visual Inspection.........................................................18
5.6
Unit Startup and Fan Testing....................................18
5.7 Electrical Stimulator Test System Setup.................19
5.8 Interferential Mode Test............................................20
5.9 Premodulated Mode Test..........................................20
5.10 Russian Mode Test....................................................21
5.11 High Voltage Pulsed Current
(HVPC) Mode Test............................................................22
5.12 Ultrasound Tests...............................................23 - 28
5.13 Ultrasound Applicator Identification Test............23
5.14 Ultrasound Applicator Output Test.......................24
5.15 Ultrasound Duty Cycle Test....................................26
5.16 Combo Operation Test............................................28
6- REMOVAL & REPLACEMENT..................... 29-40
6.1 Separating Top and Bottom......................................29
6.2 Therapy System Fan....................................................30
6.3 Power Supply .............................................................. 31
6.4 Channel 1 Stim Board................................................. 33
6.5 Channel 2 Stim Board..................................................34
6.6 Ultrasound Board ........................................................35
6.7 Control Board Assembly.............................................36
6.8 LCD.................................................................................38
6.9 Keymat, On/Off Button and Unit Top......................39
6.10 Plynth............................................................................40
7- GENERAL MAINTENANCE.............................41
7.1 Cleaning the System................................................41
7.2 Calibration Requirements.......................................41
7.3 Field Service.. .............................................................41
7.4Factory Service..........................................................41
Intelect Transport® Combo Therapy System
8- ULTRASOUND APPLICATOR CALIBRATION.42
8.1 General Procedures..................................................42
9- PARTS........................................................ 43-47
10- SCHEMATICS............................................ 48-66
11- WARRANTY.....................................................67
FOREWORD
Intelect Transport® Combo Therapy System
Read, understand, and follow the Safety Precautions and all other information contained in this
manual.
This manual contains the necessary safety and field service information for those field service
technicians, certified by DJO, LLC, to perform field service on the Intelect Transport® Combo Therapy
System.
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 DJO, LLC’s policy of continual improvement, DJO, LLC reserves the right
to make periodic changes and improvements to their equipment and documentation without any
obligation on the part of DJO, LLC. As significant changes occur to the Intelect Transport Combo
Therapy System, service bulletins may be made available on our web site (chattgroup.com) in lieu of
reprinted manuals.
Technicians repairing the Intelect Transport Combo Therapy System agree to assume all risk and
liability associated with this process.
This system is to be used only under the supervision of a licensed practitioner.
© 2010 DJO, LLC Vista, California, USA. Any use of editorial, pictorial, or layout composition of this publication without express written consent from DJO, LLC is strictly
prohibited. This publication was written, illustrated, and prepared for distribution by DJO, LLC.
1
1- SAFETY PRECAUTIONS
Intelect Transport® Combo Therapy System
1.1 PRECAUTIONARY SYMBOL DEFINITIONS
1.2 SAFETY PRECAUTIONS
The precautionary instructions found in 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:
A. CAUTION
Text with a “CAUTION” indicator will explain possible safety infractions that have the
potential to cause minor to moderate injury or
damage to equipment.
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 systems.
• Read, understand, and practice the precautionary and
operating instructions. Know the limitations and hazards
associated with using any electrical stimulation or ultrasound
device. Observe the precautionary and operational decals
placed on the unit.
• DO NOT operate the Intelect Transport Combo unit when
connected to any unit other than Chattanooga devices.
• DO NOT operate this unit in an environment where
other devices are being used that intentionally radiate
electromagnetic energy in an unshielded manner. Portable
and mobile RF communications equipment can affect Medical
Electrical Equipment.
• DO NOT use sharp objects such as a pencil point or ballpoint
pen to operate the buttons on the control panel.
• This unit should be operated, transported, and stored in
temperatures between 15 °C and 40 °C (59 °F and 104 °F),
with relative humidity ranging from 30%-60%, and where the
atmospheric pressure is between 950 h Pa and 1050 h Pa.
• The Intelect battery pack is designed for use only with
Chattanooga Intelect Transport, Stim, Combo, and Ultrasound
systems.
• The unit should be routinely checked before each use to
determine that all controls function normally; especially that
the intensity control properly adjusts the intensity of the
electrotherapy and ultrasonic power output in a stable manner.
Also, determine that the treatment time control actually
terminates electrotherapy and ultrasonic power output when
the timer reaches zero.
• Inspect cables and connectors before each use.
• The Intelect Transport Combo is not designed to prevent the
ingress of water or liquids. Ingress of water or liquids could
cause malfunction of internal components of the system and
therefore create a risk of injury to the patient.
• DO NOT permit any foreign materials or liquids to enter the
unit. Take care to prevent any foreign materials including, but
not limited to, inflammables, water, and metallic objects from
entering the unit. These may cause unit damage, malfunction,
electrical shock, fire, or personal injury.
• Handle the applicator with care. Inappropriate handling of the
applicator may adversely affect its characteristics.
• Before each use, inspect the applicator for cracks, which may
allow the ingress of conductive fluid.
• This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance
with the instructions, may cause harmful interference to other
devices in the vicinity. However, there is no guarantee that
interference will not occur in a particular installation. Harmful
interference to other devices can be determined by turning
this equipment on and off. Try to correct the interference using
one or more of the following: reorient or relocate the receiving
device, increase the separation between the equipment,
connect the equipment to an outlet on a different circuit from
that to which the other device(s) are connected and consult
the factory field service technician for help.
B. WARNING
Text with a “WARNING” indicator will explain
possible safety infractions that will potentially
cause serious injury and equipment damage.
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. DANGEROUS VOLTAGE
Text with a “Dangerous Voltage” indicator
serves to inform the user of possible hazards
resulting in the electrical charge delivered to the patient in certain treatment configurations of
TENS waveforms.
E. CORROSIVE HAZARD (NIMH BATTERY)
Text with a “Corrosive Hazard” indicator will
explain possible safety infractions if the
chemical components of this product are
exposed to air, skin, or other materials.
F. NOTE:
Throughout this manual “NOTE” may be found.
These Notes are helpful information to aid in
the particular area or function being described.
2
1- SAFETY PRECAUTIONS
Intelect Transport® Combo Therapy System
1.2 SAFETY PRECAUTIONS (CONTINUED)
• Long term effects of chronic electrical stimulation are
• Where the integrity of the external protective earth
unknown.
conductor arrangement is in doubt, equipment shall be
operated from its internal electrical power source.
• Using a high intensity electrotherapy setting in conjunction
with high intensity ultrasound setting may cause the unit to
reset.
• The battery pack should be removed when storing the unit
for extended periods of time.
• DO NOT disassemble, modify, or remodel the unit or
accessories. This may cause unit damage, malfunction,
electrical shock, fire, or personal injury.
• DO NOT remove the cover. This may cause unit damage,
malfunction, electrical shock, fire, or personal injury. There
are no user-serviceable parts inside the unit. If a malfunction
occurs, discontinue use immediately and consult the dealer
for repair service.
• Failure to use and maintain the Intelect Transport Combo
and its accessories in accordance with the instructions
outlined in this manual will invalidate your warranty.
• Nylatex® Wraps contain dry natural rubber and may cause
allergic reactions in patients with allergies to latex.
• Stimulation should not be applied over the anterior neck or
mouth. Severe spasm of the laryngeal and pharyngeal muscles
may occur and the contractions may be strong enough to
close the airway or cause difficulty in breathing.
• Stimulation should not be applied transthoracically because
the introduction of electrical current into the heart may cause
cardiac arrhythmia.
• Stimulation should not be applied over swollen, infected,
and inflamed areas or skin eruptions, e.g., phlebitis,
thrombophlebitis, varicose veins, etc.
• Stimulation should not be applied over, or in proximity to,
cancerous lesions.
• Output current density is inversely related to electrode size.
Improper application may result in patient injury.
• Always keep the sound head in constant motion.
• Always keep the sound head in full contact with the patient’s
skin or submerged under water when setting intensity.
• Use ample conductive gel to ensure good coupling
throughout the treatment. If needed, apply when setting
intensity.
• Be sure to read all instructions for operation before treating a
patient.
• Dispose of all products in accordance with local and national
regulations and codes.
• Use of controls, adjustments, or performance of procedures
other than those specified herein may result in hazardous
exposure to ultrasonic energy.
• Use of controls or adjustments or performance of procedures
other than those specified herein may result in hazardous
conditions causing damage to the battery pack or cells.
• To prevent electrical shock, disconnect the battery pack from
the system before attempting any maintenance procedures.
• Do not drop the applicator on hard surfaces. Do not cool
an overheated sound head with ice water or ice packs. Do
not allow the sound head to reach maximum temperatures
repeatedly. All of these conditions are likely to damage the
sound head crystal. Damage resulting from these conditions is
not covered under the warranty.
• In the event that an Error message or Warning appears
beginning with a 2 or 3, immediately stop all use of the unit
and contact the dealer or Chattanooga for service. Errors and
Warnings in these categories indicate an internal problem with
the unit that must be tested by DJO, LLC or a Field Service
Technician certified by DJO, LLC before any further operation
or use of the system.
• These devices are restricted to sale by, or on the order of,
a physician or licensed practitioner. This device should be
used only under the continued supervision of a physician or
licensed practitioner.
• Make certain the unit is electrically grounded by connecting
only to a grounded electrical service receptacle conforming to
the applicable national and local electrical codes.
• The Intelect Transport Combo should not be used adjacent to
or stacked with other equipment, and if adjacent or stacked
use is necessary, the Intelect Transport Combo should be
observed to verify normal operation in the configuration in
which it will be used.
• The user must keep the device out of the reach of children.
• Powered muscle stimulators should be used only with
the leads and electrodes recommended for use by the
manufacturer.
• Before administering any treatment to a patient you should
become acquainted with the operating procedures for
each mode of treatment available, as well as the indications,
contraindications, warnings, and precautions. Consult other
resources for additional information regarding the application
of electrotherapy and ultrasound.
• To prevent electrical shock, disconnect the unit from
the power source before attempting any maintenance
procedures.
• Keep electrodes separated during treatment. Electrodes in
contact with each other could result in improper stimulation
or skin burns.
3
1- SAFETY PRECAUTIONS
Intelect Transport® Combo Therapy System
1.2 SAFETY PRECAUTIONS (CONTINUED)
• Use of a unit that indicates an Error or Warning in these
• NiMH Batteries contain Class E corrosive materials.
categories may pose a risk of injury to the patient, user, or
extensive internal damage to the system.
• Do not turn the unit on or off while it is connected to the
patient.
• Do not apply the Ultrasound Applicator to the patient
during the Head Warming period. Applicator must remain in
Applicator Hook during the Head Warming period.
• Use only accessories that are specially designed for this unit.
Do not use accessories manufactured by other companies
on this unit. DJO, LLC is not responsible for any consequence
resulting from using products manufactured by other
companies. The use of other accessories or cables may result
in increased emissions or decreased immunity of this unit.
In the event of battery cell rupture or leakage,
handle battery pack wearing neoprene or
natural rubber gloves. Contents of a ruptured or
leaking battery can cause respiratory irritation.
Hypersensitivity to nickel can cause allergic
pulmonary asthma. Contents of cell coming in
contact with skin can cause skin irritation and/or
chemical burns.
• Never, under any circumstances, open the battery
pack housing or cells. Should an individual battery
from a battery pack become disassembled,
spontaneous combustion of the negative
electrode is possible. There can be a delay between
exposure to air and spontaneous combustion.
• Charge the battery pack according to the
instructions found in this manual. Never attempt
to charge the battery pack on any other charging
mechanism.
• Use the battery pack only with the Intelect
Transportable units.
• Do not reverse the polarity of the battery
pack. Doing so can increase the individual cell
temperature and cause cell rupture or leakage.
• Never dispose of the battery pack in fire. Never
short circuit the battery pack. The battery pack may
explode, ignite, leak, or get hot causing serious
personal injury.
• Dispose of NiMH batteries according to national,
state, and local codes and regulations.
• Stimulus delivered by the waveforms of this device,
in certain configurations, will deliver a charge
of 25 microcoulombs (µC) or greater per pulse
and may be sufficient to cause electrocution.
Electrical current of this magnitude must not flow
through the thorax because it may cause a cardiac
arrhythmia.
• Patients with an implanted neurostimulation
device must not be treated with or be in close
proximity to any shortwave diathermy, microwave
diathermy, therapeutic ultrasound diathermy,
or laser diathermy anywhere on their body.
Energy from diathermy (shortwave, microwave,
ultrasound, and laser) can be transferred through
the implanted neurostimulation system, can cause
tissue damage, and can result in severe injury
or death. Injury, damage, or death can occur
during diathermy therapy even if the implanted
neurostimulation system is turned “off.”
• DO NOT connect the unit to an electrical supply
without first verifying that the power supply is the
correct voltage.
• Incorrect voltage may cause unit damage,
malfunction, electrical shock, fire, or personal
injury. Your unit was constructed to operate only
on the electrical voltage specified on the Voltage
Rating and Serial Number Plate. Contact your DJO,
LLC dealer if the unit is not properly rated.
4
2- THEORY OF OPERATION
Intelect Transport® Combo Therapy System
2.1 OVERVIEW
The Intelect Transport Combo Therapy System is comprised of several PC board assemblies housed within a
common enclosure. These assemblies each support a distinct function in the product. The basic elements are
User Interface, Control Board, Stim Boards, Ultrasound Board, Ultrasound Applicator, and Power Supply
Circuits.
2.2 POWER SUPPLY CIRCUIT
A universal 75 Watt input power supply provides the system with the required 24 volts DC. The supply is connected to the mains at all times when the Mains Power Cord is attached and plugged into an outlet supplying 100 - 240 VAC. The 24 V supply is regulated locally at each PC board as required.
2.3 CONTROL BOARD
The Control Board serves just as its name implies. It controls the operation of the Stim Boards, Ultrasound Board, User Interface, and Accessories. The Control Board communicates to the Stim Boards and Ultrasound Board through a proprietary bus. The Control Board drives the display. The Control Board reads the menu buttons. The Control Board also reads the amplitude and the Contrast Control on the systems. Sound output is generated by the Control Board and routed to an internal speaker.
2.4 STIM BOARDS
The Stim Boards create all muscle stimulation output. Communication to the Stim Boards is via a proprietary bus. A Processor on each Stim Board acts on messages passed to it by the Control Board
to set up waveforms and adjust output amplitude. Information can likewise be passed from each Stim Board back to the Control Board for monitoring current, etc. If a Stim Board does not respond as expected to a command from the Control Board, output is stopped and an Error Message is generated.
2.5 ULTRASOUND BOARD AND APPLICATOR
The Ultrasound Board generates the 1 or 3.3 MHz output to drive the Sound Head of the Applicator. The Ultrasound Board is accessed through the proprietary bus by the Control Board. It can provide current
and voltage information about the ultrasound output of the board. The calibration data for the Sound Head
is passed through the Ultrasound Board from the Applicator to the Control Board. By storing the calibration
data in the Applicator, there is no calibration necessary for the Ultrasound Board and any calibrated
Chattanooga Intelect Transport Ultrasound Applicator can be connected and operated to provide
accurate output.
2.6 USER INTERFACE AND ACCESSORIES
The LCD display panel provides the operator visible feedback in the way of menu choices. Pressing the
User Interface buttons makes selections from the menus. The Control Board interprets these user inputs and responds accordingly. Audible feedback is given for such events as key presses and end of treatment.
2.7 NIMH BATTERY (OPTIONAL)
The NiMH Battery Module incorporates a Nickel Metal Hydride (NiMH) Battery Pack and a PC Board. The
PC Board monitors the Battery Charge Level. The Battery Pack supplies the required 24 VDC to the system which is then distributed to the respective PCB’s through the Universal Power Supply. The Battery
Pack is interfaced with the system via a Wire Harness that facilitates communication with the Control Board and delivery of power to the Combination Therapy System. When the Therapy System is connected
to a Mains Power Supply via the Mains Power Cord, the NiMH Battery Pack will charge. Once the Battery
Pack is fully charged, the software will stop the charging process, eliminating the possibility of overcharging.
Battery power is used only when the Therapy System is not connected to a Mains Power Supply.
5
3- NOMENCLATURE
Intelect Transport® Combo Therapy System
3.1 COMPONENTS AND CONTROLS
The nomenclature graphics below, Figure 3.1,
indicate the general locations of the exterior
components of the Intelect Transport Combo
System.
Know the components and their functions before
performing any operation of or service to the Intelect
Transport Combo System.
LCD Intensity/
Contrast Dial
Power
On/Off
Sound Head
LCD
Clinical
Library
LED Indicator
(Output Power)
Up
Arrow
TIME
INTENSITY
Applicator
Back
Parameter
Display / Enter
STOP
Down
Arrow
Channel 1
Lead Wire
Connection
START
PAUSE
Accessory
Panel
Power Cord
Connection
Battery
Compartment
Serial
Decal
FIGURE 3.1
6
Channel 2
Lead Wire
Connection
Ultrasound
Applicator
Connection
3- NOMENCLATURE
Intelect Transport® Combo Therapy System
3.2 HARDWARE AND SOFTWARE SYMBOL DEFINITIONS
The symbols below are found on the system as
well as within the software. These symbols are
defined for the purpose of recognition and
functionality when operating or performing
service on the Intelect Transport Combo System.
Know the symbols and their definitions before
performing any operation of or service to the Intelect
Transport Combo System.
Intelect Transport Combo System Hardware Symbols
Power On/Off
The Power On/Off button controls the flow of electricity to the unit.
NOTE: Make certain there are no electrodes on the patient when turning the unit on or off.
LCD
The LCD (Liquid Crystal Display) allows the user to view and monitor the information displayed before,
during, and after therapy.
Clinical Library
Select this button to access the following functions:
•Retrieve User Protocol
•
Restore Factory Settings
•
Restore Factory Protocols
•
Languages
•
View Unit Information
TIME
Press the Up or Down arrow buttons to set total treatment time of therapy.
Back
Use this button to return to the previous window.
STOP
Select this button to stop a treatment session.
Down Arrow
When the window displays a list of options, press the Down Arrow button to scroll down the list.
PAUSE
Use this button to pause the treatment session. To restart therapy, press the PAUSE button.
Sound Head
The aluminum face of the applicator that contacts the patient’s skin. It covers a transducer mechanism
that converts electrical energy to mechanical energy in the form of a vibrating crystal.
LED Indicator (Output Power)
When illuminated, this green light signifies that ultrasound energy is being distributed through
the applicator.
Applicator
The hand held assembly used to deliver ultrasonic energy. The applicator includes the sound head,
transducer, and related electronics.
Accessory Panel
The Accessory Panel serves as a port of connection for the electrodes and ultrasound applicator.
Channel 1 Lead Wire Connection
This port serves as the connection point between the unit and the Channel 1 Lead Wire.
Channel 2 Lead Wire Connection
This port serves as the connection point between the unit and the Channel 2 Lead Wire.
7
3- NOMENCLATURE
Intelect Transport® Combo Therapy System
3.2 HARDWARE AND SOFTWARE SYMBOL DEFINITIONS (CONTINUED)
Ultrasound Applicator Connection
This port serves as the connection point between the unit and the ultrasound applicator.
START
Select Start to begin a treatment session.
Parameter Display/Enter
Select this button to display the parameters of the waveform during treatment. Also, this button is
used to accept the highlighted selection.
INTENSITY
Use the up or down arrow on the INTENSITY button to increase or decrease output power.
Up Arrow
When the window displays a list of options, press the Up Arrow button to scroll up the list.
Battery Indicator
When displayed on the LCD, this symbol indicates the battery pack option is present on the unit. This
symbol also displays the charge status of the battery.
LCD Intensity/Contrast Dial
If the intensity of the LCD display diminishes, turn the dial until the display contrast is optimal.
Charge Indicator
This symbol displays when the unit is connected to mains power and the battery pack is charging.
NOTE: During battery operation, if the unit is left on, but is not active for more than five minutes, it
will power off to conserve battery power. To restore power, press the Power On/Off button.
8
4- SPECIFICATIONS
Intelect Transport® Combo Therapy System
4.1 INTELECT TRANSPORT COMBO SYSTEM
Figure 4.1 below provides physical details of the
Intelect Transport Combo. This section also
provides waveform specifications to aid in
troubleshooting.
Refer to this section when performing
troubleshooting, replacement, and repair of the
Intelect Transport Combo System.
A. Intelect Transport Combination Therapy System Physical Specifications
DEPTH
HEIGHT
WIDTH
FIGURE 4.1
Dimensions
Width................................................................................ 10.125 in (25.7 cm)
Height................................................................................. 7.250 in (18.4 cm)
Depth.................................................................................... 11.5 in (29.2 cm)
Weight
Standard Weight (with base)..................................................5.07 lb (2.3 kg)
Battery Pack............................................................................1.87 lb (0.85 kg)
Power
Input.............................................................100 - 240 VAC, 50/60 Hz 100 VA
Output...................................................................................... +24 V, 3.125 A
Electrical Class........................................................................................CLASS I
Electrical Type
Ultrasound TYPE B..............................................................................................
Operating Environment
Temperature................................................................ Between 59 °F and 104 °F
(15° C and 40° C)
Relative Humidity................................................................................. 30%-60%
Atmospheric Pressure................................................................... 950-1,050 h Pa
Complies with:
UL/IEC/EN 60601-1
IEC/EN 60601-1-2
IEC 60601-2-10
IEC 60601-2-5
Electrotherapy TYPE BF......................................................................................
Battery Type.............................................................Nickel Metal Hydride (NiMH)
(1.2 V x 20 size AA)
9
4- SPECIFICATIONS
Intelect Transport® Combo Therapy System
4.2 INTELECT TRANSPORT COMBO ELECTROTHERAPY WAVEFORM SPECIFICATIONS
The specifications found in this section provide
the necessary waveform specifications to aid in
troubleshooting. A waveform graphic from an
oscilloscope is also provided for clarification.
Refer to this section when performing
troubleshooting, replacement, and repair of the
Intelect Transport Combo System.
A. High Voltage Pulsed Current (HVPC)Figure 4.2 (Factory Default Setting)
The High Voltage Pulsed Current (HVPC) has
a very brief pulse duration characterized by 2
distinct peaks delivered at high voltage. The
waveform is monophasic (current flows in
one direction only). The high voltage causes a
decreased skin resistance, making the current
comfortable and easy to tolerate.
Output Mode. . . . . . . . . . . . . . . . . . . . . . . . Electrodes
FIGURE 4.2
Amplitude. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-500 V*
Polarity. . . . . . . . Positive or Negative (Negative)
Ramp. . . . . . . . . 0.5 sec, 1 sec, 2 sec, 5 sec (2 sec)
Display. . . . . . . . . . . Peak Current or Volts (Volts)
Sweep. . . . . . . . . . . . . . . . . . . . . . . . . Off, 80/120 pps,
1/120 pps, 1/10 pps (Off)
Frequency. . . . . . . . . . . . . . . 10-120 pps (100 pps)
Cycle Time. . . . . . . 5/5, 4/12, 10/10, 10/20, 10/30,
10/50, and Continuous (Continuous)
Constant Mode. . . . . . . . . . . . . . . . . . CV (only)** (CV)
Treatment Time. . . . . . . . . 1-60 Minutes (20 min)
* ESTI-2 Load Box
** CV = Constant Voltage
10
4- SPECIFICATIONS
Intelect Transport® Combo Therapy System
4.2 INTELECT TRANSPORT COMBO ELECTROTHERAPY WAVEFORM
SPECIFICATIONS (CONTINUED)
B. Premodulated - Figure 4.3 (Factory Default
Setting)
Premodulated Current is a medium frequency
waveform. Current is distributed from one
channel (two electrodes). The current intensity is
modulated: it increases and decreases at a regular
frequency ( the Amplitude Modulation Frequency).
Output Mode. . . . . . . . . . . . . . . . . . . . . . . . Electrodes
Amplitude. . . . . . . . . . . . . . . . . . . . . . . . . . 0-100 mA*
Carrier Frequency. . . . . . . . . . . 2500 Hz (2500 Hz)
Ramp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 sec (2 sec)
Display. . . . . . . . . . . Peak Current or Volts (Volts)
Sweep. . . . . . . . . . . . . . . . . . . . . . . On, 1-200 Hz (On)
Cycle Time. . . . . . . 5/5, 4/12, 10/10, 10/20, 10/30,
10/50, and Continuous (Continuous)
Beat Low Frequency. . . . . . . . . . . . . . . . . 1- 199 Hz
Beat High Frequency. . . . . . . . . . . . . . . . . 2-200 Hz
Constant Mode. . . . . . . . . . . . . . . . . . . CC or CV** (CC)
Treatment Time. . . . . . . . . 1-60 Minutes (20 min)
FIGURE 4.3
* ESTI-2 Load Box
**CC= Constant Current
CV= Constant Voltage
11
4- SPECIFICATIONS
Intelect Transport® Combo Therapy System
4.2 INTELECT TRANSPORT COMBO ELECTROTHERAPY WAVEFORM
SPECIFICATIONS (CONTINUED)
C. Interferential - Figure 4.4 (Factory Default
Setting)
Interferential Current is a medium frequency
waveform. Current is distributed from two
channels (four electrodes). The currents cross
in the body within the area being treated. The
two currents interfere with each other at this
crossing point, resulting in a modulation of the
intensity (the current intensity increases and
decreases at a regular frequency).
Output Mode. . . . . . . . . . . . . . . . . . . . . . . . Electrodes
Amplitude. . . . . . . . . . . . . . . . . . . . . . . . . . 0-100 mA*
Carrier Frequency. . . . 2500 - 5000 Hz (4000 Hz)
Vector Scan. . . . . Manual, Automatic 40%, 100%
(Manual)
Vector Position . . . . . . . . . . . . 0 - 90 Degrees (45˚)
Sweep. . . . . . . . . . . . . . . . . . . . . . . . . . . . On, 1-200 Hz
Beat Low Frequency. . . . . . . . . . 1-199 Hz (80Hz)
Beat High Frequency. . . . . . . . 2-200 Hz (150Hz)
Constant Mode. . . . . . . . . . . . . . . . . . . . CC or CV** (CC)
Treatment Time. . . . . . . . 1 -60 minutes (20 min)
FIGURE 4.4
D. Russian- Figure 4.5 (Factory Default Setting)
Russian Current is a sinusoidal waveform
delivered in bursts or series of pulses. This
method was claimed by its author (Kots) to
produce maximal muscle strengthening effects
without significant discomfort to the patient.
Output Mode. . . . . . . . . . . . . . . . . . . . . . . . Electrodes
FIGURE 4.5
Amplitude. . . . . . . . . . . . . . . . . . . . . . . . . . 0-100 mA*
Channel Mode. . . 10%, 20%, 30%, 40%, and 50%
(50%)
Constant Mode. . . . . . . . . . . . . . . . . . CC or CV** (CC)
Cycle Time. . . . . . . 5/5, 4/12, 10/10, 10/20, 10/30,
10/50, and Continuous (10/50)
Ramp. . . . . 0.5 sec, 1 sec, 2 sec and 5 sec (2 sec)
Carrier Frequency. . . . . . . . . . . 2500 Hz (2500 Hz)
Burst Frequency. . . . . . . . . . . . 20 -100 Hz (50 Hz)
Treatment Time. . . . . . . . 1 -60 minutes (20 min)
* ESTI-2 Load Box
**CC= Constant Current
CV= Constant Voltage
12
4- SPECIFICATIONS
Intelect Transport® Combo Therapy System
4.3 INTELECT TRANSPORT COMBO THERAPY SYSTEM ULTRASOUND SPECIFICATIONS
This section provides the necessary Ultrasound Specifications to aid in troubleshooting.
Refer to these specifications as necessary when troubleshooting the Ultrasound PC Board and
Applicators.
A. Ultrasound
Frequency. . . . . . . . . . 1 MHz, ± 5%; 3.3 MHz, ±5%
Duty Cycles. . . . 10%, 20%, 50%, and Continuous
Pulse Frequency. . . . . . . . . . . . . . . . . . . . . . . . . 100 Hz
Pulse Duration. . . . 1 mSec, ±20%; 2 mSec, ±20%
5 mSec, ±20%
Output Power
10 cm2 Crystal. . . . . . . . . . . . . . 0-20 Watts at 1 MHz,
0-10 Watts at 3.3 MHz
5 cm2 Crystal. . . . . . . . . 0-10 Watts, 1 and 3.3 MHz
2 cm2 Crystal. . . . . . . . . . 0-4 Watts, 1 and 3.3 MHz
1 cm2 Crystal. . . . . . . . . . . . 0-2 Watts 3.3 MHz Only
Amplitude. . 0 - 2.5 w/cm2 in Continuous mode,
0-3 w/cm2 in Duty Cycle modes
Output accuracy. . . . . . . . . . . ± 20% above 10% of
maximum
Temporal Peak to Average Ratios:
2:1, ± 20%, at 50% Duty Cycle
5:1, ± 20%, at 20% Duty Cycle
9:1, ± 20%, at 10% Duty Cycle
Beam Non uniformity Ratio. . . . . . . . . . . . . . 5.0 : 1
maximum
Beam Type. . . . . . . . . . . . . . . . . . . . . . . . . . . Collimating
Effective Radiating Areas
10 cm2 Crystal - 6.8 cm2 - 10.0 cm2
5 cm2 Crystal - 3.5 cm2 - 5.0 cm2
2 cm2 Crystal - 1.4 cm2 - 2.0 cm2
1 cm2 Crystal - 0.7 cm2 - 1.0 cm2
Treatment Time. . . . . . . . . . . . . . . . . . . . 1-30 Minutes
B. Head Warming Feature Specifications
The Head Warming feature of an Intelect
Transport Combo Therapy System utilizes
Ultrasound output resulting in warming of the
Sound Head to increase patient comfort.
With Head Warming enabled, ultrasound is
emitted without pressing the START button. The
Applicator LED will not illuminate during the
Head Warming period. US Channel will indicate
"Warming".
Output. . 0 - 50% Cycling of maximum power
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 MHz
Sound Head Temperature ������������ 85 °F - 110 °F
(29.4 °C - 43.3 °C)
Do not apply the Ultrasound Applicator to the
patient during the Head Warming period. Applicator
must remain in Applicator Hook during the Head
Warming period.
13
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.1 INTELECT TRANSPORT COMBO THERAPY SYSTEM ERROR MESSAGES
A. The following information is provided as an
aid in defining the Software Error Messages of
the Intelect Transport Therapy System. Once
a particular Error Message is defined, the
information will also list probable causes and
possible remedies. Once the problem area is determined, subsequent tests for verification will
be necessary to determine a “Bad Board”.
ERROR
CODE
ERROR
TYPE
DEFINITION
All Troubleshooting and tests will be to
validate a “Bad Board” only. No component
level troubleshooting information is or will be
provided by DJO, LLC for field troubleshooting
of board components.
B. Once a particular PC Board has been
determined as bad, refer to the appropriate
Removal and Replacement Section for the
board affected and follow the instructions for
replacement of the board.
PROBABLE CAUSES
POSSIBLE REMEDY
USER CORRECTABLE WARNING MESSAGES
100
101
WARNING
WARNING
Ultrasound Applicator became unplugged
Ultrasound Applicator unplugged
Ultrasound Applicator was unplugged while an Ultrasound
treatment was running
User attempted to start an Ultrasound treatment, but no
Ultrasound Applicator was plugged into unit
Plug Ultrasound Applicator into proper receptacle on unit
making certain it is completely seated
102
WARNING
Ultrasound Applicator not calibrated
The Ultrasound Applicator plugged into the unit needs to
be calibrated
Contact dealer or Chattanooga for service.
103
104
105
WARNING
WARNING
WARNING
Ultrasound Channel not available
Stim Channel not available
Stim Channel not available
User attempted to select Combo treatment, but the
Ultrasound Channel was already in use
User attempted to select Combo treatment, but the
Ultrasound Channel was already in use
User attempted to select a two channel Electrotherapy
treatment, but at least one of the two stim channels were
already in use
Wait until Ultrasound treatment is completed or stop
Ultrasound treatment and try again
106
WARNING
Over current
Stim channel has exceeded allowed current level and the
treatment has been stopped
Reset treatement parameters and attempt session again
107
WARNING
Bad Contact Quality
Electrode contact is poor
Apply new electrodes to the treatment area
108
WARNING
Shorted Lead Wires
Lead Wires are bad
Replace with new lead wires
109
WARNING
Power Supply current limit
User attempted to start two channels of Electrotherapy
while running an Ultrasound treatment with a 10 cm2
Ultrasound Applicator and Ultrasound Output is currently
set to greater than 15 Watts.
Wait until Ultrasound treatment is completed or stop
Ultrasound treatment and try again or decrease ultrasound
output to less than 15 Watts
200
ERROR
ERROR MESSAGES (200-213) REQUIRING TECHNICAL ASSISTANCE
Error while attempting to save Ultrasound
Applicator Calibration Data
Could not save the Calibration Data to the Ultrasound
Applicator
1. Replace the Ultrasound Applicator with a known good
Ultrasound Applicator
2. Replace Ultrasound Board
3. Replace Control Board
In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the unit and contact the dealer or Chattanooga
for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by DJO, LLC or a Field Service Technician
certified by DJO, LLC before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury
to the patient, user, or may cause extensive internal damage to the unit.
14
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.1
COMBOSOFTWARE
THERAPY SYSTEM
ERROR MESSAGES
(CONTINUED)
5.1 INTELECT
INTELECT TRANSPORT
TRANSPORT SYSTEM
ERROR MESSAGES
(continued)
In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the unit and contact the dealer or Chattanooga
for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by DJO, LLC or a Field Service Technician
certified by DJO, LLC before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury
to the patient, user, or may cause extensive internal damage to the unit.
ERROR
CODE
ERROR
TYPE
DEFINITION
PROBABLE CAUSES
POSSIBLE REMEDY
ERROR MESSAGES (200-213) REQUIRING TECHNICAL ASSISTANCE (CONTINUED)
201
ERROR
Error Applicator not calibrated OK.
Could not calibrate Ultrasound Applicator
1. Attempt to calibrate again
2. Replace the Ultrasound Applicator with a known good
Ultrasound Applicator
3. Replace Ultrasound Board
4. Replace Control Board
202
ERROR
Timed out while saving the Ultrasound
Applicator Calibration Data.
Could not save the Calibration Data to the
Ultrasound Applicator
1. Replace the Ultrasound Applicator with a known good
Ultrasound Applicator
2. Replace Ultrasound Board
3. Replace Control Board
203
ERROR
Error reading Protocol.
Error reading a Protocol from the EEPROM
Restore Factory Settings, restore Factory Protocols and
rebuild all User Protocols
204
205
206
207
208
ERROR
ERROR
ERROR
ERROR
ERROR
Main Software Flash Erase Error
Main Software Flash Echo
Main Software CRC Error
Main Software Program Flash Error
Main Software Acknowledge Error
Stim Main Software upgrade Error
Stim Main Software upgrade Error
Stim Main Software upgrade Error
Stim Main Software upgrade Error
Stim Main Software upgrade Error
1. Replace appropriate Stim Board
2. Replace Control Board
209
ERROR
Software CRC Acknowledge Error.
Software upgrade Error
Replace Control Board
210
211
212
213
214
ERROR
ERROR
ERROR
ERROR
ERROR
Channel Software Flash Erase Error
Channel Software CRC Error
Channel Software Program Flash Error
Channel Software Acknowledge Error
Channel Software CRC Acknowledge Error
Stim Channel Software upgrade Erro.
Stim Channel Software upgrade Error
Stim Channel Software upgrade Error
Stim Channel Software upgrade Error
Stim Channel Software upgrade Error
1. Replace appropriate Stim Board
2. Replace Control Board
CRITICAL ERRORS (300-314) DEMANDING TECHNICAL SERVICE
300
CRITICAL ERROR Unit CFG Critical Error
Error communicating with Stim Board on Powerup 1. Replace appropriate Stim Board
2. Replace Control Board
301
CRITICAL ERROR No Stim Board Critical Error
Error detecting Stim Board on Powerup
1. Replace appropriate Stim Board
2. Replace Control Board
302
CRITICAL ERROR No Ultrasound Board Critical Error
Error detecting Ultrasound Board on Powerup
1. Replace Ultrasound Board
2. Replace Control Board
303
CRITICAL ERROR EEPROM Critical Error
Error reading EEPROM on Powerup.
Replace Control Board
304
305
306
307
308
309
CRITICAL ERROR
CRITICAL ERROR
CRITICAL ERROR
CRITICAL ERROR
CRITICAL ERROR
CRITICAL ERROR
Ultrasound Board Critical Error
Ultrasound Board Write Critical Error
Ultrasound Board Read_Write Critical Error
Ultrasound Board Reset Critical Error
Ultrasound Board Read Critical Error
Ultrasound Board Calibration Critical Error
Error communicating with the Ultrasound Board
Error communicating with the Ultrasound Board
Error communicating with the Ultrasound Board
Ultrasound Board Reset Error
Error communicating with the Ultrasound Board
Error calibrating Ultrasound Board
1. Replace Ultrasound Board
2. Replace Control Board
310
311
312
313
314
315
316
CRITICAL ERROR
CRITICAL ERROR
CRITICAL ERROR
CRITICAL ERROR
CRITICAL ERROR
CRITICAL ERROR
CRITICAL ERROR
Stim Board Write Critical Error
Stim Board Bad Data Read Critical Error
Stim Board Main UP Reset Critical Error
Stim Board Channel 1 UP Reset Critical Error
Stim Board Channel 2 UP Reset Critical Error
Stim Board Reset Critical Error
Stim Powerup Test Failed Critical Error
CRITICAL ERRORS (300-314) DEMANDING TECHNICAL SERVICE
Error communicating with Stim Board
Error communicating with Stim Board
Error communicating with Stim Board
Error communicating with Stim Board
Error communicating with Stim Board
Stim Board Reset Error
Stim Board failed its Self Test on Powerup
15
1. Replace appropriate Stim Board
2. Replace Control Board
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.2 INTELECT TRANSPORT COMBO THERAPY SYSTEM TESTING
A. General
1. The following information is intended to aid in troubleshooting the major components of the
Intelect Transport Combo Therapy System to
“Board Level” only. These tests are FACTORY
standard testing procedures and methods
used at the factory before shipment of any
Intelect Therapy System.
2. Due to the complex nature of the technology
utilized by DJO, LLC, 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 DJO, LLC. 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, refer to the appropriate
Removal and Replacement Section of this
Manual for proper replacement.
B.Special Tools, Fixtures, & Materials Required
1. Certain tests require the use of special
tools and 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. Scope and other standard test equipment
settings will be listed for each test performed
to aid in performing the test to FACTORY
standards and ensure proper readings.
3. The troubleshooting and repair of the Intelect
Transport Therapy Systems and Accessories
should be performed only by authorized
technicians trained and certified by DJO, LLC.
C.Equipment Required
• Oscilloscope and Probes
• ESTI-2 Load Test Fixture
• Digital Multi meter
• Intelect Transport Applicators (Accessories)
• Dielectric Withstand (Hi-Pot) and ground resistance tester
NOTE:
Adjust Dielectric Withstand tester to indicate
fault with 120 k Ohm Load across the output
when at specified test voltage.
• Milliohm Meter
• 10k Resistor
• Ohmic Instruments UPM DT 10 or DT
100 Ultrasound Power Meter
• Dissolved Oxygen Test Kit used to test
oxygen level of Degassed Water
• # 1 Phillips Screwdriver
• # 2 Phillips Screwdriver
• Insulated Needle Nose Pliers
• 1/4" Nut driver or Wrench
• Degassed Water (<5 ppm) for
Ultrasound Power Meter
Recipe(s) for Degassed Water
1) Boil Distilled Water for 30 Minutes.
Place water in a canning jar, and cover.
Allow to cool to room temperature
of approximately 70 °F (21 °C). May be
refrigerated to aid cooling time.
or
2) Bring Distilled Water to a boil. Place
the container under vacuum for 5 to 10
Minutes.
NOTE:
Canning jars are ideal storage and transport containers
for Degassed Water. In order to minimize aeration
of Degassed Water during transport, fill to a positive
meniscus and slide the lid over the surface. Seal tightly.
When pouring Degassed Water into and out of
containers pour slowly down the side of the container
to minimize aeration.
Do not use Tap Water or Distilled Water in the
Ultrasound Power Meter. Use only Degassed Water in
order to obtain correct test results. The chart below
illustrates the oxygen content of Degassed, Tap, and
Distilled Water.
WATER TYPE
ppm of OXYGEN
Degassed
Less than 5 ppm
(per Recipe 1 or 2)
Tap Water
Up to 35 ppm
Distilled Water
Up to 20 ppm
D. Full Functional Tests
Perform the tests found in this section to verify
Full Functionality of new Therapy System and
accessories.
16
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.3 ELECTRICAL SAFETY
NOTE:
This device complies with current leakage,
ground continuity, and dielectric withstand
(Hi-Pot) limits as prescribed by IEC/EN/UL
60601-1 and CSA/CAN 601.1 Medical Electrical,
Part 1: General Requirements for Safety.
Facility, local and national limits and test
methods may vary.
Listed by Intertek Testing Services
NA Inc.
The Intelect Transport Combo System has been
tested to UL 60601-1, Standard for Safety for
Medical Equipment.
Conforms to UL Standard 60601-1
Certified to CAN/CSA Standard
C22.2 No. 601.1-M90 w/A2
A. Power Requirements
Model: 2738. . . . . . . . . . . . . . . . . . . . . . Input : 100-240V
100 VA, 50/60 Hz
5.4 LEAKAGE TESTS
Conduct all necessary leakage tests as required
per NFPA 99 (National Fire Protection Association)
“Health Care Facility” standards.
UNIT FAILING DIELECTRIC WITHSTAND OR LEAKAGE
TESTS COULD INDICATE SERIOUS INTERNAL PROBLEMS.
DO NOT PLACE UNIT BACK INTO SERVICE! SEND UNIT
TO FACTORY FOR REPAIR! DO NOT ATTEMPT TO REPAIR!
17
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.5 VISUAL INSPECTION
General
Visually inspect the Intelect Transport Therapy
System. A visual inspection can, to an experienced
technician, indicate possible abuse of the unit and
internal problems.
5.6 UNIT STARTUP AND FAN TESTING
A. Test
1. Place unit face up on work surface.
2. Connect power cord to unit and plug into
proper power receptacle.
3. Turn system on. Press the Enter button. IFC
should be highlighted. Press the Enter
button.
4. Place hand at the back of system, at Contrast
Control, to verify fan is blowing out. See
Figure 5.1.
B. Test Results
1. Unit will not start, unit failed test.
a)Possible bad Main Power Switch.
b)Possible bad Power Supply.
c)Possible bad power outlet or Mains Power
Cord.
2. Screen does not display, unit failed test.
a) Contrast Control needs adjusting.
b) Possible bad display.
c)Possible bad Control Board.
d)Possible bad Power Supply.
e) Visually check power LED. LED should
illuminate Blue. Turn system off with Power
button. Power LED should flash Blue.
If Power LED illuminates Blue with system
On and flashes Blue with system Off, the
Power Supply is good. Replace Control
Board.
3. Fan not blowing outward, Unit failed test
a)Fan blowing inward.
Fan wired wrong. Rewire or replace Fan.
b)Fan not blowing.
1) Possible bad Fan.
2) Possible bad Power Supply.
3) Possible bad Control Board.
FIGURE 5.1
18
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.7 ELECTRICAL STIMULATOR TEST SYSTEM SETUP
The following tests for Stimulator Outputs will be
performed on Channels 1 and 2.
A. Equipment Required
• ESTI-2 Load Test Box
• Calibrated Oscilloscope and Probes
B. System Set Up
1. Install known good Lead Wires to Channels 1
and 2 on the system. See Figure 5.2.
2. Connect Lead Wires from the system to the
ESTI-2 Load Test Fixture. Channel 1 to
Channel 1 IN and Channel 2 to Channel 2
IN. See Figure 5.3.
3. Connect Scope Probes to the Channel 1 To
SCOPE and Channel 2 To SCOPE Tabs on the
ESTI 2 Load Test Fixture respectively. See Figure 5.3.
4. Place ESTI-2 Load Switch in the 1 K position.
See Figure 5.3.
5. Install Power Cord into system and plug into
proper Power Supply. Turn system On.
FIGURE 5.2
SCOPE TO
ESTI-2
LOAD SWITCH TO 1 K
The ESTI - 2 Load Box contains a 10 watt resistor
which is not meant for continuous operation. Do
not run the ESTI - 2 Load Box continuously.
THERAPY SYSTEM TO
ESTI-2
NOTE:
The ESTI - 2 Load Box, part number 2757, is
used to simulate patient resistance when
testing waveforms. The ESTI - 2 is set up
for both a 1K and 10K load. The 10K load
is used for Microcurrent only which is not
available on this unit. See Figure 5.4.
FIGURE 5.3
CHANNEL 1
TO SCOPE
CHANNEL 2
TO SCOPE
LOAD SWITCH
1K
10K
OHM MICRO
COMBO
CONTACT
CHANNEL 1
LEADWIRE
CONNETORS
MICROCURRENT
PROBE CONNECTION
(NOT USED)
FIGURE 5.4
19
COMBO
INDICATOR
CHANNEL2
LEADWIRE
CONNETORS
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.8 INTERFERENTIAL MODE TEST
It is assumed that the unit is ready for tests as
described in 5.7 parts A and B. If not, set up unit
per 5.6 parts A and B prior to performing tests.
A. Interferential Mode Test Procedures
1. Set Scope; Time- 100 µS, Channel- 20 V, and
Trigger- DC.
2. Highlight Stim Channel 1. Press the Enter
button.
3. Highlight IFC. Press the Enter button.
4. Increase Intensity until 50 is displayed.
5. Press START button.
6. Compare waveform on scope to Figure 5.5.
7. Press PAUSE button.
8. Verify that the amplitude displayed below
timer drops to zero (0).
9. Verify that Paused is displayed below the
displayed amplitude.
10.Press STOP button.
B. Interferential Mode Test Results
1. Waveform is the same between scope and
Figure 5.5, amplitude dropped to zero
when paused and “Paused” displayed
below timer.
Unit passed test.
2. No waveform or considerably different
waveform.
Unit failed test. Replace appropriate Stim
Board.
3. Amplitude failed to “zero” when paused.
Unit failed test. Replace appropriate Stim
Board.
4. “Paused” did not display when unit paused.
Unit failed test. Replace appropriate Stim
Board.
FIGURE 5.5
5.9 PREMODULATED MODE TEST
FIGURE 5.6
Set up System per 5.7 parts A and B prior to
performing test.
A. Premodulated Mode Test Procedures
1. Set Scope; Time- 2.50 mS, Channel- 20 V, and
Trigger- DC
2. Highlight Stim Channel 1. Press the Enter
button.
3. Highlight Premod. Press the Enter button.
4. Increase Intensity until 50 is displayed.
5. Press START button.
6. Compare waveform on scope to Figure 5.6.
7. Press STOP button.
8. Highlight Channel 2 and repeat steps 3
through 7.
B. Premodulated Mode Test Results
1. Waveform is the same between scope and
Figure 5.6.
Unit passed test.
20
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.10 RUSSIAN MODE TEST
Set up System per 5.7 parts A and B prior to
performing test.
A. Russian Mode Test Procedures
1. Set Scope; Time- 5 mS, Channel- 50 V, and
Trigger- DC
3. Highlight Stim Channel 1. Press Enter
button.
4. Highlight Russian. Press Enter button.
5. Highlight Channel Mode. Press the Enter
button until Co-Contract is displayed.
6. Highlight Cycle Time. Press the Enter button.
7. Highlight Continuous. Press the Enter
button.
8. Increase Intensity until 100 is displayed.
9. Press START button.
10. Compare waveform on scope to Figure 5.7.
11. Verify that both Channels reach 100.
12. Press STOP button.
13. Highlight Channel 2 and repeat steps 4
through 12.
B. Russian Mode Test Results
1. Waveform is the same between scope and
Figure 5.7 and amplitude reached 100 volts peak.
Unit passed test.
2. No waveform or considerably different
waveform.
Unit failed test. Replace appropriate Stim
Board.
3. Amplitude failed to reach 100 volts peak on
both Channels.
Unit failed test. Replace appropriate Stim
Board.
SPEC: 200V PEAK TO PEAK ±10%
FIGURE 5.7
21
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.11 HIGH VOLTAGE PULSED CURRENT (HVPC) MODE TEST
Set up unit per 5.7 parts A and B prior to
performing tests.
A. High Voltage Pulsed Current (HVPC) Mode
Test Procedures
1. Set Scope; Time- 25 µS, Channel- 50 V, and
Trigger- DC
2. Highlight Stim Channel 1. Press the Enter
button.
3. Highlight High Volt. Press the Enter button.
4. Increase Intensity until 250 V is displayed.
5. Highlight Display and press the Enter button
until Peak Current is displayed. Press the
Enter button.
6. Press START button.
7. Compare waveform on scope to Figure 5.8.
8. Highlight Polarity. Press the Enter button
until Positive is displayed.
9. Compare waveform form on scope to
Figure 5.9.
10. The numbers displayed for amplitude must
not exceed 1.5 Amps. See Figure 5.10.
11. Press STOP button.
12. Highlight Channel 2.
13. Press the Enter button and repeat steps 3
through 12.
B. High Voltage Pulsed Current (HVPC) Mode
Test Results
1. Waveforms on scope the same as Figures
5.8 and 5.9. Amps do not exceed 1.5.
Unit passed test.
2. No waveform or considerably different
waveforms.
Unit failed test. Replace appropriate Stim
Board.
3. Amps exceed 1.5.
Unit failed test. Replace appropriate Stim
Board.
PROPER NEGATIVE HIGH VOLT WAVEFORM
FIGURE 5.8
PROPER POSITIVE HIGH VOLT WAVEFORM
FIGURE 5.9
AMPS MUST NOT
EXCEED 1.5
FIGURE 5.10
22
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.12 ULTRASOUND TESTS
Equipment Required for 5.13 and 5.14
• Degassed Water. Refer to page 16 for
Degassed Water Recipes.
• Ohmic Instruments DT 100 UPM or DT 10
Ultrasound Power Meter.
• Dissolved Oxygen Test Kit. Used to test
oxygen level of degassed water.
• Intelect Transport Combo Applicator.
5.13 ULTRASOUND APPLICATOR IDENTIFICATION
TEST
NOTE:
Use any Intelect Transport Combo Applicator for
this test.
A. Ultrasound Applicator Identification
Test Procedures
1. Without Ultrasound Applicator installed, turn
unit on.
2. View the Ultrasound channel in the lower right
corner of screen. It should read “Unplugged”.
See Figure 5.11.
3. Connect Ultrasound Applicator into
Applicator receptacle. See Figure 5.12. Watch
Applicator LED while connecting to system.
The LED should flash Green five times.
4. Look at the Ultrasound channel. It should
read Available. See Figure 5.12.
5. Highlight Ultrasound. Press the Enter button.
6. Highlight Warming. Press the Enter button
until On is displayed beside Warming.
7. Press the Back button. Turn System Off and
back On with Main Power Switch. After
System boots, view the Ultrasound channel,
Warming should be visible. See Figure 5.13.
FIGURE 5.11
FIGURE 5.12
FIGURE 5.13
23
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.13 ULTRASOUND APPLICATOR IDENTIFICATION
TEST (CONTINUED)
B. Ultrasound Applicator Identification Test
Results
1. Unit operates as described in steps 2, 4,
and 7.
Unit passed test.
2. "No Cal.", displays in Ultrasound channel.
a) Applicator not calibrated or needs
recalibration.
b) Possible bad Applicator. Retest with
known good Applicator.
3. Unplugged displays after ten seconds of
Applicator being connected to System.
a) Possible bad applicator. Retest with
known good Applicator.
b) Possible bad internal connection at
Ultrasound Board.
c) Possible bad Ultrasound Board.
d) Possible bad Control Board.
FIGURE 5.14
5.14 ULTRASOUND APPLICATOR OUTPUT TEST
Perform this test using all available Intelect
Transport Combo Applicators used with the
System being tested.
A. Ultrasound Applicator Output Test
Procedures
1. Set up Ohmic Instruments DT 100 or
UPM DT 10 Ultrasound Power Meter per
Operator's Instructions and fill test reservoir
with Degassed Water.
2. Place an Applicator into the Power Meter
retainer. Make certain the Sound Head is
completely submerged in the degassed
water and centered directly over the
Stainless Steel Cone. See Figure 5.14.
3. Zero or Tare meter.
4. Highlight Ultrasound. Press the Enter
button.
5. Highlight Duty Cycle. Press the Enter
button. Highlight Continuous and press
the Enter button.
6. Highlight Display. Press the Enter button
until Watts displays.
7. Press START button.
NOTE:
The position of the Sound Head over the
stainless steel cone is critical to the test results.
The Sound Head must be level and centered.
24
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.14 ULTRASOUND APPLICATOR OUTPUT
TEST (CONTINUED)
APPLICATOR OUTPUT SPECIFICATIONS
Use only Degassed Water in Power Meter for testing
Ultrasound Applicators. Use of other types of water
will cause false test results. Refer to page 16 for
Degassed Water Recipes.
Do not aerate water when filling Power Meter.
8. Increase Intensity until the appropriate
Watts is displayed per Figure 5.15.
9. Compare Power Meter readings to Figure
5.15 to all settings for the respective
Applicator being tested as shown in
Figure 5.15.
10. Press Frequency button until 3.3 MHz is
displayed within the Frequency icon.
Repeat test and compare readings to
Figure 5.15.
NOTE:
The Applicator LED should constantly
illuminate green during the Applicator Output
tests.
B. Ultrasound Applicator Output Test Results
1. Output ranges fall within the specified
ranges as listed in Figure 5.15.
Unit passed test.
2. Readings fall outside specified ranges of
Figure 5.15.
a) Possible bad Degassed Water in Power
Meter.
b) Possible use of Power Meter other than
Ohmic Instruments DT 100 or UPM DT 10
Ultrasound Power Meter.
c). Sound Head not leveled and centered
over cone in power meter.
d) Possible bad or out of calibration
Applicator.
e) Use known good Applicator.
f ) Check Ultrasound Board internal
connections.
g) Replace Ultrasound Board.
h) Replace Control Board.
APPLICATOR SIZE
POWER SETTING (WATTS)
OUTPUT RANGE
1 cm2
1*
2*
2 cm2
1
2
4
0.8 - 1.2
1.6 - 2.4
0.8 - 1.2
1.6 - 2.4
3.2 - 4.8
5 cm2
1
2
5
10
0.8 - 1.2
1.6 - 2.4
4.0 - 6.0
8.0 - 12.0
10 cm2
1
5
10
15**
20**
0.8 - 1.2
4.0 - 6.0
8.0 - 12.0
12.0 - 18.0
16.0 - 24.0
* 3.3 MHz Only
**1.0 MHz Only
FIGURE 5.15
25
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.15 ULTRASOUND DUTY CYCLE TEST
This test is performed using only the 5 cm²
Intelect Transport Combo Applicator.
A. Ultrasound Duty Cycle Test Procedures
1. Set up Ohmic Instruments DT 100 or
UPM DT 10 Ultrasound Power Meter per
Operator’s Instructions and fill test reservoir with Degassed Water.
Use only Degassed Water in Power Meter for testing
Ultrasound Applicators. Use of other types of water
will cause false test results. Refer to page 16 for
Degassed Water Recipes.
Do not aerate water when filling Power Meter.
2. Place the 5 cm² Applicator into the Power
Meter retainer. Make certain the Sound
Head is completely submerged in the
degassed water and centered directly over
the Stainless Steel Cone. See Figure 5.16.
3. Zero or Tare meter.
4. Highlight Ultrasound on system. Press the
Enter button.
5. Highlight Duty Cycle. Highlight Continuous
and press the Enter button.
6. Highlight Display. Press the Enter button
until Watts appears beside Display.
7. Press START button.
8. Increase Intensity until the appropriate
Watts is displayed. See Figure 5.17.
9. Compare Power Meter reading to
Figure 5.17.
10. Press the STOP button.
11. Highlight Duty Cycle and press the Enter
button. Highlight the next level of Duty
Cycle and repeat steps 6 through 10.
Repeat for remaining Duty Cycle levels.
12. Highlight Frequency. Press the Enter
button until 3.3 MHz is displayed beside
Frequency. Repeat steps 4 through 11.
FIGURE 5.16
DUTY CYCLE SPECIFICATIONS
APPLICATOR
SIZE
DUTY CYCLE
OUTPUT RANGE
1 cm²
at 2.7 Watts
Continuous
10%
0.2 - 0.3
20%
0.4 - 0.7
50%
1.1 - 1.6
2 cm²
at 5.4 Watts
Continuous
10%
0.2 - 0.3
20%
0.9 1.3
50%
2.2 - 3.2
5 cm²
at 12 Watts
Continuous
10%
1.0 - 1.4
20%
1.9 - 2.9
50%
4.8 - 7.2
10 cm² at 20 Watts
Continuous
Operating at 1mHz
10%
1.6 - 2.4
10 cm² at 10 Watts
Continuous
Operating at 3.3mHz
20%
3.2 - 4.8
50%
8.0 - 12.0
10%
0.8 - 1.2
20%
1.6 - 2.4
50%
4.0 - 6.0
FIGURE 5.17
26
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.15 ULTRASOUND DUTY CYCLE TEST (CONTINUED)
B. Ultrasound Duty Cycle Test Results
1. Duty Cycles fall within the specified ranges
as listed in Figure 5.17.
Unit passed test.
2. Readings fall outside specified ranges of
Figure 5.17.
a) Possible bad degassed water in Power
Meter.
b) Possible use of Power Meter other than
Ohmic Instruments DT 100 or UPM DT 10
Ultrasound Power Meter.
c) Possible bad or out of calibration
Applicator. Retest with known good
Intelect Transport Applicator.
d) Possible bad internal connection at
Ultrasound Board.
e) Replace possible bad Ultrasound Board.
f ) Replace possible bad Control Board.
27
5- TROUBLESHOOTING
Intelect Transport® Combo Therapy System
5.16 COMBO OPERATION TEST
This test is performed using the 5 cm2
Applicator.
Highlight Channel 1 and set up system per 5.6
parts A and B prior to performing tests.
Connect the Intelect Transport 5 cm2 Applicator
to the System. See Figure 5.18.
Applicator LED will flash green five times.
A. Combo Operation Test Procedures
1. Highlight Combo. Press the Enter button.
2. Highlight Display. Press the Enter button
until Watts is displayed beside Display.
3. Highlight Waveform. Press the Enter button.
4. Press the Up or Down Arrow button until
IFC is highlighted. Press the Enter button.
5. Highlight Edit Stim. Press the Enter button.
Increase Intensity until Channel 1 reads
50 mA.
7. Press START button.
8. Touch the Ultrasound Applicator to the
Combo Contact on the ESTI-2 Load Test
Box. The Combo Indicator on the ESTI-2
should illuminate. See Figure 5.19.
B. Combo Operation Test Results
1. Combo Indicator light illuminates.
Unit passed test.
2. Combo Indicator light does not
illuminate.
Unit failed test.
Replace Channel 1 Stim Board.
FIGURE 5.18
COMBO INDICATOR
ILLUMINATED
FIGURE 5.19
28
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.1 SEPARATING TOP & BOTTOM
Unplug the unit from the power source before
attempting removal or replacement procedures to
prevent electrical shock.
A. Part Numbers
Top ............................................................................. 27552
Base .......................................................................... 27983
B. Tools & Equipment Required
• #1 Phillips Screwdriver
• Flat Blade Screwdriver
C. Removing Top from Bottom
1.Place system face down on a soft work
surface.
2.Remove Lower Front Feet and Rear Fan Grill.
Use a Flat Blade Screwdriver to gently pry the Fan Grill free. See Figure 6.1.
3.Using a #1 Phillips remove the four mounting
screws securing the Top and Bottom together.
See Figure 6.2.
4.Turn system over on its feet and carefully
separate the System Top from the Bottom
Housing.
5.Raise the system Top and disconnect the Fan,
Power Supply, and Battery Harnesses from
the Control Board. See Figure 6.3.
6. Put the unit back together by reversing steps 1 through 5.
NOTE:
When assembling the unit, tuck the Ferrite
Bead between the power supply and the
case. See Figure 6.3
FIGURE 6.1
REMOVE 4 SCREWS
FIGURE 6.2
POWER SUPPLY
CONNECTOR
FERRITE BEAD
BATTERY
CONNECTOR
FAN
CONNECTOR
FIGURE 6.3
29
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.2 THERAPY SYSTEM FAN
REMOVE
SCREWS
Unplug the unit from the power source before
attempting removal or replacement procedures to
prevent electrical shock.
A. Part Number ........................................................... 27158
B. Tools and Equipment Required
• #2 Phillips Screwdriver
C. System Fan
1. Separate Top from Bottom. Refer to 6.1,
part C.
2. Using a #2 Phillips Screwdriver, remove the
two Fan Retaining Screws securing the Fan
to the system Bottom. See Figure 6.4.
3. Remove the Fan Baffle from the Fan Housing.
See Figure 6.5.
4. Replace the Fan by reversing steps 1
through 3.
FIGURE 6.4
REMOVE
BAFFLE
NOTE:
Do not over tighten the screws. Over
tightening will damage the threads of the
brass standoffs.
FIGURE 6.5
30
30
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.3 POWER SUPPLY
REMOVE
SCREWS
Unplug the unit from the power source before
attempting removal or replacement procedures to
prevent electrical shock.
A. Part Number ........................................................... 27265
B. Tools and Equipment Required
• #1 Phillips Screwdriver
• Insulated Needle Nose Pliers
• Digital Multi Meter
• 10k Resistor
• 1/2 inch Copper Tape
C. Power Supply
1. Separate Top from Bottom. Refer to 6.1,
part C.
2. Using the # 1 Phillips Screwdriver, remove the
two screws securing the Power Supply to the
system Bottom. See Figure 6.6.
FIGURE 6.6
POWER SUPPLY
SHEILD
COPPER
TAPE
POWER SUPPLIES RETAIN HIGH VOLTAGE!
WHEN REMOVING FROM SYSTEM, HANDLE
POWER SUPPLIES BY MOUNTING BRACKETS
ONLY.
GUIDE POSTS
3. Lift Power Supply Assembly up to remove
from mounting tabs. See Figure 6.7.
4. Discharge the 400V Capacitor by wrapping
a 10k resistor around the probes of a
Multi meter. Touch the leads of the
Mulit meter to the prongs on the capacitor
to discard. See Figure 6.8.
5. Watch the Multi meter to verify that the
voltage across the capacitor discharges
close to zero volts DC.
ALIGNMENT
POSTS
FIGURE 6.7
CAPACITOR C4
• When replacing the shield on the Power Supply.
Verify that the foil (CONDUCTIVE SIDE) of the
shield faces out and does not come in contact
with the components of the Power Supply.
• When installing the shield on the Power Supply
make certain that the shield does not get caught
on the Power Supply guide posts. See Figure 6.7
FIGURE 6.8
31
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.3 POWER SUPPLY (CONTINUED)
Unplug the unit from the power source before
attempting removal or replacement procedures to
prevent electrical shock.
REMOVE
HARNESSES
GREEN W/
YELLOW STRIPE
WIRE
RED
WIRE
6. Using Insulated Needle Nose Pliers,
disconnect the Power Supply Harnesses from
the Mains Connector. See Figure 6.9.
7. Remove Power Supply from system.
8. Remove the Power Supply Shield.
9. Remove the Copper Tape from the shield. See
Figure 6.7.
10. Replace the Power Supply by reversing steps
1 through 5.
NOTE:
Apply new 1/2 Copper Tape, part number
28152 to replace the tape removed in Step 8
of this procedure.
BLUE
WIRE
FIGURE 6.9
When replacing the shield on the Power Supply.
Verify that the foil (CONDUCTIVE SIDE) of the shield
faces out and does not come in contact with the
components of the Power Supply.
32
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.4 CHANNEL 1 STIM BOARD
REMOVE
SCREWS
Unplug the unit from the power source before
attempting removal or replacement procedures to
prevent electrical shock.
A. Part Number............................................. 27419
B. Tools and Equipment Required
• #1 Phillips Screwdriver
C. Channel 1 Stim Board
1. Separate Top from Bottom. Refer to 6.1,
part C.
2. Using the # 1 Phillips Screwdriver, remove the
four screws securing Channel 1 Stim Board to
the Stand Offs. See Figure 6.10.
3. Carefully lift the Channel 1 Stim Board from
the unit. Make certain not to bend any of the
Header Connector Pins on the board below
during removal. See Figure 6.11.
4. Replace Channel 1 Stim Board in reverse
order of preceding steps. Make certain all
Header Connector Pins are properly engaged.
See Figure 6.11.
NOTE:
Do not over tighten the screws. Over
tightening will damage the threads of the
brass inserts and Stand Offs.
FIGURE 6.10
HEADER CONNECTOR PINS
FIGURE 6.11
Care must be taken during removal and replacement
with the Header Pins. Bending the Header Pins may
cause the unit to fail.
33
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.5 CHANNEL 2 STIM BOARD
REMOVE STANDOFFS
Unplug the unit from the power source before
attempting removal or replacement procedures to
prevent electrical shock.
A. Part Number.............................................. 27498
B. Tools and Equipment Required
• #1 Phillips Screwdriver
• 1/4" Nut Driver or Wrench
C. Channel 2 Stim Board Removal
1. Separate Top from Bottom. Refer to 6.1,
part C.
2. Remove Channel 1 Stim Board. Refer to 6.4,
part C.
3. Using the 1/4" Nut Driver, remove the four
Stand Offs securing Channel 2 Stim Board in
place. See Figure 6.12.
4. Remove the 40 Pin Header from the back of
the Channel 2 Stim Board. See Figure 6.13.
5 Install 40 Pin Header to back of new
Channel 2 Stim Board. Make certain it is
completely seated against board. See
Figure 6.13.
6. Position the Channel 2 Stim Board over the
Ultrasound Board aligning the 40 Pin Header
with the 40 Pin Connector. See Figure 6.14.
7. Press the Channel 2 Stim Board into position
until the board rests against the Ultrasound
Board Stand Offs.
8. Secure the Channel 2 Stim Board using the
Stand Offs removed in part C, step 3 above.
9. Install the Channel 1 Stim Board. Refer to 6.4,
part C.
10. Re-assemble Top to Bottom. Refer to 6.1,
part C.
NOTE:
Do not over tighten the Stand Offs or Screws.
Over tightening will damage the threads of
the Brass Inserts and Stand Offs.
FIGURE 6.12
REMOVE 40 PIN
HEADER
FIGURE 6.13
ALIGN HEADER TO
CONNECTOR
Care must be taken during removal and replacement
with the Header Pins. Bending the Header Pins may
cause the unit to fail.
FIGURE 6.15
34
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.6 ULTRASOUND BOARD
REMOVE STANDOFFS
Unplug the unit from the power source before
attempting removal or replacement procedures to
prevent electrical shock.
A. Part Number............................................. 27269
B. Tools and Equipment Required
• #1 Phillips Screwdriver
• 1/4" Nut Driver or Wrench
C. Ultrasound Board
1. Separate Top from Bottom. Refer to 6.1,
part C.
2. Remove Channel 1 Stim Board. Refer to 6.4,
part C.
3. Remove Channel 2 Stim Board. Refer to 6.5,
part C.
4. Using the 1/4" Nut Driver, remove the four
Stand Offs securing Ultrasound Board in
place. See Figure 6.15.
5. Carefully remove the Ultrasound Board. See
Figure 6.16.
NOTE:
Headers may stay on the board being
removed or on the connector. If the header
stays with the connector, remove and install
on the replacement board.
6.Remove the 40 Pin Header from the
Ultrasound Board or the connector. See
Figure 6.16.
7. Install 40 Pin Header to back of new
Ultrasound Board. Make certain it is
completely seated against board. See
Figure 6.17.
8. Position the Ultrasound Board over the
Control Board aligning the 40 Pin Header
with the 40 Pin Connector on Control Board.
See Figure 6.16.
9. Press the Ultrasound Board into position
until the board rests against the Control
Board Stand Offs. Verify that it is well seated
by pushing on the sides of the connector.
10. Secure the Ultrasound Board using the
Stand Offs removed in part B, step 4 above.
11. Reassemble by reversing steps 1
through 3.
Care must be taken during removal and replacement
with the Header Pins. Bending the Header Pins may
cause the unit to fail.
FIGURE 6.15
CONTROL BOARD CONNECTOR
CONTROL BOARD HEADER
FIGURE 6.16
INSTALL HEADER TO BACK OF
ULTRASOUND BOARD
FIGURE 6.17
35
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.7 CONTROL BOARD ASSEMBLY
REMOVE
CONTRAST KNOB
Unplug the unit from the power source before
attempting removal or replacement procedures to
prevent electrical shock.
A. Part Number............................................... 27249
B. Tools and Equipment Required
• #1 Phillips Screwdriver
• 1/4" Nut Driver or Wrench
C. Control Board Replacement
1. Separate Top from Bottom. Refer to 6.1,
part C.
2. Remove Channel 1 Stim Board. Refer to 6.4,
part C.
3. Remove Channel 2 Stim Board. Refer to 6.5,
part C.
4. Remove Ultrasound Board, Refer to 6.6,
part C.
5. Remove the Contrast Control Knob. See
Figure 6.18.
6. Remove the seven screws securing the
Control Board Assembly in position. See
Figure 6.19.
7. Remove the four LCD Bracket Mounting
Screws. See Figure 6.21.
8. While lifting on the lower end of the Control
Board Assembly with one hand, release the
four Tabs securing the Control Board with the
other, to remove the Control Board from the
system Top. Two of the Tabs are located
above the LCD and two below. See
Figures 6.19 and 6.20.
FIGURE 6.18
REMOVE SCREWS
CONTROL BOARD
TABS ABOVE LCD
REMOVE SCREWS
FIGURE 6.19
RELEASE TABS
LIFT
HERE
FIGURE 6.20
36
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.7 CONTROL BOARD ASSEMBLY (CONTINUED)
9. On the back side of the Control Board, press
down and back on the four LCD tabs and
push back through the Control Board. See
Figure 6.21.
10. On the front side of the Control Board, pull
the LCD up to release the header from the
board. See Figure 6.22.
11. Position the new Control Board Assembly
over the Alignment Tabs of the system Top.
Press the Control Board Assembly until the Alignment Tabs lock the Control Board into
position.
12. Reverse steps 1 through 10 to install the
replacement Control Board.
NOTE:
Do not over tighten the Stand Offs or screws.
Over tightening will damage the threads of
the brass inserts and Stand Offs.
LCD TABS
FIGURE 6.21
LCD HEADER
PIN
FIGURE 6.22
37
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.8 LCD
A. Part Number............................................... 27249
B. Tools and Equipment Required
• #1 Phillips Screwdriver
• 1/4" Nut Driver or Wrench
C. LCD Replacement
1. Separate Top from Bottom. Refer to 6.1,
part C.
2. Remove Channel 1 Stim Board. Refer to 6.4,
part C.
3. Remove Channel 2 Stim Board. Refer to 6.5,
part C.
4. Remove Ultrasound Board, Refer to 6.6,
part C.
5. Remove Control Board, Refer to 6.7,
part C steps 1 through 10.
6. Once the LCD is removed from the Control
Board, per step 5, remove the LCD mounting
bracket from both sides of the LCD. See
Figure 6.23.
7. Replace the LCD by reversing the steps above.
NOTE:
Always install the LCD Brackets prior to
attaching the LCD to the Control Board.
LCD MOUNTING
BRACKETS
FIGURE 6.23
38
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.9 KEYMAT, ON/OFF BUTTON, OR UNIT TOP
KEYMAT
ON/OFF BUTTON
Unplug the unit from the power source before
attempting removal or replacement procedures to prevent electrical shock.
A. Part Number
Keymat and On/Off Button.....................27560
B. Tools and Equipment Required
• #1 Phillips Screwdriver
• 1/4 in Wrench
B. Keymat Assembly Removal
1. Separate Top from Bottom. Refer to 6.1,
part C.
2. Remove Channel 1 Stim Board. Refer to 6.4,
part C.
3. Remove Channel 2 Stim Board. Refer to 6.5,
part C.
4. Remove Ultrasound Board. Refer to 6.6,
part C.
5. Remove Control Board Assembly. Refer to 6.7, part C.
6. Lift out Keymat Assembly or On/Off Button
Keymat. See Figure 6.24.
7. Replace the Keymat by reversing steps 1
through 6.
NOTE:
Do not over tighten the Stand Offs or screws. Over tightening will damage the threads of
the brass inserts and Stand Offs.
FIGURE 6.24
39
6- REMOVAL & REPLACEMENT
Intelect Transport® Combo Therapy System
6.10 PLYNTH
A. Part Number
Plynth..........................................................27253
B. Tools and Equipment Required
• None
B. Plynth Removal
NOTE:
The plynth is secured to the unit by tabs
that fit into the five slots shown in Figure 6.25.
1. Remove the Plynth by applying pressure to
center of the top or wide part of the Plynth.
When pressing lift the Plynth out the three
slots at the top and then remove the Plynth
from the two slots at the bottom. Refer
to 6.26.
7. Replace the Plynth by reversing this
procedure.
PLYNTH MOUNTING
SLOTS
FIGURE 6.25
FIGURE 6.26
40
7- GENERAL MAINTENANCE
Intelect Transport® Combo Therapy System
7.1 CLEANING THE SYSTEM
A. Cleaning the Therapy System
With the system disconnected from the power
source, clean the system with a clean, lint free
cloth moistened with water and mild
antibacterial soap. If a more sterile cleaning is
needed, use a cloth moistened with an
antimicrobial cleaner.
Do not submerse the system in liquids. Should
the unit accidentally become submersed,
contact the dealer or DJO, LLC Service
Department immediately. Do not attempt to use
a system that has been wet inside until
inspected and tested by a Service Technician
Certified by DJO, LLC.
7.4 FACTORY SERVICE
When the Intelect Transport Combo Therapy
System requires factory service, contact
the dealer or Chattanooga Service
Department.
Do not allow liquids to enter the ventilation
holes in the optional modules. This could
permanently damage the modules.
B. Cleaning Therapy System Lens
Clean the Therapy System Lens with the
NOVUS® Plastic Polishing System. NOVUS can
be purchased by going to www.novuspolish.
com on the internet. Follow the instructions as
given by NOVUS on their product.
Do Not Use alcohol or chlorine based solvents
as this may damage the lens.
7.2 CALIBRATION REQUIREMENTS
Ultrasound Applicators:
Annual calibration is required for all Ultrasound
Applicators. Only the Applicators should be sent
to the factory or a Field Technician certified
by DJO, LLC for this procedure.
7.3 FIELD SERVICE
A. All field service procedures as described in
this Service Manual must be performed by a
Service Technician certified by DJO, LLC.
B. Any attempted outside the scope of this
Service Manual is the sole responsibility and
liability of the Field Technician performing
such procedures.
C. After the performance of any Field Service,
perform the tests as described in 5.3 through
5.16 to verify the system operates properly
and within specifications prior to placing the
unit back into operation.
41
8- ULTRASOUND APPLICATOR CALIBRATION
Intelect Transport® Combo Therapy System
8.1 GENERAL PROCEDURES
A. Tools and Equipment Required
• All Ultrasound Applicators for the unit being
serviced.
• Ohmic Instruments UPM DT 10 or UPM DT
100 Ultrasound Power Meter, set to "Watts".
• Degassed Water. Refer to page 16 for
Degassed Water Recipes.
FIGURE 8.1
Use only Degassed Water in Power Meter for
calibrating Ultrasound Applicators.
Use of other types of water will cause false readings
and bad test results.
See page 16 for Degassed Water Recipes.
Use of other brands or types of tools, equipment,
fixtures, materials, and supplies other than those
specifically listed on page 16 will give bad test and
calibration results.
If proper equipment is not available or cannot be
obtained, send the Ultrasound Applicators to the
factory for calibration.
FIGURE 8.2
B. Ultrasound Applicator Calibration
Procedures
1. Perform the following on all Ultrasound
Applicators for the unit being serviced at
least annually.
2. With the system on, press the Clinical
Resources button once. See Figure 8.1.
3. Simultaneously press and hold the Treatment
Time and Intensity Decrease buttons for
approximately 2 seconds. See Figure 8.2. The
calibration procedures screen should display.
4. Press the Down Arrow button until US
Applicator Calibration is highlighted.
5. Press the Enter button.
6. Place the Ultrasound Applicator being
calibrated into the Ohmic Instruments
UPM DT 100 or DT 10 Ultrasound Power
Meter and set meter to "Watts”. See
Figure 8.3.
7. Follow the instructions on the LCD Display.
8. When calibration is complete, follow the
test procedures in 5.13 and 5.14 to verify
that the Applicator is calibrated..
SET METER
TO WATTS
FIGURE 8.3
42
9- PARTS
Intelect Transport® Combo Therapy System
Intelect Transport Combo Top Assembly
1
3
3
2
5
ITEM
PART NO.
DESCRIPTION
QTY
1
27552
2
See LCD
Assembly
Drawing
3
27560
Keymat
1
5
27142
M3 x 6mm Pan Head Screws
11
Top Assembly
1
Intelect Transport LCD Assembly
1
43
9- PARTS
Intelect Transport® Combo Therapy System
Intelect Transport Combo Ultrasound and Stim Boards
1
2
NOTE: INSERT #3 LONG PINS DOWN, INTO PCB #2 FIRST,
THEN INTO #1
3
4
6
5
7
8
9
ITEM
PART NO.
1
See Top
Assembly
Drawing
2
DESCRIPTION
QTY
Intelect Transport Top Assembly
1
28019
Header
1
3
27269
Ultrasound PCB
1
4
28020
Connector
1
5
27498
Channel 2 Stim PCB
1
6
28017
Standoff M3 x 19mm
4
7
27419
Channel 1 Stim PCB
1
8
27770
Standoff M3 x 16mm
4
9
27142
M3 x 6mm Pan Head Screws
4
44
9- PARTS
Intelect Transport® Combo Therapy System
Intelect Transport Combo LCD Assembly
NOTE: INSERT #4 THROUGH TOP
ROW OF SOCKET CONNECTOR OF #1
1
3
DIM SWITCH POSITIONS ON
DIP SWITCH NO
1
ON
ON
ON
2
3
4
5
INSERT LONG END OF HEADER UP FROM BOTTOM OF DISPLAY. SOLDER TO DISPLAY
4
2
ITEM
PART NO.
1
27249
PCB Assembly
DESCRIPTION
1
2
27261
LCD Spacer
2
3
27012
Contrast Knob
1
4
27264
LCD
1
5
27588
Header
1
45
QTY
9- PARTS
Intelect Transport® Combo Therapy System
9
BLUE WIRE
4
GREEN WITH
RED WIRE
YELLOW STRI
PE
Intelect Transport Combo Base Assembly
L
DETAIL A (SEE FIGURE 6.9)
NOTE
TUCK FERRITE
UNDER POWER
SUPPLY
6
N
5
PLACE INSULATED SIDE OF SHIELD NEXT TO
POWER SUPPLY
TUCK FERRITE
UNDER POWER
SUPPLY AND INTO CORNER
10
11
3
7
SEE DETAIL A
2
1
ITEM
PART NO.
DESCRIPTION
1
27983
Base Deep
1
2
27256
Applicator Hang-Up
1
3
27984
Connector Infill Panel
1
4
27367
Fan Seal
1
5
27265
Power Supply
1
6
27158
Fan
1
7
27152
Snap in Inlet (IEC Socket)
1
9
27136
M4 x 35mm
2
10
27142
M3 x 6mm
2
11
27592
Shield T-Port Power Supply
1
46
QTY
9- PARTS
Intelect Transport® Combo Therapy System
Intelect Transport Combo Final Assembly
NOTE: GRAY COLOR OVERLAY
1
FAN
CONNECTOR
9
5
12
14
POWER SUPPLY CONNECTOR
2
10
10
10
10
6
LEFT
6
BATTERY
CONNECTOR
RIGHT
7
(OPTIONAL)
13
3
NOT TO SCALE
4
11
ITEM
PART
NO.
1
See Top
Assembly
Drawing
2
See Base
Assembly
Drawing
DESCRIPTION
Intelect Transport Top Assembly
Intelect Transport Base Assembly
QTY
ITEM
PART
NO.
1
7
27267
Optional Battery Pack
1
9
28018
Foam Baffle
1
1
10
27140
M3 x 8mm Pan Head Screws
4
11
27150
1/2"D x 1/4" H BLK Feet
2
12
27821
Tape 3M
13
28155
Serial Decal
1
14
27989
Harness Battery
1
3
27410
Battery Compartment Cover
1
4
27253
Plinth
1
5
27361
Rear Vent
1
6
27363
27365
Left Foot
Right Foot
1
1
47
DESCRIPTION
QTY
.17FT
11- WARRANTY
Intelect Transport® Combo Therapy System
DJO, LLC ("Company"), warrants that the Intelect Transport Combo Therapy System ("Products") are free of defects
in material and workmanship. This warranty shall remain in effect for two years (24 months) from the date of
original consumer purchase. If these Products fail to function during the two years warranty period due to a defect
in material or workmanship, at the Company's option, the Company or the selling dealer will repair or replace the
respective Product without charge within a period of thirty days from the date on which the Product is returned to
the Company or the dealer.
All repairs to the Product must be performed by a service center certified by the Company. Any modifications or
repairs performed by unauthorized centers or groups will void this warranty.
The warranty period for certain accessories is 90 days. Accessories consist of Lead Wires, Electrodes, and Nylatex®.
The warranty period for the Battery and Ultrasound Applicators is one year (12 Months).
This Warranty Does Not Cover:
• Replacement parts or labor furnished by anyone other than the Company, the selling dealer, or a certified Company service technician.
• Defects or damage caused by labor furnished by someone other than Company, the selling dealer, or a certified
Company service technician.
• Any malfunction or failure in the Product caused by product misuse, including, but not limited to, the failure to
provide reasonable and required maintenance or any use that is inconsistent with the Product User's Manual.
COMPANY SHALL NOT BE LIABLE IN ANY EVENT FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Some locations do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
To obtain service from Company or the selling dealer under this warranty:
1. A written claim must be made within the warranty period to the Company or the selling dealer. Written
claims made to the Company should be sent to:
DJO, LLC
1430 Decision St
Vista, CA 92081 USA
Phone: 1-800-592-7329 USA
Phone: 1-423-870-2281 or 1-317-406-2250
Fax: 1-317-406-2014 and
2. The Product must be returned to the Company or the selling dealer by the owner. A Return Authorization
(RA) Number must be obtained before returning any product to the Company.
This warranty gives you specific legal rights and you may also have other rights which vary from location to
location.
The Company does not authorize any person or representative to create for it any other obligation or liability in
connection with the sale of the Product.
Any representative or agreement not contained in the warranty shall be void and of no effect.
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
67
Moving
Rehabilitation
Forward™
DJO, LLC
1430 Decision St
Vista, CA 92081 USA
Phone: 1-800-592-7329 USA
Phone:1-317-406-2209
Fax: 1-317-406-2014
chattgroup.com
© 2010 DJO, LLC
28157_C
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