Chattanooga OptiFlex S

Chattanooga OptiFlex S
OptiFlex – S
Service Manual
Starting from serial number 3000
Table of contents
2. Purpose
1. History
2
2. Purpose
2
3. General
2
4. Packing and unpacking
7
5. Block diagram of service parts
8
6. Bill of material for service parts
9
7. Figure for bill of material
10
8. Special function Service Menu
(Hand held programming unit old version)
9. Special function Service Menu
(Hand held programming unit new version)
12
The purpose of this Service Manual is to help you make
simple repairs on the device.
Only authorized staff may perform repairs and maintenance as
the manufacturer’s warranty and liability would otherwise be
invalidated.
Only original parts may be used for servicing in accordance
with the attached spare parts list.
3. General
3.1 Electronics, connection cables
13
No plugs may be connected or disconnected while the
unit is switched on. Always switch the device
off before connecting or disconnecting a plug.
10. How to perform repairs
16
The locks for spiral cable for the hand-held programming
unit and the motor element assembly have to be closed at all
11. Checklist of safety and function test
(Hand held programming unit old version)
17
12. Checklist of safety and function test
(Hand held programming unit new version)
18
times.
When you assembling with electronic parts make sure
to use ESD (Electro Static Discharge) equipment.
Only original chipcards may be used. Insert the chipcards
so that OptiFlex is visible.
Possible errors: Errors will be displayed on the hand held
programming unit .
1. History
Revision
Date
Name
Change
1
01.06.2003
S. Herr
Service Manual
created
2
05.04.2004
S. Herr
Update Pos. 13,
Pos. 40,
function test
3
24.09.2007
S. Herr
New hand held
programming unit
Depending on the version of the hand held programming unit
there are different error messages.
Old version (Pos. 1.1)
Following error messages will be shown on the display:
Chipcard not readable:
The chipcard was not readable or it contains invalid data
-> Try to format the chipcard
-> Use new chipcard
-> Replace hand held programming unit
Chipcard K2 PRO
Chipcard of knee CPM K2 PRO was inserted
-> Use chipcard of shoulder CPM
-> Use new chipcard
2
Error motor X Motor error
The motor did not turn properly
-> Replace motor element assembly
Error motor X Over current
The current for motor X exceeded the maximum limit
-> Replace motor element assembly
Error motor X Motor control
Internal error in motor control of motor X
-> Replace motor element assembly
Error motor X CPM ROM error
Memory error in motor control of motor X
-> Replace motor element assembly
Error motor X Communication
Communication to motor X not possible
-> Check spiral cables and connectors
-> Replace motor element assembly
Error motor X CPM device error
General error in motor control of motor X
-> Replace motor element assembly
Error motor X Enable timeout
Motor X could not be enabled in time
-> Replace motor element assembly
Error motor X Inval. Parameter
Motor control X has received an invalid parameter from the
hand held programming unit
-> Replace motor element assembly
-> Replace hand held programming unit
Error motor X Mot. Release
The motor could not be released
-> Replace motor element assembly
-> Replace hand held programming unit
Error motor X Stop unexpected
The motor X stopped unexpected
-> Check spiral cables and connectors
-> Replace motor element assembly
Error motor X Motor disabled
The motor control X disabled the motor
-> Replace motor element assembly
Error motor X ROM exceeded
Motor X moved beyond the programmed range of motion
-> Replace motor element assembly
Error motor X CPM 5V supply
5V supply of motor control X not sufficent
-> Replace motor element assembly
Error motor X CPM 24V supply
24V supply of motor control X not sufficent
-> Replace motor element assembly
Error motor X Enable error
The motor X could not be enabled
-> Replace motor element assembly
Error motor X Disable timeout
The motor X Disable timeout
-> Replace motor element assembly
Error motor X Internal com.
Invalid interchip communication inside motor X
-> Replace motor element assembly
Error motor X Unknown CPM err.
Unknown error in motor control X
-> Replace motor element assembly
Error motor X Undefined err.
Undefined error in motor control X
-> Replace motor element assembly
Handset error H. Set ROM
Memory error in the hand held programming unit
-> Replace hand held programming unit
Handset error HS 24V supply
24V supply of hand held programming unit not sufficient
-> Replace electronic S3 complete
-> Replace hand held programming unit
Handset error HS 5V supply
5V supply of the hand held programming unit not sufficent
-> Replace hand held programming unit
Handset error HS 3.3 V
3.3V supply of the hand held programming unit not sufficent
-> Replace hand held programming unit
Handset error Internal com.
Invalid interchip communication inside the hand held
programming unit
-> Replace hand held programming unit
Handset error Bus system
System bus error
-> Replace hand held programming unit
-> Replace motor element assembly
-> Replace electronic S3 complete
Parameter not valid
Internal error in the hand held programming unit
-> Replace hand held programming unit
Configuration not valid
Invalid configuration of the hand held programming unit
-> Replace hand held programming unit
Wrong product combination
Mixup between non compatible chair and hand held
programming unit
-> Use correct hand held programming unit
Chair Memory error
Defective memory chip inside the chair
-> Replace electronic S3 complete
Chipcard unkown
A foreign or defective chipcard was inserted
-> Use new chipcard
Chipcard missing
No chipcard is inserted
-> Insert chipcard
Chipcard not writable
The chipcard is not writable
-> Use new chipcard
-> Replace hand held programming unit
Error motor X Calibration
The calibration data for the motor X is invalid or lost
-> Motor X needs to be calibrated
Error motor X Potentiometer
Potentiometer reading was invalid
-> Replace motor element assembly
Error motor X Pot. Contact
Potentiometer connection is broken
-> Replace motor element assembly
Error motor X Motor driver
The motor driver IC reported an error
-> Replace motor element assembly
3
New version (Pos. 1.2)
9 Communication:
Communication to the motor control is not possible
-> Check cables and connectors
-> Replace hand held programming unit
-> Replace motor element assembly
10 Unkown error in the motor control:
Unknown error in the motor control
-> Replace motor element assembly
11 Motor enable timeout
Motor could not be enabled in time.
-> Replace motor element assembly
12 Invalid parameter motor error:
Motor has received a invalid parameter
-> Replace hand held programming unit
-> Replace motor element assembly
13 Stop release error:
The motor could not be released
-> Replace hand held programming unit
-> Replace motor element assembly
14 Unexpected motor Stop:
-> Check cables and connectors
Following error codes in number will be shown on the
display:
1 Potentiometer error:
Wrong angle information provided from potentiometer
-> Check the settings
-> Replace motor element assembly
2 Failure at the potentiometer:
Connection to the potentiometer is interrupted
-> Replace motor element assembly
3 Motor driver error:
The motor driver IC reported an error
-> Replace motor element assembly
4 Motor error:
The motor did not turn properly.
-> Replace motor element assembly
5 Motor over current:
The current for the motor exceeded the maximum limit
-> Replace motor element assembly
6 Motor control error:
Internal error in the motor control.
-> Replace motor element assembly
7 Eprom access error:
Memory error in the access of the EPROM.
-> Replace hand held programming unit
8 CPM ROM error:
Memory error in the motor control
-> Replace motor element assembly
-> Replace motor element assembly
15 Motor disabled:
Motor control disabled the motor.
-> Replace motor element assembly
16 Wrong command in the motor :
-> Replace hand held programming unit
-> Replace motor element assembly
17 5V supply error:
5V supply of motor control not sufficient
-> Replace motor element assembly
18 Initialise error real time clock:
-> Replace hand held programming unit
19 Communication error real time clock:
-> Replace hand held programming unit
20 Error real time clock:
-> Replace hand held programming unit
21 Range exceeded:
The measured angle is out of the range of motion.
-> Replace motor element assembly
22 ROM error in the hand held programming unit:
Memory error in the hand held programming unit
-> Replace hand held programming unit
23 Invalid parameter:
Internal error in the hand held programming unit
-> Replace hand held programming unit
4
24 24V supply error motor control:
Error in the 24V supply in the motor control
-> Replace hand held programming unit
-> Replace electronic S3 complete
40 Unkown chipcard:
-> Replace chipcard
41 Chipcard is missing:
No chipcard is insert
-> Insert chipcard
25 Bus error:
Bus system error
-> Replace spiral cable of the hand held programming unit
-> Replace chipcard
-> Replace hand held programming unit
-> Replace motor element assembly
42 Chipcard write error:
The chipcard is not writable
-> Replace chipcard
26 24V supply hand held programming unit:
24V supply of the hand held programming unit is
defective
-> Replace hand held programming unit
-> Replace hand held programming unit
43 Chipcard read error
Chipcard is not readable.
-> Replace chipcard
27 5V supply hand held programming unit:
5V supply of the hand held programming unit is defective.
-> Replace hand held programming unit
-> Replace hand held programming unit
44 Chipcard verify
-> Replace chipcard
-> Replace hand held programming unit
28 3.3V supply hand held programming unit:
3.3V supply of the hand held programming unit is
defective
-> Replace hand held programming unit
45 Wrong product combination:
Mixup between non compatible device and hand held
programming unit
-> Use the correct hand held programming unit
29 Calibration:
The calibration data in the motor control are wrong.
-> Perform a calibration
46 Handset error internal communication:
Invalid interchip communication inside the hand held
programming unit
-> Replace hand held programming unit
30 Calibration error:
-> Repeat the calibration
-> Replace motor element assembly
31 Calibration timeout:
-> Replace motor element assembly
47 Internal communication error motor control:
Internal communication error motor control..
-> Replace motor element assembly
32 Motor enable error:
The motor could not be enabled
-> Replace motor element assembly
48 User stoped the special function
49 Unkown error in the motor control:
-> Replace motor element assembly
33 Motor disable error:
The motor could not be disabled
-> Replace motor element assembly
50 Decoding unit keyboard not programmed/ defect
-> Replace hand held programming unit
34 Motor stop error:
Motor stop command timeout error:
-> Replace motor element assembly
54 Decoding unit rotary encoder not programmed/
defect
-> Replace electronic S3 complete
35 Configuration error:
Invalid configuration of the hand held programming unit
-> Replace hand held programming unit
Chipcard missing
36 Parameter not valid chipcard
-> Replace chipcard
-> Replace hand held programming unit
37 Checksum error chipcard
-> Replace chipcard
-> Replace chipcard
-> Replace hand held programming unit
38 Unknow chipcard error:
-> Replace hand held programming unit
39 A chipcard of another product got
used:
-> Formate the chipcard
-> Replace chipcard
5
3.2 Motor element assembly
No plugs may be connected or disconnected while the
unit is switched on. Always switch the device
off before connecting or disconnecting a plug.
The motor element assembly plugs have to be locked at all
times.
The movable screws should not be completely unscrewed when adjustments are being made. Make sure
that the movable screws are tightened for operation
and transport.
Make sure that no load is on the profile when making
adjustments on the upper arm.
To remove the load, slightly lift motor B.
3.3 Other
The scale profiles with the labeling 2,3 and 5 must not be
lubricated or oiled.
No solvents may be used when cleaning the device.
.
6
4. Packing and unpacking
Only use orginial packaging for transport.
The following settings must be made to transport the
device:
Put the device on its legs in the carton.
Activate the packaging setting: Motor A 35 ° and motor
B 0°.
Put the proper styrofoam part on top of the chair.
Switch off the device.
Pack the hand held programming unit in the extra box.
Pull the power cord.
Put the piece parts into the styrofoam part in the
following order as shown in the figure below: Motor
element assembly and power cord.
Remove the armrest complete.
Pull the plugs of the motor element assembly and the
hand held programming unit.
Pull out the motor element assembly.
Set the ante/ retro version to 0° .
Reinsert the armrest.
Move the backrest all the way to the front.
Remove the two tube safety, pull out and reverse the
chair´s leg and reattach the tube safety.
7
5. Block diagram of service parts
Motor A
Controllogic
Display
Emergency
Shutdown
Motordriver
Microprocessor
MicroProcessor
Motor
Pot.
Control
Pot.
Distribution
Controllogic
Chair
ID
Motor B
Keyboard
Controllogic
Emergency
Shutdown
Motordriver
Power Supply
Microprocessor
8
Pot.
Control
Motor
Pot.
6. Bill of material for service parts
Position
Description
Order number
1.1
Hand held programming unit OptiFlex S + spiral cable (old version)
0.0034.082
1.2
Hand held programming unit OptiFlex S + spiral cable (new version)
0.0034.320
Spiral cable for hand held programming unit (old version)
2.0034.355
Spiral cable for hand held programming unit (new version)
2.0037.035
Protection for hand held programming unit
0.0037.103
4
Armrest assembly
2.0034.022
5
Wheel assembly
0.0034.006
6-8
Electronic S3 complete
0.0034.041
Fuse T 1.0 A
0.0000.005
10
Wing screw backrest
2.0034.044
14
Clamping piece exchange kit up to S/N 3386
0.0034.060
Clamping piece exchange kit starting from S/N 3387
0.0034.059
16+21
Motor element assembly complete (with both motors)
0.0034.065
18
Lever assembly
0.0034.012
20
Wing nut ellbow joint
GN532-40-M8-E
22
Elbow cup pad
2.0034.255
23
Armrest cup complete
0.0034.190
24
Belt loop
2.0003.001
26
Lever assembly
0.0034.012
28
Wing nut swing bar
GN-532-40-M8-E
30
Tube safety
0.0034.249
31
Chair leg right
0.0034.079
32
Chair leg left
0.0034.078
Power cord US version
0.0034.011
9
7. Figure for bill of material
Position 1.1
Position 1.2
10
16
23 + 24
20
26 + 28
1
30
32
31
21
22
18
4
14
10
6–8
5
11
8. Special function Service Menu
( Hand
held programming unit old version)
8.3 Error log
Depending on the version of the hand held programming unit
there are different special functions Service Menu.




Old version




Display: Error log
Press SET key
Display: Error log Up + Down –
By using the + and – keys you can see the entries
of the error log
Entries are always in english
The entries are ordered by causer and not in temporal
order
In the first line is shown the causer (e.g motor A) and
below the error message in shortform
There is only one line in the error log for the error
message so the words can be different to the original
words
8.4 Calibration
How to perform a calibration:






Possible functions of the Service Menu:

Device runtime

Factory settings

Error log

Calibration


Entering the Service Menu:

Switch to the programming mode



Press FUNC key
Select Service Menu using the + and - keys
Press SET for 5 Sekunden
For service only ! is flashing
Select a special function by using + and - keys








8.1 Device runtime



Display: Device runtime
Press SET key
The display shows the device runtime of each motor
Display: A: X h B: X h



8.2 Factory settings (=Packaging setting)








Display: Factory settings
Press SET key
Display: Werkseinstellung bereit
Device changes language to German
Press STOP key
Display: Bereich anfahren START drücken
Press START key, the device moves automatically to
factory settings
Display: STOP Dauerbetrieb
12
Display: Calibration
Press SET key
Display: Enter key
Press + and – keys simultaneously
Display: Select motor With +/-  A
Press SET key
Display: Move Mot A to 90° Press SET
Move motor A to 90° by using + and - keys
Press SET key
Display: Calibrating M A Please wait
Motor A moves in the complete range of motion
automatically
After motor A stops the display shows:
Display: Calibration M. A successful
Press STOP key
Display: Select motor With +/-  A
Press + key
Display: Select motor With +/-  B
Press SET key
Display: Move Mot B to 0° Press SET
Move motor B to 0° by using + and - keys
Press SET key
Display: Calibrating M B Please wait
Motor B moves in the complete range of motion
automatically
After motor B stops the display shows:
Display: Calibration M. B successful
Press STOP key two times
Display: Move to ROM Press START
9. Special function Service Menu
(Hand held programming unit new version)
Depending on the version of the hand held programming
unit there are different special functions Service Menu.
New version:
Entering the service menu:
Press the menu key until Service Menu
shows up (menu level 4).
Press
for 5 seconds,
is flashing on the display
The display will change and show:
Entering code.
For the code press: 1 3 2
4
Now you see the symbols of the service menu
Menu level 1:
Possible function of the Service Menu:
Menu level 1
Menu level 2:
Calibration motor A
Calibration motor B
Display contrast
Error log
Menu level 2
Runtime motor A
Runtime motor B
13
9.1 Calibration
9.2 Display contrast
Press the symbol display contrast
ATTENTION!
Display:
Before you do a calibration switch the device
OFF and ON.
Calibration motor A:
Press + or – to set up the requested display contrast. You can
set the display contrast from 0 – 100%.
Press the STOP key twice to save the settings and to leave
the Service Menu.
Press the symbol calibration motor A
Display:
9.3 Error log
Press + and – key to move motor A to 90 degrees.
Press the symbol error log
Press START key. The calibration starts automatically.
Motor A moves in the complete range of motion.
Wait until the motor A stops.
If the calibration was succesful motor A stops at 90
degrees and show following symbols on the display:
You will find following information on the display:
Upper line: Number of the current showed error message
and the total number of the saved error messages.
Right number is the error code of the error message (see
chapter 3.1)
Lower line: Error message
Left side: The symbol of the causer.
= Hand held
programming unit
Press the STOP key twice to leave the Service Menu
= Motor A
Calibration motor B:
Press the symbol calibration motor B
= Electronic complete
Display:
= Motor B
Press + or - to see the entries of the error log.
General note to the error log:
Press + and – key to move motor B to 0 degrees.
Entries are always in english.
Press START key. The calibration starts automatically.
Motor B moves in the complete range of motion.
Wait until the motor B stops.
If the calibration was succesful motor B stops at 0 degrees
and show following symbols on the display:
The entries are ordered by causer and not in temporal
order.
Press the STOP key twice to leave the Service Menu.
Press the STOP key twice to leave the Service Menu
14
9.4 Runtime
Runtime motor A
Press the symbol for runtime motor A
The display shows the runtime of motor A:
Runtime motor B
Press the symbol for runtime motor B
The display shows the runtime of motor B:
Press the STOP key twice to leave the Service Menu.
15
10. How to perform repairs
10.7 Wing nut (Pos. 20 + 28)
10.1 Electronic complete (Pos. 6-8)
Make sure that the new wing nut is tight.
Attention: Wing nut must not be interchanged.
ATTENTION!
10.8 Wing screw (Pos. 10)
When you assembling with electronic parts make
sure to use ESD (Electro Static Discharge) equipment.
Make sure that the new wing screw is tight.
Attention: Wing screw must not be interchanged.
Switch off the device.
First, the plug for the power cord, the motor element
assembly and the plug for the hand held programming
unit´s spiral cable have to be unplugged. Then remove the
4 screws in the plate and take the whole electronic
complete with plate off the ground wire plug connection.
Once the spare part has been installed, a function and
safety test has to be performed.
10.9 Fuse (Pos. 8)
Switch off the device and disconnect the plug. Remove the
fuse holder below the main switch and plug it back after the
fuses have been exchanged.
Only use the appropriate fuses.
10.2 Clamping piece exchange kit (Pos. 14)
10.6 Repairs of the drive unit and motor control
The exchange kit of clamping pieces contains 2 clamping
pieces (1 left and 1 right) with all of the required screws
and an exact instruction for mounting.
ATTENTION!
Only authorized and certified staff may perform repairs
and maintenance at the drive unit and motor control
otherwise the manufacturer´s warranty and liability
will be invalidated.
10.3 Lever assembly (Pos. 18 + 26)
Remove one of the side retaining rings and pull out the
pin so that the defective lever can be taken out. When
using the new lever, make sure that both springs are
properly set. The retaining rings then have to be put onto
both side of the pin.
The complete lever assembly has to be regularly serviced.
ATTENTION!
When you assembling with electronic parts make
sure to use ESD (Electro Static Discharge) equipment.
10.4 Elbow cup pad (Pos.22)
First, the defective pad has to be removed carefully so
that the new pad can be attached.
10.5 Armrest cup complete (Pos. 23)
Unscrew both screws and remove the armrest cup. Screw
the new armrest cup onto the bar using the rubber
washers and countersunk screws.
10. Belt loop (Pos. 24)
Pull the belt out through the metal loop, exchange the belt
loop and install the new belt loop.
16
11. Checkliste of safety and function test
(Hand held programming unit old version)
Safety test
Measured value
Protective earth conductor resistance
≤
0,1 Ohm
Ground leakkage current EN 60601 / IEC 601/ VDE 0751
≤
500 µA
µA
≤
300 µA
µA
Date/ Signature
Ohm
Or
Ground leakkage current as in UL 2601
OK
Function test
1. Switch on the device and press SET.
Display: Software version VX.X XX.XX.XX (X=optional)
Press SET for 5 seconds.
Display: OptiFlex S S2 Standard
2. The motion range for ab/ adduction (motor A) is 30 to 175 degrees.
At 90 degrees, the angle is to be checked with a tolerance of +/- 4 degrees.
3. The motion range for rotation (motor B) is from -90 to 90 degrees.
At 0 degrees, the angle is to be checked with a tolerance of +/- 4 degrees.
4. Check the emergency-off function.
Switch the device on in continuous operation.
Press any key to stop motors A and B immediately.
Check this for all keys.
5. Press ab/adduction and STOP simultaneously to switch to the programming mode.
Dipslay: Adduction as well as the present and the programmed angles.
6. Press FUNC. Press + to change to the special function New Patient and
press SET.
Display: New Patient Ready
Now press STOP.
Now press START.
The device moves into center position.
7. Check the set values. Press the following keys to do so:
Add/ Abduktion
Rotation
Pause
Motors ON/ OFF
Speed
Timer
-> Display: ADD 89 90 ABD 91
-> Dipslay: INT -1 0 EXT 1
-> Display: ADD/IROT 0 S, ABD/EROT 0 S
-> Display: M.A ADD/ABD EIN, M.B ROTAT. ON
-> Display: Speed 100 % = 230 °/min
-> Display: Timer Continuous
17
Error
12. Checkliste of safety and function test
(Hand held programming unit new version)
Safety test
Measured value
Protective earth conductor resistance
≤
0,1 Ohm
Ground leakkage current EN 60601 / IEC 601/ VDE 0751
≤
500 µA
µA
≤
300 µA
µA
Date/ Signature
Ohm
Or
Ground leakkage current as in UL 2601
OK
Function test
1. Switch on the device. Press the two outer buttons simultaneously.
Display: Software version VX.X XX.XX.XX (X = optional). Keep on pressing.
Display: OptiFlex S3 Standard Chip
2. The maximum range of motion Add/ Abduction (Motor A) is 30 to 175 degrees.
Check the angle of motor A in a position 90 degrees.
Tolerance +/- 4 degrees.
3. The maximum range of motion for rotation (Motor B) is -90 to +90 degrees.
Check the angle of motor B in a position 0 degrees.
Tolerance +/- 4 degrees.
4. Check the emergency-off function.
Start the device in any mode.
Press any key, motor A and B will stop immediately.
Check this for all keys.
5. Set up the special function New Patient
Following settings set up automatically:
Add/ Abduction
Rotation
Pause
Motors ON/ OFF
Speed
Timer
->
->
->
->
->
->
Dispaly: 89 91
Display: -1
1
Display: 0
Display: EIN
Display: 100 %
Display: 00:00
6. Press START key.
Motor A moves to Adduction angle of 89 degrees and stops automatically.
Motor B moves in the middle position of 0 degrees and stops automatically.
18
Error
ORMED GmbH & Co. KG • Merzhauser Straße 112 • D -79100 Freiburg
Tel +49 761 4566-01 • Fax +49 0761 4566-5501 • www.ormed.de • E-Mail: [email protected]
DIN EN 13485
ORMED Nr. 018 829-01
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