480 / 480E / 480E PRO CPM Service and Technical
Contents
1. ke el u Sei m R M E eel TENE ili 5 fr een Es hir mp eee 1 SUE E n unam In D Au 4l 6 E ilii 3 Pret ihid i 5i 1 DN AW HTHT Fyre dl E ih d i d overall Ju pi E a n gg iL TH i Mie tel JI al T A hl ANA WM o Cp pd SE Oo i Ed 2 i Fh e E i nnam z Lanssens T d i i CS B R ereeeeet m E ABRE LD t o dip ulli i44 id E oe 5 jd ER d i e P 1 i i g hwe HH HI M B d OE Lee H H meee t sl M SIN BARSANA R P cet O Ilan i E Imm In2. Not used in the Model 480 EEPROM VARIABLE ALLOCATION ERROR Error Action This causes the microcontroller to burn 13 in the EE ERROR EEPROM Display STOP Cause Each variable in software has a predetermined amount of EEPROM dedicated to it The reason being is that each byte of EEPROM can be written to only a finite number of times Upon copying a variable to EEP ROM the microcontroller checks that the copy matches the original If it does not match it goes on to the next byte of EEPROM and tries to write it again Eventually there may come a time when the variable runs out of the EEPROM that was allocated for it This generates an error 13 Corrective Action Contact QAL Medical Customer Service Department and inform them of the error The main PCB may need to be replaced There is enough EEPROM allocated for each variable to last for more than a decade of constant use EEPROM POINTER ALLOCATION ERROR Error Action This causes the microcontroller to burn 14 in the EE ERROR EEPROM Display STOP Cause Each variable in software has a predetermined amount of EEPROM dedicated to it The reason being is that each byte of EEPROM can be written to only a finite number of times Upon copying a variable to EEP ROM the microcontroller checks that the copy matches the original If it does not match an EEPROM pointer byte is incremented so the microcontroller is directed to the next byte of EEPROM It proceeds to write the va
3. Danger If you are not sure of the type of power supply consult your QAL Medical representative or local power company Danger Do not overload wall outlets or use extension cords as this may result in the risk of fire or electric shock Danger Never insert objects into the drive unit casing as they may touch dangerous voltage points or short out parts that could result in a risk of fire or electric shock Danger To reduce the risk of electric shock do not disassemble this product Take it to a qualified serviceperson when service or repair work is required Opening or removing covers may expose you to dangerous voltages or other risks Incorrect re assembly can cause electric shock when the unit is subsequently plugged in Danger If at any time during therapy the patient experiences extreme pain or discomfort stop therapy and consult their physician Danger Unplug the product from the wall outlet and refer servicing to qualified personnel under the following conditions a If the power supply cord is damaged or frayed b If liquid had been spilled into the product c If the product has been exposed to water d If the product has been dropped or the unit casing has been damaged e If the product exhibits a distinct change in performance f If the product does not operate normally according to the operating instructions Danger Patient Safety Patients must be advised to keep clear of moving parts The
4. 17 Hold kneepot side cradle at maximum extension 18 Press EXT 19 Hold kneepot side cradle at maximum flexion 20 Press FLEX 21 Lay unit flat 22 Reassemble the cradle 23 Press Start Stop 24 The machine will run through a complete cycle Note if the screen displays Binding this indicates excessive current draw by the motor caused by excessive friction in the drive chain or a problem with the motor Resolve the problem and repeat the calibration procedure 25 When the screen displays CAL COMPLETE turn power off 26 Remove the calibration jumper 27 Reassemble unit 11 2 Calibration Diagram 480 480E Fig 2 SET LOCK MUSCLE STIM BI LATERAL STRIPED LEAD THIS END KNEEPOT PENDANT POWER CALIBRATION MOTOR oe JUMPER Models use 11 3 Calibration 480E PRO If the motor Potentiometer Lead Screw or the Base Unit Actuator PCB have been replaced the device will need to be recalibrated Minimum and Maximum thigh extension limits as well as 0 and 90 settings will also need to be calibrated Screen prompts in the PRO Controller will lead you through the process To Calibrate Once the device has been turned on go to the Setting Mode in the PRO Controller and enter the following special key sequence using the soft keys and the select button soft key 4 right directional key soft key 4 right directional key select Fig BELOW Two new blank tabs will appear To calibrate go
5. Corrective Action Re calibrate the unit EE EXT CAL OR EE FLEX CAL EEPROM VARIABLE ERROR Error Action This error prevents the CPM from entering the run mode Display CALIBRATE E3 Cause On power up the microcontroller checks the values of EE_EXT_CAL and EE_FLEX_CAL Limits are imposed on the value of these variables at calibration If the values read from EEPROM are not within these limits the variable is assumed to be corrupted and an error is generated Corrective Action Re calibrate the unit SOFTWARE TIMER ERROR Error Action This error causes the microcontroller to burn 4 in the EE ERROR EEPROM Display STOP Cause A software variable called Timer Overflow Interrupt Count T01 Count is incremented every time the timer overflows After the value of the T01 Count becomes greater than 2746 the timer value in EEP ROM is incremented and the 2746 is subtracted from T01 Count If for some reason this process fails and T01 Count becomes greater than 32000 Error 4 is generated Corrective Action Contact the Technical Service Department and inform them of the error The main PCB may need to be replaced MOTOR SPEED MEASUREMENT ERROR Error Action This error causes the microcontroller to burn 5 in the EE ERROR EEPROM and causes the CPM to stop Display STOP Cause With every revolution of the motor the MC33039 detects when the sensor in the motor makes a transition That is when the sensor goes from high to l
6. Slide the kneepot cable through both the top cover and the base frame 4 Reinstall the kneepot cable refer to section 4 2 For Technical Service 1 888 430 1625 1 715 735 4727 8 480 480E 480E PRO CPM Service and Technical Manual 4 0 KNEEPOT Potentiometer 480 480E 480E PRO 4 1 Kneepot Cover Note Plastic rivets may be re used if not damaged during removal Removal 1 With a pair of diagonal cutters carefully remove the rivets to free the kneepot cover 2 Remove the kneepot cover Important Remove center of kneepot rivet from casting by moving outer thigh tube so they fall out Installation 1 Install the kneepot cover over the casting aligning the cable with the small divot in the cover and the holes in the plastic with the holes in the casting 2 Install the rivets in their appropriate holes and insert the plastic rivet centers 3 With a small hammer gently tap the centers of the plastic kneepot rivets flush with the rivet casting 4 2 Kneepot Cable Removal 1 Remove the bottom cover refer to section 2 1 2 Remove kneepot cover refer to section 4 1 3 Remove kneepot cable plug from the socket on the main PC board 4 With diagonal cutters remove all ty raps from the kneepot cable 5 Remove strain relief from top cover by removing the nut on the underside strain relief side of the top cover 6 Pull cable through cover 7 De solder the cable from the terminals on the kneepot Installation 1 Wrap wir
7. incremented Every six minutes of operation the timer is incremented and the total cycle count is increased by the cycles since save after which cycles since save is zeroed If this process goes awry and cycles since save becomes greater than 500 Error 7 is generated Corrective Action Contact the Technical Service Department and inform them of the error The main PCB may need to be replaced MOTOR SPEED ERROR Error Action This error causes the microcontroller to burn 8 in the EE_ ERROR EEPROM and causes the CPM to stop Display STOP Cause The maximum CPM rpms is less than 200 If the speed measured is greater than 254 counts in one timer overflow roughly 500 rpm then error 8 is generated Corrective Action Troubleshoot PCB MC33039 OSC Resistor Capacitor combination may be out of tolerance There can be excessive noise on the Hall Effect sensor inputs a bad MC33039 a bad microcontroller etc Reset EE ERROR byte by entering the calibration routine START STOP ERROR Error Action This error causes the microcontroller to burn 9 in the EE ERROR EEPROM and causes the CPM to stop Display WAIT Cause The microcontroller has detected that the START STOP key was depressed for more than 16 4 seconds The START STOP on the main or auxiliary controller may have been depressed for that period The PCC Patient Control Cord may have an open circuit The main controller may have a short circuit It is normally open Co
8. 480 480E Attention The Printed Circuit Board is a Static Sensitive Device Repair should be attempted by qualified personnel only All anti static handling procedures should be observed Removal 1 Remove bottom cover of device refer to section 2 1 2 Remove all connectors from the main PC board 3 The PC board may be removed by one of three procedures depending on when a particular device was manufactured a Gently push the PC board toward the top cover until the nylon standoff is disengaged from the board b Or remove the nylon screws securing the PC board to the nylon standoffs c Or remove the nylon nuts securing the Shield insulator and PC board to the nylon standoffs Lift the shield off 4 Lift the insulator off 5 Remove the four Spacers 6 Lift the PC board from the standoffs Installation 1 Place the main PC board above the nylon standoffs 2 While guiding the nylon standoffs into the mounting holes place the PC board on them 3 To reinstall the PC board perform the following procedure depending on when the device was manufactured a Gently push the PC board toward the bare frame until the PC board seats firmly against the stopping pad on the nylon standoff b Or install the nylon screws securing the PC board to the nylon standoff c Or place the PC board on to the four standoffs Install the four Spacers on the standoffs Place the insulator into the Shield Place the Shield on to the standoffs an
9. 480 Only EE Motion Controller 480 480 E wii ccsicsecccttcecteciedsevacetateencssatscacuvsanesteedaces uo dei sacbencycdiseiesnavenaeeebniceaetesines 8 1 Controller Cable gs geegent eege 8 2 Controller Keypad oceans utente ve cett eer er eee nia eee cer gees 8 3 Controller Printed Circuit Board PRO Controller 480E PRO Only 2 2 cte aire torrent vets cancdecees dasezcneusehat tte czech svdazaacedics 9 1 Front Cover Keypad Replacement sess nnne enne 9 2 Speaker Replaceiment cette Eie terio pec Sege i edi 9 3 Display Ee EE E 9 4 Battery replacement for real time doch cee ccceeeseeeeeseeeeseeceneeeeeeeeeeeeeeseeeeneeeenseeeeeseeeeeeses 9 5 PCB Printed Circuit Board PCB or PCBA Assembly MAIN PRINTED CIRCUIT BOARD PCB ssccsseeeeseeeeeseeeeseneeeeeeeseneeeeeeaeeeasueesneesneasaseesseesseenseeaeaeeeeenees 10 1 Replacing PCB 480 480E sess nre n rnt re een rene nennen 10 2 Replacing PCB 480E PRO EE eju 11 1 lee TREI ET 11 2 Calibration Diagram O89014390E enne aieia nennen nennen nnne 11 3 Calibration Cice sud 0 wat nes eis nn hk inh e IdjoReLc 12 1 Error Codes 480 480E virinse iasa arira a e ia erae a Pe NEESS nee 12 2 Error Codes 480E EE Tro bleshootliig 6 reir arri nonni na s cta has ur kr ras ni xh aba eaa EE S12
10. 888 430 1625 1 715 735 4727 26 480 480E 480E PRO CPM Service and Technical Manual 14 2 Thigh Assembly 480 L480SA007 480E L480SA018 480 L480SA009 480E L480SA017 11307 2 480 12605 KIT ADULT THIGH ASSEMBLY 480E 480E PRO L480SA019 KIT THIGH ASSEMBLY 480E STANDARD For Technical Service 1 888 430 1625 1 715 735 4727 27 480 480E 480E PRO CPM Service and Technical Manual lt lt 14 3 Cradle Sub assembly 480 L480SA011 LABOSAOT1 A 11329 uc 12635 3 ME f 12686 480E L480SA022 L480020 NOTE APPLY LOCTITE 262 TO THREADS FS832D 2 AN SN L480019 ee H NS D Els L480021 2 FB018 2 241DUT 2 LABOSAO22 A Ki N 11307 12635 3 13458 For Technical Service 1 888 430 1625 1 715 735 4727 28 480 480E 480E PRO CPM Service and Technical Manual 14 4 Foot Cradle Assembly 10744 07 10745 02 2 12505 2 12216 2 12397 ENS 12608 Kit Adult Foot Assembly 400 Series L480SA016 FOOT CRADLE ASSEMBLY 480E 480E PRO For Technical Service 1 888 430 1625 1 715 735 4727 29 480 480E 480E PRO CPM Service and Technical Manual 14 5 Ballscrew Assembly GvZzl AI8SN3SSV MAYOSTIVE ZS jo 1MVd 900087 Sag RN n ggzzl 2621 OF LZL 308v O8r LIA NOLON SLOVSO8 1 20VSO8v OMJd 308v 308v o G9cZ G t M3QHs
11. Static Sensitive Device Repair should be attempted by qualified personnel only All anti static handling procedures should be observed 1 The calibration jumper must be in place during initial start up After machine calibration is complete remove the calibration jumper 2 Do not remove the EEPROM from the printed circuit board The printed circuit board is designed for use only with the latest revision of firmware loaded into the EEPROM installed by the factory 3 Thoroughly test all machine functions and test run the machine a minimum of two 2 hours prior to patient use Procedure 1 Turn off CPM 2 Remove bottom cover refer to section 2 1 3 Lay the unit on its side 4 Make sure all connectors are connected 5 Install calibration jumper on the PC board on J1 at CTE 6 Turn power on 7 If the error code screen is displayed record the error codes Fix error before calibration and re power base to clear error 8 Press Start Stop to clear error codes 9 Choose machine model using arrow keys 10 Press Start Stop 11 When screen displays motor type press Start Stop 12 Remove cradle from thigh assembly 13 Hold the kneepot side cradle at zero degrees straight using calibration fixture 14 Press EXT 15 Hold the kneepot side cradle at 90 degrees right angle using calibration fixture 16 Press FLEX For Technical Service 1 888 430 1625 1 715 735 4727 15 480 480E 480E PRO CPM Service and Technical Manual
12. cm Range of Motion 5 extension to 110 flexion 5 extension to 110 flexion 5 extension to 120 flexion Speed 16 160 degrees per minute Pause 0 30 seconds at maximum programmed extension and or flexion Mode of Operation Continuous 480 Only Power Supply Input 120 VAC 0 12A 60Hz or 230 VAC 0 6A 50 Hz Output 14 VDC 730mA Power Supply Input 100 240VDC 1 6A 50 60 Hz Output 15 VDC 2 0A NMES 480 480E Only Compatible with various NMES devices Shock Classification Type B Classification Class 1 Medical Device USA Class 11a 93 42 EEC Environmental 10 to 35 C 14 to 95 F temperature 90 max humidity Conditions ATM pressure 750 hPa to 1040 hPa The device must remain in the operational environment a minimum of one hour prior to use Type of Shock Protection Class Il Degree of Shock Protection Type B applied part 1 4 Symbols Power Off Warm Up Standby Enter Start Stop Stopped Power on ZB roos D timer KA Decrease Z Seconds A Attention T Consult Accompanying Documents Ge Extension P Minutes ON Danger Electric Shock dw Flexion Service by qualified individual only AC Speed This Way Up Danger Explosive Risk gt Hours Cycles fad O3 If used with flammable anaesthetic O y Fragile x Pause Type B Applied Part amp m Lock Set ER Keep Dry Alternating Current Use specified power supply only amp Indicates CSA certification to 23000 North American
13. risks of accident or injury Attention Warning messages regarding possible technical damages Note Information regarding operation of the device Note Information for service staff Attention Please read the Instruction for Use first General Safety Considerations When using your CPM to reduce the risk of fire electric shock and injury to persons basic safety precautions should always be observed including the following Danger Keep hair loose clothing fingers etc away from moving components of the device Danger Do not expose the device to water including ice bags Do not expose to extreme temperatures Danger Turn the power off before unplugging Note Read and understand all instructions Note Follow all warnings and instructions marked on the product Danger Never install the power supply in wet locations Danger Never touch uninsulated wires or terminals unless the power supply has been unplugged from the wall Danger Unplug the power supply from the wall outlet before cleaning the unit Do not use liquid cleaners or aerosol cleaners Use a damp cloth for cleaning Danger Do not use this product near water Danger Do not place this product on an unstable cart stand or table The product may fall causing serious injury to the patient or damage to the CPM For Technical Service 1 888 430 1625 1 715 735 4727 PP SEPP 480 480E 480E PRO CPM Service and Technical Manual
14. standards Direct Current X i CE Indicates compliance to safety and Dispose of through your Registered 0120 quality standards throughout all Protective Earth Ground wm m Waste Carrier or Take back Facility member states in the EC For Technical Service 1 888 430 1625 1 715 735 4727 6 480 480E 480E PRO CPM Service and Technical Manual 1 5 Suggested Maintenance Schedule Between Patients 1 Check entire unit for any visible evidence of damage such as bent sliders cracked or broken covers frayed or damaged wires etc If any signs of damage are found the unit must be repaired before use Ensure that all knobs and or levers are usable and in place Ensure that all moving components move freely as required Check all displays and electronic controls for proper operation Check all mechanical pivot and linkage points for smooth operation and secure mechanical connection Make sure all screws nuts bolts rivets pivot pins and other fasteners are secure Gently wipe clean all exposed surfaces with a soft cloth dampened with a mild soap solution or alcohol Avoid abrasive cleansers To disinfect wipe all exposed surfaces with a 1 to 10 solution of bleach and water or other suitable disinfectants Ensure that all labels are present Replace patient softgoods Verify that the device operates to its set limits over several complete cycles 0 For devices offering absolute Range of Motion ROM settings ve
15. to the leftmost new tab and select the button marked calibrate and follow the on screen prompts For Technical Service 1 888 430 1625 1 715 735 4727 16 480 480E 480E PRO CPM Service and Technical Manual Fig 3 I Session Number Operating A Screen Title Screen with J Time e B Flexion ROM Knee Joint Setup F 1 39 13 47 Gate Setting Box exio K Flexion Force Setting Foroa 4 L Flexion Pause Setting C Display Screen M Flexion Speed Setting 55 N Angle D Extension ROM 5 sd O Extension Force Setting Setting Box Speed P Extension Pause Setting Q Extension Speed Setting E Soft Keys use to tab left or right through EXT screens or directly access flexion and extension settings F Direction Keys G Select Key H Start Stop Button Fig 3 Overview of PRO Controller Pendant controls At the bottom of the screen you will see Calibrate button that can be highlighted using the Direction Keys and Selected with the Select button The PRO Controller will lead you through the steps necessary for the following calibrations e 0 Calibration e 90 Calibration e Maximum thigh extension e Minimum thigh extension For 0 Calibration Remove cradle from thigh assembly and apply 0 calibration fixture following steps in PRO Controller For 90 Calibration Remove cradle from thigh assembly and apply 90 calibration fixture following steps in PRO Controller For minimum thigh extension make sure the
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17. 1349VM8 n Us NC SCH Z 16901 A 8W3SSv 102vVO8t1 M3NOSTIVS LIM R Era SCH amp L wo ee NC L6Z LL AINO Od 3087 OLSOL ATAWASSV ENs NOLON f dS00vs08r1 30 For Technical Service 1 888 430 1625 1 715 735 4727 480 480E 480E PRO CPM Service and Technical Manual 14 6 480 U Bracket Slider Assembly 10153 4 B g L480SA038 12135 2 12274 2 480 12319 Kit Slider Block Assembly 12365 Kit U Bracket Slider Assembly Complete For Technical Service 1 888 430 1625 1 715 735 4727 480 480E 480E PRO CPM Service and Technical Manual 14 7 480E 480E PRO U Bracket Slider Assembly fo j J L480SA025 CR l T OM S L480020 L480SA038 L480SA024 For Technical Service 1 888 430 1625 1 715 735 4727 480E PRO L480SA020 KIT U BRKT SLIDER ASSY L480019 480E L480019 AND L480020 ARE NOT INCLUDED BUT SHOWN FOR INFORMATION ONLY 32 480 480E 480E PRO CPM Service and Technical Manual 14 8 480E or 480E PRO Motor Assembly Faulhaber FN832A 4 10216 4 L480SA015 MOTOR KIT SFRIAI NUMBFRS 480 0535332 AND HIGHFR For Technical Service 1 888 430 1625 1 715 735 4727 33 480 480E 480E PRO CPM Service and Technical Manual 14 9 480E PRO ONLY Motor Assembly Maxon FN832A 4 ML CS 10216 4 L4805A005P SUB ASSEMBLY 480E PRO MOTOR For Tec
18. 480 480E 480E PRO CPM Service and Technical Manual QAL Medical OrthoAgiLity www QALMedical com CUSTOMER CONTACT QAL Medical LLC A division of Quality Assembly and Logistics LLC 3000 Woleske Road Marinette Wisconsin 54143 USA 1 888 430 1625 1 715 735 4727 E mail info QALMedical com 2012 QAL Medical LLC Printed in the USA 05070812d 5 2012 480 480E 480E PRO CPM Service and Technical Manual For Technical Service 1 888 430 1625 1 715 735 4727 1 0 2 0 3 0 4 0 9 0 480 480E 480E PRO CPM Service and Technical Manual TABLE OF CONTENTS General OVerViOw mee 1 1 Introduction for 480 480E 480E PRO 1 2 Safety Een Ee Ee le 1 3 Tee le UE De EE 1 5 Suggested Maintenance Gchedule nne Covers 480 480E 480E RROK eege gegEegeeeEEegEReEN SEENEN SCENE NEE dee 2 1 Bottom COVEN sores 2 2 Reefer VE Cradle 480 480E 480E PRO E Kneepot Potentiometer 480 480E 480E PRO csseccesssssceeseeeseeseseeeneeeeeeeeesseeeseeeneeaseeeeseesaseneeeeeeeaee 4 1 Kneepot TE 4 2 Kneepot Cable sm Prem 4 3 Knee Potentiometer POT Beplacemenmt eene nennen Motor 480 480E 480E PRO eede cernere enti enin e EHEEE evince ravra suse leoua evteuennesberesedvocie ye Ballscrew 480 480E 480E PRO sini tccccscecesssceccccnecececetcersatisetdessicssieetecectecestessotecscivsccctevscteubeyseideeenecccusce Power Supply
19. A3SSV 8s AI8A3SSV Alddfls JLLOVSOS 1 M3MOd IfOVSO87T 38 For Technical Service 1 888 430 1625 1 715 735 4727 480 480E 480E PRO CPM Service and Technical Manual 14 14 480E PRO Wiring Diagram 318VO HLM LOd 33N ATaW3ssv ans IvILLOvSO8r 1 ATSIAHSSV YOLOW UN d 00vS08Y 1 INVIO VIC ONIMIM Odd 308t i 1e oo og JANG OLOIA TVNe 3LENI ATAWASSY ddd d AdIA3SSV J1aVoO PO ON cOODON lOd TWNYALNI SS3NHVH YOLdvVdv 8 AdIA3SSV J1dVO 80099N GOODON TWN INI AAWASSY 318v2 0005N Od A T bessen 7 WS dS00YS08P7 ut p pnpu qJ14Y9 YOSNAS HOLOI SLODON dS00 S08P 1 ur pepnjoul JIdvOo JA YOLOW SLODON uonoeuuoo N JVNe3ANI 9 AAWASSY T1dvo 90099N X JidvO INVONJd 0L ON AN VON3d VOL ON AlaWASSY Add 43MOd L 0vSO8F 1 TVNS3LINI L AldWASSY q14Y9 LOODON TVNH3LINI Z AlAaWASSY 318 VO LOODON HOLIMS GZEL 39 For Technical Service 1 888 430 1625 1 715 735 4727 480 480E 480E PRO CPM Service and Technical Manual 14 15 480 480E Electrical Schematic
20. Manual or on request from QAL Medical 2 0 COVERS 480 480E 480E PRO 2 1 Bottom Cover Removal Note Avoid cutting the heads off the plastic fasteners as these can be reused to reattach the covers 1 Remove the Handle by removing the two Phillips screws located at each end of the Handle attachment 2 Remove all 11 plastic fasteners from around the cover and separate the bottom cover from the unit For Technical Service 1 888 430 1625 1 715 735 4727 7 480 480E 480E PRO CPM Service and Technical Manual Installation 1 With the unit upside down carefully place the bottom cover on the exposed frame 2 Align the bottom cover s holes with the holes in the top cover 3 Insert the female halves of the plastic fastener into the holes from which they came and insert one male half into each of the female halves 4 With a small hammer gently seat the male halves of the fasteners 5 Reinstall the handle Use one drop of Loctite 425 on each attachment screw 2 2 Top Cover Removal 1 Remove bottom cover refer to section 2 1 2 Remove cradle refer to section 3 3 With the bottom cover and cradle removed the top cover comes free Installation 1 Place the top cover on top of the exposed base frame 2 Install cradle refer to section 3 3 Install bottom cover refer to section 2 1 3 0 CRADLE 480 480E 480E PRO Removal 1 Remove the bottom cover refer to section 2 1 2 Using a pair of diagonal cut
21. Mni V NT E II V T 14 SS Maaa devia le j t ml HEHE n ii un H EN DEPI ml PLI rri WW prepr SAAR adgdgdgniag ai d L H D H EH Bert if 5 i SR BB S N Pate w f H i 8 a4 3J S SCH LHH Af av 4 34 et Let Hl X V g a II S 3 a e i ik IEEE al f i oT T i eet RA i af Ho at i LU Brey Es SER Me lt E m z B envase Tissen a b I TTTT L in Se Jan S8884588 jh ics HIL l E e AN rH n d n TE G Va aks e Weg mE gui j Lit EN JM For Technical Service 1 888 430 1625 1 715 735 4727 40 480 480E 480E PRO CPM Service and Technical Manual For Technical Service 1 888 430 1625 1 715 735 4727 41 480 480E 480E PRO CPM Service and Technical Manual QAL Medical OrthoAgility Www OAL Medical com CUSTOMER CONTACT QAL Medical LLC A division of Quality Assembly and Logistics LLC 3000 Woleske Road Marinette Wisconsin 54143 USA 1 888 430 1625 1 715 735 4727 E mail info QALMedical com For Technical Service 1 888 430 1625 1 715 735 4727 42
22. Steps Reset machine repairreplace pot replace motor board 02 01 05 00 Hall Error reset machine replace motor replace motor board 02 01 07 00 Actuator EEPROM Error reset machine replace motor board 02 01 08 xx e Ero reset machine replace cables replace motor board replace EES pendant PCB 02 01 09 00 Too Many ROL s reset machine replace motor board replace motor 09 01 10 01 Heartbeat Lost reset machine replace cables replace motor board replace SE pendant PCB For Technical Service 1 888 430 1625 1 715 735 4727 23 480 480E 480E PRO CPM Service and Technical Manual 13 0 Troubleshooting 13 1 Troubleshooting 480 480E Only PROBLEM Unit will not power up Unit does not beep Controller erratic display Error codes E1 2 3 4 6 7 8 12 13 14 15 16 18 Error code E9 Error codes E10 11 Error code E20 Mechanical binding jerking Insufficient lifting power POSSIBLE CAUSE No voltage to Main PCB No voltage to Main PCB Main PCB failure Controller cable disconnected connections Controller cable break Controller PCB failure Main PCB failure Poor connection at ribbon cable cable Qut of calibration Main PCB failure Controller cable break Controller PCB failure Calibration error Controller cable break Controller PCB failure Knee pot cable break Knee pot Main PCB failure Insufficient lubrication on track Ballscrew failure Motor failure Motor failur
23. aci u da Fo ani E EH 2E00A E 2RA LER ERR RE ETE RN RR RARE AK Ra aU 13 1 Troubleshooting 480 480E ONT Wi 13 2 Troubleshooting 480E PRO ONLY reno sariari petu oc ten Tere cede bee Foo Su E E Assembly E EE 14 1 MaineASsem bly ees 14 2 elle une EE 14 3 Cradle Sub Assembly 5 t rct athens erger ee getdate eed dace ee 14 4 Foot Cradle Aesemthy AAA 14 5 Ele Ntc E 14 6 480 U Bracket Slider Assembly essent nnne neret nnne 14 7 480E 480E PRO U Bracket Slider Aesembly nennen 14 8 480 Motor Assembly Faulhaber seen nnne 14 9 480E or 480E PRO Motor Assembly Maxvon 14 10 Motion Controller Assembly 480 A480E ssssssseeeeeeeeeeenenennen nennen nennen 14 11 480E PRO Controller Assembly sees nnne tnnt nnn nnns 14 12 480 Wining HEI iR c 14 13 480E WARING RTE TT DEE 14 14 480E PRO Wiring Diagrami sessies nenna naa na reaa a aAA NAA EEA SAANEN 14 15 480 480E Electrical SchematiC airiran annee a eaii a Neni a Ea id dasa anasa For Technical Service 1 888 430 1625 1 715 735 4727 OO cO cO oO OO OO JJ Joo PS PS A A A H H A A A A A 480 480E 480E PRO CPM Service and Technical Manual General Overview Introduction The purpose of this manual is to provide instructions for the basic maintenance repair and service for the 480 480E and 480E PRO CPM systems Safety Symbols Danger Warning messages regarding possible
24. and Technical Manual FIRMWARE CHECHSUN ERROR Error Action This error prevents the CPM from entering the run mode Display CHECKSUM ERROR E20 Cause The Firmware in the EEPROM has become corrupted Corrective Action Replace the PCB Assembly and the EEPROM KNEEPOT VOLTAGE NOT CHANGING FAST ENOUGH Error Action This error causes the CPM to exit the run mode Display ERROR 21 Cause If the CPM is in the run mode and the A D converter reading does not change by more than two counts in a short pre determined amount of time an error 21 is generated The problem could be due to a faulty kneepot or kneepot cable Corrective Action Check for a faulty kneepot or kneepot cable and replace Re start the unit by turning the power off and then on This error code is not burned into the EE ERROR EEPROM EEprom has not been updated If this occurs on 3 or more consecutive cycles replace PCB Assy For Technical Service 1 888 430 1625 1 715 735 4727 22 480 480E 480E PRO CPM Service and Technical Manual 12 2 Error Codes 480E PRO If an error occurs in the PRO Controller a pop up window will appear with the error code A list of all error codes appears below e CPM Pro Error 1 Check cable connections 2 Turn CPM off and on 3 If error repeats call service Error Details 01 01 03 03 Memory Issue Pendant 01 02 01 08 03 Comm Issue Motor 01 Error Code Table with Repair Steps Ero D jEmorDesc Repar
25. ation 1 2 3 4 5 6 Slide the cable connector onto the board mounted connector pins Carefully insert the board into the front controller housing Gently push the cable into place in the cutout of the housing and tie wrap the cable flat to the board Reinstall the back of the controller housing making sure that the cable is not pinched between the two halves Reinstall the four Phillips head screws in the holes on the back of the controller and tighten Place back cover label on back side of controller housing 9 0 PRO CONTROLLER PENDANT 480E PRO Only Attention The PRO Controller Pendant is a Static Sensitive Device Repair should be attempted by Note qualified personnel only All anti static handling procedures should be observed It will be necessary to access the settings mode to access the systems setting service and error log To enter the settings mode enter the following key sequence Up Direction Arrow Right Arrow Down Arrow Left Arrow and Select 9 1 Front Cover Key Pad Replacement Note 1 2 3 4 Note The Front Cover and Keypad NG SA001 is a single unit Remove all 4 screws from back of unit Pull off back and fish paper insulator Carefully remove front which contains keypad it is connected to the Printed Circuit Board PCB with a ZIF connector REF DES J8 Release Key Pad ribbon cable by retracting the 2 tabs on either side of the ZIF connector The ribbon cable sho
26. checking to be sure that the locator pins have come through the pad Position the controller control board so that the locator pins also pass through the appropriate holes in the PC board Place the front controller housing on top of the bezel and control board assembly and secure with four locknuts Place the LCD window into the opening being sure that the printing is readable from the front of the controller Carefully position the main controller board in the front half of the controller housing Gently push the cable into the appropriate cutout in the housing Position the back controller housing making sure that the cable is not pinched between the two halves Install the four Phillips screws in the holes on the back of the controller and tighten Replace back cover label on back side of controller housing For Technical Service 1 888 430 1625 1 715 735 4727 12 480 480E 480E PRO CPM Service and Technical Manual 8 3 Controller Printed Circuit board Removal 1 NOOR wh Remove back cover label from controller Using a No 2 Phillips head screwdriver remove the four screws from the back of the controller Remove the back controller housing Carefully pull the controller board straight away from the front half of the controller housing Cut the ty rap which holds the cable flat to the board Carefully slide cable connector from the board mounted connector pins Lift the board out of the controller housing Install
27. d route the cables through the slots in the Shield Position the ferrite loops as close to the Shield as possible and secure such that they do not contact any moving parts For Technical Service 1 888 430 1625 1 715 735 4727 14 480 480E 480E PRO CPM Service and Technical Manual 4 Install the connectors into main PC board 5 Note Cable connectors are installed on the following PCB connectors Controller cord J2 Kneepot Cable J4 1 2 3 Power switch cord J4 4 5 Motor cord J5 6 Reinstall bottom cover refer to section 2 1 10 2 Replacing PCB 480E PRO Remove bottom cover see section 2 1 Disconnect wire harnesses from PCB Remove the two screws that fasten the PCB Replace PCB Reconnect the wire harnesses according to the printing on the PCB Replace the two screws Replace the bottom cover ooRcomNm Note 1 The PCB is by default configured for the Maxon motor For use with a Faulhaber motor connect a pendant switch the power on and go to the Service Screen Select Set to 480e Maxon use the up and down arrows to choose Set to 480e Faulhaber and press Select to save the change Wait for the system to turn itself off and on Note 2 The system will need to be recalibrated see section 11 3 Note 3 Go to the System Settings screen If the System Hours are not 0 go to the Service Screen and select Zero Mtr Hrs 11 0 CALIBRATION 11 1 Calibration 480 480E Attention The Printed Circuit Board is a
28. e For Technical Service 1 888 430 1625 1 715 735 4727 24 ballscrew and track seals Bearing bracket assembly failure U Bracket Slider Assembly failure FIX Replace Power Supply Replace Switch Replace PCB Check controller cable at both ends Return for service Replace cable Replace PCB Check for faulty ribbon Return for service Re calibrate unit following calibration procedures Replace PCB Replace Controller cable Replace Controller Return for service Re calibrate following calibration procedures Replace Controller cable Replace Controller Return for service Replace Knee Pot cable Replace Knee Pot Return for service Replace PCB Return for service Use a Light Lithium based lubricant Lubriplate 105 on tracks and baliscrews and a Silicone spray on track seals Replace bearing bracket Assembly Replace Ball Screw Assembly Replace U bracket Slider Assembly Bracket Assembly Replace Motor Return for service Replace motor Return for service 480 480E 480E PRO CPM Service and Technical Manual 13 2 Troubleshooting 480E PRO Only PROBLEM Unit will not power up Unit does not beep Pendant erratic display Mechanical binding jerking insufficient lifting power POSSIBLE CAUSE FIX No voltage to Unit Replace Power Supply No voltage to Unit Replace Switch Pendant failure Replace Pendant Check pendant cable at both ends Return for service Pendant failure Replace Pendant Re
29. engages with the inside pin Steps for 480 480E 1 4 5 6 Enter calibration mode using the Calibration Procedure in section 11 1 steps 1 through 13 The motion controller screen will display EXT 40 50 xx where xx is a number indicating the angle the Potentiometer is currently at Gently insert the Potentiometer into the casting The Potentiometer must be able to rotate in the casting Make sure that the pin on the Potentiometer shaft enters the long slot end of the Potentiometer Drive Coupling Rotate the body of the Potentiometer until xx number on the controller screen is between 40 amp 50 Press the Potentiometer firmly into the casting until the shoulder of the Potentiometer contacts the casting Confirm that the xx number on the controller screen is between 40 amp 50 Confirm that the Potentiometer is secure in the casting Proceed with steps 14 through 27 of the Calibration Procedure in Section 11 1 Steps for 480E PRO 1 2 5 6 Switch the 480E PRO power on Gently insert the Potentiometer into the casting The Potentiometer must be able to rotate in the casting Make sure that the pin on the Potentiometer shaft enters the long slot of the Potentiometer Drive Coupling Rotate the Potentiometer body until the angle indicated on the Motion Controller is O degrees Press the Potentiometer body firmly into the casting until the shoulder of the Potentiometer contacts the casting Confirm that t
30. es one and one quarter turns around kneepot terminals and solder as follows 480 pin 1 white pin 2 red pin 3 black 480E pin 1 black pin 2 red pin 3 white Install kneepot cover refer to section 4 1 Carefully put kneepot cable through top cover Feed the free end of the cable through the hole in the top cover until the cable strain relief is reached only tighten the strain relief nut 1 4 turn past finger tight Put rubber washer on kneepot cable Install bottom strain relief nut on kneepot cable Tighten strain relief bottom nut 1 4 turn past finger tight Install the kneepot cable plug onto the main PC board connector pins 1 2 3 Gather excess cable and secure to the front of the base frame with a ty rap Install bottom cover refer to section 2 1 on mom 4 3 Knee Potentiometer POT Replacement Removal 1 Remove Knee Potentiometer cover 4 1 2 De solder wires from Potentiometer 3 Insert the tip of a small screwdriver into the notch in the casting beside the Potentiometer and pry Potentiometer away from casting 4 Retain Potentiometer Drive Coupling For Technical Service 1 888 430 1625 1 715 735 4727 9 480 480E 480E PRO CPM Service and Technical Manual Installation 1 2 Solder the Potentiometer cable wires to replacement Potentiometer if required See section 4 2 Install the Potentiometer Drive Coupling end with the short slot into the casting Make sure that the slot
31. he angle indicated on the Motion Controller is 0 degrees 3 degrees Confirm that the Potentiometer is secure in the casting Proceed with the Calibration Procedure in Section 11 3 5 0 MOTOR 480 480E 480E PRO Note Transfer the ferrite loops to the new motor and install them in the same location on the cable Removal 1 2 3 4 5 Remove bottom cover refer to section 2 1 Remove motor plug from main PC board in 480 480E from Motor Board in 480E PRO and pull connector through the hole in base frame Remove the four nuts from the rubber mounts inside the bearing bracket assembly Take the motor out of the assembly Remove the rubber coupling from either the motor or ball screw assembly Installation 1 2 3 Insert the rubber coupling onto the end of the ballscrew bearing bracket assembly Place two internal star tooth washers on each of the rubber mounts part number 13585 motors only Insert the four motor mount bolts through the base and into the mounting bracket and tighten nuts Take care not to twist the rubber mounts when tightening nuts Reattach motor cables Reinstall the bottom cover For Technical Service 1 888 430 1625 1 715 735 4727 10 480 480E 480E PRO CPM Service and Technical Manual 6 0 BALLSCREW 480 480E 480E PRO Removal Remove bottom cover refer to section 2 1 Disconnect the motor and remove from the Bearing Bracket and Frame refer to section 5 Lo
32. hnical Service 1 888 430 1625 1 715 735 4727 34 480 480E 480E PRO CPM Service and Technical Manual 14 10 Motion Controller Assembly 480 480E 11320 BEZEL W STUDS 135258 KEYPAD 13311 ASSY 12584 UPPER PENDANT KIT PENDANT PCB SECURITY STRA 155357 PENDANT ENCLOSUR U 10407 4 NUTS W BLUE LOCTITE 425 12413 14240 LE 15382 PCB W LCD LOWER 11307 CABLE TIE CABLE 480 13254 480E L480032 15 5 5 ENDANT ENCLOSURE U LABEL 480 12587 p e 480E L480L009 7 480EJ L480L010 For Technical Service 1 888 430 1625 1 715 735 4727 35 480 480E 480E PRO CPM Service and Technical Manual 14 11 480E PRO Controller Assembly NG SA001 NGOO7 EABBE NG SA002 Front Housing LCD Battery Top End Cap Sub Assembly Sub Assembly SE os SCH eh hs NG SA003 NG 104A LCD Mount Bottom End Cap PCB Assembly Sub Assembly For Technical Service 1 888 430 1625 1 715 735 4727 FS4400 4 Screw 4 40 x 1 Flat ee Rear Housing not available due to serial number label NGOO9 Fish Paper Insulator FS440BC 2 Screw 4 x 1 2 Pan 480E PRO NG 104 Pendant 36 480 480E 480E PRO CPM Service and Technical Manual 14 12 480 Wiring Diagram QT3HS 44 c0008r 82d NIV 08v AT8EW3SSV 8ns c00YS08T 1 LIY JHM HOLIMS H3MOd BELL INVON3d LOOVSO8
33. n the cable so the shielded cable comes up over the edge of the controller board Ty rap the cable in place flat to the board Guide the pins from the controller keypad board into the connector on the main controller board Carefully squeeze the two boards together until the connector is well seated Reinstall the back of the controller housing Reinstall the four Phillips screws and tighten Replace the back cover label Steps 7 11 for 480 only 7 8 9 Slide the board end of the cable through the opening in the base of the unit Re position the strain relief Connect the cable to the board mounted connector 10 Join the controller and ribbon cables with ty raps 11 Reinstall the bottom cover refer to section 2 1 8 2 Controller Keypad Removal 1 c0 7 0 0 ROI Remove back cover label from controller Using a No 2 Phillips screwdriver remove the four screws from the back of the controller Remove the back of the controller housing Carefully pull the control board straight away from the face of the controller housing Lift the board out of the controller housing Lift the LCD window out of the front half of the controller Using a 1 4 nut driver remove the four locknuts from the inside of the front half Carefully lift the controller housing away from the front bezel Lift out the controller control board to remove the keypad Installation 1 2 Gently press keypad into position inside the bezel
34. osen the ballscrew nut Slide the U bracket assembly to full extension Slide the motor mount end of the ballscrew into the corner of the frame and twist it into a vertical position while lifting the end of the ballscrew OP ON gt Installation 1 Check to make sure that the plastic bearing for the ballscrew is located in its proper position Then carefully place the ballscrew free end into the plastic bearing Reverse step 5 above to replace the ballscrew 2 Slide the motor mount end down into place The four holes in the assembly should align with the frame holes 3 Place the rubber mounts into the frame holes and through the motor mount making sure that the washers are on the threaded side of the mounts 4 Secure the ballscrew in place by screwing the rubber mount nuts on the inside of the motor mount on the end of each rubber mount and tightening 5 Tighten the ballscrew nut use Loctite 242 6 Re install the motor assembly 7 Reinstall the bottom cover refer to section 2 1 7 0 POWER SUPPLY 480 ONLY Removal 1 Remove bottom cover refer to section 2 1 2 Disconnect power supply cable connection from the power switch and the ground wire from the frame 3 Carefully pull the power supply wires from the unit Installation Insert the power supply cable through the base frame Install the strain relief Re connect and or solder wires according to color codes Install tie wraps as needed Reinstall bottom co
35. ow or low to high It generates a pulse of fixed width The microcontroller measures the speed of the motor by counting the number of pulses that occur in one timer overflow period This happens in 131 seconds When the unit runs too fast over 230 RPM For Technical Service 1 888 430 1625 1 715 735 4727 18 E6 E7 E8 E9 480 480E 480E PRO CPM Service and Technical Manual the time between sensor transitions becomes less than the pulse width The microcontroller counts 0 pulses therefore the speed measured 0 even though the motor is revolving Corrective Action Troubleshoot PCB MC33039 OSC Resistor Capacitor combination may be out of tolerance There can be excessive noise on the Hall Effect sensor inputs a bad MC33039 a bad microcontroller etc Reset EE_ERROR byte by entering the calibration routine EEPROM INITIALIZATION ERROR Error action This error prevents the CPM from entering the run mode Display EEPROM ERR E6 Cause During initial calibration certain variables in EEPROM are initialized If there is some problem and one of these variables cannot be written to EEPROM Error 6 is generated Corrective Action If the problem recurs replace the microcontroller or the PCB CYCLE COUNTER ERROR Error Action This error causes the microcontroller to burn 7 in the EE ERROR EEPROM Display STOP Cause Every time the unit pauses in extension a variable in the software called cycles since save is
36. place Pendant Display Insufficient lubrication on track Use a Light Lithium ballscrew and track seals based lubricant Lubriplate 105 on tracks and ballscrews and a Silicone spray on track seals Bearing bracket assembly failure Replace bearing bracket Assembly Ballscrew failure Replace Ball Screw Assembly U Bracket Slider Assembly failure Replace U bracket Slider Assembly Bracket Assembly Motor failure Replace Motor Return for service Check that return on load ROL Increase force setting with setting is sufficient pendant controller Note For error codes see error codes in section 12 2 For Technical Service 1 888 430 1625 1 715 735 4727 25 480 480E 480E PRO CPM Service and Technical Manual 14 0 Assembly Drawings 14 1 Main Assembly 480 12606 480E 480E PRO L480SA016 KIT FOOT CRADLE ASSEMBLY 480 L480SA011 480E 480E PRO L480SA022 SUB ASSEMBLY CRADLE 12309 4 KNOB 1 4 20 MALE 11274 KIT PLASTIC FASTENERS 480 L480SA008 480E L480SA026 480E PRO L480SA026P i J SUB ASSEMBLY TOP 12387 2 COVER BRACKET ARI Dn tes HANDLE gs 12388 2 Fe 12206 r 480 12605 HANDLE 480E 480E PRO L480SA019 KIT ADULT THIGH L480SA032 2 BUMPER ASSEMBLY 480E 480E PRO ONLY FS1420U 2 480E 480E PRO ONLY 480 00480 A 480E OO480E A 480E PRO OO480EP A FRAME WITH WIRING L480SA006 SUB ASSEMBLY BOTTOM COVER For Technical Service 1
37. riable again However if the EEPROM pointer a byte of EEPROM cannot be incremented an error 14 is generated The variable cannot be written to the EEPROM correctly Corrective Action Contact the Technical Service Department and inform them of the error The main PCB may need to be replaced For Technical Service 1 888 430 1625 1 715 735 4727 20 E15 E16 E17 E18 E19 480 480E 480E PRO CPM Service and Technical Manual KNEEPOT WIPER VOLTAGE NOT CHANGING QUICKLY ENOUGH Error Action This causes the microcontroller to burn 15 in the EE ERROR EEPROM and causes the CPM to stop Display STOP Cause If the CPM is in the run mode and the A D converter reading doesn t change by more than two counts in a short pre determined amount of time an error 15 is generated The problem could be due to a faulty kneepot or kneepot cable Corrective Action Check for a faulty kneepot or kneepot cable Reset EE ERROR byte by entering the calibration routine CONFIGURATION ERROR Error Action This error prevents the CPM from entering the run mode Display EEPROM ERR E16 Cause The CONFIG register is latched on power up from a CONFIG byte in EEPROM located at the same address The CONFIG register configures the microcontroller The EEPROM CONFIG is burned each time the micro controller is put through calibration If for some reason the CONFIG is not equal to the correct value an error 16 is generated Correcti
38. rify device calibration by observing the ROM of the device while taking a visual reading using a goniometer at the machine s pivot points Compare the ROM settings of the device with the goniometer readings ROM readings should be within 5 degrees of the set parameters If the readings do not fall within the set parameters the unit needs to be checked and recalibrated by a properly trained Service Technician arwn 9 2 QgM Every Six Months 1 Repeat steps 1 through 10 of BETWEEN PATIENTS procedures 2 Verify ground continuity where applicable from the device frame to ground pin of the power supply if so equipped using a Safety Analyzer or appropriate device Every Eighteen Months A full inspection of the device by a properly trained Service Technician is recommended every 18 months The following points should be covered 1 Steps 1 and 2 of EVERY SIX MONTHS above 2 Fully inspect all internal and external mechanical and drive components and repair or replace as necessary 3 Fully inspect all internal and external electrical components including wires connectors and solder joints and repair or replace as necessary 4 Perform a complete recalibration and subsequent check of electronic and mechanical safety systems including Reverse On Load and Range of Motion 5 Complete a final check of the device in accordance with QAL Medical Final Inspection criteria these are available in the appropriate Technical Service
39. rrective Action Troubleshoot the controller and the main PCB Reset EE ERROR byte by entering the calibration routine For Technical Service 1 888 430 1625 1 715 735 4727 19 E10 E11 E12 E13 E14 480 480E 480E PRO CPM Service and Technical Manual KNEEPOT WIPER VOLTAGE TOO LOW Error Action This error causes the microcontroller to burn 10 in the EE_ERROR EEPROM and causes the CPM to stop Display ANGLE ERROR E10 Cause The kneepot wiper or 8v may have an open The main PCB may have a problem Corrective Action Examine the kneepot the kneepot cable and kneepot connector for possible opens and troubleshoot the main PCB Perform the extension limit check in the calibration mode to assure that the cradle is not traveling outside the kneepot s voltage range Reset EE_ERROR byte by entering the calibration routine KNEEPOT WIPER VOLTAGE TOO HIGH Error Action This error causes the microcontroller to burn 11 in the EE ERROR EEPROM and causes the unit to stop Display ANGLE ERROR E11 Cause The problem may be in the main PCB or the kneepot ground may have an open Corrective Action Examine the kneepot the kneepot cable and kneepot connector for possible opens and troubleshoot the main PCB Perform the extension limit check in the calibration mode to assure that the cradle is not traveling outside the kneepot s voltage range Reset EE ERROR byte by entering the calibration routine refer to section 10 0
40. ters remove the ty rap that holds the kneepot cable secure to the base 3 Remove the kneepot cable strain relief from the top cover by removing the underside nut 4 Pull the kneepot cable gently through the hole in the top cover 5a 480 Remove both 3 16 cradle pivot cap screws from the U bracket assembly to detach the cradle from the ballscrew If you run into difficulty removing the cap screw apply a slight tilt to the Allen wrench and pull the entire cap screw threaded insert and pivot sleeve straight out 5b 480E Remove the six cap screws that fasten the U bracket and angle brackets to the sliders 6 Lift the cradle through the top cover Installation 1 Gently spread apart the rubber track seals and slide cradle struts 480 or angle brackets 480E between the track seals through the top cover 2a 480 Replace the slider blocks with new ones Position the cradle strut between the slider blocks and the U bracket and reinsert the spacer into the hole in the cradle strut Place both pivot sleeves into their proper locations Apply one drop of Loctite 242 on the threads of each cradle pivot Allen bolt and using a 3 16 hex key install the two cap screws into the U bracket assembly 2b 480E Replace the slider blocks if they are worn On one side line up the slider block angle bracket and U bracket and fasten them together with three of the cap screws passing through star washers Repeat on the other side 3
41. thigh cradle is in place and that the calibration jig has been removed For maximum thigh extension make sure the thigh cradle is in place and that the calibration jig has been removed When you are finished with the calibration restart the device For Technical Service 1 888 430 1625 1 715 735 4727 17 480 480E 480E PRO CPM Service and Technical Manual 12 0 ERROR CODES 12 1 Error Codes 480 480E Important Errors are handled on a case by case basis Detection of some errors stops the CPM At that time it will display an error code It then burns the associated error code into the EE ERROR byte in EEPROM For other lesser errors the only action taken is to burn the code into EEPROM The specific actions of each error are detailed in the following text The EE ERROR byte is reset by getting into the calibration mode Refer to section 10 0 for further instructions E1 E2 E3 E4 E5 KNEE PIVOT ANGLE CALIBRATION ERROR Error Action This error prevents the CPM from entering the run mode Display CALIBRATE E1 Cause An invalid knee pivot angle calibration is indicated by bit 0 of EE_CAL_STATUS being zero Corrective Action Re calibrate the unit MECHANICAL LIMIT CHECK OR FORCE CHECK VALIDATION ERROR Error Action See Display Display CALIBRATE lt Cause The extension limit check the flexion limit check of the force check was not fully executed This action occurs when the unit is calibrated
42. uld release with minimal force 9 2 Speaker Replacement Remove Cover following steps 1 through 4 above 5 ON Remove Top End Cap Carefully move LCD display out of the way Remove 2 lead connector on right hand side of board Remove Bottom End Cap and replace with new sub assembly Reverse above order to put the PRO Controller back together For Technical Service 1 888 430 1625 1 715 735 4727 13 480 480E 480E PRO CPM Service and Technical Manual 9 3 Display Replacement The Display is held in place by the top end cap and the bottom display holder To replace Display first remove cover following steps 1 through 6 above 10 Remove 20 pin Ribbon Cable from ZIF connector to remove display REF DES J3 11 Connect Ribbon Cable insert Display into bottom display holder 9 4 Battery Replacement for Real Time Clock Follow steps 1 through 6 to remove speaker as described above Once LCD Display is out of the way simply slide the 3V Battery out of its retainer and insert the new one Reassemble in reverse order 9 5 PCB Printed Circuit Board PCB or PCBA Assembly Disassemble PRO Controller following steps 1 through 11 above 1 Remove battery 2 Remove bottom Display holder by removing the 2 screws 3 Reattach all components to new board 4 Reassemble front back and end caps Note When replacing cover be careful not to damage Keypad ribbon cable 10 0 MAIN PRINTED CIRCUIT BOARD PCB 10 1 Replacing PCB
43. unit is designed to force reverse if an obstruction is under the cradle however a patient could experience pain or be injured by the downward pressure of the cradle if a body part is positioned under the cradle Danger Equipment not suitable for use in the presence of flammable anesthetic mixture with air or Nitrous Oxide Danger Unplug the product from wall outlet before servicing Attention Use only QAL Medical parts for repair and or replacement Attention Never use parts from other manufacturers even though they may seem to fit Attention This product should be operated only from the type of power source indicated on the marking label Attention Do not allow anything to rest on the power cord Do not locate this product where the cord will become damaged Attention Adjust only those controls that are covered by the operating instructions For Technical Service 1 888 430 1625 1 715 735 4727 480 480E 480E PRO CPM Service and Technical Manual 1 3 Specification Weight Approximately 24 Ibs 11 kg 480 480 480E 480E PRO 480E 480E PRO Standard Pediatric Standard Pediatric Limb Length 80 5 42 in 77 107 cm 19 5 34 5 in 50 88 cm 28 5 41 in 78 104 cm 21 5 35 5 in 58 90 cm Calf Length 16 5 24 in 43 61 cm 95 18 5in 22 47 cm 16 5 24 in 48 61 cm 9 5 18 5 in 24 47 cm Thigh Length 14 18 in 36 46 cm 10 16 in 25 41 cm 12 17 in 30 48 cm 12 17 in 80 43
44. ve Action Reset EE ERROR byte by performing the calibration routine If the problem persists the main PCB may need to be replaced TOO MANY FORCE REVERSALS Error Action This error causes the microcontroller to burn 17 in the EE ERROR EEPROM and causes the CPM to stop Display STOP Cause If the unit has seven force reversals in a 30 second period an error 17 will be generated Corrective Action With the unit traveling look for binding in the unit Reset EE ERROR byte by entering the calibration routine INVALID EE MOTOR TYPE Error Action This error causes the CPM to exit the run mode Display CALIBRATE E18 Cause Calibration includes a motor type selection If the EE MOTOR TYPE is found to contain something other than the correct selection an error 18 is generated Corrective Action In the calibration mode re select the motor type If the error persists contact the Technical Service Department INVALID EE MODEL TYPE Error Action This error causes the CPM to exit the run mode Display CALIBRATE E19 Cause Calibration includes a model type selection If the EE MODEL TYPE is found to contain something other than the correct selection an error 19 is generated Corrective Action In the calibration mode re select the model type If the error persists contact the Technical Service Department For Technical Service 1 888 430 1625 1 715 735 4727 21 E20 E21 E23 480 480E 480E PRO CPM Service
45. ver refer to section 2 1 Quid o mu 8 0 MOTION CONTROLLER PENDANT 480 480E 8 1 Controller Cable Attention The Motion Controller is a Static Sensitive Device Repair should be attempted by qualified personnel only All anti static handling procedures should be observed Note Transfer the ferrite loops to the new cable and install them in the same location Ensure the cable and ferrite loops will not come in contact with any moving parts Removal Steps 1 through 4 for 480 only 1 Remove bottom cover refer to section 2 1 2 Cut ty raps from the entire length of the controller cable being careful not to damage the ribbon cable 3 Pull the cable connector off the board mounted connector 4 Remove the strain relief and pull the cord through the base frame For Technical Service 1 888 430 1625 1 715 735 4727 11 480 480E 480E PRO CPM Service and Technical Manual Steps for both 480 and 480E 1 2 3 4 5 Remove back cover label from controller Using a No 2 Phillips screwdriver remove the four screws from the back of the controller to open the controller housing Carefully pull the controller board straight away from the face of the controller housing Cut the ty rap which holds the cable flat to the board Carefully slide cable connector from the board mounted connector pins Installation 1 2 3 4 5 6 Carefully slide cable connector onto the main controller board connector Positio
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