Summary of Contents for QAL Medical 480
- Page 1 480 / 480E / 480E PRO CPM Service and Technical Manual ©2011 QAL Medical • 05070812.3 Rev. C 08/11...
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Page 3: Table Of Contents
TablE Of COnTEnTS 1 General Overview ................................4 1.1 Introduction for 480/480E/480E PRO ........................4 1.2 Safety Considerations ..............................4 1.3 Specifications ................................6 1.4 Symbols ...................................6 1.5 Suggested Maintenance Schedule ..........................7 2 Covers (480/480E/480E PRO)............................7 2.1 Bottom Cover ................................7 2.2 Top Cover .................................8 3 Cradle (480/480E/480E PRO) ............................8... -
Page 4: General Overview
1 General Overview 1.1 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. 1.2 Safety Symbols Danger! Warning messages regarding possible risks of accident or injury. - Page 5 Danger! If you are not sure of the type of power supply, consult your Otto Bock 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.
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Page 6: Specifications
Output: 14 VDC 730 mA Power Supply Input: 100 - 240 VAC 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°... -
Page 7: Suggested Maintenance Schedule
Reverse-On-Load and Range of Motion. 5. Complete a final check of the device in accordance with Otto Bock Final Inspection criteria (these are available in the appropriate Technical Service Manual or on request from Otto Bock). 2 COVERS (480/480E/480E PRO) 2.1 bottom Cover Removal: Avoid cutting the heads off the plastic fasteners as these can be reused to reattach the covers. -
Page 8: Top Cover
Remove the six cap screws that fasten the U-bracket and angle brackets to the sliders. 7. Lift the cradle through the top cover. Installation: 1. Gently spread apart 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. -
Page 9: Kneepot (Potentiometer) (480/480E/480E Pro)
1. Wrap wires 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 2. -
Page 10: Motor (480/480E/480E Pro)
Removal: 1. Remove bottom cover (refer to section 2.1). 2. 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. 3. Remove the four nuts from the rubber mounts inside the bearing bracket assembly. -
Page 11: Ballscrew (480/480E/480E Pro)
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. -
Page 12: Controller Keypad
(Steps for both 480 and 480E): 5. Remove back cover label from controller. 6. Using a No. 2 Phillips screwdriver, remove the four screws from the back of the controller to open the controller housing. 7. Carefully pull the controller board straight away from the face of the controller housing. -
Page 13: Controller Printed Circuit Board
6. Gently push the cable into the appropriate cutout in the housing. 7. Position the back controller housing making sure that the cable is not pinched between the two halves. 8. Install the four Phillips screws in the holes on the back of the controller and tighten. 9. -
Page 14: Display Replacement
When replacing cover, be careful not to damage Keypad ribbon cable. note: 10 MAIN PRINTED CIRCUIT BOARD (PCB) 10.1 Replacing PCb (480/480E) The Printed Circuit Board is a Static Sensitive Device. Repair should be attempted by qualified attention: personnel only. All anti-static handling procedures should be observed. -
Page 15: Replacing Pcb (480E Pro)
Go to the System Settings screen. If the System Hours are not 0, go to the Service Screen and select note 3: "Zero Mtr Hrs". 11 CALIBRATION 11.1 Calibration (480/480E) The Printed Circuit Board is a Static Sensitive Device. Repair should be attempted by qualified attention: personnel only. All anti-static handling procedures should be observed. -
Page 16: Calibration Diagram (480/480E)
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 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. - Page 17 fig 3 I. Session Number A. Screen Title Operating J. Time Screen with functional B. Flexion ROM Knee Joint Setup elements Setting Box K. Flexion Force Setting Flexion called out. Force L. Flexion Pause Setting Pause C. Display Screen Speed M.
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Page 18: Error Codes
12 ERROR CODES 12.1 Error Codes (480/480E) Errors are handled on a case by case basis. Detection of some errors stops the CPM. At that time Important: 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. - Page 19 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.
- Page 20 Reset EE_ERROR byte by entering the calibration routine (refer to section 10.0). [E12]: Not used in the Model 480 [E13]: EEPROM VARIABLE ALLOCATION ERROR Error Action: This causes the microcontroller to burn 13 in the EE_ERROR EEPROM.
- Page 21 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.
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Page 22: Error Codes (480E Pro)
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. Error Code Table with Repair Steps Error ID Error Desc. Repair Steps 01.01.01.00 Keypad... -
Page 23: Troubleshooting
13 Troubleshooting 13.1 Troubleshooting (480/480E Only) PROblEM POSSIblE CaUSE Unit will not power up No voltage to Main PCB Replace Power Supply Unit does not beep No voltage to Main PCB Replace Switch Main PCB failure Replace PCB Controller cable... -
Page 24: Troubleshooting (480E Pro Only)
13.2 Troubleshooting (480E PRO Only) PROblEM POSSIblE CaUSE Unit will not power up No voltage to Unit Replace Power Supply Unit does not beep No voltage to Unit Replace Switch Pendant failure Replace Pendant Check pendant cable at both ends Return for service Pendant, erratic display Pendant failure... -
Page 25: Assembly Drawings
14 Assembly Drawings 14.1 Main assembly... -
Page 26: Thigh Assembly
14.2 Thigh assembly... - Page 27 14.3 Cradle Sub-assembly 480 = l480Sa011 480E = l480Sa022...
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Page 28: Foot Assembly
14.4 foot Cradle assembly... -
Page 29: Ballscrew Assembly
14.5 ballscrew assembly... -
Page 30: 480 U-Bracket/Slider Assembly
14.6 480 U-bracket/Slider assembly... -
Page 31: 480E/480E Pro U-Bracket/Slider Assembly
14.7 480E/480E PRO U-bracket/Slider assembly... -
Page 32: 480 Motor Assembly (Globe)
14.8 480E (or 480E PRO) Motor assembly (faulhaber) -
Page 33: 480E (Or 480E Pro) Motor Assembly (Faulhaber)
14.9 480E PRO OnlY Motor assembly (Maxon) -
Page 34: Motion Controller Assembly (480/480E)
14.10 Motion Controller assembly (480/480E) -
Page 35: 480E Pro Controller Assembly
14.11 480E PRO Controller assembly NG-SA001 NG007 EABBE NG-SA002 FS440O (4) Front Housing Battery Top End Cap Screw 4-40 x 1" Flat Sub-Assembly Sub-Assembly Rear Housing (not available due to serial number label) NG009 Fish Paper Insulator NG006 NG-SA003 NG-104A FS440BC (2) LCD Mount Bottom End Cap... -
Page 36: 480 Wiring Diagram
14.12 480 Wiring Diagram... -
Page 37: 480E Wiring Diagram
14.13 480E Wiring Diagram... -
Page 38: 480E Pro Wiring Diagram
14.14 480E PRO Wiring Diagram... -
Page 39: 480/480E Electrical Schematic
14.15 480/480E Electrical Schematic... - Page 42 CUSTOMER CONTACTS: International: In the USA: QAL Medical QAL Medical 3000 Woleske Road Website: www.qalmedical.com PO Box 166 1-888-430-1625 Marinette, WI 54143 1-715-735-4700 Fax 1-715-732-6402...