Intelect GENiSYS Model 2776, 2782 and 2792 Service Manual

TABLE of CONTENTS

Intelect®/Genisys® Ultrasound Therapy Systems

Foreword...1 1- Safety Precautions...2 2- Theory of Operation...3 3- Nomenclature...4-5 Intelect/Genisys Ultrasound Therapy System...4 Intelect/Genisys Ultrasound Symbol Definitions...5 4- Specifications...6 5- Troubleshooting...7-14 5.1 Intelect/Genisys Ultrasound Software Error Messages .7-9 5.2 Intelect/Genisys Ultrasound Diagnostics...10 5.3 Visual Inspection...11 5.4 Leakage Tests...11 5.5 Unit Startop and Fan Testing...11 5.6 Ultrasound Tests...12 5.7 Ultrasound Applicator Identification Test...12 5.8 Ultrasound Applicator Output Test...13 5.9 Ultrasound Duty Cycle Test...14 6- Removal & Replacement...15-20 6.1 General...15 6.2 Top & Bottom of Unit...15 6.3 Fan Removal & Replacement...16 6.4 Power Supply Removal & Replacement...17 6.5 Ultrasound Board Removal & Replacement...18 6.6 LCD Display Removal & Replacement...19 6.7 Control Board Removal & Repalcement...20 7- Ultrasound Applicator Calibration...21 8- Parts...22-27 9- Schematics...28-33 10- Warranty...34

©2004 Encore Medical Corporation or its affiliates, Austin, Texas, USA. Any use of editorial, pictorial or layout composition of this publication without express written consent from the Chattanooga Group of Encore Medical, L.P. is strictly prohibited. This publication was written, illustrated and prepared for print by the Chattanooga Group of Encore Medical, L.P.

FOREWORD

Intelect®/Genisys® Ultrasound Therapy Systems

Read, understand and follow the Safety Precautions and information contained in this manual. This manual contains the necessary safety, and field service information for those Field Service Technicians, approved by Chattanooga Group, to perform field service on the Intelect/Genisys Ultrasound Therapy Systems. At the time of publication the information contained herein was current and up to date. However, due to continual technological improvements and increased clinical knowledge in the field of electrotherapy, as well as Chattanooga Group’s policy of continual improvement, Chattanooga Group reserves the right to make periodic changes and improvements to their equipment and documentation without any obligation on the part of Chattanooga Group. It is the sole responsibility of field technicians to stay informed and trained in the latest technology utilized in the Intelect/Genisys Ultrasound Therapy Systems by Chattanooga Group. From time to time, as significant improvements are incorporated, Service Bulletins will be produced and made available on our web site (www.chattgroup.com) in lieu of reprinting a complete manual prematurely. These Service Bulletins will provide updated service information and technology improvements to the Intelect/Genisys Ultrasound Therapy Systems for use by certified service technicians. “Certified Service Technician” Definitions; 1. Level I- Those Field Service Technicians that have successfully completed the minimal training required by Chattanooga Group in basic service techniques. 2. Level II- Those Field Service Technicians that have successfully completed Level I Training as well as Level II training as required to perform specific troubleshooting and repair techniques and procedures. 3. Level III- Those Field Service Technicians that have successfully completed Levels I & II Training as well as Level III Advanced Training as required to perform all necessary Troubleshooting and Repair techniques. The Technician having successfully completed the three levels of training and coupled with experience should have the ability to train other technicians in Level I and Level II Training with the necessary Training Materials from Chattanooga Group. 4. Temporary- Chattanooga Group, at its discretion and based on known experience of the technician, may grant a “Temporary Certification” to a field technician for particular troubleshooting and repair of a specific system requiring immediate attention. This “Temporary Certification” in no fashion acknowledges the training level of a technician as defined above. This “Temporary Certification” is utilized only in unique situations for a specific unit for a specific service technique only and is documented as such. Due to the complex nature of the technology utilized by Chattanooga Group, the recommended troubleshooting techniques are to determine “Bad Board” and board replacement only. No board component level troubleshooting is recommended nor will information or parts be supplied by Chattanooga Group. Any board component level troubleshooting performed will be at sole risk and liability of the Service Technician performing such troubleshooting techniques. This equipment is to be used only under the prescription and supervision of a licensed medical practitioner. This equipment is to be serviced only by a “Certified Service Technician”.

1

1- SAFETY PRECAUTIONS

Intelect®/Genisys® Ultrasound Therapy Systems

1.2 Safety Precautions Read, understand and follow all safety precautions found in this manual. Below are general safety precautions that must be read and understood before attempting any service techniques on these units. Throughout this manual specific safety precautions will be found. Read, understand and follow all safety precautions.

1.1 Precautionary Symbol Definitions The precautionary instructions found in this manual are indicated by specific symbols. Understand these symbols and their definitions before operating or servicing this equipment. The definitions of these symbols are as follows; A. CAUTION

!

CAUTION

!

Text with a “CAUTION” indicator will explain possible safety infractions that have the potential to cause minor to moderate injury or damage to equipment.

• Read, understand and practice the precautionary and operating instructions. Know the limitations and hazards associated with using any ultrasound device. Observe the precautionary and operational decals placed on the unit. • DO NOT operate the Intelect or Genisys when connected to any unit other than Chattanooga Group devices. Do not operate the unit in an environment of short-wave diathermy use. • The Ultrasound modality should be routinely checked before each use to determine that all controls function normally; especially that the intensity control does properly adjust the intensity of the ultrasonic power output in a stable manner. Also, determine that the treatment time control does actually terminate ultrasonic power output when the timer reaches zero. • Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous exposure to ultrasonic energy. • DO NOT use sharp objects such as a pencil point or ballpoint pen to operate the buttons on the control panel as damage may result. • Operate, transport and store this unit in temperatures between 59 °F and 104 °F (15 °C and 40 °C), with Relative Humidity ranging from 30%- 60%. • Inappropriate handling of, and subjecting the ultrasound applicator to physical abuse, may adversely affect its characteristics. • Inspect Sound Head for cracks, which may allow the ingress of conductive fluid before each use. • Inspect all cables, leads and associated connectors before each use.

B. WARNING

!

CAUTION

WARNING

Text with a “WARNING” indicator will explain possible safety infractions that will potentially cause serious injury and equipment damage. C. DANGER

! DANGER Text with a “DANGER” indicator will explain possible safety infractions that are imminently hazardous situations that would result in death or serious injury. D. EXPLOSION HAZARD Do not use this equipment in the presence of flammable anesthetics. This symbol is also prominently displayed on the serial number plate of the unit. E. DANGEROUS VOLTAGE Text with a “Dangerous Voltage” indicator serves to inform the Service Technician of possible hazards resulting in the electrical charge retained by faulty power supplies. F. CORROSIVE HAZARD (NiMH Battery) Text with a “Corrosive Hazard” indicator will explain possible safety infractions if the chemical components of this product are exposed to air, skin or other materials. G. NOTE: Throughout this manual “NOTE” may be found. The Notes are helpful information to aid in the particular area or function being described.

2

2- THEORY of OPERATION

Intelect®/Genisys® Ultrasound Therapy Systems

2.1 Overview The Intelect/Genisys Ultrasound Therapy Systems are comprised of several PC board assemblies housed within a common enclosure. These assemblies each support a distinct function in the product. The basic elements are User Interface, Control Board, Ultrasound Board, Ultrasound Applicator, and Power Supply Circuits. 2.2 Power Supply Circuits A universal input power supply provides all parts of the system with 12 volts DC. The supply is connected to the mains at all times when the cord is attached. The power switch on the top of the unit, switch the 12V output of the power supply to the different components in the system by way of the Power Distribution Board. The 12V supply is regulated locally at each PC board as required. 2.3 Control Board The Control Board serves just as its name implies. It controls the operation of the ultrasound board, user interface and optional accessories. The control board communicates to the ultrasound board through a proprietary 8-bit parallel bus. The control board drives the display. The control board reads the menu buttons. The control board also reads the amplitude and the contrast control on the system. Sound output is generated by the control board and routed to an internal speaker. 2.4 Ultrasound Board and Applicator The ultrasound board generates the 1 or 3.3 MHz output to drive the ultrasound Sound Head. The ultrasound board is accessed much like an I/O port by the control board. It can provide current and voltage information about the ultrasound output of the board. The calibration data for the Sound Head is passed through the ultrasound board from the applicator up to the control board. By storing the calibration data in the applicator there is no calibration necessary for the ultrasound board. Calibrated Chattanooga Group Ultrasound Applicators, designed specifically for the Intelect/Genisys Ultrasound Therapy Systems, can be connected and operated to provide accurate coupling and output. 2.5 User Interface and Accessories The LCD display panel provides the operator visible feedback in the way of menu choices. Pressing the menu buttons makes selections from the menus. The control board interprets these user inputs and responds accordingly. Audible feedback is given as well for events such as keypresses and end of treatment. The Optional Battery mounts in the system bottom and supplies 24 VDC to the power supply. The Power Supply distributes the power required to the system as needed. The charging circuit for the battery is incorporated on the Control PCB. An icon on the display reflects the available amount of charge in the battery. When the system is connected to an approved power outlet and a battery is installed in the system, the system will charge the battery to full capacity. The incorporated charger will not overcharge the battery.

3

3- NOMENCLATURE

Intelect®/Genisys® Ultrasound Therapy Systems

3.1 Intelect/Genisys Ultrasound Therapy System The nomenclature graphics below, Figure 3.1, indicates the general locations of the exterior components of the Ultrasound Therapy System.

Know the components and their functions before performing any operation on or service to the Ultrasound Therapy System.

1

3 2

16

15 4

17 5

14

13

6

7

8

12 10 11 9

FIGURE 3.1 1. On/Off Switch- Turns system On and Off. 2. Fan Grill- Allow exhaust of air circulated by system fan. 3. LCD Contrast Knob-Adjusts contrast of LCD Display. 4. Plynth- Allows for wall mounting or sitting on a flat surface. 5. Ultrasound Applicator- Used to administer Ultrasound Therapy to patient. 6. Applicator LED Indicator- Flashes 5 times upon connecting applicator to system. Illuminates constantly when applicator is coupled to patient treatment area. 7. Ultrasound Intensity Button- Used to increase and decrease ultrasound output intensity. 8. Ultrasound Applicator Hook- Used to store applicator when not in use. 9. Ultrasound Applicator Connector- Used to connect the Ultrasound Applicators to the System 10. Treatment Start Button- Press to start therapy session.

11. Treatment Pause Button- Press to pause therapy session. Press again to continue session. 12. Treatment Stop Button- Press to completely stop therapy session. 13. Multi-Control Button- Press the respective icon on this button to change parameters and to scroll through Clinical Resources Library 14. Treatment Time Button- Press to adjust treatment time up or down. 15. Clinical Resources Library Button- Press to access the Clinical Resources Library. 16. LCD Display- Displays necessary information for operation and maintenance. 17. Mains Power Cord- Connects system to required electrical outlet. Not Illustrated- Battery Access Cover located beneath the plynth.

4

3- NOMENCLATURE

Intelect®/Genisys® Ultrasound Therapy Systems

3.2 Intelect/Genisys Ultrasound Symbol Definitions The graphic symbols listed below can be found on the Ultrasound Therapy System and within the software.

Become familiar with these symbols and their definitions prior to any operation, mainteneance or repairs of the system. Frequency Press to change frequency to 3.3 MHz or 1MHz

On/Off Switch- Flashes when plugged into power outlet. Illuminates steady when system is On

Intensity Display- Press to display “Watts” or “Watts per cm2“ for the output of the ultrasound.

Stop Treatment- Press to stop therapy session.

Intensity Control- Press the Increase or Decrease symbol to adjust ultrasound intensity to the prescribed level.

Pause Treatment- Press to pause therapy session and retain time remaining. Press again to continue therapy session

Duty Cycle- Press to select and display the Duty Cycle of the Ultrasound as prescribed. Options avaliable are: 10%, 20%, 50, or Continuous (100%).

Start Treatment- Press to start therapy session

Increase- Found in two locations on the system, press to increase session time and/or ultrasound intensity respectively.

LCD Display Contrast- Located on the Fan Grill, this indicates the control to increase or decrease the LCD Display contrast.

Decrease- Found in two locations on the system, press to decrease session time and/or ultrasound intensity respectively. Back- Press to return back one screen on the LCD Display. Clinical Resources- Press to access the Clinical Resourses area of the system software. Scroll Up- Press to scroll up when making menu selections Ultrasound Applicator- Indicates connector for the ultrasound applicators. Scroll Down- Press to scroll down when making menu selections Charge Level- This icon indicates the charge level of the battery, if installed. Accept & Return- Press to accept menu selection and to return to the Home Screen Battery Charging- Indicates the system is charging the battery when plugged into power outlet.

Treatment Time- Press the Increase or Decrease symbol to adjust ultrasound treatment time to the prescribed level. Head Warming- Press to turn Off or On the Head Warming feature of the system.

5

4- SPECIFICATIONS

Intelect®/Genisys® Ultrasound Therapy Systems

4.1 Intelect/Genisys Ultrasound Therapy System Physical Specifications

B.Outputs One Ultrasound Output C. Ultrasound Applicator Sizes Available 1. 1 cm2 2. 2 cm2 3. 5 cm2 (Standard) 4. 10 cm2

A. Dimensions 1. 28.8 cm (11.3”) Width 32.8 cm (12.9”) Depth 16.3 cm (6.4”) Height 2. 2.3 kg (5.07 lbs) with 5 cm2 Applicator and Plynth 3. Case Material: Polycarbonate Plastic 4. Optional Battery Weight: 0.85 kg (1.87 lbs)

D. Power Input Requirements 1. 100-240VAC, 50/60 Hz, 75W

4.2 Intelect/Genisys Ultrasound Specifications Frequency... 1 MHz, +/- 5%; 3.3 Mhz, +/- 5% Duty Cycles... 10%, 20%, 50%, Continuous Pulse Frequency... 100Hz Pulse Duration... 1mSec, +/-20% 2mSec, +/-20% 5mSec, +/-20% Output Power 10cm2 Crystal... 0-20 Watts at 1MHz 0-10 Watts at 3.3 MHz 5cm2 Crystal... 0-10 Watts, 1 and 3.3 MHz 2cm2 Crystal... 0-4 Watts, 1 and 3.3 MHz 1cm2 Crystal... 0-2 Watts 3.3 MHz Only Amplitude... 0 to 2.5 w/cm2 in continuous mode, ... 0-3 w/cm2 in pulsed modes Output accuracy... +/- 20% above 10% of maximum Temporal Peak to Average Ratios:... 2:1, ± 20%, at 50% Duty Cycle 5:1, ± 20%, at 20% Duty Cycle 9:1, ± 20%, at 10% Duty Cycle Beam Nonuniformity Ratio... 5.0 : 1 maximum Beam Type... Collimating Effective Radiating Areas... 10cm2 Crystal - 8.5cm2, +/- 1.5 ... 5 cm2 Crystal - 4.0cm2, +/- 1.0 ... 2cm2 Crystal - 1.8cm2, +0.2/-0.4 ... 1cm2 Crystal - 0.8cm2, +0.2/-0.4 Treatment Time... 1-60 Minutes Ultrasound Head Warming Feature... 50% of maximum output until Crystal Temp reaches approx. 38 °C (100 °F) then 10% of maximum or Off to maintain Temperature

6

5- TROUBLESHOOTING

Intelect®/Genisys® Ultrasound Therapy Systems

primarily user definable and remedied by following the instructions given by the unit. Error meesages in the ranges of 200- 299 and 300-399, require the attention of a field technician certified by Chattanooga Group in order to perform the necessary diagnostics and properly replace any necessary components.

5.1 Intelect/Genisys Ultrasound Software Error Messages A. The information provided below is intended to aid in defining the Software Error Messages of the Ultrasound Therapy System. Once a particular Error Message is defined the information will also list probable causes and possible remedies. Once the problem area is determined subsequent diagnostics for verification will be necessary to determine “Bad Board”. All diagnostic tests will be to validate a “Bad Board” only. No component level troubleshooting information is or will be provided by Chattanooga Group for field troubleshooting of board components. Error messages in the range of 100 to 199 are CODE No.

100

101

B. Once a particular PCB has been determined as bad, refer to the appropriate Removal and Replacement Section for the board affected for proper instructions for replacement of the board.

TYPE MESSAGE Icon- Sound Head overtemp

PROBABLE CAUSES POSSIBLE REMEDIES 1. Sound Head has overheated to a A. Turn Off Head Warming feature. temperature that could cause damage B. Allow Sound Head to cool before to the crystal. continuing therapy. C. Connect a known good Applicator to the system and try again. If system works properly, re-calibrate Applicator or replace with new Applicator.

Icon- No applicator plugged into system

1. Applicator not plugged into system connector.

A. Plug Applicator into system.

2. Applicator connector not completely seated in system connector.

A. Make certain Applicator connector is completely seated in system connector.

3. Applicator Cable disconnected from Applicator PCB.

A. Connect Applicator Cable to Applicator PCB

4. Applicator cable damaged.

A. Replace with new Applicator.

5. Applicator not calibrated

A. Calibrate Applicator.

6. Bad Ultrasound Board WARN_US_UNPLUGGED 1. Applicator not plugged into system Technician attempted to connector. calibrate an ultrasound 2. Applicator connector not completely applicator but none is seated in system connector. plugged into system.

A. Replace Ultrasound Board

3. Applicator Cable disconnected from Applicator PCB.

A. Connect Applicator Cable to Applicator PCB

4. Applicator cable damaged. 1. Applicator not plugged into system connector.

A. Replace with new Applicator.

A. Plug Applicator into system. A. Make certain Applicator connector is completely seated in system connector.

WARN_US_APPL_ BECAME_UNPLUGGED Applicator came unplugged 2. Applicator connector not completely from system while seated in system connector. administering therapy.

A. Plug Applicator into system.

3. Applicator Cable disconnected from Applicator PCB.

A. Connect Applicator Cable to Applicator PCB

4. Applicator cable damaged.

A. Replace with new Applicator.

7

A. Make certain Applicator connector is completely seated in system connector.

5- TROUBLESHOOTING

Intelect®/Genisys® Ultrasound Therapy Systems

5.1 Intelect/Genisys Software Error Messages (Continued) CODE No. 200

201

202

203

TYPE MESSAGE

PROBABLE CAUSES

ERR_EEPROM 1. Bad Control Board Error accessing the internal EEPROM used to store system configuration settings and protocols. ERR_APPL_SAVE_CAL_ 1. Bad Applicator DATA 2. Bad Applicator Cable Error attempting to save 3. Applicator PCB Connector Bad data to applicator EEPROM 4. Bad Ultrasound Board during applicator calibration. ERR_APPL_NOT_ 1. Bad Applicator CALLED_OK 2. Bad Applicator Cable General error attempting to 3. Applicator PCB Connector Bad calibrate an applicator. 4. Bad Ultrasound Board ERR_APPL_SAVE_ 1. Bad Applicator TIMEOUT 2. Bad Applicator Cable Error attempting to save 3. Applicator PCB Connector Bad data to applicator EEPROM during applicator calibration 4. Bad Ultrasound Board

8

POSSIBLE REMEDIES A. Replace Control Board.

A. Replace with known good Applicator. A. Replace with known good Applicator. A. Replace Ultrasound Board. A. Replace Ultrasound Board. A. Replace with known good Applicator. A. Replace with known good Applicator. A. Replace Ultrasound Board. A. Replace Ultrasound Board. A. Replace with known good Applicator. A. Replace with known good Applicator. A. Replace Ultrasound Board. A. Replace Ultrasound Board.

5- TROUBLESHOOTING

Intelect®/Genisys® Ultrasound Therapy Systems

5.1 Intelect/Genisys Software Error Messages (Continued) CODE No. TYPE MESSAGE PROBABLE CAUSES 300 CRIT_ERR_US_BOARD 1. Ultrasound Board to Control Board Some type of critical Connecting Header loose or ultrasound board error has disconnected. occurred. 2. Bad Ultrasound Board. 3. Bad Control Board. 301 CRIT_ERR_US_BOARD_ 1. Ultrasound Board to Control Board NOT_DETECTED Connecting Header loose or No ultrasound board is disconnected. detected in unit. 2. Bad Ultrasound Board. 3. Bad Control Board. 302 CRIT_ERR_US_RESET 1. Ultrasound Board to Control Board Ultrasound board has reset Connecting Header loose or for some unknown reason. disconnected. 2. Bad Ultrasound Board. 3. Bad Control Board. 303 CRIT_ERR_US_BOARD_ 1. Ultrasound Board to Control Board READ Connecting Header loose or Error reading from disconnected. ultrasound board. 2. Bad Ultrasound Board. 3. Bad Control Board. 304 CRIT_ERR_US_ 1. Ultrasound Board to Control Board BOARD_WRITE Connecting Header loose or Error writing to ultrasound disconnected. board 2. Bad Ultrasound Board. 3. Bad Control Board. 305 CRIT_ERR_US_BOARD_ 1. Ultrasound Board to Control Board CALIBRATION_ERROR Connecting Header loose or Error calibrating applicator disconnected. 2. Bad Ultrasound Board. 3. Bad Control Board.

9

POSSIBLE REMEDIES A. Reseat Connecting Header into Control Board. A. Replace Ultrasound Board. A. Replace Control Board. A. Reseat Connecting Header into Control Board. A. Replace Ultrasound Board. A. Replace Control Board. A. Reseat Connecting Header into Control Board. A. Replace Ultrasound Board. A. Replace Control Board. A. Reseat Connecting Header into Control Board. A. Replace Ultrasound Board. A. Replace Control Board. A. Reseat Connecting Header into Control Board. A. Replace Ultrasound Board. A. Replace Control Board. A. Reseat Connecting Header into Control Board. A. Replace Ultrasound Board. A. Replace Control Board.

5- TROUBLESHOOTING

Intelect®/Genisys® Ultrasound Therapy Systems

5.2 Intelect/Genisys Ultrasound Diagnostics A. General 1. The following information is intended to aid in troubleshooting the major components of the Ultrasound Therapy Systems to “Board Level” only. These tests are OEM standard testing procedures and methods used at the factory before shipment of any Ultrasound Therapy System. 2. Due to the complex nature of the technology utilized by Chattanooga Group, the recommended troubleshooting techniques are to determine “Bad Board” and board replacement only. No board component level troubleshooting is recommended nor will information or parts be supplied by Chattanooga Group. Any board component level troubleshooting performed will be at sole risk and liability of the Service Technician performing such troubleshooting techniques. B. Special Tools, Fixtures & Materials Required 1. Certain tests require the use of special Tools and/or Fixtures. These will be listed at the particular test where they are required. Testing with any other special tool or fixture other than those stated could give erroneous readings or test results. Always perform the tests exactly as stated to ensure accurate results. 2. Any special tools or fixtures required can be obtained through Chattanooga Group, Service Department. 3. Scope and other standard test equipment settings will be listed for each test performed to aid in performing the test to OEM standards and ensure proper readings. 4. The troubleshooting and repair of the Ultrasound Therapy Systems should be performed only by authorized technicians trained and certified by Chattanooga Group. C. Equipment Required 1. Oscilloscope and Probes 2. Electrotherapy Service Technician Interface (ESTI) Diagnostics Kit. 3. Digital Multimeter 4. Milliohm Meter 5. Dielectric Withstand (Hi-Pot) and ground resistance tester. NOTE: Adjust Dielectric Withstand tester to indicate fault with 120k Ohm Load across the output when at specified test voltage.

6. Ohmic Instruments UPM DT 10 or UPM DT 100 Ultrasound Power Meter. NOTE: The Ohmic Industries UPM DT 10 or UPM DT 100 Ultrasound Power Meters are the only power meters on the market that will meet the strict specifications set forth for Chattanooga Group Ultrasound Products. It is absolutely necessary for the Field Technician to have available and use the Ohmic Industries UPM DT 10 or UPM DT 100 Power Meter when performing any service or calibration of any Chattanooga Group Ultrasound products. 7. Degassed Water (< 5 ppm) for Ultrasound Power Meter. Recipe(s) for Degassed Water 1) Boil Distilled Water for 30 minutes. Place water in a nonporous container and immediately cover with cellophane. Allow to cool to room temperature of approximately 21°C (70°F). May be refrigerated to aid cooling time. 2) Bring Distilled Water to a boil. Place the container under vacuum for 5 to 10 minutes. 8. Dissolved Oxygen Test Kit. Used to test oxygen level of degassed water. NOTE: Two liter softdrink bottles are ideal storage and transport containers for degassed water as they are designed to keep oxygen out. Do not allow aeration of degassed water during transport or filling of the power meter. Do not use Tap Water or Distilled water in the Ultrasound Power Meter. Use only Degassed Water in order to obtain correct test results. The chart below illustrates the oxygen content of Degassed, Tap and Distilled Water. WATER TYPE

ppm of Oxygen

Degassed (per recipe 1 or 2)

Less than 5 ppm

Tap Water

Up to 35 ppm

Distilled Water

Up to 20 ppm

9. Ultrasound Applicators (Intelect/Genisys Accessories).

10

5- TROUBLESHOOTING

Intelect®/Genisys® Ultrasound Therapy Systems

5.3 Visual Inspection A. General Visually inspect the Ultrasound Therapy System. A visual inspection can, to an experienced Technician, indicate possible abuse of the system and/or internal problems. 5.4 Leakage Tests Conduct all necessary leakage tests as required per “Chapter 7 Electrical Equipment” of the 1999, or later, edition of the NFPA (National Fire Protection Association) “Health Care Facility” standards. See Figure 5.1.

!

WARNING

UNIT FAILING DIELECTRIC WITHSTAND AND/OR LEAKAGE TESTS COULD INDICATE SERIOUS INTERNAL SYSTEM PROBLEMS. DO NOT PLACE UNIT BACK INTO SERVICE! SEND UNIT TO FACTORY FOR REPAIR! DO NOT ATTEMPT TO REPAIR IN THE FIELD!

5.5 Unit Startup and Fan Testing A. Equipment Required 1. N/A B. Test 1. Place unit face up on work surface. 2. Connect power cord to unit and plug into proper power receptacle. 3. Turn system on. Adjust intensity up and press Start. Fan will begin to run after the audible beep tones. 4. Place hand at the back of unit to verify fan is blowing out. See Figure 5.2. C. Test Results 1. Unit will not Start= Unit Failed Test a) Possible Bad Power Supply 2. Main menu does not display= Unit Failed Test a) Possible Bad Control Board b) Possible Bad Power Supply 1). Visually check power button LED. If flashing, Power Supply is good, replace Control Board. If not flashing, replace Power Supply. 3. Fan not blowing outward= Unit Failed Test a) Fan Blowing Inward 1) Fan wired wrong- Rewire or replace fan b) Fan not blowing 1) Possible Bad Fan 2) Possible Bad Power Supply

FIGURE 5.1

VERIFY FAN IS BLOWING OUT

FIGURE 5.2

11

5- TROUBLESHOOTING

Intelect®/Genisys® Ultrasound Therapy Systems

5.6 Ultrasound Tests A. Equipment Required 1. Degassed Water. Refer to page 10 for Degassed Water Recipes. 2. Ohmic Instruments UPM DT 10 or UPM DT 100 Ultrasound Power Meter. 3. Dissolved Oxygen Test Kit. Used to test oxygen level of degassed water. 4. Known good Ultrasound Applicator 5.7 Ultrasound Applicator Identification Test NOTE: Use any Ultrasound Applicator for this test. A. Ultrasound Applicator Identification Test Procedures 1. Without Applicator installed, turn unit on. 2. Look at the display center. The Applicator not detected icon should appear. See Figure 5.3. 3. Plug Applicator into Applicator port on the front R.H. corner of the system. Applicator LED should flash five (5) times. See Figure 5.4. 4. Look at the display center. The Applicator detected icon should appear. See Figure 5.5. B. Ultrasound Applicator Identification Test Results 1. Unit operates as described in steps 2 and 4. a) Unit passed test. 2. “NO CAL” icon displays center of system display. a) Applicator not calibrated. b) Possible bad Applicator. Re-test with known good Applicator. c) Possible bad Ultrasound PCB. 3. Not detected icon displayed after ten seconds of Applicator being plugged in. a) Possible bad applicator. Re-test with known good Applicator. b) Possible bad Ultrasound Board.

FIGURE 5.3

FIGURE 5.4

FIGURE 5.5

12

5- TROUBLESHOOTING

Intelect®/Genisys® Ultrasound Therapy Systems

5.8 Ultrasound Applicator Output Test Perform this test using all available Applicators for the unit being tested. A. Ultrasound Applicator Output Test Procedures 1.Set up Ohmic Instruments UPM DT 10 or UPM DT 100 Ultrasound Power Meter per Operator’s Instructions and fill test reservoir with Degassed Water.

!

WARNING

USE ONLY DEGASSED WATER IN POWER METER FOR TESTING ULTRASOUND APPLICATORS. USE OF OTHER TYPES OF WATER WILL CAUSE FALSE TEST RESULTS. SEE PAGE 10 FOR DEGASSED WATER RECIPES. DO NOT AERATE WATER WHEN FILLING POWER METER.

2.Place an Applicator into the Power Meter retainer. As per Ohmic Manual, make certain the Applicator’s aluminum face is submerged in the degassed water and centered directly over the S.S. cone. 3. “Zero” the Power Meter. 4. Turn the Ultrasound Therapy System on. 5. Press the button until “Continuous” is displayed in the Duty Cycle area of the display. 6. Press the button until “Watts” appears in the intensity area of the display. 7. Increase Intensity for the applicator being tested according to Figure 5.6 8. Press “Start”. 9. Compare Power Meter readings, displayed on power meter for all the settings for each respective applicator being tested to the values in Figure 5.6. 10. Press the button until “3.3 MHz” is diplayed in the Frequency area of the display. Repeat test and compare readings to Figure 5.6. B. Ultrasound Applicator Output Test Results 1. Output ranges fall within the specified ranges as listed in Figure 5.6. a) Unit passed test. 2. Readings fall outside specified ranges of Figure 5.6. a)Possible bad Degassed Water in Power Meter. b)Possible use of Power Meter other than Ohmic Instruments UPM DT 10 or UPM DT 100 Ultrasound Power Meter. c)Possible bad or out of calibration Applicator. d)Possible bad Ultrasound Board.

APPLICATOR OUTPUT SPECIFICATIONS APPLICATOR SIZE 1 cm2

2 cm2

5 cm2

10 cm2

POWER SETTING (WATTS) 1

0.8 - 1.2

2

1.6 - 2.4

1

0.8 - 1.2

2

1.6 - 2.4

4

3.2 - 4.8

1

0.8 - 1.2

2

1.6 - 2.4

5

4.0 - 6.0

10

8.0 - 12.0

1

0.8 - 1.2

5

4.0 - 6.0

10

8.0 - 12.0

15

12.0 - 18.0

20

16.0 - 24.0

FIGURE 5.6

13

OUTPUT RANGE

5- TROUBLESHOOTING

Intelect®/Genisys® Ultrasound Therapy Systems

5.9 Ultrasound Duty Cycle Test This test is performed using only the 5 cm2 Applicator. A. Ultrasound Duty Cycle Test Procedures 1. Set up Ohmic Instruments UPM DT 10 or UPM DT 100 Ultrasound Power Meter per Operator’s Instructions and fill test reservoir with Degassed Water.

!

WARNING

USE ONLY DEGASSED WATER IN POWER METER FOR TESTING ULTRASOUND APPLICATORS. USE OF OTHER TYPES OF WATER WILL CAUSE FALSE TEST RESULTS. SEE PAGE 10 FOR DEGASSED WATER RECIPES. DO NOT AERATE WATER WHEN FILLING POWER METER.

2. Place an Applicator into the Power Meter retainer. As per Ohmic Manual, make certain the Applicator’s aluminum face is submerged in the degassed water and centered directly over the S.S. cone. 3. “Zero” the Power Meter. 4. Turn the Ultrasound Therapy System on. 5. Press the button until “Watts” appears in the intensity area of the display. 6. Increase Intensity ( ) to maximum. 7. Press “Start”. 8. Press the button until “10%” is displayed in the Duty Cycle area of the display. 9. Compare Power Meter readings to Figure 5.7 for each of the following Duty Cycle settings listed in the chart. 10. Press the button until “3.3 MHz” is displayed in the Frequency area of display. Repeat test and compare readings to Figure 5.7. B. Ultrasound Duty Cycle Test Results 1. Duty Cycles fall within the specified ranges as listed in Figure 5.7. a) Unit passed test 2. Readings fall outside specified ranges of Figure 5.7. a) Possible bad Degassed Water in Power Meter. b) Possible use of Power Meter other than Ohmic Instruments UPM DT 10 or UPM DT 100 Ultrasound Power Meter. c) Possible bad or out of calibration Applicator. d) Check Ultrasound Board. e) Check Control Board.

DUTY CYCLE SPECIFICATIONS APPLICATOR SIZE

5 cm2

DUTY CYCLE

OUTPUT RANGE

10%

0.8 - 1.2

20%

1.6 - 2.4

50%

4.0 - 6.0

100% (Continuous)

8.0 - 12.0

FIGURE 5.7

14

6- REMOVAL & REPLACEMENT

Intelect®/Genisys® Ultrasound Therapy Systems

6.1 General

!

REMOVE MAINS POWER CORD

REMOVE PLYNTH

WARNING

UNPLUG THE UNIT FROM THE POWER SOURCE AND/OR REMOVE BATTERY BEFORE ATTEMPTING ANY REMOVAL OR REPLACEMENT PROCEDURES TO PREVENT ELECTRICAL SHOCK. A. Tools & Equipment Required 1. #1 Phillips Screwdriver 2. Flat Blade Screwdriver 6.2. Top & Bottom of Unit A. Removing Top from Bottom 1. Place unit face down on a grounded work surface. NOTE: Use a clean, soft cloth or cushion underneath the display lens to prevent scratching or damage to the lens. 2. Remove the plynth from the bottom of the system. See Figure 6.1. 3. Remove the Mains Power Cord from the system. See Figure 6.1. 4. Remove Battery Cover with the Flat Blade Screwdriver and remove Battery from the system if equipped. See Figure 6.2. 5. Remove the Rear Fan Grill from the system to gain access to the two rear mounting screws. See Figure 6.2. 6. Remove the two front feet from the system to gain access to the two front screws. See Figure 6.3. 7. Remove the four mounting screws from the bottom housing using the #1 Phillips Screwdriver. See Figure 6.3. 8. Carefully separate the upper and lower housings of the system. It may be necessary to pry the housings apart at the Applicator Hook. See Figure 6.4. 9. Disconnect the Power Supply and Fan Harnesses from the Control PCB of the system. See Figure 6.4. B. Installing Top to Bottom 1. With top laying face down, carefully place the bottom housing in position over the top housing. 2. Connect the Power Supply and Fan Harnesses to the Control PCB onto their respective connectors. 3. Make certain the front insert and the Applicator Hook are in position, then lightly press housings together to properly seat them. 4. Secure housings together with the four phillips head screws. NOTE: Do not overtighten the screws. Overtightening will damage the threads of the brass inserts. 5. Follow Steps 1 - 7 in 6.2, A above in reverse order to complete reassembly of system.

FIGURE 6.1

REMOVE FAN GRILL

REMOVE BATTERY COVER AND BATTERY

FIGURE 6.2

REMOVE FOUR SCREWS

REMOVE FRONT FEET

FIGURE 6.3 CAREFULLY PRY APART HERE IF NECESSARY

APPLICATOR HOOK

DISCONNECT POWER SUPPLY AND FAN HARNESSES

FIGURE 6.4

15

6- REMOVAL & REPLACEMENT

Intelect®/Genisys® Ultrasound Therapy Systems

6.3 Fan Removal & Replacement

!

FAN BAFFLE

REMOVE SCREWS

WARNING

UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE ATTEMPTING ANY REMOVAL OR REPLACEMENT PROCEDURES TO PREVENT ELECTRICAL SHOCK. A. Fan Removal 1. Separate Top from Bottom. Refer to 6.2, part A. 2. With #1 Phillips screwdriver, remove the 2 screws securing the Fan. See Figure 6.5. 3. Remove Fan from the unit. 4. Remove Fan Baffle from fan. See Figure 6.5. B. Installing Fan 1. Route Fan Harness underneath fan as shown in Figure 6.6. 2. Install Fan Baffle onto fan as shown in Figure 6.6. 3. Place new Fan, Part Number 27266, into system base. 4. Make certain the Fan Baffle sits onto System Housing Baffle Tabs as shown in Figure 6.7. 5. Secure fan to housing with the 2 mounting screws. See Figure 6.8. NOTE: Do not overtighten the screws. Overtightening will damage the threads of the brass inserts.

FIGURE 6.5 FAN BAFFLE

ROUTE HARNESS AS SHOWN

FIGURE 6.6

BAFFLE TABS

6. Reassemble the Top and Bottom Housing. Refer to 6.2, part B.

FIGURE 6.7 SECURELY TIGHTEN MOUNTING SCREWS

FIGURE 6.8

16

6- REMOVAL & REPLACEMENT

Intelect®/Genisys® Ultrasound Therapy Systems

6.4 Power Supply Removal & Replacement

!

WARNING

UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE ATTEMPTING ANY REMOVAL OR REPLACEMENT PROCEDURES TO PREVENT ELECTRICAL SHOCK. REMOVE SCREWS

DANGER

FIGURE 6.9

IF POWER SUPPLY HAS FAILED HI-POT TEST, IT WILL RETAIN HIGH VOLTAGE IN THE POWER SUPPLY CAPACITOR C4. DISCHARGE CAPACITOR USING A MULTIMETER PRIOR ANY SERVICE OF THE POWER SUPPLY

GREEN WITH YELLOW STRIPE

A. Power Supply Removal 1. Separate Top from Bottom. Refer to 6.2, part A. 2. Discharge Power Supply Capacitor, C4, with multimeter. 3. With #1 Phillips screwdriver, remove the 2 screws securing the Power Supply. See Figure 6.9. 4. Lift Power Supply and disconnect the Power Supply Harnesses from the Mains Disconnect. See Figure 6.10. 5. Remove Power Supply from system. B. Installing Power Supply 1. Route Power Supply PCB Harness of new Power Supply, Part Number 27265, as shown in Figure 6.11. 2. Connect Power Supply Mains Harness to Mains Disconnect as shown in Figure 6.10 3. Make certain the Power Supply sits onto alignment pins as shown in Figure 6.12. 5. Secure Power Supply to housing with the 2 mounting screws. See Figure 6.9. NOTE: Do not overtighten the screws. Overtightening will damage the threads of the brass inserts.

BLUE

FIGURE 6.10 ROUTE HARNESS AS SHOWN

FIGURE 6.11 POWER SUPPLY ALIGNMENT PINS

6. Reassemble the Top and Bottom Housing. Refer to 6.2, part B.

FIGURE 6.12

17

RED

6- REMOVAL & REPLACEMENT

Intelect®/Genisys® Ultrasound Therapy Systems

6.5 Ultrasound Board Removal & Replacement

!

SCREW

SCREW

WARNING

UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE ATTEMPTING ANY REMOVAL OR REPLACEMENT PROCEDURES TO PREVENT ELECTRICAL SHOCK. A. Ultrasound Board Removal 1. Separate Top from Bottom. Refer to 6.2, part A. 2. With #1 Phillips screwdriver remove the 4 screws securing the Ultrasound Board to the unit. See Figure 6.13. 3. Carefully remove Ultrasound Board from the Control Board/Ultrasound Board Connector. See Figure 6.14. 4. Remove Control Board/Ultrasound Board Connector from the Control Board. Be careful not to bend or damage any of the pins. See Figure 6.14.

SCREW

SCREW

FIGURE 6.13 REMOVE CONNECTOR FROM CONTROL BOARD

REMOVE US BOARD FROM CONNECTOR

B. Installing Ultrasound Board 1. Install Control Board/Ultrasound Board Connector into new Ultrasound Board, Part Number 27269. NOTE: Install the connector with the long pins inserted into Ultrasound Board. Make certain connector is completely seated against Ultrasound Board. See Figure 6.15. 2. Place new Ultrasound board as shown in Figure 6.16 over Control Board and align connector pins up with Control Board Connector. 3. Carefully press the connector and board into place until the connector is completely seated into Control Board. 4. Secure Ultrasound Board with the 4 retaining screws.

FIGURE 6.14

INSTALL CONNECTOR TO US BOARD AS SHOWN

FIGURE 6.15 ALIGN CONNECTOR PINS WITH CONTROL BOARD CONNECTOR

NOTE: Do not overtighten the screws. Overtightening will damage the threads of the brass inserts. 5. Reassemble the Top and Bottom Housing. Refer to 6.2, part B.

FIGURE 6.16

18