Intelect TransSport combo Model 2738 Service Manual Rev C

TABLE OF CONTENTS FOREWORD... 1 1- SAFETY PRECAUTIONS...2-4 1.1 Precautionary Symbol Definitions... 2 1.2 Safety Precautions ... 2 2- THEORY OF OPERATION... 5 2.1 Overview... 5 2.2 Power Supply Circuit... 5 2.3 Control Board... 5 2.4 Stim Boards... 5 2.5 Ultrasound Board and Applicator ... 5 2.6 User Interface and Accessories... 5 2.7 NIMH Battery (Optional)... 5 3- NOMENCLATURE...6-8 3.1 Components and Controls... 6 3.2 Hardware and Software Symbol Definitions... 7 4- SPECIFICATIONS... 9-13 4.1 Intelect Transport Combo System... 9 4.2 Intelect Transport Electrotherapy Waveform Specifications...10 4.3 Intelect Transport Combo Ultrasound Specifications...13 5- TROUBLESHOOTING... 14-28 5.1 Intelect Transport Combo Error Messages...14 5.2 Intelect Transport Combo System Testing...16 5.3 Electrical Safety...17 5.4 Leakage Tests...17 5.5 Visual Inspection...18 5.6 Unit Startup and Fan Testing...18 5.7 Electrical Stimulator Test System Setup...19 5.8 Interferential Mode Test...20 5.9 Premodulated Mode Test...20 5.10 Russian Mode Test...21 5.11 High Voltage Pulsed Current (HVPC) Mode Test...22 5.12 Ultrasound Tests...23 - 28 5.13 Ultrasound Applicator Identification Test...23 5.14 Ultrasound Applicator Output Test...24 5.15 Ultrasound Duty Cycle Test...26 5.16 Combo Operation Test...28 6- REMOVAL & REPLACEMENT... 29-40 6.1 Separating Top and Bottom...29 6.2 Therapy System Fan...30 6.3 Power Supply ... 31 6.4 Channel 1 Stim Board... 33 6.5 Channel 2 Stim Board...34 6.6 Ultrasound Board ...35 6.7 Control Board Assembly...36 6.8 LCD...38 6.9 Keymat, On/Off Button and Unit Top...39 6.10 Plynth...40 7- GENERAL MAINTENANCE...41 7.1 Cleaning the System...41 7.2 Calibration Requirements...41 7.3 Field Service.. ...41 7.4 Factory Service...41

Intelect Transport® Combo Therapy System 8- ULTRASOUND APPLICATOR CALIBRATION.42 8.1 General Procedures...42 9- PARTS... 43-47 10- SCHEMATICS... 48-66 11- WARRANTY...67

FOREWORD

Intelect Transport® Combo Therapy System

Read, understand, and follow the Safety Precautions and all other information contained in this manual. This manual contains the necessary safety and field service information for those field service technicians, certified by DJO, LLC, to perform field service on the Intelect Transport® Combo Therapy System. At the time of publication, the information contained herein was current and up-to-date. However, due to continual technological improvements and increased clinical knowledge in the field of electrotherapy, as well as DJO, LLC’s policy of continual improvement, DJO, LLC reserves the right to make periodic changes and improvements to their equipment and documentation without any obligation on the part of DJO, LLC. As significant changes occur to the Intelect Transport Combo Therapy System, service bulletins may be made available on our web site (chattgroup.com) in lieu of reprinted manuals. Technicians repairing the Intelect Transport Combo Therapy System agree to assume all risk and liability associated with this process. This system is to be used only under the supervision of a licensed practitioner.

© 2010 DJO, LLC Vista, California, USA. Any use of editorial, pictorial, or layout composition of this publication without express written consent from DJO, LLC is strictly prohibited. This publication was written, illustrated, and prepared for distribution by DJO, LLC.

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1- SAFETY PRECAUTIONS

Intelect Transport® Combo Therapy System

1.1 PRECAUTIONARY SYMBOL DEFINITIONS

1.2 SAFETY PRECAUTIONS

The precautionary instructions found in this manual are indicated by specific symbols. Understand these symbols and their definitions before operating or servicing this equipment. The definitions of these symbols are as follows:

Read, understand, and follow all safety precautions found in this manual. Below are general safety precautions that must be read and understood before attempting any service techniques on these systems.

A. CAUTION

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

• Read, understand, and practice the precautionary and

operating instructions. Know the limitations and hazards associated with using any electrical stimulation or ultrasound device. Observe the precautionary and operational decals placed on the unit. • DO NOT operate the Intelect Transport Combo unit when connected to any unit other than Chattanooga devices. • DO NOT operate this unit in an environment where other devices are being used that intentionally radiate electromagnetic energy in an unshielded manner. Portable and mobile RF communications equipment can affect Medical Electrical Equipment. • DO NOT use sharp objects such as a pencil point or ballpoint pen to operate the buttons on the control panel. • This unit should be operated, transported, and stored in temperatures between 15 °C and 40 °C (59 °F and 104 °F), with relative humidity ranging from 30%-60%, and where the atmospheric pressure is between 950 h Pa and 1050 h Pa. • The Intelect battery pack is designed for use only with Chattanooga Intelect Transport, Stim, Combo, and Ultrasound systems. • The unit should be routinely checked before each use to determine that all controls function normally; especially that the intensity control properly adjusts the intensity of the electrotherapy and ultrasonic power output in a stable manner. Also, determine that the treatment time control actually terminates electrotherapy and ultrasonic power output when the timer reaches zero. • Inspect cables and connectors before each use. • The Intelect Transport Combo is not designed to prevent the ingress of water or liquids. Ingress of water or liquids could cause malfunction of internal components of the system and therefore create a risk of injury to the patient. • DO NOT permit any foreign materials or liquids to enter the unit. Take care to prevent any foreign materials including, but not limited to, inflammables, water, and metallic objects from entering the unit. These may cause unit damage, malfunction, electrical shock, fire, or personal injury. • Handle the applicator with care. Inappropriate handling of the applicator may adversely affect its characteristics. • Before each use, inspect the applicator for cracks, which may allow the ingress of conductive fluid. • This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to other devices in the vicinity. However, there is no guarantee that interference will not occur in a particular installation. Harmful interference to other devices can be determined by turning this equipment on and off. Try to correct the interference using one or more of the following: reorient or relocate the receiving device, increase the separation between the equipment, connect the equipment to an outlet on a different circuit from that to which the other device(s) are connected and consult the factory field service technician for help.

B. WARNING

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

C. DANGER

Text with a “DANGER” indicator will explain possible safety infractions that are imminently hazardous situations that would result in death or serious injury.

D. DANGEROUS VOLTAGE

Text with a “Dangerous Voltage” indicator serves to inform the user of possible hazards resulting in the electrical charge delivered to the patient in certain treatment configurations of TENS waveforms. E. CORROSIVE HAZARD (NIMH BATTERY)

Text with a “Corrosive Hazard” indicator will explain possible safety infractions if the chemical components of this product are exposed to air, skin, or other materials. F. NOTE:

Throughout this manual “NOTE” may be found. These Notes are helpful information to aid in the particular area or function being described.

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1- SAFETY PRECAUTIONS

Intelect Transport® Combo Therapy System

1.2 SAFETY PRECAUTIONS (CONTINUED)

• Long term effects of chronic electrical stimulation are

• Where the integrity of the external protective earth

unknown.

conductor arrangement is in doubt, equipment shall be operated from its internal electrical power source. • Using a high intensity electrotherapy setting in conjunction with high intensity ultrasound setting may cause the unit to reset. • The battery pack should be removed when storing the unit for extended periods of time. • DO NOT disassemble, modify, or remodel the unit or accessories. This may cause unit damage, malfunction, electrical shock, fire, or personal injury. • DO NOT remove the cover. This may cause unit damage, malfunction, electrical shock, fire, or personal injury. There are no user-serviceable parts inside the unit. If a malfunction occurs, discontinue use immediately and consult the dealer for repair service. • Failure to use and maintain the Intelect Transport Combo and its accessories in accordance with the instructions outlined in this manual will invalidate your warranty. • Nylatex® Wraps contain dry natural rubber and may cause allergic reactions in patients with allergies to latex.

• Stimulation should not be applied over the anterior neck or

mouth. Severe spasm of the laryngeal and pharyngeal muscles may occur and the contractions may be strong enough to close the airway or cause difficulty in breathing. • Stimulation should not be applied transthoracically because the introduction of electrical current into the heart may cause cardiac arrhythmia. • Stimulation should not be applied over swollen, infected, and inflamed areas or skin eruptions, e.g., phlebitis, thrombophlebitis, varicose veins, etc. • Stimulation should not be applied over, or in proximity to, cancerous lesions. • Output current density is inversely related to electrode size. Improper application may result in patient injury. • Always keep the sound head in constant motion. • Always keep the sound head in full contact with the patient’s skin or submerged under water when setting intensity. • Use ample conductive gel to ensure good coupling throughout the treatment. If needed, apply when setting intensity. • Be sure to read all instructions for operation before treating a patient. • Dispose of all products in accordance with local and national regulations and codes. • Use of controls, adjustments, or performance of procedures other than those specified herein may result in hazardous exposure to ultrasonic energy. • Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous conditions causing damage to the battery pack or cells. • To prevent electrical shock, disconnect the battery pack from the system before attempting any maintenance procedures. • Do not drop the applicator on hard surfaces. Do not cool an overheated sound head with ice water or ice packs. Do not allow the sound head to reach maximum temperatures repeatedly. All of these conditions are likely to damage the sound head crystal. Damage resulting from these conditions is not covered under the warranty. • In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the unit and contact the dealer or Chattanooga for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by DJO, LLC or a Field Service Technician certified by DJO, LLC before any further operation or use of the system.

• These devices are restricted to sale by, or on the order of,

a physician or licensed practitioner. This device should be used only under the continued supervision of a physician or licensed practitioner. • Make certain the unit is electrically grounded by connecting only to a grounded electrical service receptacle conforming to the applicable national and local electrical codes. • The Intelect Transport Combo should not be used adjacent to or stacked with other equipment, and if adjacent or stacked use is necessary, the Intelect Transport Combo should be observed to verify normal operation in the configuration in which it will be used. • The user must keep the device out of the reach of children. • Powered muscle stimulators should be used only with the leads and electrodes recommended for use by the manufacturer. • Before administering any treatment to a patient you should become acquainted with the operating procedures for each mode of treatment available, as well as the indications, contraindications, warnings, and precautions. Consult other resources for additional information regarding the application of electrotherapy and ultrasound. • To prevent electrical shock, disconnect the unit from the power source before attempting any maintenance procedures. • Keep electrodes separated during treatment. Electrodes in contact with each other could result in improper stimulation or skin burns.

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1- SAFETY PRECAUTIONS

Intelect Transport® Combo Therapy System

1.2 SAFETY PRECAUTIONS (CONTINUED)

• Use of a unit that indicates an Error or Warning in these

• NiMH Batteries contain Class E corrosive materials.

categories may pose a risk of injury to the patient, user, or extensive internal damage to the system. • Do not turn the unit on or off while it is connected to the patient. • Do not apply the Ultrasound Applicator to the patient during the Head Warming period. Applicator must remain in Applicator Hook during the Head Warming period. • Use only accessories that are specially designed for this unit. Do not use accessories manufactured by other companies on this unit. DJO, LLC is not responsible for any consequence resulting from using products manufactured by other companies. The use of other accessories or cables may result in increased emissions or decreased immunity of this unit.

In the event of battery cell rupture or leakage, handle battery pack wearing neoprene or natural rubber gloves. Contents of a ruptured or leaking battery can cause respiratory irritation. Hypersensitivity to nickel can cause allergic pulmonary asthma. Contents of cell coming in contact with skin can cause skin irritation and/or chemical burns. • Never, under any circumstances, open the battery pack housing or cells. Should an individual battery from a battery pack become disassembled, spontaneous combustion of the negative electrode is possible. There can be a delay between exposure to air and spontaneous combustion. • Charge the battery pack according to the instructions found in this manual. Never attempt to charge the battery pack on any other charging mechanism. • Use the battery pack only with the Intelect Transportable units. • Do not reverse the polarity of the battery pack. Doing so can increase the individual cell temperature and cause cell rupture or leakage. • Never dispose of the battery pack in fire. Never short circuit the battery pack. The battery pack may explode, ignite, leak, or get hot causing serious personal injury. • Dispose of NiMH batteries according to national, state, and local codes and regulations.

• Stimulus delivered by the waveforms of this device, in certain configurations, will deliver a charge of 25 microcoulombs (µC) or greater per pulse and may be sufficient to cause electrocution. Electrical current of this magnitude must not flow through the thorax because it may cause a cardiac arrhythmia. • Patients with an implanted neurostimulation device must not be treated with or be in close proximity to any shortwave diathermy, microwave diathermy, therapeutic ultrasound diathermy, or laser diathermy anywhere on their body. Energy from diathermy (shortwave, microwave, ultrasound, and laser) can be transferred through the implanted neurostimulation system, can cause tissue damage, and can result in severe injury or death. Injury, damage, or death can occur during diathermy therapy even if the implanted neurostimulation system is turned “off.” • DO NOT connect the unit to an electrical supply without first verifying that the power supply is the correct voltage. • Incorrect voltage may cause unit damage, malfunction, electrical shock, fire, or personal injury. Your unit was constructed to operate only on the electrical voltage specified on the Voltage Rating and Serial Number Plate. Contact your DJO, LLC dealer if the unit is not properly rated.

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2- THEORY OF OPERATION

Intelect Transport® Combo Therapy System

2.1 OVERVIEW

The Intelect Transport Combo Therapy System is comprised of several PC board assemblies housed within a common enclosure. These assemblies each support a distinct function in the product. The basic elements are User Interface, Control Board, Stim Boards, Ultrasound Board, Ultrasound Applicator, and Power Supply Circuits.

2.2 POWER SUPPLY CIRCUIT

A universal 75 Watt input power supply provides the system with the required 24 volts DC. The supply is connected to the mains at all times when the Mains Power Cord is attached and plugged into an outlet supplying 100 - 240 VAC. The 24 V supply is regulated locally at each PC board as required.

2.3 CONTROL BOARD

The Control Board serves just as its name implies. It controls the operation of the Stim Boards, Ultrasound Board, User Interface, and Accessories. The Control Board communicates to the Stim Boards and Ultrasound Board through a proprietary bus. The Control Board drives the display. The Control Board reads the menu buttons. The Control Board also reads the amplitude and the Contrast Control on the systems. Sound output is generated by the Control Board and routed to an internal speaker.

2.4 STIM BOARDS

The Stim Boards create all muscle stimulation output. Communication to the Stim Boards is via a proprietary bus. A Processor on each Stim Board acts on messages passed to it by the Control Board to set up waveforms and adjust output amplitude. Information can likewise be passed from each Stim Board back to the Control Board for monitoring current, etc. If a Stim Board does not respond as expected to a command from the Control Board, output is stopped and an Error Message is generated.

2.5 ULTRASOUND BOARD AND APPLICATOR

The Ultrasound Board generates the 1 or 3.3 MHz output to drive the Sound Head of the Applicator. The Ultrasound Board is accessed through the proprietary bus by the Control Board. It can provide current and voltage information about the ultrasound output of the board. The calibration data for the Sound Head is passed through the Ultrasound Board from the Applicator to the Control Board. By storing the calibration data in the Applicator, there is no calibration necessary for the Ultrasound Board and any calibrated Chattanooga Intelect Transport Ultrasound Applicator can be connected and operated to provide accurate output.

2.6 USER INTERFACE AND ACCESSORIES

The LCD display panel provides the operator visible feedback in the way of menu choices. Pressing the User Interface buttons makes selections from the menus. The Control Board interprets these user inputs and responds accordingly. Audible feedback is given for such events as key presses and end of treatment.

2.7 NIMH BATTERY (OPTIONAL)

The NiMH Battery Module incorporates a Nickel Metal Hydride (NiMH) Battery Pack and a PC Board. The PC Board monitors the Battery Charge Level. The Battery Pack supplies the required 24 VDC to the system which is then distributed to the respective PCB’s through the Universal Power Supply. The Battery Pack is interfaced with the system via a Wire Harness that facilitates communication with the Control Board and delivery of power to the Combination Therapy System. When the Therapy System is connected to a Mains Power Supply via the Mains Power Cord, the NiMH Battery Pack will charge. Once the Battery Pack is fully charged, the software will stop the charging process, eliminating the possibility of overcharging. Battery power is used only when the Therapy System is not connected to a Mains Power Supply.

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3- NOMENCLATURE

Intelect Transport® Combo Therapy System

3.1 COMPONENTS AND CONTROLS

The nomenclature graphics below, Figure 3.1, indicate the general locations of the exterior components of the Intelect Transport Combo System.

Know the components and their functions before performing any operation of or service to the Intelect Transport Combo System. LCD Intensity/ Contrast Dial

Power On/Off

Sound Head LCD Clinical Library

LED Indicator (Output Power)

Up Arrow

TIME

INTENSITY Applicator

Back

Parameter Display / Enter

STOP Down Arrow

Channel 1 Lead Wire Connection

START PAUSE Accessory Panel Power Cord Connection

Battery Compartment Serial Decal

FIGURE 3.1

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Channel 2 Lead Wire Connection

Ultrasound Applicator Connection

3- NOMENCLATURE

Intelect Transport® Combo Therapy System

3.2 HARDWARE AND SOFTWARE SYMBOL DEFINITIONS

The symbols below are found on the system as well as within the software. These symbols are defined for the purpose of recognition and functionality when operating or performing service on the Intelect Transport Combo System.

Know the symbols and their definitions before performing any operation of or service to the Intelect Transport Combo System.

Intelect Transport Combo System Hardware Symbols

Power On/Off

The Power On/Off button controls the flow of electricity to the unit. NOTE: Make certain there are no electrodes on the patient when turning the unit on or off.

LCD

The LCD (Liquid Crystal Display) allows the user to view and monitor the information displayed before, during, and after therapy.

Clinical Library

Select this button to access the following functions:

• Retrieve User Protocol • Restore Factory Settings • Restore Factory Protocols • Languages • View Unit Information TIME

Press the Up or Down arrow buttons to set total treatment time of therapy.

Back

Use this button to return to the previous window.

STOP

Select this button to stop a treatment session.

Down Arrow

When the window displays a list of options, press the Down Arrow button to scroll down the list.

PAUSE

Use this button to pause the treatment session. To restart therapy, press the PAUSE button.

Sound Head

The aluminum face of the applicator that contacts the patient’s skin. It covers a transducer mechanism that converts electrical energy to mechanical energy in the form of a vibrating crystal.

LED Indicator (Output Power)

When illuminated, this green light signifies that ultrasound energy is being distributed through the applicator.

Applicator

The hand held assembly used to deliver ultrasonic energy. The applicator includes the sound head, transducer, and related electronics.

Accessory Panel

The Accessory Panel serves as a port of connection for the electrodes and ultrasound applicator.

Channel 1 Lead Wire Connection

This port serves as the connection point between the unit and the Channel 1 Lead Wire.

Channel 2 Lead Wire Connection

This port serves as the connection point between the unit and the Channel 2 Lead Wire.

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3- NOMENCLATURE

Intelect Transport® Combo Therapy System

3.2 HARDWARE AND SOFTWARE SYMBOL DEFINITIONS (CONTINUED)

Ultrasound Applicator Connection

This port serves as the connection point between the unit and the ultrasound applicator.

START

Select Start to begin a treatment session.

Parameter Display/Enter

Select this button to display the parameters of the waveform during treatment. Also, this button is used to accept the highlighted selection.

INTENSITY

Use the up or down arrow on the INTENSITY button to increase or decrease output power.

Up Arrow

When the window displays a list of options, press the Up Arrow button to scroll up the list.

Battery Indicator

When displayed on the LCD, this symbol indicates the battery pack option is present on the unit. This symbol also displays the charge status of the battery.

LCD Intensity/Contrast Dial

If the intensity of the LCD display diminishes, turn the dial until the display contrast is optimal.

Charge Indicator

This symbol displays when the unit is connected to mains power and the battery pack is charging.

NOTE: During battery operation, if the unit is left on, but is not active for more than five minutes, it will power off to conserve battery power. To restore power, press the Power On/Off button.

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4- SPECIFICATIONS

Intelect Transport® Combo Therapy System

4.1 INTELECT TRANSPORT COMBO SYSTEM

Figure 4.1 below provides physical details of the Intelect Transport Combo. This section also provides waveform specifications to aid in troubleshooting.

Refer to this section when performing troubleshooting, replacement, and repair of the Intelect Transport Combo System.

A. Intelect Transport Combination Therapy System Physical Specifications

DEPTH

HEIGHT

WIDTH

FIGURE 4.1

Dimensions Width... 10.125 in (25.7 cm) Height... 7.250 in (18.4 cm) Depth... 11.5 in (29.2 cm) Weight Standard Weight (with base)...5.07 lb (2.3 kg) Battery Pack...1.87 lb (0.85 kg) Power Input...100 - 240 VAC, 50/60 Hz 100 VA Output... +24 V, 3.125 A Electrical Class...CLASS I Electrical Type Ultrasound TYPE B...

Operating Environment Temperature... Between 59 °F and 104 °F (15° C and 40° C) Relative Humidity... 30%-60% Atmospheric Pressure... 950-1,050 h Pa Complies with: UL/IEC/EN 60601-1 IEC/EN 60601-1-2 IEC 60601-2-10 IEC 60601-2-5

Electrotherapy TYPE BF... Battery Type...Nickel Metal Hydride (NiMH) (1.2 V x 20 size AA)

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4- SPECIFICATIONS

Intelect Transport® Combo Therapy System

4.2 INTELECT TRANSPORT COMBO ELECTROTHERAPY WAVEFORM SPECIFICATIONS

The specifications found in this section provide the necessary waveform specifications to aid in troubleshooting. A waveform graphic from an oscilloscope is also provided for clarification. Refer to this section when performing troubleshooting, replacement, and repair of the Intelect Transport Combo System. A. High Voltage Pulsed Current (HVPC)Figure 4.2 (Factory Default Setting) The High Voltage Pulsed Current (HVPC) has a very brief pulse duration characterized by 2 distinct peaks delivered at high voltage. The waveform is monophasic (current flows in one direction only). The high voltage causes a decreased skin resistance, making the current comfortable and easy to tolerate. Output Mode... Electrodes

FIGURE 4.2

Amplitude... 0-500 V* Polarity... Positive or Negative (Negative) Ramp... 0.5 sec, 1 sec, 2 sec, 5 sec (2 sec) Display... Peak Current or Volts (Volts) Sweep... Off, 80/120 pps, 1/120 pps, 1/10 pps (Off) Frequency... 10-120 pps (100 pps) Cycle Time... 5/5, 4/12, 10/10, 10/20, 10/30, 10/50, and Continuous (Continuous) Constant Mode... CV (only)** (CV) Treatment Time... 1-60 Minutes (20 min)

* ESTI-2 Load Box ** CV = Constant Voltage

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4- SPECIFICATIONS

Intelect Transport® Combo Therapy System

4.2 INTELECT TRANSPORT COMBO ELECTROTHERAPY WAVEFORM SPECIFICATIONS (CONTINUED)

B. Premodulated - Figure 4.3 (Factory Default Setting) Premodulated Current is a medium frequency waveform. Current is distributed from one channel (two electrodes). The current intensity is modulated: it increases and decreases at a regular frequency ( the Amplitude Modulation Frequency). Output Mode... Electrodes Amplitude... 0-100 mA* Carrier Frequency... 2500 Hz (2500 Hz) Ramp... 2 sec (2 sec) Display... Peak Current or Volts (Volts) Sweep... On, 1-200 Hz (On) Cycle Time... 5/5, 4/12, 10/10, 10/20, 10/30, 10/50, and Continuous (Continuous) Beat Low Frequency... 1- 199 Hz Beat High Frequency... 2-200 Hz Constant Mode... CC or CV** (CC) Treatment Time... 1-60 Minutes (20 min)

FIGURE 4.3

* ESTI-2 Load Box **CC= Constant Current CV= Constant Voltage

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4- SPECIFICATIONS

Intelect Transport® Combo Therapy System

4.2 INTELECT TRANSPORT COMBO ELECTROTHERAPY WAVEFORM SPECIFICATIONS (CONTINUED)

C. Interferential - Figure 4.4 (Factory Default Setting) Interferential Current is a medium frequency waveform. Current is distributed from two channels (four electrodes). The currents cross in the body within the area being treated. The two currents interfere with each other at this crossing point, resulting in a modulation of the intensity (the current intensity increases and decreases at a regular frequency). Output Mode... Electrodes Amplitude... 0-100 mA* Carrier Frequency... 2500 - 5000 Hz (4000 Hz) Vector Scan... Manual, Automatic 40%, 100% (Manual) Vector Position... 0 - 90 Degrees (45˚) Sweep... On, 1-200 Hz Beat Low Frequency... 1-199 Hz (80Hz) Beat High Frequency... 2-200 Hz (150Hz) Constant Mode... CC or CV** (CC) Treatment Time... 1 -60 minutes (20 min)

FIGURE 4.4

D. Russian- Figure 4.5 (Factory Default Setting) Russian Current is a sinusoidal waveform delivered in bursts or series of pulses. This method was claimed by its author (Kots) to produce maximal muscle strengthening effects without significant discomfort to the patient. Output Mode... Electrodes

FIGURE 4.5

Amplitude... 0-100 mA* Channel Mode. . . 10%, 20%, 30%, 40%, and 50% (50%) Constant Mode... CC or CV** (CC) Cycle Time... 5/5, 4/12, 10/10, 10/20, 10/30, 10/50, and Continuous (10/50) Ramp... 0.5 sec, 1 sec, 2 sec and 5 sec (2 sec) Carrier Frequency... 2500 Hz (2500 Hz) Burst Frequency... 20 -100 Hz (50 Hz) Treatment Time... 1 -60 minutes (20 min)

* ESTI-2 Load Box **CC= Constant Current CV= Constant Voltage

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4- SPECIFICATIONS

Intelect Transport® Combo Therapy System

4.3 INTELECT TRANSPORT COMBO THERAPY SYSTEM ULTRASOUND SPECIFICATIONS

This section provides the necessary Ultrasound Specifications to aid in troubleshooting. Refer to these specifications as necessary when troubleshooting the Ultrasound PC Board and Applicators. A. Ultrasound Frequency... 1 MHz, ± 5%; 3.3 MHz, ±5% Duty Cycles... 10%, 20%, 50%, and Continuous Pulse Frequency... 100 Hz Pulse Duration... 1 mSec, ±20%; 2 mSec, ±20% 5 mSec, ±20% Output Power 10 cm2 Crystal... 0-20 Watts at 1 MHz, 0-10 Watts at 3.3 MHz 5 cm2 Crystal... 0-10 Watts, 1 and 3.3 MHz 2 cm2 Crystal... 0-4 Watts, 1 and 3.3 MHz 1 cm2 Crystal... 0-2 Watts 3.3 MHz Only Amplitude. . 0 - 2.5 w/cm2 in Continuous mode, 0-3 w/cm2 in Duty Cycle modes Output accuracy... ± 20% above 10% of maximum Temporal Peak to Average Ratios: 2:1, ± 20%, at 50% Duty Cycle 5:1, ± 20%, at 20% Duty Cycle 9:1, ± 20%, at 10% Duty Cycle Beam Non uniformity Ratio... ... 5.0 : 1 maximum Beam Type... Collimating Effective Radiating Areas 10 cm2 Crystal - 6.8 cm2 - 10.0 cm2 5 cm2 Crystal - 3.5 cm2 - 5.0 cm2 2 cm2 Crystal - 1.4 cm2 - 2.0 cm2 1 cm2 Crystal - 0.7 cm2 - 1.0 cm2 Treatment Time... 1-30 Minutes

B. Head Warming Feature Specifications The Head Warming feature of an Intelect Transport Combo Therapy System utilizes Ultrasound output resulting in warming of the Sound Head to increase patient comfort. With Head Warming enabled, ultrasound is emitted without pressing the START button. The Applicator LED will not illuminate during the Head Warming period. US Channel will indicate "Warming". Output. . 0 - 50% Cycling of maximum power Frequency... 3.3 MHz Sound Head Temperature ������������ 85 °F - 110 °F (29.4 °C - 43.3 °C)

Do not apply the Ultrasound Applicator to the patient during the Head Warming period. Applicator must remain in Applicator Hook during the Head Warming period.

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5- TROUBLESHOOTING

Intelect Transport® Combo Therapy System

5.1 INTELECT TRANSPORT COMBO THERAPY SYSTEM ERROR MESSAGES

A. The following information is provided as an aid in defining the Software Error Messages of the Intelect Transport Therapy System. Once a particular Error Message is defined, the information will also list probable causes and possible remedies. Once the problem area is determined, subsequent tests for verification will be necessary to determine a “Bad Board”.

ERROR CODE

ERROR TYPE

DEFINITION

All Troubleshooting and tests will be to validate a “Bad Board” only. No component level troubleshooting information is or will be provided by DJO, LLC for field troubleshooting of board components. B. Once a particular PC Board has been determined as bad, refer to the appropriate Removal and Replacement Section for the board affected and follow the instructions for replacement of the board.

PROBABLE CAUSES

POSSIBLE REMEDY

USER CORRECTABLE WARNING MESSAGES 100 101

WARNING WARNING

Ultrasound Applicator became unplugged Ultrasound Applicator unplugged

Ultrasound Applicator was unplugged while an Ultrasound treatment was running User attempted to start an Ultrasound treatment, but no Ultrasound Applicator was plugged into unit

Plug Ultrasound Applicator into proper receptacle on unit making certain it is completely seated

102

WARNING

Ultrasound Applicator not calibrated

The Ultrasound Applicator plugged into the unit needs to be calibrated

Contact dealer or Chattanooga for service.

103 104 105

WARNING WARNING WARNING

Ultrasound Channel not available Stim Channel not available Stim Channel not available

User attempted to select Combo treatment, but the Ultrasound Channel was already in use User attempted to select Combo treatment, but the Ultrasound Channel was already in use User attempted to select a two channel Electrotherapy treatment, but at least one of the two stim channels were already in use

Wait until Ultrasound treatment is completed or stop Ultrasound treatment and try again

106

WARNING

Over current

Stim channel has exceeded allowed current level and the treatment has been stopped

Reset treatement parameters and attempt session again

107

WARNING

Bad Contact Quality

Electrode contact is poor

Apply new electrodes to the treatment area

108

WARNING

Shorted Lead Wires

Lead Wires are bad

Replace with new lead wires

109

WARNING

Power Supply current limit

User attempted to start two channels of Electrotherapy while running an Ultrasound treatment with a 10 cm2 Ultrasound Applicator and Ultrasound Output is currently set to greater than 15 Watts.

Wait until Ultrasound treatment is completed or stop Ultrasound treatment and try again or decrease ultrasound output to less than 15 Watts

200

ERROR

Error while attempting to save Ultrasound Applicator Calibration Data

ERROR MESSAGES (200-213) REQUIRING TECHNICAL ASSISTANCE Could not save the Calibration Data to the Ultrasound Applicator

1. Replace the Ultrasound Applicator with a known good Ultrasound Applicator 2. Replace Ultrasound Board 3. Replace Control Board

In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the unit and contact the dealer or Chattanooga for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by DJO, LLC or a Field Service Technician certified by DJO, LLC before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury to the patient, user, or may cause extensive internal damage to the unit.

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5- TROUBLESHOOTING

Intelect Transport® Combo Therapy System

5.1 COMBOSOFTWARE THERAPY SYSTEM ERROR MESSAGES (CONTINUED) 5.1 INTELECT INTELECT TRANSPORT TRANSPORT SYSTEM ERROR MESSAGES (continued)

In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the unit and contact the dealer or Chattanooga for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by DJO, LLC or a Field Service Technician certified by DJO, LLC before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury to the patient, user, or may cause extensive internal damage to the unit. ERROR CODE

ERROR TYPE

DEFINITION

PROBABLE CAUSES

POSSIBLE REMEDY

ERROR MESSAGES (200-213) REQUIRING TECHNICAL ASSISTANCE (CONTINUED) 201

ERROR

Error Applicator not calibrated OK.

Could not calibrate Ultrasound Applicator

1. Attempt to calibrate again 2. Replace the Ultrasound Applicator with a known good Ultrasound Applicator 3. Replace Ultrasound Board 4. Replace Control Board

202

ERROR

Timed out while saving the Ultrasound Applicator Calibration Data.

Could not save the Calibration Data to the Ultrasound Applicator

1. Replace the Ultrasound Applicator with a known good Ultrasound Applicator 2. Replace Ultrasound Board 3. Replace Control Board

203

ERROR

Error reading Protocol.

Error reading a Protocol from the EEPROM

Restore Factory Settings, restore Factory Protocols and rebuild all User Protocols

204 205 206 207 208

ERROR ERROR ERROR ERROR ERROR

Main Software Flash Erase Error Main Software Flash Echo Main Software CRC Error Main Software Program Flash Error Main Software Acknowledge Error

Stim Main Software upgrade Error Stim Main Software upgrade Error Stim Main Software upgrade Error Stim Main Software upgrade Error Stim Main Software upgrade Error

1. Replace appropriate Stim Board 2. Replace Control Board

209

ERROR

Software CRC Acknowledge Error.

Software upgrade Error

Replace Control Board

210 211 212 213 214

ERROR ERROR ERROR ERROR ERROR

Channel Software Flash Erase Error Channel Software CRC Error Channel Software Program Flash Error Channel Software Acknowledge Error Channel Software CRC Acknowledge Error

Stim Channel Software upgrade Erro. Stim Channel Software upgrade Error Stim Channel Software upgrade Error Stim Channel Software upgrade Error Stim Channel Software upgrade Error

1. Replace appropriate Stim Board 2. Replace Control Board

CRITICAL ERRORS (300-314) DEMANDING TECHNICAL SERVICE 300

CRITICAL ERROR Unit CFG Critical Error

Error communicating with Stim Board on Powerup 1. Replace appropriate Stim Board 2. Replace Control Board

301

CRITICAL ERROR No Stim Board Critical Error

Error detecting Stim Board on Powerup

1. Replace appropriate Stim Board 2. Replace Control Board

302

CRITICAL ERROR No Ultrasound Board Critical Error

Error detecting Ultrasound Board on Powerup

1. Replace Ultrasound Board 2. Replace Control Board

303

CRITICAL ERROR EEPROM Critical Error

Error reading EEPROM on Powerup.

Replace Control Board

304 305 306 307 308 309

CRITICAL ERROR CRITICAL ERROR CRITICAL ERROR CRITICAL ERROR CRITICAL ERROR CRITICAL ERROR

Ultrasound Board Critical Error Ultrasound Board Write Critical Error Ultrasound Board Read_Write Critical Error Ultrasound Board Reset Critical Error Ultrasound Board Read Critical Error Ultrasound Board Calibration Critical Error

Error communicating with the Ultrasound Board Error communicating with the Ultrasound Board Error communicating with the Ultrasound Board Ultrasound Board Reset Error Error communicating with the Ultrasound Board Error calibrating Ultrasound Board

1. Replace Ultrasound Board 2. Replace Control Board

310 311 312 313 314 315 316

CRITICAL ERROR CRITICAL ERROR CRITICAL ERROR CRITICAL ERROR CRITICAL ERROR CRITICAL ERROR CRITICAL ERROR

Stim Board Write Critical Error Stim Board Bad Data Read Critical Error Stim Board Main UP Reset Critical Error Stim Board Channel 1 UP Reset Critical Error Stim Board Channel 2 UP Reset Critical Error Stim Board Reset Critical Error Stim Powerup Test Failed Critical Error

CRITICAL ERRORS (300-314) DEMANDING TECHNICAL SERVICE Error communicating with Stim Board Error communicating with Stim Board Error communicating with Stim Board Error communicating with Stim Board Error communicating with Stim Board Stim Board Reset Error Stim Board failed its Self Test on Powerup

15

1. Replace appropriate Stim Board 2. Replace Control Board

5- TROUBLESHOOTING

Intelect Transport® Combo Therapy System

5.2 INTELECT TRANSPORT COMBO THERAPY SYSTEM TESTING

A. General 1. The following information is intended to aid in troubleshooting the major components of the Intelect Transport Combo Therapy System to “Board Level” only. These tests are FACTORY standard testing procedures and methods used at the factory before shipment of any Intelect Therapy System. 2. Due to the complex nature of the technology utilized by DJO, LLC, the recommended troubleshooting techniques are to determine “Bad Board” and board replacement only. No board component level troubleshooting is recommended, nor will information or parts be supplied by DJO, LLC. Any board component level troubleshooting performed will be at sole risk and liability of the Service Technician performing such troubleshooting techniques. 3. Once a particular PC Board has been determined as bad, refer to the appropriate Removal and Replacement Section of this Manual for proper replacement. B. Special Tools, Fixtures, & Materials Required 1. Certain tests require the use of special tools and fixtures. These will be listed at the particular test where they are required. Testing with any other special tool or fixture other than those stated could give erroneous readings or test results. Always perform the tests exactly as stated to ensure accurate results. 2. Scope and other standard test equipment settings will be listed for each test performed to aid in performing the test to FACTORY standards and ensure proper readings. 3. The troubleshooting and repair of the Intelect Transport Therapy Systems and Accessories should be performed only by authorized technicians trained and certified by DJO, LLC. C. Equipment Required • Oscilloscope and Probes • ESTI-2 Load Test Fixture • Digital Multi meter • Intelect Transport Applicators (Accessories) • Dielectric Withstand (Hi-Pot) and ground resistance tester NOTE: Adjust Dielectric Withstand tester to indicate fault with 120 k Ohm Load across the output when at specified test voltage. • Milliohm Meter

• 10k Resistor • Ohmic Instruments UPM DT 10 or DT 100 Ultrasound Power Meter • Dissolved Oxygen Test Kit used to test oxygen level of Degassed Water • # 1 Phillips Screwdriver • # 2 Phillips Screwdriver • Insulated Needle Nose Pliers • 1/4" Nut driver or Wrench • Degassed Water (<5 ppm) for Ultrasound Power Meter Recipe(s) for Degassed Water 1) Boil Distilled Water for 30 Minutes. Place water in a canning jar, and cover. Allow to cool to room temperature of approximately 70 °F (21 °C). May be refrigerated to aid cooling time. or 2) Bring Distilled Water to a boil. Place the container under vacuum for 5 to 10 Minutes. NOTE: Canning jars are ideal storage and transport containers for Degassed Water. In order to minimize aeration of Degassed Water during transport, fill to a positive meniscus and slide the lid over the surface. Seal tightly. When pouring Degassed Water into and out of containers pour slowly down the side of the container to minimize aeration. Do not use Tap Water or Distilled Water in the Ultrasound Power Meter. Use only Degassed Water in order to obtain correct test results. The chart below illustrates the oxygen content of Degassed, Tap, and Distilled Water. WATER TYPE ppm of OXYGEN Degassed Less than 5 ppm (per Recipe 1 or 2) Tap Water Up to 35 ppm Distilled Water Up to 20 ppm D. Full Functional Tests Perform the tests found in this section to verify Full Functionality of new Therapy System and accessories.

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5- TROUBLESHOOTING

Intelect Transport® Combo Therapy System

5.3 ELECTRICAL SAFETY

Listed by Intertek Testing Services NA Inc.

The Intelect Transport Combo System has been tested to UL 60601-1, Standard for Safety for Medical Equipment.

Conforms to UL Standard 60601-1 Certified to CAN/CSA Standard C22.2 No. 601.1-M90 w/A2

NOTE: This device complies with current leakage, ground continuity, and dielectric withstand (Hi-Pot) limits as prescribed by IEC/EN/UL 60601-1 and CSA/CAN 601.1 Medical Electrical, Part 1: General Requirements for Safety. Facility, local and national limits and test methods may vary. A. Power Requirements

Model: 2738... Input : 100-240V 100 VA, 50/60 Hz 5.4 LEAKAGE TESTS

Conduct all necessary leakage tests as required per NFPA 99 (National Fire Protection Association) “Health Care Facility” standards.

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

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5- TROUBLESHOOTING

Intelect Transport® Combo Therapy System

5.5 VISUAL INSPECTION

General Visually inspect the Intelect Transport Therapy System. A visual inspection can, to an experienced technician, indicate possible abuse of the unit and internal problems.

5.6 UNIT STARTUP AND FAN TESTING

A. Test 1. Place unit face up on work surface. 2. Connect power cord to unit and plug into proper power receptacle. 3. Turn system on. Press the Enter button. IFC should be highlighted. Press the Enter button. 4. Place hand at the back of system, at Contrast Control, to verify fan is blowing out. See Figure 5.1. B. Test Results 1. Unit will not start, unit failed test. a) Possible bad Main Power Switch. b) Possible bad Power Supply. c) Possible bad power outlet or Mains Power Cord. 2. Screen does not display, unit failed test. a) Contrast Control needs adjusting. b) Possible bad display. c) Possible bad Control Board. d) Possible bad Power Supply. e) Visually check power LED. LED should illuminate Blue. Turn system off with Power button. Power LED should flash Blue. If Power LED illuminates Blue with system On and flashes Blue with system Off, the Power Supply is good. Replace Control Board. 3. Fan not blowing outward, Unit failed test a) Fan blowing inward. Fan wired wrong. Rewire or replace Fan. b) Fan not blowing. 1) Possible bad Fan. 2) Possible bad Power Supply. 3) Possible bad Control Board.

FIGURE 5.1

18