OptiFlex 3 Model 2090 Service Manual

TABLE OF CONTENTS

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

FOREWORD... 1 1 THEORY OF OPERATION... 2 2 SAFETY PRECAUTIONS... 35 3 NOMENCLATURE... 67 4 SPECIFICATIONS... 89 4.1 OPTIFLEX3 CPM THERAPY UNIT SPECIFICATIONS... 8 4.2 DESCRIPTION OF DEVICE MARKINGS... 9 4.3 ADDITIONAL DEVICE MARKINGS... 9 5 TROUBLESHOOTING...1015 5.1 OPTIFLEX3 SOFTWARE ERROR MESSAGES...10 5.2 OPTIFLEX3 SYSTEM TESTING...11 5.3 VISUAL INSPECTION...12 5.4 FUNCTIONAL INSPECTION...12 5.5 ELECTRICAL SAFETY...12 5.6 ELECTRICAL SAFETY TESTS...12 5.7 FLEXION ANGLE AND CALIBRATION TEST...13 5.8 TRAVEL SPEED TEST...15 5.9 EMERGENCY START/STOP FUNCTION TEST...15 5.10 PENDANT DISCONNECT TEST...15 6 REMOVAL & REPLACEMENT...1631 6.1 UNIT COVERS...16 6.2 MANUAL MOVEMENT OF THE CARRIAGE...17 6.3 MOTOR CONTROL BOARD...18 6.4 DRIVE BELT...19 6.5 MOTOR ASSEMBLY...20 6.6 POWER SUPPLY...21 6.7 POTENTIOMETER KNEEPOT...22 6.8 ACME SCREW BALL SCREW...24 6.9 PENDANT RECEPTACLE CABLE...26 6.10 PENDANT CABLE...27 6.11 PENDANT CONTROL BOARD...28 6.12 PENDANT BATTERY...29 6.13 UPPER AND LOWER PENDANT KEYMATS...30 6.14 PENDANT DISPLAY...31 7 CALIBRATION...3234 7.1 ANGLE POTENTIOMETER POSITION CALIBRATION...32 7.2 FORCE REVERSAL CALIBRATION...34 8MAINTENANCE...3537 9 PARTS...3840 10 SCHEMATICS...4144 11 WARRANTY...45

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

FOREWORD

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 Chattanooga Group, to perform field service on the OptiFlex3 CPM Therapy Unit. The specifications put forth in this manual were in effect at the time of the publication. However, owing to Chattanooga Group’s policy of continuous improvement, changes to these specifications may be made at any time without obligation on the part of Chattanooga Group. Chattanooga Group requires all Field Technicians stay informed and trained on all changes pertaining to the OptiFlex3 CPM Therapy Unit. As significant changes occur to the OptiFlex3 CPM Therapy Unit, service bulletins may be made available on our web site (chattgroup.com) in lieu of reprinted manuals. Technicians repairing the OptiFlex3 CPM Therapy Unit agrees to assume all risk and liability associated with this process. 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.

©2008 Encore Medical, L.P. and its affiliates, Austin, Texas, USA. Any use of editorial, pictorial, or layout composition of this publication without express written consent from Chattanooga Group of Encore Medical, L.P. is strictly prohibited. This publication was written, illustrated, and prepared for print by Chattanooga Group of Encore Medical, L.P.

1

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

1 THEORY OF OPERATION

1.1 OVERVIEW The OptiFlex3 CPM product is comprised of one Universal Power Supply and one Motor Control Board housed within the head section of the unit along with the Motor and Gearbox Assembly. These components are linked to a Pendant via a cable connection that provides the operator access for set up and operation of the unit. The basic components of the OptiFlex3 CPM units are Frame Base, Motor and Gearbox Assembly, Universal Power Supply, Motor Control PC Board, Adjustable Foot Plate, Adjustable Femur Bar and User Interface (Pendant). The unit is designed for patient use only with the Patient Softgoods Kit (Part Number 20533). This single patient use softgoods kit is designed specifically for the OptiFlex3 CPM unit and provides proper installation and support to the patient during therapy. If necessary, two units may be used simultaneously for patients that have been prescribed dual therapy by a licensed professional. If two units are prescribed for use simultaneously, use with the optional bed mount (Part Number 89900) to secure the units in position during therapy.

2

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

2 SAFETY PRECAUTIONS 2.1 PRECAUTIONARY DEFINITIONS The precautionary instructions found in this section and throughout this manual are indicated by specific symbols. Understand these symbols and their definitions before operating this equipment. The definition of these symbols are as follows:

E. Biohazard

Text with a “BIOHAZARD" indicator will explain possible safety infractions that could cause biohazardous conditions if the material is not properly handled and disposed of.

A. Caution

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

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

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 technician of possible hazards resulting in the electrical charge disbursement from certain components if handled or serviced improperly.

3

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

2 SAFETY PRECAUTIONS 2.2 PRECAUTIONARY INSTRUCTIONS

• Read, understand and practice the precautionary and

• The lubricants and locking compounds listed in

operating instructions found in this manual before operating or using the unit. Know the limitations and hazards associated with using the OptiFlex3 Continuous Passive Motion (CPM) Therapy Unit. Observe any and all precautionary and operational decals placed on the unit. • Only use OptiFlex3 on firm, flat, level surfaces. • Extreme caution should be taken when in use with or around children. • Use OptiFlex3 only for its intended purpose as described in this manual. • Turn power switch off before unplugging unit from its power source. • Do not use the cord to unplug the power cord from the unit. Grasp at the power cord base. • Transport and store the OptiFlex3 in temperatures between 0° and 140 °F (-18° to 60 °C) to prevent damage to the unit or its components. • Use extra care when touching metal of OptiFlex3 after exposure to cold or heat to prevent static shock to persons and or the unit. • Condensation could result and damage OptiFlex3 if unit is subjected to periods of low temperatures followed by periods of high temperatures. • Use care when carrying, transporting or storing the OptiFlex3 unit to prevent damage to the unit from dropping or improper transport and storage methods. • Keep hair, loose clothing, fingers and all parts of the body except the limb being treated, away from moving parts of the OptiFlex3. • Unplug the Power Cord when not in use. • Do not use Power Cords that are damaged or frayed. • OptiFlex3 is made from high impact materials. However, structural failure or hidden damage can be caused by shock, impact, or dropping the unit. Use care when transporting and storing unit to avoid equipment damage. • To isolate the unit from the power source, disconnect the power cord at the wall outlet. • Rapid increases in ROM can cause complications. • Tool, lubrication, and locking compound requirements are critical to component removal and replacement of the OptiFlex3. • All hardware, bolts, nuts, and screws used to assemble the OptiFlex3 are SAE Standard. Due to the size of these components, no metric equivalent is available. Therefore, it will be necessary to obtain the proper size tools for removal and replacement of certain components.

this manual are crucial in the assembly of certain components to ensure patient safety and efficient operation of the unit. Use only the recommended products listed or an approved equivalent possessing the same properties and qualities.

• Federal law restricts this device to sale by, or on the order of, a physician or licensed practitioner.

• Make certain that the unit is electrically grounded by connecting only to a grounded electrical service receptacle conforming to the applicable national and local electrical codes. • Keep hair, loose clothing, loose bedding, fingers and toes away from the hinge components of the unit. • Do not use the OptiFlex3 outdoors or on wet surfaces. Use only on firm, flat, stable level surfaces to ensure stability of the unit while in operation. • Materials of the unit may become flammable or combustible if exposed to a source of ignition. • Heat generated within the pendant may cause ignition of the pendant if wrapped in bedding or other materials. • Do not use OptiFlex3 while smoking or around open flame. • OptiFlex3 has been designed for protection against the exposure of urinary incontinence. Precautionary measures should still be taken when any type of liquid comes in contact with an electrical apparatus. • Always turn off and unplug unit from electrical source before servicing or cleaning. Failure to do so could result in electrical shock or personal injury. • Handle the unit only when unit is dry and hands are dry to prevent electrical shock. • Do not use the OptiFlex3 as a toy. • A unit failing dielectric withstand and/or leakage tests could indicate serious internal system problems. Do not place unit back into service. Contact the factory for repair. Do not attempt to repair the unit in the field. • Unplug the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock.

4

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

2 SAFETY PRECAUTIONS 2.2 PRECAUTIONARY INSTRUCTIONS (CONTINUED)

• 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 Chattanooga Group dealer if the unit is not properly rated. • Power Supplies retain High Voltage!

• Failure to re-install and properly tighten all screws may result in Electrical Safety System degradation which may cause unit damage, malfunction, electrical shock or personal injury.

• Materials that have been in contact with bodily fluids must be handled and disposed of in accordance with National, Local, and Facility disposal rules, regulations, and procedures. • Exercise caution when using accessories and auxiliary devices such as muscle stimulators, cold packs and other modalities. Route lead wires, hoses, tubes, etc. away from the working mechanism of the OptiFlex3 to help prevent damage to the OptiFlex3 and any other modality used with it. • Unconscious patients or patients under heavy influence of medication must be constantly attended and monitored while the OptiFlex3 is in use. • The OptiFlex3 must be completely visible at all times during use. Never cover the unit with bedding or any other means of concealment while in operation. • If the OptiFlex3 is used in conjunction with the optional OptiFlex “T” Trolley, make certain the OptiFlex3 unit is resting on the mattress of the bed and the OptiFlex “T” is suspended with no weight on the casters to prevent possible movement of the unit and possible injury to patient. • This unit must not be operated with any adapter attached to the three prong plug that would disable the earth connection. Disruption of the earth connection may cause unit damage, malfunction, electrical shock, fire, or personal injury.

5

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

3 NOMENCLATURE 3.1 OPTIFLEX3 The nomenclature graphic below, Figure 3.1, indicates the general locations of the major components of the OptiFlex3 CPM unit.

Know the components and their functions before performing any operation of or service to the OptiFlex3 CPM unit.

14

13

15

1

12

2 16 3 4

11

10

9

8

7 6 17

FIGURE 3.1

1. 2. 3. 4. 5. 6. 7. 8. 9.

Adjustable Foot Plate Foot Rest Pivot Adjustment Tibial Adjustment Knob Angle Potentiometer (Knee Pot) Femur Bar Adjustment Scale Femur Bar Adjustment Knob Frame Base Pendant (User Interface)- Refer to Page 7 Carrying and Storage Handle

10. Rear Access Cover 11. On/Off Switch 12. Mains Power Cord 13. Universal Power Supply 14. Motor and Gearbox Assembly 15. Motor Control Board 16. Pendant Receptacle Cable 17. Front Access Cover

6

5

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

3 NOMENCLATURE 3.2 OPTIFLEX3 PENDANT The Pendant nomenclature graphic below, Figure 3.2, indicates the location and functions of the OptiFlex3 CPM Pendant (user interface).

Know the components and their functions before performing any operation of or service to the OptiFlex3 CPM unit.

14 13 1

2

3

4

12

5

11

10

6

9

7

8

FIGURE 3.2

1.

2.

3. 4.

5. 6. 7.

OSCILLATION ZONE™ Carriage will oscillate three times between the flexion angle and 10° less than the flexion angle. PROGRESSIVE *ROM™ Unit will automatically increase the programmed flexion angle by 1° every hour up to a maximum of 5° per day. USER INTERFACE SCREEN Displays settings and status of therapy session. RESET Clear previous treatment settings and completed cycles. UP ARROW Allows user to increase treatment parameters. DOWN ARROW Allows user to decrease treatment parameters. COMFORT ZONE™ Temporarily decreases the flexion ROM* when discomfort is experienced.

EMERGENCY START/STOP Start or stop treatment. EXTENSION/FLEXION DELAY 9. Allows user to program carriage to stop at both the extension and flexion angle for the time programmed. 10. SPEED Displays the speed of operation. 11. FLEXION Displays the flexion angle. 12. EXTENSION Displays the extension angle. 13. MODE Used with Fast Back, Oscillation Zone, and Progressive ROM*. 14. FAST BACK™ Carriage will slow down within 15° of the flexion angle. * ROM= Range of Motion 8.

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OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

4 SPECIFICATIONS 4.1 OPTIFLEX3 CPM THERAPY UNIT SPECIFICATIONS

FIGURE 4.1 Input . .. .. .. .. .. .. .. .. .. .. .. .. .. 100-240 VAC, 50/60 Hz, 75 VA Weight .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .27 pounds (12 kg) Length .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 37" (94 cm) Electrical Class .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..Class I Electrical Type .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .Type B Mode of Operation .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .Continuous OPERATION Flexion .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .120° Maximum Extension . .. .. .. .. .. .. .. .. .. -10° Maximum Hyper Extension Speed .. .. .. .. .. .. .. .. .. .. 30° per minute to 150° per minute Maximum Patient Weight. .. .. .. .. .. . 350 pounds (159 kg) Lower Leg Length Range.. .. .. .. 10-23.5" (25.4- -59.7 cm) (Center of knee to sole of heel) Thigh Length Range .. .. .. .. .. .. .. .. .. 12-19" (30.5-48.3 cm) (Hip joint to center of knee)

REGULATORY COMPLIANCE UL 60601-1 CAN/CSA C22.2 No. 601.1-M90 w/A2 IEC/EN 60601-1, 60601-1-2 Meets MDD 93/42/EEC, CE 0413

TRANSPORTATION AND STORAGE REQUIREMENTS Unit should be transported and stored under the following conditions: Temperature .. .. .. .. .. .. .. .. .0° F to 140° F (-18° C to 60° C) Humidity .. .. .. .. .. .. .. .. .. .. .. ..0% to 75% Relative Humidity

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OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

4 SPECIFICATIONS

4.2 DESCRIPTION OF DEVICE MARKINGS The markings on the OptiFlex3 CPM unit are your assurance of its conformity to the highest applicable standards of medical equipment safety and electromagnetic compatibility. One or more of the following markings may appear on the device: This product complies with WEEE Meets Directive 93 /42 /EEC Directive 2002/96/EG (waste electrical IEC/UL/EN 60601-1, 60601-1-2 and electronic equipment). Separate collection for electrical and electronic equipment.

Listed by Intertek Testing Services NA Inc. Conforms to UL Standard 60601-1 9700675

Certified to CAN/CSA Standard C22.2 No. 601.1-M90 w/A2

Refer to Instruction Manual/Booklet

Type B Equipment

Protected Earth 4.3 ADDITIONAL DEVICE MARKINGS

Emergency Stop

Standby Power ON

Standby Power OFF

Start 9

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

5 TROUBLESHOOTING 5.1 OPTIFLEX3 SOFTWARE ERROR MESSAGES A. The information provided below is intended to aid in troubleshooting Software Error Messages of the OptiFlex3 units to “Board Level” only. No component level troubleshooting information is or will be provided by Chattanooga Group for field troubleshooting of board components. ERROR

ERROR DEFINITION

B. Once a particular PCB has been determined as bad, replace the suspected board.

PROBABLE CAUSE

POSSIBLE REMEDY

1&2

Pendant isn't communicating correctly with unit.

Defective Cable, Pendant, or Motor Control Board.

Replace the Cable, Pendant, or Motor Control Board.

3

Error reading the EEPROM on the Motor PCB.

Defective Cable, Pendant, or Motor Control Board.

Replace the Cable, Pendant, or Motor Control Board.

5

RTC battery voltage is too low indicating bad battery.

Pendant Battery voltage is low.

Replace Battery or Pendant.

6

A general error on the Motor PCB has occurred.

Motor Control Board Failure.

Replace the Motor Control Board.

7

The Angle Potentiometer sensor is Carriage angle below -10° out of range. limit.

Loosen the Femur Adjustment Knobs. Raise the carriage to above zero and tighten the Femur Adjustment Knobs. Turn the unit off and back on with the power switch.

8

The Angle Potentiometer is not changing when the carriage is supposed to be moving.

Femur Knobs loose.

Remove the obstruction. Tighten the Angle Potentiometer Screw and Calibrate unit. Tighten Fermur Knobs

Carriage obstruction or the Angle Pot Screw is loose.

9

The Motor Tachometer does not match expected value.

Motor Control Board Failure.

Replace the Motor Control Board.

10

The Motor PCB has not communicated with the pendant in a reasonable amount of time.

Motor Control Board Failure.

Replace the Motor Control Board.

11

The Motor PCB was reset via the watchdog.

Motor Control Board Failure.

Replace the Motor Control Board.

Unit needs to be calibrated.

Various

Calibrate unit. Refer to pages 32-34 for calibration procedures.

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OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

5 TROUBLESHOOTING 5.2 OPTIFLEX3 SYSTEM TESTING A. General 1. The following information is intended to aid in troubleshooting the major components of the OptiFlex3 units to “Board Level” only. These tests are OEM standard testing procedures and methods used at the factory before shipment of any OptiFlex3 unit. 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. 3. Once a particular PC Board has been determined to be bad, replace the board only with Chattanooga Group OEM replacement parts and hardware. B. Special Tools, Fixtures, and 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. Standard test equipment settings will be listed for each test performed to aid in performing the test to OEM standards and to ensure proper readings. 3. The troubleshooting and repair of the OptiFlex3 units should be performed only by authorized technicians trained and certified by Chattanooga Group. C. Equipment Required 1. Digital Multimeter 2. Fine Edged Tool for removing decals 3. Tape Measure or Ruler

The following tool, lubrication, and locking compound requirements are critical to component removal and replacement of the OptiFlex3. All hardware, bolts, nuts, and screws used to assemble the OptiFlex3 are SAE Standard. Due to the size of these components, no metric equivalent is available. Therefore, it will be necessary to obtain the proper size tools for removal and replacement of certain components. The lubricants and locking compounds listed in this manual are crucial in the assembly of certain components to ensure patient safety and efficient operation of the unit. Use only the recommended products listed or an approved equivalent possessing the same properties and qualities. 4. Required SAE Tools • #1 Phillips Screwdriver • #2 Phillips Screwdriver • Preset and calibrated, 5 inch pound “T”-Handle Torque Wrench with 1/4” square drive and 5/64” straight hex key socket • Preset and calibrated, 10 inch pound “T”Handle Torque Wrench with 1/4” square drive and 9/64” straight hex key socket • 5/16” Socket Driver • 3/32” Allen Wrench • 9/64" Allen Wrench • 5/64" Allen Wrench • Heyco Tool # 29 • Miniature Diagonal Cutters • 11/32" Open End Wrench • Gear Puller • Needle Nose Pliers • Small Flatehead Screwdriver • Snap Ring Pliers • Large Flathead Screwdriver • Adjustable Pliers • Soldering Iron 5. Required Lubricants • MolyGraph Grease (Black) by Sta-Lube 6. Required Locking Compound and Primer • Type N Primer by Loctite • Loctite 222 (Purple) 7. Inclinometer, Protractor, or Goniometer accurate to 1° 8. Certified, calibrated Stop Watch NOTE: The tool, lubricant, and locking compound requirements will be listed at their respective removal and replacement procedures throughout this manual. 11

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

5 TROUBLESHOOTING

5.6 ELECTRICAL SAFETY TESTS Conduct all necessary Electrical Safety tests as required per your facility, local or national regulatory agency. In the USA follow NFPA 99 (National Fire Protection Association) "Health care Facility" standards. NOTE: Use the rivet shown in Figure 5.1 as a connection point for Grounding Tests.

5.3 VISUAL INSPECTION A. General Visually inspect the OptiFlex3 for and visible damage to the unit or pendant that may interfere with operation of the unit. Make sure that all screws are secure. Verify that the appropriate hook or loop fastener is secured to the carriage. Check for proper labeling. Make sure that the Femur adjustment decals are in good condition. Verify that the serial decal for the unit is present. Verify that the LCD lens is in good condition and clean if necessary. Verify that the domed heads of the femur hinge rivets are in good condition. Make sure that the hinges are secure, by attempting to pull them apart. 5.4 FUNCTIONAL INSPECTION Check the calibration of the unit by running it successively through its full ROM with femur length adjusted first to maximum and then to its minimum length. NOTE: Verify that the lead screw is unobstructed and no abnormal noises are present during operation. Disconnect the pendant while the unit is running to verify that the unit will stop. Perform the Speed test found on page 15. Clears all settings by activating the Reset.

Rivet

FIGURE 5.1

A unit failing dielectric withstand and/or leakage tests could indicate serious internal system problems. Do not place unit back into service. Contact the factory for repair. Do not attempt to repair the unit in the field.

5.5 ELECTRICAL SAFETY The OptiFlex3 has been tested to UL 60601-1, Standard for Safety for Medical Equipment. NOTE: The device complies with current leakage, ground continuity, and dielectric withstand (Hi-Pot) limits as prescribed by IEC/EN/UL 60601-1 and C22.2 No. 601.1-M90 w/A2 Medical Electrical, Part 1: General Requirements for Safety.

This unit must not be operated with any adapter attached to the three prong plug that would disable the earth connection. Disruption of the earth connection may cause unit damage, malfunction, electrical shock, fire, or personal injury.

Facility, local and national limits and test methods may vary. A. Power Requirements Model: 2090 ...Input: 100-240 VAC 50/60 HZ, 75 VA

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OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

5 TROUBLESHOOTING 5.7 FLEXION ANGLE & CALIBRATION TEST Specification...90° ± 3° A. Equipment Required Inclinometer, Protractor, or Goniometer accurate to 1°. B. Test 1. Place unit on level work surface. 2. Plug Power Cord into grounded wall outlet with appropriate voltage. See Specifications on page 8. 3. Connect Pendant to unit and turn unit power ON. 4. Press and hold the Extension button. While holding the Extension button down, press the Down Arrow button until 0 is displayed on the Pendant. Refer to Figure 5.2.

EXTENSION BUTTON DOWN ARROW BUTTON

FIGURE 5.2

5. Press and hold the Time and Extension buttons. While holding the Time and Extension buttons, press the Up or Down Arrow button until 5 Sec is displayed on the Pendant. Refer to Figure 5.3.

EXTENSION BUTTON

UP ARROW BUTTON

TIME BUTTON

DOWN ARROW BUTTON

FIGURE 5.3 6. Press and hold the Time and Flexion buttons. While holding the Time and Flexion buttons, press the Up or Down Arrow button until 5 Sec is displayed on the Pendant. Refer to Figure 5.4.

FLEXION BUTTON

UP ARROW BUTTON

TIME BUTTON

DOWN ARROW BUTTON

FIGURE 5.4

13

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

5 TROUBLESHOOTING 7. Press and hold the Flexion button. While holding the Flexion button down, press the Up Arrow button until 90° is displayed on the Pendant. Refer to Figure 5.5.

UP ARROW BUTTON FLEXION BUTTON

FIGURE 5.5 8. Press and hold the Speed button. While holding the Speed button down, press the Up or Down Arrow button until 90° /Min is displayed on the Pendant. Refer to Figure 5.6. 9. While continuing to hold the Speed Button, press the Emergency Start/Stop button on the Pendant. When movement of the unit stops, press the Emergency Start/Stop button. Verify the display reads 90° /Min.

UP ARROW BUTTON SPEED BUTTON DOWN ARROW BUTTON

FIGURE 5.6

10. Using the Inclinometer or Protractor, measure the angle of the flexion of the unit. Refer to Figure 5.7. NOTE: In Figure 5.7, a Digital Inclinometer is used to measure each side and the two numbers are added together. If angle is out of specified range, perform 7.1 Angle Potentiometer Position Calibration.

FIGURE 5.7

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OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

5 TROUBLESHOOTING 5.8 TRAVEL SPEED TEST Spec... 0° to 90° in 60 Sec ±10% of seconds A. Equipment Required Calibrated stop watch B. Test 1. Set unit up as described in the “Flexion Angle Test." 2. Adjust the Femur Bar length to 34 and tighten. 3. Move to 0° by pressing the Emergency Start/Stop button. When motion stops and Display reads 0°, press the Emergency Start/ Stop button to stop the unit. Then, simultaneously press the Emergency Start/ Stop button and the stop watch start button. The unit should move from 0° to 90° within the specification listed above. 4. Repeat three times. Calculate and Record the average. 5. If unit fails test, troubleshoot the following components and replace if necessary: a. Check Pendant Cable connector to Motor Control Board b. Motor Control Board c. Pendant d. Motor Assembly e. Drive Belt f. Pulleys 5.9 EMERGENCY START/STOP FUNCTION TEST Spec...Unit start or stop upon pushing button A. Equipment Required OptiFlex3 with Pendant B. Test 1. Place unit on a level work surface. 2. Plug unit power cord into grounded wall outlet with appropriate voltage. See Specifications on page 8. 3. Connect Pendant to unit and turn unit power ON. 4. Press the Emergency Start/Stop button to start and stop the unit. Repeat several times. 5. If unit fails test, troubleshoot the following components and replace if necessary: a. Pendant Cable connector to Motor Control Board. b. Motor Control Board. c. Pendant.

5.10 PENDANT DISCONNECT TEST Spec...Unit stops immediately upon Pendant disconnect A. Equipment Required OptiFlex3 with Pendant B. Test 1. Place unit on a level work surface. 2. Plug unit power cord into grounded wall outlet with appropriate voltage. See Specifications on page 8. 3. Connect Pendant to unit and turn unit power ON. 4. Press the Emergency Start/Stop button to start the unit. 5. Disconnect the Pendant from the unit while moving. Unit should stop. 6. If unit fails test, troubleshoot the following components and replace if necessary: a. Pendant Cable connector to Motor Control Board b. Motor Control Board c. Pendant

15

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

6 REMOVAL & REPLACEMENT 6.1 UNIT COVERS

2. Lift up and rotate the Rear Acess Cover toward the Carrying Handle of the unit. Slide the cover over the Carrying Handle to completely remove from the unit.

Unplug the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock.

3. To install the Rear AcessCover, reverse the above steps.

A. Part Number Push Rivet (Male & Female Components). . J6004 Rear Cover... J6089 Front Access Cover... J6103 B. Tools and Equipment Required • Miniature Diagonal Cutters C. Rear Cover Removal and Replacement NOTE: Miniature Diagonal Cutter are used only to remove the Rivets. They are not intended to cut the Rivets. Only apply enough pressure to grasp the Rivet. They will be used to re-install the Cover. NOTE: If Carriage is close to full extension, there may not be sufficient clearance to remove the Cover. For inoperable units, refer to Section 6.2 Manual Movement of the Carriage for carriage adjustment.

D. Front Access Cover Removal and Replacement NOTE: Miniature Diagonal Cutter are used only to remove the Rivets. They are not intended to cut the Rivets. Only apply enough pressure to grasp the Rivet. They will be used to re-install the Cover. NOTE: If Carriage is close to full extension, there may not be sufficient clearance to remove the Cover. For inoperable units, refer to Section 6.2 Manual Movement of the Carriage for carriage adjustment. 1. Using a pair of miniature diagonal cutters remove the 8 Rivets securing the Rear or Motor Cover. Grasp the Rivets from behind and gently pry the Rivets up to release. This will release both the male and female parts of the Rivet. 2. Lift to remove. 3. Reverse above steps to install.

1. Using a pair of miniature diagonal cutters remove the 11 Rivets securing the Rear or Motor Cover. Grasp the Rivets from behind and gently pry the Rivets up to release. This will release both the male and female parts of the Rivet. Refer to Figure 6.1.

FIGURE 6.1

16

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

6 REMOVAL & REPLACEMENT 6.2 MANUAL MOVEMENT OF THE CARRIAGE

Unplug the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock. When the unit fails electronically the carriage can be moved manually. A. Part Number...None B. Tools and Equipment Required NOTE: Refer to Section B of each sections referenced below for additional tools needed. C. Manual Carriage Adjustment 1. Refer to Section 6.1, part C, Rear Cover Removal and Replacement to remove the rivets from the Rear Cover of the unit. 2. Lift the bottom of the Rear Cover just enough to be able to manipulate the Pulley. Rotate the Pulley, moving the Carriage until the Cover can be completely removed.

17

OptiFlex® 3 Continuous Passive Motion (CPM) Therapy Unit

6 REMOVAL & REPLACEMENT 6.3 MOTOR CONTROL BOARD

3. Using the #2 Phillips Screwdriver, remove the two mounting screws securing the Motor Control Board to the Base. Refer to Figure 6.3.

Unplug the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock. A. Part Number ...J6088 B. Tools and Equipment Required • #2 Phillips Screwdriver NOTE: Refer to Section B of each sections referenced below for additional tools needed. C. Control Removal & Replacement 1. Refer to Section 6.1, part C, Rear Cover Removal and Replacement to remove the rear cover of the unit. 2. Disconnect the four wiring harnesses from the Control Board. Refer to Figure 6.2.

MOUNTING SCREWS

FIGURE 6.3

4. Replace in reverse order. NOTE: When connecting harnesses, each harness will connect only to their respective locations on the board. 5. After Motor Control Board replacement perform the following in the order listed: 7.1 Angle Potentiometer Position Calibration

WIRING HARNESSES

5.7 Flexion Angle and Calibration Test 7.2 Force Reversal Calibration 5.4 Functional Inspection

Failure to re-install and properly tighten all screws may result in Electrical Safety System degradation which may cause unit damage, malfunction, electrical shock or personal injury.

FIGURE 6.2

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