Chattanooga 2090 - CPM Sales & Service
Contents
1. 12004 Tools Equipment Required SCREW SECURING BASE e 5 64 Allen wrench mm Using a 2 Phillips screwdriver remove the screw on each side of the Frame Base to release the Base Refer to Figure 6 13 aza e 2 Phillips screwdriver Gear Puller Snap Ring Pliers 5 16 Nut Driver e Large Flathead Screwdriver C Acme Rod Removal amp Replacement 1 Refer to Section 6 1 parts C and D Rear FIGURE 6 13 Cover and Front Cover Removal and Replacement to remove the Covers of the unit 7 Using a 5 16 nut driver remove the 4 2 Refer to Section 6 4 part C Drive Belt nuts and washers securing the Base Removal and Replacement to remove the Plate at the end of the Frame Base Refer to Drive Belt Figure 6 14 3 Using a 5 64 Allen wrench remove the set screw from the Pulley attached to the Ball cipi i c SCREWDRIVER BEHIND Sew THIS PLATE NOTE Retain all rivets nuts washers bearing and 4 screws for installation of the Ball Screw the Ball Screw NOTE Using a gear puller will decrease the possibility of damage to the Pulley C N NUTS SECURING 4 Use a gear puller to remove the Pulley from BASE PLATE S FIGURE 6 14 5 Remove the 2 washers and the bearing 8 Using a large Flathead screwdriver gently from the end of the Ball Screw Refer to pry the plate off of the Ball Screw Refer to Figure 6 12 Figure 6 14 N2. J6086 B Tools and Equipment Required 1 Phillips Screwdriver C Pendant Cable Removal amp Replacement j 23 RUBBER 1 Disconnect the Pendant Cable from the Pendant Cable Receptacle by turning the n Pendant Cable connector counterclockwise Continue to unscrew to release 2 Turn the Pendant face down Using a 1 Phillips screwdriver loosen the 7 screws FIGURE 6 22 securing the back Cover of the Pendant Refer to Figure 6 21 5 Lift the Rubber Gasket and pull to release the Gasket and the Cable from the base of the Pendant 6 Replace in reverse order SCREWS FOLD BACK P THIS GASKET FIGURE 6 21 NOTE The part number for the screws securing the back of the pendant is J1120 The O ring is part number J1121 3 Fold the Rubber Gasket on the handle of the Pendant and lift the back Cover off to remove 27 6 REMOVAL amp REPLACEMNT CU 6 11 PENDANT CONTROL BOARD NOTE Carefully slide the Display Ribbon Cable through the slot in the Control Board when Unplug the unit from the power source before removing the board Handle the Ribbon attempting any removal or replacement procedures Cable gently to avoid damage to prevent electrical shock Part Number J1102 5 Lift the Control Board to remove B Tools and Equipment Required 6 Reverse for installation 1 Phillips Screwdriver C Pendant Control Board Removal amp Repl
3. Equipment Required 1 Phillips Screwdriver C Pendant Receptacle Cable Removal amp Replacement 1 Refer to Section 6 11 part C Control Board Removal and Replacement to open the Pendant remove the Cable and remove the Control Board 2 Using a 1 Phillips screwdriver remove the 4 screws securing the Pendant Display to the Upper case of the Pendant Refer to Figure 6 27 FIGURE 6 27 3 Lift the display to remove 4 Reverse for installation 31 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 7 C A E 0 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 7 1 ANGLE POTENTIOMETER POSITION CALIBRATION C Initial Position Calibration Procedure The following procedure constitutes the required 1 Enter the Calibration Mode of the Pendant calibration of the Angle Potentiometer by pressing and holding the Comfort Zone aq button A Tools Required 2 While holding down the Comfort Zone 2 Phillips Screwdriver button press the following buttons in the e Calibrated and certified Protractor with 1 Ga ise accuracy or other angle measuring device a Progressive ROM calibrated with 1 accuracy b Fast Back 444 Digital Multimeter c Oscillation Zone V 7 Small Flathead Screwdriver 3 32 Allen Wrench a Preset 5 inch pound Torque 3 Release the Comfort Zone button each Calibration Mode Move to 0 deg should be displayed at the bottom of the P
4. FIGURE 6 10 5 Using Tool squeeze the sides of the Heyco and pull out to remove Refer to Figure 6 10 6 Using a small Flathead screwdriver positioned behind the Potentiometer apply just enough pressure to free the Potentiometer Refer to Figure 6 10 NOTE On the back of the Potentiometer make certain that the Nylon Covers part number J2022 on each side of the split pin are installed Refer to Figure 6 11 SPLIT PIN WITH NYLON COVERS FIGURE 6 11 6 REMOVAL amp REPLACEMENT 6 7 POTENTIOMETER CONTINUED On the front end of the unit press the tab on the connector attaching the Potentiometer to the Control Board and detach 8 Turn the unit over and using a Heyco Tool remove the Heyco securing the Potentiometer Cable to the Base Slide the cable wire through the Base to release 9 Install the replacement Potentiometer by reversing steps 4 8 When step 8 is complete refer to section 7 1 Angle Potentiometer Position Calibration Perform the calibration Once the calibration is done complete the installation by reversing steps 1 5 23 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 6 8 ACME ROD BALL SCREW NOTE Observe the locations of the washers and bearing for installation Inset A on page 38 details proper installation Unplug the unit from the power source before 6 attempting any removal or replacement procedures to prevent electrical shock
5. 60 EN Eran EN 66 EX EN EN Ru EA Em EN Lomo EC MOTOR BRUSHLESS 1 OOTRAE SPACER NYLONFOOT 2 _ KNOB FEMALE fos WASHER 3 GEARBOX FORMED FOOT PLATE f 1 STOvEBOT __ 2_ PN FOOTROTATION 1 _ BEARING SPLTFIANGE 2 _ PENDANT OPTIFLEX3KT 1 _ PENDANT RECEPTACLE CABLE 1 wen 72 COVER FRONTTOP 1 _ 1 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 39 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 9 PARTS 9 2 OPTIFLEX3 PENDANT PARTS LIST PART NO DESCRIPTION m omwwos 0 SCREW 4 20 PLAS 3 16 PH PAN 100 101 106 1119 1120 1121 1123 1124 1 1102 40 3 Continuous Passive Motion CPM Therapy Unit OptiFlex 10 SCHEMATICS 10 1 BLOCK DIAGRAM LANDSCAPED 01011 J0 NMOS ddd O 20 gt C FH TT m 7 104 1011509 m E 1 Adds M0 110025 DU X 1 1 11002 6609 41 inuous Passive Motion CPM Therapy Uni e ont iFlex Opt 10 SCHEMATICS 10 2 CONTROL BOARD 1 LANDSCAPED Bi xO t OL oey OL val SNC K ye tH 15 10
6. A Power Requirements Model 2090 Input 100 240 VAC 50 60 HZ 75 VA 12 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 5 TROUBLESHOOTING 5 7 FLEXION ANGLE amp 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 Connect Pendant to unit and turn unit power ON 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 1 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 2 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 3 EXTENSION BUTTON EXTENSION BUTTON TIME BUTTON FLEXION BUTTON TIME BUTTON 13 DOWN ARROW BUTTON UP ARROW BUTTON DOWN ARROW BUTTON FIGURE 5 2 UptIFIEx al e ee Hse Flex Delau UP ARROW BUTTON DOWN ARROW BUTTON FIGURE 5 3 5 TROU LESHOOTI NG Opti
7. 72 J2030 DECAL POWER OFF ON 9 J6090 COVER REAR BOTTOM 4 66058 RIVET DE 1057 76 12001 PULLEY BALL SCREW Ti J2002 PULLEY MOTOR 8 J2000 DRIVE BELT 19 16048 SCREW 232 gt On 70105 WASHER 10 FLAT J6054 O RING J6040 KNEE POT CABLE NOT ILLUSTRATED ITEM PART NO DESCRIPTION 62066 SCREW 1 4 20 X 5 8 FEMUR LINKAGE J 6599 TUBE PLUG J609 DECAL THIGH SCALE J J WELDMENT TUBE 6023 SPLITPIN 1 16 X 9 16 KNOB MALE 1 4 20 On J605 SNAP RING J6005 BEARING SPLIT FLANGE LEFT FEMUR HINGE 8 898 SPLIT PIN 1 8 X 3 4 6027 RIVET FEMUR HINGE RIGHT FEMUR HINGE DECAL POT 6 SCREW 86 32 POT MOUNT COVER POT SCREW 84 40 SERVO MOUNT CLEAT TUBE POT PIN FEMUR BAR CATCH J J PIN J 9 61 62 63 64 65 1 1 1 1 1 1 J6006 WASHER 312 ID X 1 OD 10 SLEEVE CARRIAGE PIVOT 0 10 1 1 114 1 12 1 115 lie 107 105 4 J6007 SCREW 1 4 28 X 5 8 179 116 176 14 11 100 13 71 1 103 Ml CALF S A J VELCRO HOOK FOOT ROD S A SCREW 1 4 20 X 5 8 MOTOR BRUSHLESS FOOT PLATE SPACER NYLON FOOT KNOB FEMALE WASHER GEAR BOX FORMED FOOT PLATE STOVE BOLT PIN FOOT ROTATION BEARING SPLIT FLANGE PENDANT OPTIFLEX 3 KIT PENDANT RECEPTACLE CABLE WIPER COVER FRONT TOP WASHER NYLON 6 EN E __so E EN Ru EN Ea EN EN
8. apo 1001 ly de uyog 019 00 01 du X de el 3189 067 pel 9 nr 80 42 1 0 SCH EMATICS OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 10 2 CONTROL BOARD 2 LANDSCAPED V uf 10K 03 DE Brake 10K y R27 Pen avaiable Mode RE E r dv PWMI Tach 4 0 21 pf 21 pf 2 26 f NV 02 ca eo P co r c es e nQ Tx e2 T ca x a A a a Et L 14 ES 55 Be 5V R2 10K 7 c 25 ER 5 m gt P ag gt ce Ss 43 OptiFlex 3 Continuous Passive Motion CPM Therapy Uni 10 SCHEMATICS 10 2 PENDANT LANDSCAPED 9d mu t ND Ast X Ory T ef hi a TV wy apy Ww w pi Ex 1 a1 nu M 5 w w 8 m H 4 UA 9 DA SHAY 4 K _ ON 9D KK 1 0 A N K s t i ey V OT n As As rli Xx 4 0IWXzd 150 l 14 60 00000 04 80 E j Sun S
9. 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 f unit fails test troubleshoot the following components and replace if necessary a Pendant Cable connector to Motor Control Board 15 REMOVAL amp RE LACEM OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 6 1 UNIT COVERS 2 Lift up and rotate the Motor Cover toward the Carrying Handle of the unit Slide the cover over the Carrying Handle to completely Unplug the unit from the power source before remove from the unit attempting any removal or replacement procedures to prevent electrical shock 3 To install the Rear Cover reverse the above steps A Part Number Push Rivet Male amp Female Components J6004 D Front Access Cover Removal and NO J6089 Replacement FONTACCESS COVER J6103 NOTE B Tools and Equipment Required Miniature Diagonal Cutter are used only to remove the Rivets They are not intended to Miniature Diagonal Cutters cut the Rivets Only apply enough pressure to C Rear Cover Removal and Replacement grasp the Rivet They will be used to NOTE re install the Cover Miniature Diagonal Cutter are used only to NOTE remove the Rivets They are not intended to If Carriage is close to full extension there may cut
10. 3 Repeat this process on the second solder point 4 To install the Battery use a soldering iron and solder to place a small bead of solder on each of the solder points on the Control Board 5 Hold the Battery on the beads of solder placed on the Control Board 6 Use a soldering iron to heat the beads of solder securing the Battery to the Control Board 29 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 6 REMOVAL amp REPLACEMENT 6 13 UPPER AND LOWER PENDANT KEYMATS Unpluq the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock A Part Numbers Upper J6100 Lower Keymat 16101 Tools Equipment Required 1 Phillips Screwdriver C Upper and Lower Keymat Pendant Removal amp Replacement Refer to Section 6 11 part C Control Board Removal and Replacement to open the Pendant remove the Cable and remove the Control Board Lift to remove the Keymat Refer to Figure 6 26 LOWER FIGURE 6 26 3 Reverse for installation 30 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 6 REMOVAL amp REPLACEMENT 6 14 PENDANT DISPLAY Unpluq the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock 11123 Tools
11. SERVICE N MANUAL _ Model 2090 UP TA L CO N T M TS OptiFlex Continuous Passive Motion CPM Therapy Unit FOREWORD si s nun n n ke WERANE b PRSE EN K WEDA N S0 WO n ENTRE WNN HE 1 THEORY OF OPERATIODE 2 Ra ARE E P E RE dpa 2 2 SAFETY PREGAUTIONS gt ss sack o san RR br ERR TEE EP RE RE C E ne la entice CER RET A RT EP oes 3 5 3 NOMENCLATURE Wa da ba W w EOM REEF ERE REPRE CERA CHF ad xix de edm NEM 6 7 AF SPECIFICATIONS ss s se 91322 n n 63 ak aa shew eed ay ewl be der aee el k w r vaa e a ERG NEE aise Wi ek 8 9 4 1 OPTIFLEX CPM THERAPY UNIT SPECIFICATIONS oo 8 4 2 DESCRIPTION OF DEVICE MARBKINGS Sa 9 4 5 ADDITIONAL DEVICE MARKINGS udo QA NDS 9 S TROUBLESHOOTING sma ao ye yey GA RAN NGO E Der Rich vee Orco m G r E A argk a e s ne AE e dle 10 15 5 1 OPTIFLEX3 SOFTWARE ERROR MESSAGES pp 10 5 2 OPTIFLEX SYSTEM TESTING 4 1 22 2222 2424221 1 11 5 5 VISUAL INSPECTION 2 ci cs xua sun da ak
12. this Product s warranty registration card included with Product must be filled out and returned to the Company by the original owner within ten business days of purchase This Warranty Does Not Cover Replacement parts or labor furnished by anyone other than the Company the selling dealer or a certified Company service agent Defects or damage caused by labor furnished by someone other than the Company the selling dealer or a certified Company service agent Any malfunction or failure in the Product caused by product misuse including but not limited to the failure to provide reasonable and necessary maintenance or any use that is inconsistent with the Product User Manual COMPANY SHALL NOT BE LIABLE IN ANY EVENT FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES Some locations do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you To obtain service from Company or the selling dealer under this warranty 1 A written claim must be made within the warranty period to the Company or the selling dealer Written claims made to the Company should be sent to 4717 Adams Road P O Box 489 Hixson IN 37343 USA Phone USA 800 592 7329 Fax 423 875 5497 Canada 800 361 666 Outside USA 1 423 870 7200 Outside USA Fax 1 423 870 2046 2 he Product must be returned to the Company or the selling dealer by the owner This warranty give
13. 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 his 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 3 N 0 M C L ATU RE OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 3 1 OPTIFLEX3 The nomenclature graphic below Figure 3 1 indicates Know the components and their functions before the general locations of the major components of the performing any operation of or service to the OptiFlex3 CPM unit OptiFlex3 CPM unit 13 14 FIGURE 3 1 1 Adjustable Foot Plate 10 Motor Cover 2 Foot Rest Pivot Adjustment 11 On Off Switch 3 Tibial Adjustment Knob 12 Mains Power Cord 4 Angle Potentiometer Knee Pot 13 Universal Power Supply 5 Femur B
14. 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 2 SAF ETY RECAUTIO N S OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 2 2 PRECAUTIONARY INSTRUCTIONS CONTINUED N DANGER NDANGER DO NOT connect the unit to an electrical Failure to re install and properly tighten all screws supply without first verifying that the may result in Electrical Safety System degradation power supply is the correct voltage which may cause unit damage malfuction Incorrect voltage may cause unit damage electrical shock or personal injury 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 e 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
15. Group for field troubleshooting of board components ERROR ERROR DEFINITION PROBABLE CAUSE POSSIBLE REMEDY 1 amp 2 Pendant isn t communicating Defective Cable Pendant Replace the Cable Pendant or Motor Control correctly with unit Motor Control Board Board Error reading the EEPROM on the Defective Cable Pendant or Replace the Cable Pendant or Motor Control motor pcb Motor Control Board Board RTC battery voltage is too low Pendant Battery voltage is Replace Pendant indicating bad battery low A general error motor pcb Motor Control Board Failure Replace the Motor Control Board has occurred The Angle Potentiometer sensor is Carriage angle below 10 Loosen the Femur Adjustment Knobs Raise out of range the carriage to above zero and tighten the Femur Adjustment Knobs Turn the unit off and back on with the power switch The Angle Potentiometer is not Carriage obstruction or the Remove the obstruction changing when the carriage is Angle Pot Screw is loose Tighten the Angle Potentiometer Screw and supposed to be moving Calibrate unit Femur Knobs loose Tighten Fermur Knobs The motor tachometer does Motor Control Board Failure Replace the Motor Control Board match expected value The motor pcb has not Motor Control Board Failure Replace the Motor Control Board communicated with the pendant in a reasonable amount of time The motor pcb was reset via the Motor Control Boa
16. 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 OptiFlex 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 Measure or Ruler 11 OptiFlex Continuous Passive Motion CPM Therapy Unit 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 e Preset and calibrated 5 inch pound T Handle Torque Wrench with 1 4 square drive and 5 64 straight hex key socket e Preset and calibrated 10 inch pound Handl
17. catty N pC FIGURE 6 2 3 Using the 2 Phillips Screwdriver remove the two mounting screws securing the Motor Control Board to the Base Refer to Figure 6 3 FIGURE 6 3 18 6 REMOVAL amp RE LACEM OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 6 4 DRIVE BELT Failure to re install and tighten screws may result in Electrical Safety System degradation which may cause unit damage malfuction electrical shock or personal injury Unplug the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock A Part J2000 B Tools and Equipment Required 2 Phillips Screwdriver 9 64 Allen Wrench e Preset 10 inch pound T Handle Torque Wrench and 9 64 Hex Key Socket C Drive Belt Removal amp Replacement 1 Refer to Section 6 1 part C Rear Cover Removal and Replacement to remove the rear cover of the unit 2 Using a 9 16 Allen wrench loosen the three motor mounting screws Refer to Figure 6 4 LOOSEN THREE MOTOR MOUNTING SCREWS FIGURE 6 4 3 Remove the old belt from the pulleys 4 Replace Drive Belt in reverse order NOTE When replacing the Drive Belt rotate Motor by hand applying tension to the belt Make certain the Belt is seated into the Pulley teeth Torque Motor Mounting screws using the Pre
18. qualities Federal law restricts this device to sale by or on the order of a physician or licensed practitioner e 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 e 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 e 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 e 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
19. result in Electrical Safety System degradation which may cause unit damage malfuction electrical shock or personal injury 5 Use a gear pullers remove the Pulley from the Motor shaft NOTE Using gear puller should decrease the possibility of damage to the Pulley 6 Remove the three motor mounting screws using the 9 64 Allen wrench and remove Motor from unit Refer to Figure 6 6 e s E 3 gt VREMOVE THREE MOTOR MOUNTING SCREWS FIGURE 6 6 7 Install the Motor with ribbon cable up Install the three motor mounting screws and Nylon Lock nuts Do not completely tighten 8 Position the Pulley onto the Motor shaft Make certain the set screw hole is aligned with the flat area of the shaft 9 Push the Pulley onto the shaft until the face of the Pulley collar is flush with the end of the Motor shaft 10 Prime the Pulley set screw with the Type N primer and apply the Loctite 222 or approved equivalent per the manufacturer s instructions to the threads of the set screw 11 Install the set screw until seated against Motor shaft and then torque using the Preset 5 inch pound T Handle Torque wrench with 5 64 straight hex key socket 12 Refer to Section 6 4 part C Drive Belt Removal and Replacement to install the Drive Belt 13 Refer to Section 6 3 part C Control Board Removal and Replacement to install the Control Board 14 Refer to Section 6 1 part C Rear Cover Removal and Replacement to inst
20. the Rivets Only apply enough pressure to not be sufficient clearance to remove the grasp the Rivet They will be used to Cover For inoperable units refer to Section re install the Cover 6 2 Manual Movement of the Carriage for NOTE carriage adjustment 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 1 Using a pair of miniature diagonal cutters the Rivet remove the 11 Rivets securing the Rear or 2 Lift to remove 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 3 Reverse above steps to install FIGURE 6 1 16 m 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 Part Tools and Equipment Required Miniature Diagonal Cutters C Manual Carriage Adjustment 1 Refer to Section 6 1 part C R
21. the front end of the Frame Base 25 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 6 REMOVAL amp REPLACEMENT 6 9 PENDANT RECEPTACLE CABLE 3 Hold the nut inside of the unit Frame securing the Receptacle Cable Using a pair of adjustable pliers turn the housing on the outside of the unit counterclockwise to release Continue to unscrew and remove the Unplug the unit from the power source before Receptacle Cable Refer to Figure 6 19 attempting any removal or replacement procedures to prevent electrical shock Part 89852 Tools and Equipment Required Adjustable Pliers C Pendant Receptacle Cable Removal amp 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 Pendant Cable from the Pendant Cable Receptacle by turning the Pendant Cable connector counterclockwise Continue to unscrew to release Refer to Figure 6 18 FIGURE 6 19 4 Disconnect the 5 pin from the Control Board Refer to Figure 6 20 FIGURE 6 18 FIGURE 6 20 5 Replace in reverse order 26 E 6 10 PENDANT CABLE 4 Detach the 5 pin connector from the Control Board of the Pendant Refer to Figure 6 22 Unplug the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock A Part
22. DANGER Failure to re install and properly tighten all WASHERS BEARING screws may result in Electrical Safety System degradation which may cause unit damage malfuction electrical shock or personal injury Ve se FIGURE 6 12 24 6 8 ACME ROD CONTINUED 9 Remove both of the Wiper Blades by sliding 14 Using Snap Ring pliers remove the snap out of the open end of the Frame Base ring inside of the Frame Base to release the Ball Screw Refer to Figure 6 17 10 On the front end of the unit loosen the Femur Knobs and raise the Femur Bars to full Frame Base and tighten Refer to Figure 6 15 E E 4 vn ANTT e Y HOUSING FIGURE 6 17 15 Pull out the Ball Screw FIGURE 6 15 16 Reverse for installation NOTE NOTE Cotter Pins are not supplied with the After installing the replacement Ball replacement Acme Rod Carefully remove Screw and prior to installing the Wipers the Cotter Pin and retain for installation of coat the Screw with MolyGraph Grease the Ball Screw Refer to Figure 6 16 Black by Sta Lube 11 Remove the Cotter Pin securing the Ball Screw to the front end of the unit Refer to Figure 6 16 FIGURE 6 16 12 Remove the steel washer and the bearing by using a Phillips screwdriver to push the shaft of the Ball Screw through the Front Plate NOTE Inset B on page 38 details proper installation of the washers and bearing 13 Slide the Carriage to
23. Flex gt Continuous Passive Motion CPM Therapy Unit 7 Press and hold the Flexion button While holding the Flexion button down press the OptiFlex gt Up Arrow button until 90 is displayed on the Pendant Refer to Figure 5 4 UP ARROW BUTTON FLEXION BUTTON 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 5 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 BUTTON DOWN ARROW BUTTON 10 Using the Inclinometer or Protractor measure the angle of the flexion of the unit Refer to Figure 5 6 NOTE In Figure 5 6 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 6 14 OptiFlex Continuous Passive Motion CPM Therapy Unit 5 TROUBLESHOOTING 5 8 TRAVEL SPEED TEST b Motor Control Board PCT 0 to 90 in 60 Sec 10 c Pendant of seconds 5 10 DISCONNECT TEST A Equipment Required Unit stops immediately Calibrated stop watch B Test 1 Set unit up as described in the Flexion Angle Te
24. N Ema 0 Nd HA 0 NMS TT yi Mh a W sae H Neg 6 IL WA n tli i 9098 z Al a 5 Dh di 7 J O 0550 M Y D GU ss n O Tp 5 9 i li 0 n nu mo qup WSL gi ro b 1 I 1 D 0 n um ran 9 44 1 1 WARRA NTY OptiFlex 3 Continuous Passive Motion CPM Therapy Unit Chattanooga Group a division of Encore Medical L P Company warrants that the OptiFlex3 Continuous Passive Motion CPM therapy unit Product is free of defects in material and workmanship This warranty shall remain in effect for two years 24 months from the date of original consumer purchase If this Product fails to function during the two year warranty period due to a defect in material or workmanship at the Company s option the Company or the selling dealer will repair or replace this Product without charge within a period of thirty days from the date on which the Product is returned to the Company or the dealer All repairs to the Product must be performed by a service center authorized by the Company Any modifications or repairs performed by unauthorized centers or groups will void this warranty The warranty period for accessories is thirty days Accessories consist of the Patient Softgoods Kit shipped with the unit To participate in warranty coverage
25. T 19 65 MOTOR ASSEMBLY Ko G l x A Rma RUE PR SA E h e nora A UR RO EW N dex VO A AL 20 6 6 POWER SUPPLY su sen ko na 2 sirr VIOLETS Rada dena qiu PR dq Eg de 21 67 POTENTIOMETER KNEE POT acy KE S A FOR Ca En r DI E k 22 oS ACME SCREW BALL 24 6 9 PENDANT RECEPIACLE CABLE ERE 45554 RP E EE 26 6 10 PENDANT CABLE s su kenya ka nada Ga k CERRAR QE GA DS ax TERR 27 6 11 PENDANT CONTROL BOARD RPG Eee SR OE nesses E REN ERR RUN CER RU W Ra ora E PR C 28 6 12 PENDANT BATTERY i sun na bu Ea AG ERR EDITIONS SILICOSIS d 8 4 8 SNN 62450444 29 0 13 UPPER AND LOWER PENDANT KEYMA TS 30 PENDANT DISPERY xu xh nir kn a dE ca deoa n ib obe WANE ace duc KE ruine ace are E N 31 7 CALIBRANION con sc sus yan e tees s n nan nand koa da na DA E Alb oa a n Wan d 32 34 7 1 ANGLE POTENTIOMETER POSITION CALIBRATION u su can asma lk aa RR a a EROR RERO k 32 7 2 n cee eerie
26. Therapy Unit 8 MAINTENANCE 8 3 FACTORY SERVICE When the OptiFlex3 CPM unit requires factory service contact the dealer or Chattanooga Group Service Department WARRANTY REPAIR OUT OF WARRANTY REPAIR 1 Written statement containing the following information Unplug the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock 8 1 CLEANING THE SYSTEM With the system disconnected from the power source clean the system with a clean lint free cloth moistened with water and mild antibacterial soap If a more sterile cleaning is needed use a cloth moistened with an antimicrobial cleaner e RA Number Obtain from Factory System Model Number System Serial Number Contact Person with Phone and Fax Numbers Billing Address for Out of Warranty Repair Shipping Address Where to Ship Unit after Repair 8 2 PREVENTIVE MAINTENANCE A The OptiFlex CPM unit should be placed on a regular maintenance and inspection schedule based on the practices of the healthy care facility e Detailed Description of Problem or Symptoms 2 Copy of original invoice issued at purchase of the System B Inspect the OptiFlex3 CPM unit thoroughly during scheduled maintenance and perform a functional inspection verifying the calibration 3 Ship the unit to address specified by an authorized service technician and angle of the unit Recommended Visual and Functional Inspect
27. acement 1 Refer to Section 6 10 part C Pendant Cable Removal and Replacement to open the Pendant and remove the Cable 2 Using a finger nail lift the brown plastic bar securing the Display Ribbon Cable to the Control Board Slide the Ribbon Cable back to free from the Control Board Refer to Figure 6 23 PLASTIC BAR SECURING RIBBON CABLE FIGURE 6 23 3 Disconnect the 2 Pin connector harness from the Display attached to the Control Board Refer to Figure 6 24 2 PIN CONNECTOR 20 0 11 HARNESS T 22 TOTAL T 1 s FY FIGURE 6 24 4 Using a 1 Phillip screwdriver remove the 22 screw securing the Control Board to the Pendant Base Refer to Figure 6 24 28 6 REMOVAL amp REPLACEMENT 6 12 PENDANT BATTERY Unplug the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock A Part 89870 B Tools and Equipment Required 1 Phillips Screwdriver Soldering Iron Solder C Pendant Battery Removal amp Replacement 1 Refer to Section 6 10 part C Pendant Cable Removal and Replacement to open the Pendant and remove the Cable 2 Hold the sides of the Battery While holding touch one of the solder points securing the Battery to the Control Board and lift to detach that side of the Battery from the Control Board Refer to Figure 6 25 BATTERY SOLDERING POINTS FIGURE 6 25
28. all the Rear Cover of the unit 6 REMOVAL amp RE LACEM OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 6 6 POWER SUPPLY 6 Remove the two screws securing the Power Supply to the Base using a 2 Phillips screwdriver Refer to Figure 6 8 Reverse for installation Unplug the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock 21267 Tools Equipment Required Needle Nose Pliers 2 Phillips Screwdriver C Power Supply Removal amp Replacement 1 Refer to Section 6 1 part C Rear Cover Removal and Replacement to remove the Rear Cover of the unit FIGURE 6 8 2 Disconnect the 2 pin Power Harness from the Extension Harness Refer to DAN G E R Failure to re install and properly tighten all UN GROUND CONNECTOR NI screws may result in Electrical Safety System degradation which may cause unit damage malfuction electrical shock or personal injury RED AND BLUE WIRES FIGURE 6 7 3 Using Needle Nose pliers disconnect the ground wire Refer to Figure 6 7 4 Using Needle Nose pliers disconnect the red wire from the Rocker Switch and the blue wire from the IEC Connector Refer to Figure 6 7 21 6 REMOVAL amp REPLACEMENT 6 7 POTENTIOMETER KNEE POT Unplug the unit from the power source before attempting any removal or replacement procedu
29. ar SAKO WE K PEREAT ERR WE K RU Ea rw FR RE J Ad 34 S MAINTENANCE 4 5 5s or RR ROCHE QA d Wa ay dorada KE k 35 37 RAR 38 40 TO SCHEMATICS SS oo 41 44 ji R EWO R D OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 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 Groups 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 Gr
30. ar Adjustment Scale 14 Motor and Gearbox Assembly 6 Femur Bar Adjustment Knob 15 Motor Control Board 7 Frame Base 16 Pendant Receptacle Cable 8 Pendant User Interface Refer to Page 7 17 Front Access Cover 9 Carrying and Storage Handle 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 14 13 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit Know the components and their functions before performing any operation of or service to the OptiFlex3 CPM unit oO Optiklens 12 11 FIGURE 3 2 1 V 7 OSCILLATION ZONE Carriage will oscillate three times between the flexion angle and 10 less than the flexion angle 2 PROGRESSIVE ROM Unit will automatically increase the programmed flexion angle by 1 every hour up to a maximum of 5 per day 3 USER INTERFACE SCREEN Displays settings and status of therapy session 4 d RESET Clear previous treatment settings and completed cycles 5 UP ARROW Allows user to increase treatment parameters 6 DOWN ARROW Allows user to decrease treatment parameters 7 4 COMFORT ZONEm Temporarily decreases the flexion ROM when discomfort is experienced 8 HA EMERGENCY START STOP Start or stop treatment 9 a EXTENSION FLEXION DELAY Allows user to program carriage to stop at both the extension and flexion angle for th
31. e Torque Wrench with 1 4 square drive and 9 64 straight hex key socket 5 16 Socket Driver 3 32 Allen Wrench 5 Required Lubricants e MolyGraph Grease Black by Sta Lube 6 Required Locking Compound and Primer Type N Primer by Loctite e Loctite 222 Purple e Loctite 242 Blue e Loctite 262 Red 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 5 TRO i ESH 00TI M G 3 Continuous Passive Motion CPM Therapy Unit 5 3 VISUAL INSPECTION 5 6 ELECTRICAL SAFETY TESTS A General Conduct all necessary Electrical Safety tests as Visually inspect the OptiFlex for and visible required per your facility local or national damage to the unit or pendant that may interfere regulatory agency In the USA follow NFPA 99 with operation of the unit Make sure that all National Fire Protection Association Health care screws are secure Verify that the appropriate hook Facility standards 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 unit failing dielectric withstand and or leakage Verify that the LCD lens is in good condition and tests could indicate serious internal syste
32. e time programmed 10 SPEED Displays the speed of operation 11 4 FLEXION Displays the flexion angle 12 mma EXTENSION Displays the extension angle 13 MODE Used with Fast Back Oscillation Zone and Progressive 14 FAST BACK Carriage will slow down within 15 of the flexion angle ROM Range of Motion 4 SPECIFICATIONS 4 1 OPTIFLEX3 CPM THERAPY UNIT SPECIFICATIONS OptiFlex 3 Continuous Passive Motion CPM Therapy Unit FIGURE 4 1 100 240 50 60 Hz 75 VA REGULATORY COMPLIANCE 27 105 12 kg UL 60601 1 Hye CAN CSA C22 2 No 601 1 M90 w A2 dead 2 IEC EN 60601 1 60601 1 2 Electrical TY j am DB e Mees MDD 95 42 CE 0419 Mode CONTINUOUS OPERATION uiae k dl a sss 120 Maximum Extension 10 Maximum Hyper Extension 5 30 per min to 150 per min Maximum Patient Weight 350 105 159 kg Lower Leg Length Range 10 23 5 in 25 4 59 7 cm Center of knee to sole of heel Thigh Length Range 12 19 in 30 5 48 3 Hip joint to center of knee TRANSPORTATION AND STORAGE REQUIREMENTS Unit should be transported and stored under the following conditions Temperature 0 F to 140 F 18 C to 60 Hu
33. ear 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 mainpulate the Pulley Rotate the Pulley moving the Carriage until the Cover can be completely removed 17 6 REMOVAL amp RE LACEM E NT OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 6 3 MOTOR CONTROL BOARD 4 Replace in reverse order NOTE When connecting harnesses each harness will connect only to their respective locations Unplug the unit from the power source before on the board attempting any removal or replacement procedures 5 After Motor Control Board replacement to prevent electrical shock perform the following in the order listed A Part Number 11 4 11 4 0 9 4 86 4 J6088 7 1 Angle Potentiometer Position Calibration B Tools and Equipment Required 5 7 Flexion Angle and Calibration Test e 2 Phillips Screwdriver 2 Force Reversal Calibration C Control Removal amp Replacement 5 4 Functional Inspection 1 Refer to Section 6 1 part C Rear Cover Removal and Replacement to remove the rear cover of the unit NDANGER 2 Disconnect the four wiring harnesses from Failure to re install and properly tighten all the Control Board Refer to Figure 6 2 screws may result in Electrical Safety System degradation which may cause unit damage malfuction electrical shock or personal injury WIRING HARNESSES
34. endant Display window Refer to Figure 7 3 Tape Measure B Potentiomenter Decal and Cover Removal NOTE Be careful not to damage decal It will be used for installation after the calibration procedure is complete M Se NNN NL n kO RD WIN Refer to Section 6 1 part C Rear Cover Removal and Replacement to remove the Rear Cover of the unit Using a small fine edged tool carefully remove the Decal from the Potentiometer Cover Refer to Figure 7 1 FIGURE 7 3 4 Place the calibrated Protractor with 1 accuracy across the carriage and press the Up and Down Arrow button on the Pendant until the protractor reads zero Refer to Figure 7 4 PLACE PROTRACTOR ACROSS THESE TWO SURFACES AND ADJUST UNTIL PROTRACTOR READS ZERO FIGURE 7 1 Using the 2 Phillips Screwdriver remove the three Potentiometer cover mounting screws Refer to Figure 7 2 REMOVE THE THREE _ MOUNTING SCREWS Wo FIGURE 7 4 FIGURE 7 2 32 7 CALIBRATION OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 7 1 ANGLE POTENTIOMETER POSITION CALIBRATION CONTINUED 5 With the 3 32 Allen wrench loosen the two set screws retaining the potentiometer Refer to Figure 7 5 i RETAINING POTENTIOMETER E m IN POSITION FIGURE 7 5 6 Connect the negative black lead from the Digital Multimeter to the Motor Control Board Mounting Bracke
35. herapy 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 v 2 SAFETY P RECAUTIO NS OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 2 1 PRECAUTIONARY DEFINITIONS The precautionary instructions found in this E Biohazard 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 A Caution 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 Text with a CAUTION indicator will explain possible safety infractions that could have the F Note potential to cause minor to moderate injury or damage to equipment Throughout this manual NOTE may be found These Notes are helpful information to aid in B Warning the particular area or function being described 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 haza
36. ion information can be found in sections 5 3 and 5 4 of Service to these units should be performed only by Service Technicians certified by Chattanooga Group Troubleshooting Inspection should be performed by a person qualified to recognize any signs of wear or tear looseness of bolts parts or inconsistancies in function 35 MAI INI TE NA N CE OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 8 4 MAINTENANCE RECORDS 36 iFlex 3 Cont iva Mat 8 4 MAINTENANCE RECORDS CONTINUED 37 9 PA RTS OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 8 1 OPTIFLEX gt CPM THERAPY UNIT PARTS 38 9 PA RTS OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 9 1 OPTIFLEX CPM THERAPY UNIT PARTS LIST ITEM PART DESCRIPTION 45 54931 PING SIR J OST 46 J1089 CLEVIS PIN 1 4 X 1 3 8 SS 7 WELDMENT BASE FRAME 48 J6000 SCREW 10 24 SELF TAP 49 J2003 EXTRUSION 0 16104 COVER FRONT BOTTOM J1058 PAD FRONT J1055 PIN TRUNION J1034 SLIDER J2004 ACME ROD 2 2 DECAL PENDANT REMOVAL J6089 COVER REAR TOP J6064 WASHER FLAT BEARING J6009 BEARING ROLLER J1072 BUSHING NYLON 3 8 OD J6008 BEARING FLANGE J6035 BI ONE 21733 NUT 6 32 ESNA J6088 BOARD MOTOR CONTROL J6065 STRAIN RELIEF 21267 POWER 74312 SCREW 6 32 X 1 4 16058 SWITCH ROCKER 68964 FOAM HANDLE GRIP 527195 SCREW 10 X 1 2 PAN TEK 0 J1111 BASE REAR S A J6004 NYLON SNAP RIVET
37. ko a anan ed Karin l kundala kay a anin d A I W au d WE PETRI la are an di 12 54 FUNCTIONALINSPECTION 12 ELECTRICAL SAFETY uada d rosas orb Rar bac da Ed Ca V ee ewes aU tees Ss 12 SO ELECTRICAL SAFETY TESTS su u sya xa kwa en SA KADER aou da Ee E bs eR var a exa qu E EM da FER A 12 54 FLEXION ANGLE AND CALIBRATION TES s lt si sa ORC key yan OR Ie RO k N SOR ER nel ns Er dad RS E Re E 13 5 8 IRAVEL SPEED TEST da wastes husa ku swed n ne Wa le k n DOCERE h b W n ON PE N W kerb VERE UE ab AW IUE 15 5 9 EMERGENCY STARI STOP FUNGTION TES E si 5s su so ma 2 n m nak k caw e l dik d L PEE kn eos 15 540 PENDANT DISCONNECT TEST na n n na h ERG E hex GOES EP SA OL r R y a RE ES Ed Wy 15 REMOVAL amp REPLACEMEN 5i 55553455583555 RATE 40 82549445405505 203404 26 S r ses SSO 16 31 COVERS cu s a uu ne Sal h k ara wal ka n AE RI READER TOKENS EDS SESE 16 6 2 MANUAL MOVEMENT OF THE CARRIAGE sy i 17 6 3 MOTOR CONTROL BOARD gc sc ss ui sus un anan s s a cala a Dib an e aga qu TA Vd A n i UE a k 18 GA DRIVE BEL
38. m clean if necessary problems Do not place unit back into service Contact the factory for repair Do not attempt to repair the unit in the field 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 VAN DA N G E H Check the calibration of the unit by running it successively through its full ROM with femur length This unit must not be operated with any adjusted first to maximum and then to its adapter attached to the three prong plug minimum length that would disable the earth connection NOTE Disruption of the earth connection may cause nit dam malfunction electrical shock fire Verify that the lead screw is unobstructed and no or personal injury abnormal noises are present during operation Pull out the pendant while the unit is running to verify that the unit will stop Perform the Speed test found on page 15 Activating the New Patient Reset clears all settings 5 5 ELECTRICAL SAFETY The OptiFlex 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 Facility local and national limits and test methods may vary
39. midity O to 75 Relative Humidity 4 SPECIFICATIONS 4 2 DESCRIPTION OF DEVICE MARKINGS OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 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 Meets Directive 93 42 EEC 0413 EC UL EN 60601 1 60601 1 2 a Conforms to UL Standard 60601 1 veren Certified to CAN CSA Standard C22 2 No 601 1 M90 w A2 Refer Instruction Manual Booklet 2 Equipment ab Protected Earth 4 3 ADDITIONAL DEVICE MARKINGS 7 Emergency Stop Standby Power d Standby Power OFF D Start Listed by Intertek Testing Services NA Inc This product complies with WEEE Directive 2002 96 EG waste electrical and electronic equipment Separate collection for electrical and electronic equipment 5 TRO T ES 00TI v G OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 5 1 OPTIFLEX gt SOFTWARE ERROR MESSAGES A The information provided below is intended to B Once a particular PCB has been determined as aid in troubleshooting Software Error Messages bad replace the suspected board of the OptiFlex3 units to Board Level only No component level troubleshooting information is or will be provided by Chattanooga
40. on button This programs the upper limit position in the software 12 Install the Potentiometer Cover and Decal 13 Power unit off and on This completes Potentiometer Position Calibration 14 Perform Force Reversal Calibration Section 7 2 DANGER Failure to re install and properly tighten all screws may result in Electrical Safety System degradation which may cause unit damage malfuction electrical shock or personal injury 7 AT 0 M OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 7 2 FORCE REVERSAL CALIBRATION A Position Carriage Move the carriage to a position of 5 to 10 B Set Unit to Force Reversal Calibration Mode While holding down the SPEED button press the following buttons in th ence listed 1 Progressive ROM 2 Fast Back 3 Oscillation 4 4 Mode New 5 Release Speed button STAND BACK Unit Self Calibrating should be displayed at the bottom of the Pendant display and a Timer should begin counting down from approximately 30 sec Refer to Figure 7 10 m 528217 32 car STAND BACK Unit Self FIGURE 7 10 6 After all movement of the unit has stopped the Display will prompt the technician to turn the unit off and back on Refer to Figure 7 11 This completes Force Reversal Calibration Turn Unit OFF then back FIGURE 7 11 34 OptiFlex 3 Continuous Passive Motion CPM
41. oup 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 02007 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 T E EQ RY 0 5 0 PF R AT 0 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 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 t
42. ratures 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 OptiFlex2 All hardware bolts nuts and screws used to assemble the OptiFlex2 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 he 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
43. rd Failure Replace the Motor Control Board watchdog Unit needs to be calibrated Various Calibrate unit Refer to pages 32 34 for calibration procedures 5 5 10 11 10 5 TROUBLESHOOTING 5 2 OPTIFLEX SYSTEM TESTING A General 1 The following information is intended to aid in troubleshooting the major components of the OptiFlex units to Board Level only These tests are OEM standard testing procedures and methods used at the factory before shipment of any OptiFlex 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
44. rdous 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 2 SAFETY PRECAUTIONS OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 2 2 PRECAUTIONARY INSTRUCTIONS e Read understand and practice the precautionary and 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 tempe
45. res to prevent electrical shock NOTE To order a replacement Potentiometer order all three parts listed in section A A Part Numbers 16040 16023 Nylon 16022 Tools Equipment Required e 3 32 Allen Wrench 2 Phillips Screwdriver Heyco C Potentiometer Removal amp Replacement 1 Refer to Section 6 1 parts C and D Rear Cover and Front Cover Removal and Replacement to remove the Covers of the unit 2 Use a fine edged tool to lift the Decal on the Potentiometer and remove Refer to Figure 6 9 NOTE Save the Decal J6107 for installation of the replacement Potentiometer COVER T SCREWS FIGURE 6 9 Failure to re install and tighten screws may result in Electrical Safety System degradation which may cause unit damage malfuction electrical shock or personal injury OptiFlex 3 Continuous Passive Motion CPM Therapy Unit 3 Use a 2 Phillips screwdriver to remove the 3 screws securing the Potentiometer Cover and remove the Cover NOTE When installing the Potentiometer Cover part number J6105 hand tighten the three screws until snug Overtightening the screws will crack the Cover 4 Using a 3 32 Allen wrench remove the cleat screw Refer to Figure 6 10 SMALL J SCREWDRIVER
46. s you specific legal rights and you may also have other rights which vary from state to state or location to location The Company does not authorize any person or representative to create for it any other obligation or liability in connection with the sale of the Product Any representation or agreement not contained in the warranty shall be void and of no effect THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE 45 2007 Encore Medical L P Moving Rehabilitation Forward MDSS GMBH Schiffgraben 41 30175 Hanovre Allemagne Telephone 4 49 511 6262 8630 Fax 49 511 6262 8633 CHATTANOOGA b GROUP ISO 13485 CERTIFIED 4717 Adams Road PO Box 489 Hixson TN 37343 1 423 870 2281 1 800 592 7329 1 800 361 6661 CANADA 1 423 870 7200 OUTSIDE U S A 1 423 870 2046 OUTSIDE U S A FAX chattgroup com J2046B 0413
47. set 10 inch pound T Handle Torque wrench with 9 64 straight hex key socket Check the tension on the Drive Belt A properly installed Belt should exhibit between 1 16 and 1 8 deflection when pressed 19 6 REMOVAL amp REPLACEMENT 6 5 MOTOR ASSEMBLY Unplug the unit from the power source before attempting any removal or replacement procedures to prevent electrical shock A Part Number J2054 B Tools and Equipment Required 11 32 Open End Wrench 2 Phillips Screwdriver 5 64 Allen Wrench 9 64 Allen Wrench 3 32 Allen Wrench e Preset 10 inch pound T Handle Torque Wrench e Preset 5 inch pound T Handle Torque Wrench Type N locking compound primer e Loctite 222 Purple or approved equivalent Molykote or approved equivalent grease e Gear Puller C Motor Removal amp Replacement 1 Refer to Section 6 1 part C Rear Cover Removal and Replacement to remove the rear cover of the unit 2 Refer to Section 6 3 part C Control Board Removal and Replacement to remove the Control Board 3 Refer to Section 6 4 part C Drive Belt Removal and Replacement to remove the Drive Belt 4 Using a 5 64 Allen wrench remove the set screw from the Motor Pulley Refer to Figure 6 5 y REMOVE PULLEY SET SCREW FIGURE 6 5 20 OptiFlex 3 Continuous Passive Motion CPM Therapy Unit DANGER Failure to re install and properly tighten all screws may
48. st 2 Adjust the Fermur Bar length to 34 and tighten 2 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 3 Repeat three times Calculate and Record the average 4 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 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 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
49. t and the Positive red Lead to the Red Wire on the Potentiometer Refer to Figure 7 6 CONTROL BOARD MOUNTING BRACKET k E Fs E 1 a E 1 la a POTENTIOMETER RED WIRE FIGURE 7 6 7 Rotate the Potentiometer by hand until a value between 1 018 Volts 1 081 Volts is displayed on the Digital Multimeter Refer to Figure 7 7 ROTATE POTENTIOMETER UNTIL 18 VOLTS IS DISPLAYED ON METER FIGURE 7 7 8 Torque the two potentiometer set screws with the preset 5 inch pound T Handle Torque Wrench Verify voltage Refer to step 7 9 Press the Extension button This programs the zero position in the software 10 Press the Up Arrow button until the front of the Carriage Guide Bar is approximately 1 250 32 mm from the cut out in the Front Cover Refer to Figure 7 8 NOTE At any time during this process if the Carriage is moved too far an Error Message may be display It will then be necessary to manually move the Carriage by loosening the Femur Bar and raising it until the Carriage Guide Bar is approximately at 0 to cancel the Error Once the Guide Bar is zeroed turn the unit off to Clear the error meassage If the Carriage is required to be manually moved then it will be necessary to re start the Initial Position Calibration Procedure Refer to 7 1 part C FIGURE 7 8 11 Press the Flexi
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