QAL Medical 480, Service And Technical Manual

Page 1: ...480 480E 480E PRO CPM Service and Technical Manual 2011 QAL Medical 05070812 3 Rev C 08 11...

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Page 3: ...e clock 14 9 5 PCB Printed Circuit Board PCB or PCBA assembly 14 10 MAIN PRINTED CIRCUIT BOARD PCB 14 10 1 Replacing PCB 480 480E 14 10 2 Replacing PCB 480E PRO 15 11 Calibration 15 11 1 Calibration 4...

Page 4: ...the following Danger Keep hair loose clothing fingers etc away from moving components of the device Danger Do not expose the device to water including ice bags Do not expose to extreme temperatures Da...

Page 5: ...If liquid had been spilled into the product c If the product has been exposed to water d If the product has been dropped or the unit casing has been damaged e If the product exhibits a distinct change...

Page 6: ...ification Type B Classification Class 1 Medical Device USA Class 11a 93 42 EEC Environmental 10 to 35 C 14 to 95 F temperature 90 max humidity Conditions ATM pressure 750 hPa to 1040 hPa The device mu...

Page 7: ...parameters If the readings do not fall within the set parameters the unit needs to be checked and recalibrated by a properly trained Service Technician Every six Months 1 Repeat steps 1 through 10 of...

Page 8: ...r 6a 480 Remove both 3 16 cradle pivot cap screws from the U bracket assembly to detach the cradle from the ballscrew If you run into difficulty removing the cap screw apply a slight tilt to the Allen...

Page 9: ...the underside strain relief side of the top cover 6 Pull cable through cover 7 De solder the cable from the terminals on the kneepot Installation 1 Wrap wires one and one quarter turns around kneepot...

Page 10: ...to rotate in the casting Make sure that the pin on the Potentiometer shaft enters the long slot of the Potentiometer Drive Coupling 11 Rotate the Potentiometer body until the angle indicated on the M...

Page 11: ...te 242 6 Re install the motor assembly 7 Reinstall the bottom cover refer to section 2 1 7 POWER SUPPLY 480 ONLY Removal 1 Remove bottom cover refer to section 2 1 2 Disconnect power supply cable conn...

Page 12: ...unted connector 10 Join the controller and ribbon cables with ty raps 11 Reinstall the bottom cover refer to section 2 1 8 2 Controller Keypad Removal 1 Remove back cover label from controller 2 Using...

Page 13: ...two halves 5 Reinstall the four Phillips head screws in the holes on the back of the controller and tighten 6 Place back cover label on back side of controller housing 9 PRO CONTROLLER PENDANT 480E PR...

Page 14: ...n 2 1 2 Remove all connectors from the main PC board 3 The PC board may be removed by one of three procedures depending on when a particular device was manufactured a Gently push the PC board toward t...

Page 15: ...ention The Printed Circuit Board is a Static Sensitive Device Repair should be attempted by qualified personnel only All anti static handling procedures should be observed 1 The calibration jumper mus...

Page 16: ...ve the calibration jumper 27 Reassemble unit 11 2 Calibration Diagram 480 480E Fig 2 11 3 Calibration 480E PRO If the motor Potentiometer Lead Screw or the Base Unit Actuator PCB have been replaced th...

Page 17: ...the screen you will see Calibrate button that can be highlighted using the Direction Keys and Selected with the Select button The PRO Controller will lead you through the steps necessary for the follo...

Page 18: ...s are imposed on the value of these variables at calibration If the values read from EEPROM are not within these limits the variable is assumed to be corrupted and an error is generated Corrective act...

Page 19: ...need to be replaced E8 MOTOR SPEED ERROR Error Action This error causes the microcontroller to burn 8 in the EE_ERROR EEPROM and causes the CPM to stop Display STOP Cause The maximum CPM rpms is less...

Page 20: ...his generates an error 13 Corrective Action Contact OrthoLogic Customer Service Department and inform them of the error The main PCB may need to be replaced There is enough EEPROM allocated for each v...

Page 21: ...ated Corrective Action In the calibration mode re select the motor type If the error persists contact the Technical Service Department E19 INVALID EE MODEL TYPE Error Action This error causes the CPM...

Page 22: ...s replace pendant 02 01 02 xx Leading Pot Reset machine repair replace pot replace motor board 02 01 03 00 Raw pot value too large 02 01 04 00 Raw pot value too low 02 01 05 00 Hall Error reset machin...

Page 23: ...ller PCB failure Replace Controller Return for service Error code E9 Calibration error Re calibrate following calibration procedures Controller cable break Replace Controller cable Controller PCB fail...

Page 24: ...ufficient lubrication on track Use a Light Lithium ballscrew and track seals based lubricant Lubriplate 105 on tracks and ballscrews and a Silicone spray on track seals Bearing bracket assembly failur...

Page 25: ...25 14 Assembly Drawings 14 1 Main Assembly...

Page 26: ...26 14 2 Thigh Assembly...

Page 27: ...27 14 3 Cradle Sub Assembly 480 L480SA011 480E L480SA022...

Page 28: ...28 14 4 Foot Cradle Assembly...

Page 29: ...29 14 5 Ballscrew Assembly...

Page 30: ...30 14 6 480 U Bracket Slider Assembly...

Page 31: ...31 14 7 480E 480E PRO U Bracket Slider Assembly...

Page 32: ...32 14 8 480E or 480E PRO Motor Assembly Faulhaber...

Page 33: ...33 14 9 480E PRO ONLY Motor Assembly Maxon...

Page 34: ...34 14 10 Motion Controller Assembly 480 480E...

Page 35: ...1 Flat FS440BC 2 Screw 4 x 1 2 Pan NG007 LCD NG SA001 Front Housing Sub Assembly NG SA002 Top End Cap Sub Assembly NG SA003 Bottom End Cap Sub Assembly EABBE Battery NG006 LCD Mount NG009 Fish Paper I...

Page 36: ...36 14 12 480 Wiring Diagram...

Page 37: ...37 14 13 480E Wiring Diagram...

Page 38: ...ABLE ASSEMBY 2 INTERNAL NGG007 CABLE ASSEMBLY 7 INTERNAL NGG003 CABLE ASSEMBY 3 INTERNAL NGG005 CABLE ASSEMBY 5 INTERNAL NGG006 CABLE ASSEMBY 6 INTERNAL NGG008 ADAPTOR HARNESS POT NG 204 PCB ASSEMBLY...

Page 39: ...39 14 15 480 480E Electrical Schematic...

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Page 42: ...CUSTOMER CONTACTS In the USA QAL Medical Website www qalmedical com 1 888 430 1625 International QAL Medical 3000 Woleske Road PO Box 166 Marinette WI 54143 1 715 735 4700 Fax 1 715 732 6402...