ARTROMOT K3 User manual

Service
Manual
(New
Generation)
Starting
from
Serial
number
3000
ARTROMOT
®
-
K3

1.
History
2
2. Purpose 2
3. General 2
4. Packing and unpacking 4
5. Block diagram of electronic parts 4
6. Bill of material for service parts 5
7. How to perform the repair 9
8. Explosion drawing part 1 10
9. Explosion drawing part 2 11
10. Checklist for safety- and function test 12

Revision
Date
Name
Change
1 17.09.2001 M. Nunnenmacher Initial Release
2 19.09.2001 M. Nunnenmacher Pos. 4.8
3 15.10.2001 M. Nunnenmacher Pos. 1.9, 1.15,
1.16
4 6.11.2001 M. Nunnenmacher Update
reference run,
new packaging
5 15.01.2002 M. Nunnenmacher Update Pos.
3.13, 3.45, 4.3,
4.5, Safetytest
6 06.02.2002 M. Nunnenmacher Update Pos.
3.12 Labeled
casting
7 27.03.2002 M. Nunnenmacher Update Pos. 1.1
8 21.10.2002 S. Herr Update for all
electronic parts,
explosion
drawings and
reference run
9 02.06.2003 S. Herr Update Pos.
2.10 explosion
drawing
10 05.04.2004 S. Herr Update Pos.1.6,
function test
11 11.07.2006 S. Herr Update
chapter 4, 8, 9
Pos. 1.25 –1.28,
Pos. 4.20 – 4.26
This
service
manual
is
to
perform
some
repairs
on
ARTROMOT®-K3 products. Repair and maintenance work
may only be carried out by authorised persons, as other-
wis
e all warranty services and liabilities shall be void.
It is not allowed to utilize any other spare part which is
not mentioned in chapter 6.
3.1
Electronic
and
cable
Electronic
devices
as
hand
-
held
programming
unit,
motor
electronics and spiral cable are not interchangeable with
ARTROMOT®-K3 serial number < 3000.
Make sure that the characteristic values of your power
supply correspond to the voltage and frequency data
indicated on the power adapter.
Error possibilities, showed by the hand-held pro-
gramming unit:
DEVICE NEEDS
REFERENCE RUN: The reference run was interrupted
or the electronics were replaced.
-> Perform a reference run. See chapter 7.4
POTENTIOMETER: Potentiometer shows incorrect value
-> Check plug connection, replace potentiometer if
persistent
POTENTIOM. CABLE: Spiral cable for knee case
defective
-> Replace spiral cable for knee case (Pos. 5.9),
check plug connection
MOTOR DRIVER: Motor electronics defective
-> Replace motor electronics (see chapter 7.3) if
persistent
OVER CURRENT: Motor power to high
-> Replace motor electronics (see chapter 7.3) if
persistent
UNWANTED BUSY: Motor control unit is not answering
-> Hand-held programming unit, motor electronics or
spiral cable of the hand-held programming unit defective
CPM MEMORY RAM: Memory fault in the motor control
unit
-> Replace motor electronics (see chapter 7.3) if
persistent
CPM MEMORY ROM: Memory fault in the motor control
unit
-> Replace motor electronics (see chapter 7.3) if
persistent
2
Table
of
contents
2
.
Purpose
3.
General
1.
Historie
History

COMMUNICATION:
Communication
problem
between
hand-held programming unit and the motor control unit
-> Hand-held programming unit, motor electronics or
spiral cable of the hand-held programming unit defective
CPM-DEVICE ERROR: General mistake in the motor
control unit
-> Replace motor electronics (see chapter 7.3) if
persistent
MOT. EN. TIMEOUT: Motor can not be activated
-> Check motor electronics and plug connection for
motor. Replace motor electronics (see chapter 7.3) and
spiral cable of the hand-held programming unit if
persistent
INVALID PARAMET.: Motor control unit received a
wrong
parameter
-> Hand-held programming unit, motor electronics or
spiral cable of the hand-held programming unit defective
STOP RELEASE ERR: Stop line can not be released
-> Remove hand-held programming unit or spiral cable
(see chapter 7.2) if persistent
UNEXP. MOT. STOP: Motor stopped unexpectedly
-> Motor electronics or connecting line to motor defective
MOTOR DISABLED: Motor is disconnected
-> Motor electronics or connecting line to motor defective
MOTOR ERROR: Motor is not turning
-> Check motor cable and motor. Replace motor
electronics (see chapter 7.3) if persistent
RTC INIT ERROR: Hand-held programming unit defective
-> Replace hand-held programming unit (see chapter7.2)
if persistent
RTC COM ERROR: Communication problem with hand-
held programming unit
-> Replace hand-held programming unit (see chapter7.2)
if persistent
RTC ERROR: Hand-held programming unit defective
-> Replace hand-held programming unit (see chapter7.2)
if persistent
RANGE EXCEEDED: Potentiometer shows a value out
of range
-> Replace Potentiometer and/ or spiral cable
UNKNOWN CPM ERR.: Unknown error in the motor
control unit
-> Replace motor electronics (see chapter 7.3) if
persistent
UNDEFINED ERROR: Undefined error
-> Hand-held programming unit, motor electronics or
spiral cable of the hand-held programming unit defective
CPM 24V SUPPLY: 24V supply in motor control out of
range
-> Check power supply. Replace motor electronics (see
chapter 7.3) if persistent
CPM
3.3V
SUPPLY:
3.3V
supply
in
motor
control
out
of
range
-> Replace motor electronics(see chapter 7.3) if persistent
HS 24V SUPPLY: 24V supply in hand-held programming
out of range
-> Replace hand-held programming unit or spiral cable if
persistent
HS 5V SUPPLY: 5V supply in hand-held programming unit
out of range
-> Replace hand-held programming unit if persistent
HS 3.3V SUPPLY: 3.3V supply in hand-held programming
unit out of range
-> Replace hand-held programming unit if persistent
3.2 Mechanics
The
Threaded
spindle
is
not
interchangeable
with
ARTROMOT®-K3 serial number < 3000.
Do not loosen the knurled handles completely for any
adjustment. For operation or transport, make sure that
the knurled handles are tight.
3.3
Others
Do
not
clean
the
casing
or
the
support
with
grease
or oil.
Do not utilize any solvent for cleaning the
ARTROMOT®-K3.
3

The following settings has to be made to transport the device
correct:
The
first
step
is
to
move
the
device
in
a
position
of
EXTENSION = 0 degrees.
Switch off the device. Remove the power adapter, power cord
and put it into the specified cutouts of the styrofoam.
Loosen the two knurled handles (Pos. 6.2), pull out the
ankle joint (Pos. 4.x).
For transportation, use the original packaging.
Move the two styrofoam parts on the device.
Put the hand-held programming unit into the specified cutout
of the styrofoam.
Put the device with the styrofoam parts in the carton.
Move the tubes of the ankle joint upside down into the
specified cutouts of the styrofoam.
Put separate pads around the foot plate and frame to protect
the device against vibration and damage.
4
4.
Packing
and
unpacking
5.
Block
diagram
of
electronic parts
Controller
for
Hand-held
programming unit
Di
splay
K3
motor
control
Power
adapter
Knee
adjustment
Hand-held programming unit
Power
cord
Tubes of the
ankle joint Power adapter

5
Position
Description
Order
-
Number
1.0 Electronics
1.1 Power adapter 115V / 230V 0.0031.107W
Power cord USA - version to 0.0031.107W 0.0032.011
Power cord EU - version to 0.0031.107W 0.0032.012
1.2 Hand-held programming unit 0.0032.113
1.4 Rubber mat 2.0031.195
1.5 Sheet metal cover 2.0032.136
1.6 Motor electronics 2.0032.900RevB
1.7 Fantype lock washer DIN6798AD3,2vz
1.8 Screw thread slab 962.903
1.9 Screw LIKOM4x8A2
1.11 Hexagonal nut DIN934M3vz
1.13 Cloth white 0.0010.144
1.14 Sticker 2.0013.362
1.15 Phillips screw 9B2.013
1.16 Cover top black 9B2.013
1.17 Spiral cable 2.0032.137
Holding clip 0.0031.004
1.19 Countersunk screw DIN7991M3x10sw
1.20 Flat connector 0.0013.125
1.21 Washer DIN125D3,2vz
1.22 Wire-Set Motor 2.0032.139
1.23 Pan head screw DIN912M3x6A2
1.24 Washer 2.0013.3
1.25 Holder set motor plate (Pos. 1.25 – 1.28) 0.0032.010
2.0 Exterior underframe
2.1 Right profile 2.0032.107
2.2 Left profile 2.0032.106
2.3 Right rubber mat 2.0032.116
2.4 Left rubber mat 2.0032.115
2.5 Lip 2.0031.193
2.6 Interior slit 2.0032.113
2.7 Interior slit 2.0032.128
2.8 Right cover 2.0032.105
2.9 Left cover 2.0032.104
2.10 Shaft bearing 2.0031.112
2.11 DU collar 0.0031.110
6.
Bill
of
material
for
service
parts

6
2.12
Interior
slit
2.0031.197
2.14 Exterior slit 2.0032.114
2.15 Exterior slit 2.0032.114
2.16 Bottom plate 2.0032.108
2.17 Attachment plate femur bow 2.0032.101
2.18 Attachment plate femur bow 2.0032.100
2.19 Thread plate M6 962.901
2.20 Pan head screw DIN912M6x8A2
2.21 Pan head screw DIN7984M5x25A2
2.22 Countersunk screw DIN7991M4x8A2
2.23 Cylinder pin DIN6325D5x10
2.24 Shell nut 0.0032.122
2.25 Countersunk screw DIN7991M6x10A2
2.26 Sping wire 0.0031.300
2.27 Band white 2.0020.163
2.28 Cloth black 0.0032.110
2.29 Inplementation spout 0.0031.145
3.0 Drive technology
3.1 Motor including transmission 0.0031.100
3.2 Right slide 2.0031.108
3.3 Left slide 2.0031.109
3.4 Threaded spindle 2.0032.138
3.5 Rubber ring 2.0031.176
3.7 Rubber plate 2.0028.170
3.8 Motor plate 2.0031.156
3.9 Spline shaft drive 2.0031.181
3.10 Toothed belt 0.0031.130
3.11 Toothed lock washer drive 2.0031.180
3.12 Labeled Casing 2.0032.032
3.13 Bearing plate left 2.0031.165
3.14 Rubber plate 2.0031.102
3.15 Sheet metal 2.0031.115
3.17 Ball bearing 910.008
3.18 Rubber ring 2.0031.105
3.19 Rubber disk 2.0031.104
3.20 Joint plate 2.0031.113
3.22 Covering plate 0.0028.105
3.23 Ring 0.0028.106
3.24 Split rivet 0.0031.136
3.25 Wire-Set power supply 2.0032.140
3.26 Retaining ring DIN471A8x0,8
3.27 Rubber buffer 0.0031.109

7
3.28
Spacer
sleeve
0.0031.104
3.29 Pin 2.0031.188
3.30 Countersunk screw DIN7991M5x20vz
3.31 Screw thread pin DIN916M4x4sw
3.32 Screw thread pin DIN914M4x4sw
3.33 Countersunk screw DIN7991M4x10vz
3.34 Hexagonal nut DIN934M5vz
3.35 Pan head crew DIN912M5x6vz
3.36 Countersunk screw DIN7991M5x25A2
3.37 Countersunk screw DIN7991M5x55vz
3.38 Countersunk screw DIN7991M5x16vz
3.39 Bearing plate right 2.0031.103
3.50 Countersunk screw DIN7991M4x16vz
3.51 Pan head screw DIN912M4x12vz
3.53 Spindle nut 2.0032.141
4.0 Ankle joint
4.1 Ankle joint bowl 2.0031.120
4.2 Base plate 2.0031.170
4.3 Knurled handle GN534-40-M6-10sw
4.4 Washer DIN9021D6,4vz
4.5 Washer 0.0031.111
4.6 Washer 0.0031.142
4.7 Screw rosette 0.0031.137
4.8 Spacer sleeve 0.0013.104
4.9 Sleeve nut 2.0031.178
4.10 Fastening band 0.0031.144
4.11 Rigid pipe 2.0031.117
4.12 Knurled handle 2.0031.031
4.13 Washer DIN7349D6,4vz
4.14 Hinge box 2.0031.119
4.15 Washer 2.0031.118
4.16 Countersunk screw DIN7991M5x8A2
4.17 Cylinder pin DIN7D4x20A2
4.18 Nut 0.0031.108
4.19 Nut 0.0031.105
New Ankle joint complete 2.0037.022K3K4
4.20 Supporting disk 2.0031.213
4.21 Akle joint bow 2.0037.163
4.22 Base plate 2.0037.168
4.23 Countersunk screw DIN79991M5x12A2
,

8
4.24 Ankle joint nut 2.0037.165
4.25 Distance disk 0.0037.027
4.26 Wing screw GN531-32-M6-10sw
4.28 Pin DIN6325D4x12
5.0 Knee case
5.1 Knee case 2.0032.125
5.2 Retaining ring DIN471A10x1
5.3 Bearing shell 2.0032.122
5.4 Washer 2.0032.123
5.5 Shim DIN988D10x16x0,1
5.6 Knee case 2.0032.119
5.7 Knee case (Poti) 2.0032.121
5.8 Knee electronics 0.0031.121
5.9 Spiral cable for knee case 0.0031.122
5.10 Lid potentiometer 2.0031.189
5.11 Shaft 2.0032.120
5.12 Countersunk screw DIN7991M4x12A2
5.13 Countersunk screw DIN7991M4x20A2
5.15 Screw thread pin DIN913M4x8sw
5.17 Shim DIN988D10x16x0,3
6.0 Femur bow
6.1 Femur bow 2.0032.001
6.2 Knurled handle GN534-32-M6-10
6.3 Right pipe thigh 2.0032.004
6.4 Left pipe thigh 2.0032.006
6.5 Stop bow femur adjustment 2.0032.127
6.6 Support 2.0032.005
6.7 Washer DIN125D2,2A2
6.8 Washer DIN125D3,2A2
6.9 Hexagonal nut DIN934M2A2
6.10 Pin DIN1481D3x16A2
6.11 Sticker precaution 0.0031.146
6.12 Sticker precaution 0.0031.147
Patient kits
No illustration Patient kit fleece 2.0032.155
No illustration Patient kit cool-quilt 2.0032.155B
No illustration Foot rest reconstruction K3 + K4 2.0032.012
No illustration Leg supports reconstruction kit K3 + K4 2.0032.013
No illustration Stereo jack connector 0.0032.200

9
7
.
How
to
perform
the
repair
7.1
How
to
remove
the
casing
(Pos.
3.12)
Move
the
ARTROMOT®
-
K3
in
a
position
of
approximately
110 degrees.
Turn the power OFF at the ARTROMOT®-K3 and remove
the power adapter.
Hit the 4 pins of the split rivet (Pos. 3.24) inwards.
Remove the 2 covering plates (Pos. 3.22)
Loosen the 2 countersunk screws (Pos. 3.50) and remove
the casing.
Remove the 4 pins of the split rivet, which are inside the
casing.
If you have exchanged any of the printed circuit boards
including the knee electronics and the hand held pro-
gramming unit or any parts of the drive technology (Pos.
3.x), you have to perform a reference run. See chapter 7.4
Finally, a function- and safetytest has to be performed.
7.2
How
to
exchange
the
hand
-
held
programming
unit
(Pos. 1.2)
Remove
the
casing.
See
chapter
7.1
Pull out the connector of the hand held programming unit.
Attention:
equipment.
Use
your
ESD
(Electro
Static
Discharge)
-
Put
in
the
c
onnector
of
the
new
hand
held
programming
unit.
Rebuild the casing.
Perform a reference run. See chapter 7.4
Finally, a function- and safetytest has to be performed.
7.3
How
to
exchange
the
motor
electronics
(Pos. 1.6)
Remove
the
c
asing.
See
chapter
7.1
Pull out the required cables at the printed circuit board
(Pos. 1.6)
Attention:
equipment.
Use
your
ESD
(Electro
Static
Discharge)
-
Exchange
the
defect
printed
circuit
board.
Put in the cables at the same position. (Pay attention to
the code)
Rebuild
the
casing.
Perform a reference run. See chapter 7.4
Finally, a function- and safetytest has to be performed.
7.4
How
to
perform
a
reference
run.
Adjust
a
maximum
femur
length
(red
Point),
a
mini
mum
lower leg length and the middle position of the foot rotation.
Under special functions select the operation
REFERENCE RUN by using „+“ and „-“. Press „SET“
for five seconds.
The
display
shows:
REFERENCE
RUN
(flashing
for
5
sec.)
FOR SERVICE ONLY
Then the display shows: REFERENCE RUN
ENTER KEY
To
start
the
reference
run
press
„+“
and
„
-
“
at
the
same
time. While the reference run is in progress the display
shows: PERFORMING R-RUN
PLEASE WAIT
The reference run starts automatically and will take up to 10
minutes. The ARTROMOT®-K3 will reach both points of
the mechanical stud (first minimum at EXTENSION after-
wards
maximum at FLEXION).
Now the ARTROMOT®-K3 moves between 0 to 110
degrees or parts of this range with different speed and will
stop at a position of 0 degrees. After the ARTROMOT®-K3
stops the display will show: REFERENCE RUN
SUCCESSFUL
The
ARTROMOT®
-
K3
is
now
ready
for
operation.
Finally, a function- and safetytest has to be performed.
Attention:
If the reference run was interrupted the display shows:
REFERENCE RUN
INTERRUPTED (The ARTROMOT®-K3 stops)
If you try to start the ARTROMOT®-K3 the display will show:
DEVICE NEEDS
REFERENCE RUN(The ARTROMOT®-K3 is inoperable)
Performe a reference run.

10
8.
Explosion
drawing
part
1

11
9.
Explosion
drawing
part
2

12
10.
Che
cklist
for
safety
-
and
function test
Safetytest
Enclosure Leakage Current EN60601-1/ VDE 0751
Or
Enclosure Leakage Current UL2601 (115 Volt)
Functiontest
1. Turn the power ON at the ARTROMOT® -K3
Measuring
Date/Signature
100 µA µA
100 µA µA
OK Error



and
press
"SET"
.
Display: Software Version K3 V40 161002
2. The set range of motion for Extension/Flexion is from -5 to 110 degrees.
Verify the angle in a position of 0 degrees with a tolerance of +/- 5 degrees.
Verify the angle in a position of 60 degrees with a tolerance of +/- 5 degrees.
Verify the angle in a position of 105 degrees with a tolerance of +/- 5 degrees.
3. Safety - OFF Functions.
Start the ARTROMOT® -K3 in a continuos mode.
Press any of the buttons to stop the motor immediately.
Verify this for all buttons.
4. Perform the following settings.
Extension: -5 degrees
Flexion: 110 degrees
Pause Ex.: 5 sec.
Pause Flex.: 10 sec.
Force: 45 kp
Speed: 100%
Adjust a maximum femur length.
5. First press "STOP" and afterwards press "START".
The ARTROMOT®-K3 should then reach both points of changing direction
within 60 to 75 seconds.
6. Change the speed to 50% and afterwards press "START".
The ARTROMOT®-K3 should then reach both points of changing direction
within 105 to 120 seconds.
7. Verify the settings for "Pause Ex." and "Pause Flex."
The tolerance for both is +/- 3 seconds.

DIN
EN
13485
ORMED
Nr.
018
829
-
01
ORMED
GmbH
&
Co.
KG
•
Merzhauser
Straße
112
•
D
-
79100
Freiburg
Tel [phone] • Fax [phone] • www.ormed.de • E-Mail: [e-mail]
St. Paul/USA,Tel [phone], Fax [phone] • Wien/A, Tel [phone],
Fax [phone]