ARTROMOT K4 User manual

Service
Manual
Starting from serial number 10000
ARTROMOT
-
K4
®

2
3.1
Electronics,
connection
cables
Table
of
contents
2.
Purpose
1.
History
3.
General
ERROR
XX
(XX
=
Number
of
the
error)
1 Potentiometer error:
Wrong angle information provided from potentiometer
-> Check the femur settings
-> Replace knee electronics (Pos. 9.11)
-> Replace motor control (Pos. 1.35)
2 Failure at the potentiometer:
Connection to the potentiometer is interrupted
-> Replace the spiral cable of the potentiometer(Pos 9.12)
-> Replace knee electronics (Pos. 9.11)
-> Replace motor control (Pos. 1.35)
3 Motor driver error:
The motor driver IC reported an error
-> Replace motor control (Pos. 1.35)
4 Motor error:
The motor did not turn properly.
-> Replace motor control (Pos. 1.35)
-> Replace the motor (Pos. 3.1)
1.
History
2
2. Purpose 2
3. General 2
4. Packing and unpacking 5
5. Block diagram of electronic parts 6
6. Bill of material for service parts 7
7. Explosion drawing part 1 12
8. Explosion drawing part 2 13
9. Special function Service menu 14
10. How to perform repairs 16
10. Checklist for safety- and function test 17
Revision
Date
Name
Change
1 31.01.2008 S. Herr Service Manual created
This
service
manual
is
to
perform
some
repairs
on
ARTROMOT®-K4 products. Repair and maintenance work
may only be carried out by authorised persons, as other-
wise
all warranty services and liabilities shall be void.
Only original parts may be used for servicing in accordance
with the attached spare part list.
Electronic devices as hand-held programming unit, motor
electronics, power supply electronics and spiral cable are
not interchangeable with
ARTROMOT®-K4 serial number < 10000.
NEW PROCEDURE to perform a reference run/ calibration.
See chapter Special function Service menu.
No plugs may be connected or disconnected while the
unit is switched on. Always switch the ARTROMOT®-K4
off before connecting or disconnecting a plug.
The locks for spiral cable for the hand-held programming
unit have to be closed at all times.
When you assembling with electronic parts make sure
to use ESD (Electro Static Discharge) equipment.
If you have to exchange any of the printed circuit boards
including the knee electronics or motor control you have
to perform a calibration.
Possible errors: Following error codes in number
will be sho
wn on the display:

3
5 Motor over current:
The current for the motor exceeded the maximum limit
-> Check the mechanics
-> Replace motor control (Pos. 1.35)
-> Replace motor (Pos. 3.1)
6 Motor control error:
Internal error in the motor control.
-> Replace motor control (Pos. 1.35)
7 Eprom access error:
Memory error in the access of the EPROM.
-> Replace hand held programming unit (Pos. 1.31)
8 CPM ROM error:
Memory error in the motor control
-> Replace motor control (Pos. 1.35)
9 Communication:
Communication to the motor control is not possible
-> Check spiral cable and connector
-> Replace hand held programming unit (Pos. 1.31)
-> Replace motor control (Pos. 1.35)
10 Unkown error in the motor control:
Unknown error in the motor control
-> Replace motor control (Pos. 1.35)
11 Motor enable timeout
Motor could not be enabled in time.
-> Replace motor control (Pos. 1.35)
12 Invalid parameter motor error:
Motor has received a invalid parameter
-> Replace motor control (Pos. 1.35)
-> Replace hand held programming unit (Pos. 1.31)
13 Stop release error:
The motor could not be released
-> Replace motor control (Pos. 1.35)
-> Replace hand held programming unit (Pos. 1.31)
14 Unexpected motor Stop:
-> Check cables and connectors
-> Replace motor control (Pos. 1.35)
15 Motor disabled:
Motor control disabled the motor.
-> Replace motor control (Pos. 1.35)
16 Wrong command in the motor :
-> Replace motor control (Pos. 1.35)
-> Replace hand held programming unit (Pos. 1.31)
17 5V supply error:
5V supply of motor control not sufficient
-> Replace motor control (Pos. 1.35)
18 Initialise error real time clock:
-> Replace hand held programming unit (Pos. 1.31)
19 Communication error real time clock:
-> Replace hand held programming unit (Pos. 1.31)
20 Error real time clock:
-> Replace hand held programming unit (Pos. 1.31)
21 Range exceeded:
The measured angle is out of the range of motion.
-> Replace motor control (Pos. 1.35)
22 ROM error in the hand held programming unit:
Memory error in the hand held programming unit
-> Replace hand held programming unit (Pos. 1.31)
23 Invalid parameter:
Internal error in the hand held programming unit
-> Replace hand held programming unit (Pos. 1.31)
24 24V supply error motor control:
Error in the 24V supply in the motor control
-> Replace motor control (Pos. 1.35)
-> Replace the power supply electronics (Pos. 1.41)
25 Bus error:
Bus system error
-> Replace spiral cable of the hand held programming unit
-> Replace hand held programming unit (Pos. 1.31)
-> Replace motor control (Pos. 1.35)
26 24V supply hand held programming unit:
24V supply of the hand held programming unit is
defective
-> Replace hand held programming unit (Pos. 1.31)
27 5V supply hand held programming unit:
5V supply of the hand held programming unit is defective.
-> Replace hand held programming unit (Pos. 1.31)
28 3.3V supply hand held programming unit:
3.3V supply of the hand held programming unit is
defective
-> Replace hand held programming unit (Pos. 1.31)
29 Calibration:
The calibration data in the motor control are wrong.
-> Perform a calibration
30 Calibration error:
-> Repeat the calibration
-> Replace knee electronics (Pos. 9.11)
-> Replace motor control (Pos. 1.35)
31 Calibration timeout:
-> Replace motor control (Pos. 1.35)
32 Motor enable error:
The motor could not be enabled
-> Replace motor control (Pos. 1.35)
33 Motor disable error:
The motor could not be disabled
-> Replace motor control (Pos. 1.35)
34 Motor stop error:
Motor stop command timeout error:
-> Replace motor control (Pos. 1.35)
35 Configuration error:
Invalid configuration of the hand held programming unit
-> Replace hand held programming unit (Pos. 1.31)

4
45 Wrong product combination:
Mixup between non compatible device and hand held
programming unit
-> Use the correct hand held programming unit (Pos. 1.31)
46 Handset error internal communication:
Invalid interchip communication inside the hand held
programming unit
-> Replace hand held programming unit (Pos. 1.31)
47 Internal communication error motor control:
Internal communication error motor control..
-> Replace motor control (Pos. 1.35)
48 User stoped the special function
49 Unknown error in the motor control:
-> Replace motor control (Pos. 1.35)
3.2
Mechanics
The threaded spindle and spindle nut is not
interchangeable with ARTROMOT®-K4
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.
The frame is unstable:
Possible cause: Bolt / screws missing or loose. Tighten
the screws / bolts.
3.3 Others
Do not clean the casing or the support with grease
or oil.
Do not utilize any solvent for cleaning the
ARTROMOT®-K4.

The
following
settings
must
be
made
to
transport
the
ARTROMOT®
-
K4:
5
4.
Packing
and
unpacking
Set the packing setting in the menu or move the devi
ce in a position of
EXTENSION
=
1
0
degrees.
Switch off the device.
Remove power cord and disconnect the hand-held programming unit.
Remove the the femur extension assembly.
For transportation, use the original packaging.
Put the hand-held programming unit and the femur extension assembly into a extra box.
Set the angle joint horizontal.
Put three extra protection for the knee joint on the device as shown on the figure below.
Move the two styrofoam parts on the device.
Put the device with the styrofoam parts in the carton.
First put the power cord in the extra box, the femur extension assembly in the extra box, the hand held programming unit in
the extra box and the extra pad in the packing as shown in figure below.
Power cord in
the extra box
Hand held programming unit in the
extra box and on top of it the extra pad
Extra protection for the knee joint
Femur extension assembly
in the extra box

6
5.
Block
diagramm
of
the
electronic
parts
Display
Control
-
logic
Motor
driver
Micro
-
processor
Motor
Control
Hand
-
held programming unit
Microprocessor
Control
-
logic
Pot.
Control
Motor
Pot.
Power
s
upply
24
V
DV
Keypad
5
2
24
V
Ground
Memory
Clock
Stop

6.
Bill
of
material
for
service
parts
Position
Description
Ordernumber
Electronics
1.30 Power cord EU version 0.0034.118
Power cord USA version 0.0034.011
1.31 Hand held programming unit K4 with spiral cable SN > 10000 0.0031.400
1.32 Spiral cable for hand held programming unit 2.0037.035
1.33 Rubber mat 2.0031.235
1.34 Base plate complete 2.0031.005
1.35 Motor control K4 SN > 10000 2.0031.921
1.36 Distance piece 0.0031.017
1.39 Cable retainer 0.0031.003
1.40 Wire set 2.0031.036
1.41 Power supply electronics 0.0034.244
1.42 Wire set K3 K4 2.0032.139
1.43 Wire set hand held programming unit 2.0037.004
1.44 Nomex insolation paper 2.0031.239
1.45 Pan head screw DIN912M3x6
1.46 Wire set power connector 2.0038.017
1.47 Cable retainer 0.0013.118
1.48 Self –adhesive tie mounts 0.0013.001
1.49 Grounding connector 2.0034.358
1.50 Hex-nut DIN934M4vz
1.51 Serrated washer DIN6798AD4,3vz
1.53 Fuses holder 0.0034.246
1.54 Fuse 1 AT 0.0000.005
1.55 Grounding connector 0.0034.126
1.56 Grounding symbol 0.0038.058
1.57 Puffer 2.0031.238
1.58 Washer DIN125D4,3vz
1.59 Hexagon head screw DIN933M4x40vz
1.60 Head screw LIKOM4x8A2
1.61 Washer DIN125D4,3vz
1.62 Power switch (ON/OFF) with connection 0.0034.245
1.63 Holding clip 0.0031.004
1.64 Protection for hand held programming unit 0.0037.103
7

8
Position
Description
Ordernumber
Exterior underframe
2.40 Right profile 2.0031.244
2.41 Left profile 2.0031.243
2.42 Rubber mat femur 2.0031.234
2.43 Lip 2.0031.193
2.44 Interior slit 750 mm 2.0031.155
2.45 Interior slit 125 mm 2.0031.242
2.47 Shaft bearing 2.0031.112
2.48 DU collar 0.0031.110
2.49 Interior slit 480 mm 2.0031.197
2.50 Interior slit 190 mm 2.0032.156
2.51 Exterior slit 870 mm 2.0031.168
2.52 Connecting plate 2.0031.233
2.55 Thread plate M6 962.901
2.56 Pan head screw DIN912M6x8A2
2.57 Pan head screw 2.0031.166
2.58 Blind rivet DIN7337D4ALST1
2.59 Sping wire 0.0031.300
2.64 Inplementation spout 0.0031.145
2.65 Left cover 2.0031.110
2.66 Right cover 2.0031.111
2.67 Threaded plate 962.903
2.68 Split pin DIN1481D3x12
Drive technology
3.1 Motor including transmission 0.0031.100
3.2 Left slide 2.0031.109
3.3 Right slide 2.0031.108
3.4 Threaded spindle 2.0031.212
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
3.13 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

9
Position
Description
Ordernumber
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
3.26 Retaining ring DIN471A8x0,8
3.27 Rubber buffer 0.0031.109
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
3.54 Sticker ARTROMOT K4 right 2.0031.241
3.55 Sticker ARTROMOT K4 left 2.0031.240
3.60 Housing K4 complete with stickers SN > 10000 0.0031.232
Femur extension
Femur extension assembly (7.1 –7.8) 2.0031.051
7.1 Leaf Spring 2.0031.143
7.2 Stud bolt 2.0031.142
7.3 Square tube 2.0031.025
7.4 Push-button 2.0031.141
7.5 Dwell bolt GN617-5-A-NI
7.6 Countersunk screw DIN7991M4x8A2
7.7 Hexagonal nut DIN985M4vz
7.8 Nut 0.0031.106
Ankle joint
8.5 Washer 0.0031.111
8.10 Fastening band 0.0031.144
8.11 Rigid pipe 2.0031.117
8.12 Knurled handle 2.0031.031
8.13 Washer DIN440D6,6vz
8.14 Hinge box 2.0031.119

10
Position
Description
Ordernumber
8.15 Washer 2.0031.118
8.18 Nut 0.0031.108
8.19 Nut 0.0031.105
8.20 Supporting disk 2.0031.213
8.21 Akle joint bow 2.0037.163
8.22 Base plate 2.0037.168
8.23 Countersunk screw DIN79991M5x12A2
8.24 Ankle joint nut 2.0037.165
8.25 Distance disk 0.0037.027
8.26 Wing screw GN531-32-M6-10sw
8.28 Pin DIN6325D4x12
8.29 Holder hand held programming unit 2.0037.166
8.30 Rivet top part 0.0028.300
8.31 Rivet buttom part 0.0028.301
Knee case
9.1 Cover knee case 2.0031.245
9.2 Retaining ring DIN471A10x1
9.3 Bearing shell 2.0031.146
9.4 Knee case 2.0031.231
9.5 Disk 2.0031.248
9.6 Shim DIN988D10x16x0,1
9.7 Catch 2.0031.150
9.8 Shaft 2.0031.147
9.9 Knee case potentiometer 2.0031.247
9.10 Cover knee case potentiometer 2.0031.246
9.11 Knee electronics 2.0031.033
9.12 Spiral cable for knee electronics 0.0031.122
9.13 Thread grooving screw 0.0031.013
9.14 Cylinder pin DIN6325D5x40
9.15 Threaded pin DIN913M6x6A2
9.16 Shim DIN988D10x16x0,1
9.17 Plastic bolt DIN964M3x12PA
Femur bow
10.1 Frame (shank) 2.0031.027
10.2 Knurled handle GN534-32-M6-10
10.3 Frame (thigh) 2.0031.028
10.4 Tube end plug 2.0031.023
10.5 Retaining ring DIN472I20x1
10.6 CB-Disc spring 0.0028.109
10.7 Compression spring 2.0031.179