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

11
Position
Description
Ordernumber
10.8 Bolt 2.0031.127
10.9 Knurled handle 2.0031.135
10.10 Joint bolt 2.0031.237
10.11 Femur tube 2.0031.236
10.12 Split pin DIN1481D3x16
10.13 Disc 0.0037.027
10.14 Tube 2.0031.139
10.15 Washer DIN9021D6,4vz
10.16 Flat head screw 0.0031.025
10.17 Flat head screw DIN921M3x5A2
10.18 Screw thread in DIN914M5x6A2
10.19 Edge-protection profile 2.0031.202
10.20 Sticker (lock insert) 0.0031.153
10.21 Sticker (insert) 0.0031.152
10.23 Sticker (PRECAUTION) 0.0031.146
10.24 Round nut 0.0031.026
Patient kits
No illustration Patient kit fleece 2.0032.155
No illustration Patient kit cool-quilt 2.0032.155B
.

12
7. Explosion drawing part 1

13
8. Explosion drawing part 2
13

14
Function
of
service
Menu
Calibration
Display contrast
Error log
Device runtime
Entering
the
service
menu:
Press
the
menu
key
until
Service
Menu
shows up (menu 3).
Press for for 5 seconds,
is flashing on the display.
The display will change and show:
Entering code.
For the code press: 1 3 2 4
Now you see the symbols of the service menu
9.1
Calibration
Adjust a maximum femur length, a min
imum lower leg
length, hip axis in smallest position and the middle
position of the foot rotation.
Press the symbol calibration .
Display:
Press + or
-
to
move
the
ARTROMOT®
-
K4
to
0
degrees.
Press START, the calibration starts automatically. The
device will reach both maximum points and move
between –10 bis 125 degrees with different speed.
Wait until the ARTROMOT®-K4 stops.
If the calibration was succesful the device stops at
0 degrees and show following symbols on the display:
Display:
Press
STOP
twice
to
leave
the
service
menu.
Finally,
a
safety
and
function
test
has
to
be
performed
(see chapter 11).
9.2
Display
contrast
Press
the
symbol
display
contrast
.
Display:
XX
%
Press + or
-
to
set
up
the
requested
display
contrast.
You
can
set
the
display
contrast
from
0
–
100%.
Press
STOP
twice
to
save
the
settings
and
leave
the
service
menu.
ATTENTION!
Before you do a calibration switch the device
OFF and ON.
9.
Special
function
Service
Menu

15
9.3
Error
log
Press
the
symbol
error
log
You will find following information on the display:
Upper line: Number of the current showed error message
and the total number of the saved error messages.
Right number is the error code of the error message (see
chapter 3.1)
Lower line: Error message
Left side: The symbol of the causer.
= Hand held programming unit = Motor
Press + or - to see the entries of the error log.
Press STOP twice to leave the service menu.
General
note
to
the
error
log:
Entries
are
always
in
english.
The entries are ordered by causer and not in temporal
order.
9.4
Device
runtime
Press
the
symbol
device
runtime
.
The display shows the device runtime
Display: XX (XX = Runtime in hours).
Press
STOP
twice
to
leave
the
service
menu.

16
10.
How
to
perform
repairs
10.1
How
to
remove
the
housing
cover
(Pos.
3.60).
Remove
the
housing
cover,
see
chapter
10.1.
Pull out the connectors of the motor control.
Loosen the four screws.
Exchange the defective motor control and fix it with the
screws.
Put back in the connectors in the same position.
3-pin connector 2-pin connector
Rebuild the housing cover.
A calibration has to be performed.
Finally, a safety and function test has to be performed.
10.3
How
to
exchange
the
power
supply
electronics
(Pos. 1.41).
ATTENTION!
When you assembling with electronic parts make sure
to use ESD (Electro Static Discharge) equipment.
Remove
the
housing
cover,
see
chapter
10.1.
Pull out the connectors of the power supply electronics.
Loosen the four screws.
Exchange the defective electronics and fix it with the
screws.
Put back in the connectors in the same position.
Rebuild the housing cover.
A calibration has to be performed.
Finally, a safety and function test has to be performed.
10.4
Repairs of the drive unit.
Move
the
ARTROMOT®
-
K4
in
a
position
of
approximately
110 degrees.
Turn the power OFF at the ARTROMOT®-K4 and remove
the power cord.
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
programming unit or any parts of the drive technology,
you have to perform a calibration. See chapter 9.1.
Finally, a safety and function test has to be performed.
10.2
How
to
exchange
the
motor
control
(Pos.
1.35).
ATTENTION!
When you assembling with electronic parts make
sure to use ESD (Electro Static Discharge) equipment.
ATTENTION!
Only authorized and certified staff may perform repairs
and maintenance at the drive unit otherwise the
manufacturer´s warranty and liability will be invalidated.

Safety
test
Protective earth conductor resistance
Ground leakkage current EN 60601 / IEC 601/ VDE 0751
Or
Ground leakkage current as in UL 2601
Function test
1. Switch on the ARTROMOT® K4. Press the two outer buttons simultaneously.
Measured
value
Date/
Signature
0,1 Ohm Ohm
500 µA µA
300 µA µA
OK Error
Display:
Software
version
VX.X
XX.XX.XX
(X
=
optional)
Keep
on
pressing.
Display: ARTROMOT K4 “Product version”
2. The
maximum
range
of
motion
for
Extension/
Flexion
is
-
10
to
125
degrees.
Check
the
angle
in
position
0
degrees.
Tolerance
+/
-
5
degrees.
Check the angle in position 60 degrees. Tolerance +/- 5 degrees.
Check the angle in position 100 degrees. Tolerance +/- 5 degrees.
3. Check
the
emergency
-
off
function.
Start the ARTROMOT® K4 in any mode.
Press
any
key,
the
ARTROMOT®
K4
will
stop
immediately.
Check this for all keys.
4. Set
up
the
special
function
“new
patient“
press to
activate
it.
Press
START
.
The
ARTROMOT®
-
K4
will
move
automatically
to
30
degrees
and stop there.
5. Check the set values of “new patient”
Extension
Flexion
Speed
Reverse
Therapy Duration
-
>
->
->
->
->
Display:
25°
Display: 35°
Display: 100 %
Display: 25
Display: 00:00
6. Start
the
ARTROMOT®
-
K4
in
the
motion
range
between
–
10
to
120
degrees.
Set the speed to 100%.
Both
extreme
points
should
be
reached
within
70
–
100
seconds.
7. All
special
funtion
are
deactivated.
Select
a
therapy
time
of
3
minutes.
At
the
end
of
the
3
minutes
the
ARTROMOT®
-
K4
will
stop automatically
in the set up value of extension + 10 degrees.
17
11.
Checkl
ist
of
safety
and
function
test
ARTROMOT®
-
K4

DIN
EN
13485
ORMED
Nr.
018
829
-
01
ORMED
GmbH
&
Co.
KG
•
Merzhauser
Straße
112
•
D
-
79100
Fre
iburg
Tel [phone] • Fax [phone] • www.ormed.de • E-Mail: [e-mail]