Chattanooga Intelect Genisys 2776 Intelect Genisys 2782 Intelect Genisys... User manual

SERVICE
M
MANUAL
Ultrasound Therapy Systems
ISO 13485 CERTIFIED
Ultrasound Therapy System
Models:
2776 - Serial numbers 1000 and above
2782 - Serial numbers 1000 and above
2792 - Serial numbers 1000 and above
®

Intelect®/Genisys®Ultrasound Therapy Systems
TABLE of CONTENTS
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1- Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2- Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3- Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Intelect/Genisys Ultrasound Therapy System . . . . . . . . . . . . .4
Intelect/Genisys Ultrasound Symbol Definitions . . . . . . . . . . .5
4- Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
5- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
5.1 Intelect/Genisys Ultrasound Software Error Messages .7-9
5.2 Intelect/Genisys Ultrasound Diagnostics . . . . . . . . . . . .10
5.3 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.4 Leakage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.5 Unit Startop and Fan Testing . . . . . . . . . . . . . . . . . . . . .11
5.6 Ultrasound Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.7 Ultrasound Applicator Identification Test . . . . . . . . . . . . .12
5.8 Ultrasound Applicator Output Test . . . . . . . . . . . . . . . . .13
5.9 Ultrasound Duty Cycle Test . . . . . . . . . . . . . . . . . . . . . .14
6- Removal & Replacement . . . . . . . . . . . . . . . . . . . . . . . .15-20
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6.2 Top & Bottom of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6.3 Fan Removal & Replacement . . . . . . . . . . . . . . . . . . . . .16
6.4 Power Supply Removal & Replacement . . . . . . . . . . . . .17
6.5 Ultrasound Board Removal & Replacement . . . . . . . . . .18
6.6 LCD Display Removal & Replacement . . . . . . . . . . . . . .19
6.7 Control Board Removal & Repalcement . . . . . . . . . . . . .20
7- Ultrasound Applicator Calibration . . . . . . . . . . . . . . . . . .21
8- Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-27
9- Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-33
10- Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
©2004 Encore Medical Corporation or its affiliates, Austin, Texas, USA. Any use of editorial, pictorial or layout composition of this publication without express written consent
from the Chattanooga Group of Encore Medical, L.P. is strictly prohibited. This publication was written, illustrated and prepared for print by the Chattanooga Group of Encore
Medical, L.P.

Intelect®/Genisys®Ultrasound Therapy Systems
1
FOREWORD
Read, understand and follow the Safety Precautions and information contained in this manual.
This manual contains the necessary safety, and field service information for those Field Service Technicians,
approved by Chattanooga Group, to perform field service on the Intelect/Genisys Ultrasound Therapy Systems.
At the time of publication the information contained herein was current and up to date. However, due to
continual technological improvements and increased clinical knowledge in the field of electrotherapy, as well as
Chattanooga Group’s policy of continual improvement, Chattanooga Group reserves the right to make periodic
changes and improvements to their equipment and documentation without any obligation on the part of
Chattanooga Group.
It is the sole responsibility of field technicians to stay informed and trained in the latest technology utilized in
the Intelect/Genisys Ultrasound Therapy Systems by Chattanooga Group. From time to time, as significant
improvements are incorporated, Service Bulletins will be produced and made available on our web site
(www.chattgroup.com) in lieu of reprinting a complete manual prematurely. These Service Bulletins will provide
updated service information and technology improvements to the Intelect/Genisys Ultrasound Therapy Systems
for use by certified service technicians.
“Certified Service Technician” Definitions;
1. Level I- Those Field Service Technicians that have successfully completed the minimal training required by
Chattanooga Group in basic service techniques.
2. Level II- Those Field Service Technicians that have successfully completed Level I Training as well as
Level II training as required to perform specific troubleshooting and repair techniques and
procedures.
3. Level III- Those Field Service Technicians that have successfully completed Levels I & II Training as well as
Level III Advanced Training as required to perform all necessary Troubleshooting and Repair
techniques. The Technician having successfully completed the three levels of training and coupled
with experience should have the ability to train other technicians in Level I and Level II Training
with the necessary Training Materials from Chattanooga Group.
4. Temporary- Chattanooga Group, at its discretion and based on known experience of the technician, may
grant a “Temporary Certification” to a field technician for particular troubleshooting and repair
of a specific system requiring immediate attention. This “Temporary Certification” in no fashion
acknowledges the training level of a technician as defined above. This “Temporary
Certification” is utilized only in unique situations for a specific unit for a specific service
technique only and is documented as such.
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.
This equipment is to be used only under the prescription and supervision of a licensed medical practitioner.
This equipment is to be serviced only by a “Certified Service Technician”.

1.1 Precautionary Symbol Definitions
The precautionary instructions found in this manual are
indicated by specific symbols. Understand these
symbols and their definitions before operating or
servicing this equipment. The definitions of
these symbols are as follows;
A. CAUTION
Text with a “CAUTION” indicator will explain
possible safety infractions that have the potential to
cause minor to moderate injury or damage to
equipment.
B. WARNING
Text with a “WARNING” indicator will explain
possible safety infractions that will potentially cause
serious injury and equipment damage.
C. DANGER
Text with a “DANGER” indicator will explain
possible safety infractions that are imminently
hazardous situations that would result in death or
serious injury.
D. EXPLOSION HAZARD
Do not use this equipment in the presence
of flammable anesthetics. This symbol is
also prominently displayed on the serial
number plate of the unit.
E. DANGEROUS VOLTAGE
Text with a “Dangerous Voltage” indicator serves to
inform the Service Technician of possible hazards
resulting in the electrical charge retained by faulty
power supplies.
F. CORROSIVE HAZARD (NiMH Battery)
Text with a “Corrosive Hazard” indicator
will explain possible safety infractions if the
chemical components of this product are
exposed to air, skin or other materials.
G. NOTE:
Throughout this manual “NOTE” may be found.
The Notes are helpful information to aid in the
particular area or function being described.
1.2 Safety Precautions
Read, understand and follow all safety precautions
found in this manual. Below are general safety
precautions that must be read and understood before
attempting any service techniques on these units.
Throughout this manual specific safety precautions will
be found. Read, understand and follow all safety
precautions.
• Read, understand and practice the precautionary
and operating instructions. Know the limitations
and hazards associated with using any ultrasound
device. Observe the precautionary and operational
decals placed on the unit.
•DO NOT operate the Intelect or Genisys when
connected to any unit other than Chattanooga
Group devices. Do not operate the unit in an
environment of short-wave diathermy use.
•The Ultrasound modality should be routinely
checked before each use to determine that all
controls function normally; especially that the
intensity control does properly adjust the intensity
of the ultrasonic power output in a stable manner.
Also, determine that the treatment time control
does actually terminate ultrasonic power output
when the timer reaches zero.
• Use of controls or adjustments or performance of
procedures
other than those specified herein may
result in hazardous exposure to ultrasonic energy.
•DO NOT use sharp objects such as a pencil point
or ballpoint pen to operate the buttons on the
control panel as damage may result.
•Operate, transport and store this unit in
temperatures between 59 °F and 104 °F (15 °C
and 40 °C), with Relative Humidity ranging from
30%-60%.
• Inappropriate handling of, and subjecting the
ultrasound applicator to physical abuse, may
adversely affect its characteristics.
• Inspect Sound Head for cracks, which may allow
the ingress
of conductive fluid before each use.
•Inspect all cables, leads and associated
connectors before each use.
Intelect®/Genisys®Ultrasound Therapy Systems
2
1- SAFETY PRECAUTIONS
!
CAUTION
WARNING
!
!
!
CAUTION
DANGER

2- THEORY of OPERATION
2.1 Overview
The Intelect/Genisys Ultrasound Therapy Systems are comprised of several PC board assemblies housed within a
common enclosure. These assemblies each support a distinct function in the product. The basic elements are User
Interface, Control Board, Ultrasound Board, Ultrasound Applicator, and Power Supply Circuits.
2.2 Power Supply Circuits
A universal input power supply provides all parts of the system with 12 volts DC. The supply is connected to the mains
at all times when the cord is attached. The power switch on the top of the unit, switch the 12V output of the power
supply to the different components in the system by way of the Power Distribution Board. The 12V supply is regulated
locally at each PC board as required.
2.3 Control Board
The Control Board serves just as its name implies. It controls the operation of the ultrasound board, user interface and
optional accessories. The control board communicates to the ultrasound board through a proprietary 8-bit parallel bus.
The control board drives the display. The control board reads the menu buttons. The control board also reads the
amplitude and the contrast control on the system. Sound output is generated by the control board and routed to an
internal speaker.
2.4 Ultrasound Board and Applicator
The ultrasound board generates the 1 or 3.3 MHz output to drive the ultrasound Sound Head. The ultrasound
board is accessed much like an I/O port by the control board. It can provide current and voltage information
about the ultrasound output of the board. The calibration data for the Sound Head is passed through the
ultrasound board from the applicator up to the control board. By storing the calibration data in the applicator
there is no calibration necessary for the ultrasound board. Calibrated Chattanooga Group Ultrasound Applicators,
designed specifically for the Intelect/Genisys Ultrasound Therapy Systems, can be connected and operated to
provide accurate coupling and output.
2.5 User Interface and Accessories
The LCD display panel provides the operator visible feedback in the way of menu choices. Pressing the menu
buttons makes selections from the menus. The control board interprets these user inputs and responds
accordingly. Audible feedback is given as well for events such as keypresses and end of treatment.
The Optional Battery mounts in the system bottom and supplies 24 VDC to the power supply. The Power Supply
distributes the power required to the system as needed. The charging circuit for the battery is incorporated on the
Control PCB. An icon on the display reflects the available amount of charge in the battery. When the system is
connected to an approved power outlet and a battery is installed in the system, the system will charge the battery
to full capacity. The incorporated charger will not overcharge the battery.
Intelect®/Genisys®Ultrasound Therapy Systems
3

3- NOMENCLATURE
3.1 Intelect/Genisys Ultrasound Therapy System
The nomenclature graphics below, Figure 3.1, indicates
the general locations of the exterior components of the
Ultrasound Therapy System.
Know the components and their functions before
performing any operation on or service to the Ultrasound
Therapy System.
FIGURE 3.1
1. On/Off Switch- Turns system On and Off.
2. Fan Grill- Allow exhaust of air circulated by system fan.
3. LCD Contrast Knob-Adjusts contrast of LCD Display.
4. Plynth- Allows for wall mounting or sitting on a flat surface.
5. Ultrasound Applicator- Used to administer Ultrasound
Therapy to patient.
6. Applicator LED Indicator- Flashes 5 times upon connecting
applicator to system. Illuminates constantly when applicator
is coupled to patient treatment area.
7. Ultrasound Intensity Button- Used to increase and
decrease ultrasound output intensity.
8. Ultrasound Applicator Hook- Used to store applicator when
not in use.
9. Ultrasound Applicator Connector- Used to connect the
Ultrasound Applicators to the System
10. Treatment Start Button- Press to start therapy session.
11. Treatment Pause Button- Press to pause therapy session.
Press again to continue session.
12. Treatment Stop Button- Press to completely stop therapy
session.
13. Multi-Control Button- Press the respective icon on this
button to change parameters and to scroll through Clinical
Resources Library
14. Treatment Time Button- Press to adjust treatment time up
or down.
15. Clinical Resources Library Button- Press to access the
Clinical Resources Library.
16. LCD Display- Displays necessary information for operation
and maintenance.
17. Mains Power Cord- Connects system to required electrical
outlet.
Not Illustrated- Battery Access Cover located beneath the
plynth.
Intelect®/Genisys®Ultrasound Therapy Systems
4
1
23
4
5
6
7
8
9
10
11
12
13
14
15
16
17

5
3- NOMENCLATURE
3.2 Intelect/Genisys Ultrasound Symbol Definitions
The graphic symbols listed below can be found on the
Ultrasound Therapy System and within the software.
Become familiar with these symbols and their definitions
prior to any operation, mainteneance or repairs of the
system.
Intelect®/Genisys®Ultrasound Therapy Systems
On/Off Switch-
Flashes when plugged into
power outlet. Illuminates steady when system
is On
Stop Treatment-
Press to stop therapy session.
Pause Treatment-
Press to pause therapy session
and retain time remaining. Press again to continue
therapy session
Start Treatment-
Press to start therapy session
Ultrasound Applicator-
Indicates connector for the
ultrasound applicators.
Clinical Resources-
Press to access the Clinical
Resourses area of the system software.
Increase-
Found in two locations on the system,
press to increase session time and/or ultrasound
intensity respectively.
Decrease-
Found in two locations on the system,
press to decrease session time and/or ultrasound
intensity respectively.
Charge Level-
This icon indicates the charge
level of the battery, if installed.
Battery Charging-
Indicates the system is charging
the battery when plugged into power outlet.
Frequency
Press to change frequency to 3.3 MHz or
1MHz
Intensity Display-
Press to display “Watts” or
“Watts per cm2“ for the output of the ultrasound.
Intensity Control-
Press the Increase or
Decrease symbol to adjust ultrasound intensity
to the prescribed level.
Duty Cycle-
Press to select and display the Duty
Cycle of the Ultrasound as prescribed. Options
avaliable are: 10%, 20%, 50, or Continuous (100%).
LCD Display Contrast-
Located on the Fan Grill, this
indicates the control to increase or decrease the
LCD Display contrast.
Treatment Time-
Press the Increase or Decrease
symbol to adjust ultrasound treatment time to the
prescribed level.
Head Warming-
Press to turn Off or On the Head
Warming feature of the system.
Back-
Press to return back one screen on the LCD
Display.
Scroll Up-
Press to scroll up when making menu
selections
Scroll Down-
Press to scroll down when making
menu selections
Accept & Return-
Press to accept menu
selection and to return to the Home Screen

Intelect®/Genisys®Ultrasound Therapy Systems
6
4- SPECIFICATIONS
4.1 Intelect/Genisys Ultrasound Therapy System
Physical Specifications
A. Dimensions
1. 28.8 cm (11.3”) Width
32.8 cm (12.9”) Depth
16.3 cm (6.4”) Height
2. 2.3 kg (5.07 lbs) with 5 cm2Applicator and Plynth
3. Case Material: Polycarbonate Plastic
4. Optional Battery Weight: 0.85 kg (1.87 lbs)
B.Outputs
One Ultrasound Output
C. Ultrasound Applicator Sizes Available
1. 1 cm2
2. 2 cm2
3. 5 cm2(Standard)
4. 10 cm2
D. Power Input Requirements
1. 100-240VAC, 50/60 Hz, 75W
4.2 Intelect/Genisys Ultrasound Specifications
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MHz, +/- 5%; 3.3 Mhz, +/- 5%
Duty Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10%, 20%, 50%, Continuous
Pulse Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Hz
Pulse Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1mSec, +/-20%
2mSec, +/-20%
5mSec, +/-20%
Output Power
10cm2Crystal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-20 Watts at 1MHz
0-10 Watts at 3.3 MHz
5cm2Crystal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10 Watts, 1 and 3.3 MHz
2cm2Crystal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 Watts, 1 and 3.3 MHz
1cm2Crystal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 Watts 3.3 MHz Only
Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 2.5 w/cm2in continuous mode,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 w/cm2in pulsed modes
Output accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +/- 20% above 10% of maximum
Temporal Peak to Average Ratios: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:1, ± 20%, at 50% Duty Cycle
5:1, ± 20%, at 20% Duty Cycle
9:1, ± 20%, at 10% Duty Cycle
Beam Nonuniformity Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 : 1 maximum
Beam Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Collimating
Effective Radiating Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10cm2Crystal - 8.5cm2, +/- 1.5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 cm2Crystal - 4.0cm2, +/- 1.0
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2cm2Crystal - 1.8cm2, +0.2/-0.4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1cm2Crystal - 0.8cm2, +0.2/-0.4
Treatment Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60 Minutes
Ultrasound Head Warming Feature. . . . . . . . . . . 50% of maximum output until Crystal Temp reaches approx. 38 °C (100 °F)
then 10% of maximum or Off to maintain Temperature

5- TROUBLESHOOTING
5.1 Intelect/Genisys Ultrasound Software Error Messages
A. The information provided below is intended to aid in
defining the Software Error Messages of the Ultrasound
Therapy System. Once a particular Error Message is
defined the information will also list probable causes
and possible remedies. Once the problem area is
determined subsequent diagnostics for verification
will be necessary to determine “Bad Board”. All
diagnostic tests will be to validate a “Bad
Board” only. No component level troubleshooting
information is or will be provided by Chattanooga
Group for field troubleshooting of board components.
Error messages in the range of 100 to 199 are
primarily user definable and remedied by following
the instructions given by the unit. Error meesages
in the ranges of 200- 299 and 300-399, require the
attention of a field technician certified by
Chattanooga Group in order to perform the
necessary diagnostics and properly replace any
necessary components.
B. Once a particular PCB has been determined as
bad, refer to the appropriate Removal and
Replacement Section for the board affected for
proper instructions for replacement of the board.
Intelect®/Genisys®Ultrasound Therapy Systems
7
CODE No. TYPE MESSAGE PROBABLE CAUSES POSSIBLE REMEDIES
Icon- Sound Head
overtemp
1. Sound Head has overheated to a
temperature that could cause damage
to the crystal.
A. Turn Off Head Warming feature.
B. Allow Sound Head to cool before
continuing therapy.
C. Connect a known good Applicator to
the system and try again. If system
works properly, re-calibrate Applicator
or replace with new Applicator.
Icon- No applicator
plugged into
system
1. Applicator not plugged into system
connector.
2. Applicator connector not completely
seated in system connector.
3. Applicator Cable disconnected from
Applicator PCB.
4. Applicator cable damaged.
5. Applicator not calibrated
6. Bad Ultrasound Board
A. Plug Applicator into system.
A. Make certain Applicator connector is
completely seated in system
connector.
A. Connect Applicator Cable to
Applicator PCB
A. Replace with new Applicator.
A. Calibrate Applicator.
A. Replace Ultrasound Board
100 WARN_US_UNPLUGGED
Technician attempted to
calibrate an ultrasound
applicator but none is
plugged into system.
1. Applicator not plugged into system
connector.
2. Applicator connector not completely
seated in system connector.
3. Applicator Cable disconnected from
Applicator PCB.
4. Applicator cable damaged.
A. Plug Applicator into system.
A. Make certain Applicator connector is
completely seated in system
connector.
A. Connect Applicator Cable to
Applicator PCB
A. Replace with new Applicator.
101 WARN_US_APPL_
BECAME_UNPLUGGED
Applicator came unplugged
from system while
administering therapy.
1. Applicator not plugged into system
connector.
2. Applicator connector not completely
seated in system connector.
3. Applicator Cable disconnected from
Applicator PCB.
4. Applicator cable damaged.
A. Plug Applicator into system.
A. Make certain Applicator connector is
completely seated in system
connector.
A. Connect Applicator Cable to
Applicator PCB
A. Replace with new Applicator.

Intelect®/Genisys®Ultrasound Therapy Systems
8
5- TROUBLESHOOTING
5.1 Intelect/Genisys Software Error Messages (Continued)
CODE No. TYPE MESSAGE PROBABLE CAUSES POSSIBLE REMEDIES
200 ERR_EEPROM
Error accessing the internal
EEPROM used to store
system configuration
settings and protocols.
1. Bad Control Board A. Replace Control Board.
201 ERR_APPL_SAVE_CAL_
DATA
Error attempting to save
data to applicator EEPROM
during applicator
calibration.
1. Bad Applicator
2. Bad Applicator Cable
3. Applicator PCB Connector Bad
4. Bad Ultrasound Board
A. Replace with known good Applicator.
A. Replace with known good Applicator.
A. Replace Ultrasound Board.
A. Replace Ultrasound Board.
202 ERR_APPL_NOT_
CALLED_OK
General error attempting to
calibrate an applicator.
1. Bad Applicator
2. Bad Applicator Cable
3. Applicator PCB Connector Bad
4. Bad Ultrasound Board
A. Replace with known good Applicator.
A. Replace with known good Applicator.
A. Replace Ultrasound Board.
A. Replace Ultrasound Board.
203 ERR_APPL_SAVE_
TIMEOUT
Error attempting to save
data to applicator EEPROM
during applicator calibration
1. Bad Applicator
2. Bad Applicator Cable
3. Applicator PCB Connector Bad
4. Bad Ultrasound Board
A. Replace with known good Applicator.
A. Replace with known good Applicator.
A. Replace Ultrasound Board.
A. Replace Ultrasound Board.

Intelect®/Genisys®Ultrasound Therapy Systems
9
CODE No. TYPE MESSAGE PROBABLE CAUSES POSSIBLE REMEDIES
300 CRIT_ERR_US_BOARD
Some type of critical
ultrasound board error has
occurred.
1. Ultrasound Board to Control Board
Connecting Header loose or
disconnected.
2. Bad Ultrasound Board.
3. Bad Control Board.
A. Reseat Connecting Header into
Control Board.
A. Replace Ultrasound Board.
A. Replace Control Board.
301 CRIT_ERR_US_BOARD_
NOT_DETECTED
No ultrasound board is
detected in unit.
1. Ultrasound Board to Control Board
Connecting Header loose or
disconnected.
2. Bad Ultrasound Board.
3. Bad Control Board.
A. Reseat Connecting Header into
Control Board.
A. Replace Ultrasound Board.
A. Replace Control Board.
302 CRIT_ERR_US_RESET
Ultrasound board has reset
for some unknown reason.
1. Ultrasound Board to Control Board
Connecting Header loose or
disconnected.
2. Bad Ultrasound Board.
3. Bad Control Board.
A. Reseat Connecting Header into
Control Board.
A. Replace Ultrasound Board.
A. Replace Control Board.
303 CRIT_ERR_US_BOARD_
READ
Error reading from
ultrasound board.
1. Ultrasound Board to Control Board
Connecting Header loose or
disconnected.
2. Bad Ultrasound Board.
3. Bad Control Board.
A. Reseat Connecting Header into
Control Board.
A. Replace Ultrasound Board.
A. Replace Control Board.
304 CRIT_ERR_US_
BOARD_WRITE
Error writing to ultrasound
board
1. Ultrasound Board to Control Board
Connecting Header loose or
disconnected.
2. Bad Ultrasound Board.
3. Bad Control Board.
A. Reseat Connecting Header into
Control Board.
A. Replace Ultrasound Board.
A. Replace Control Board.
305 CRIT_ERR_US_BOARD_
CALIBRATION_ERROR
Error calibrating applicator
1. Ultrasound Board to Control Board
Connecting Header loose or
disconnected.
2. Bad Ultrasound Board.
3. Bad Control Board.
A. Reseat Connecting Header into
Control Board.
A. Replace Ultrasound Board.
A. Replace Control Board.
5- TROUBLESHOOTING
5.1 Intelect/Genisys Software Error Messages (Continued)

5- TROUBLESHOOTING
5.2 Intelect/Genisys Ultrasound Diagnostics
A. General
1. The following information is intended to aid in
troubleshooting the major components of the
Ultrasound Therapy Systems to “Board Level”
only. These tests are OEM standard testing
procedures and methods used at the factory
before shipment of any Ultrasound Therapy
System.
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.
B. Special Tools, Fixtures & Materials Required
1. Certain tests require the use of special Tools
and/or 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 accurate results.
2. Any special tools or fixtures required can be
obtained through Chattanooga Group, Service
Department.
3. Scope and other standard test equipment
settings will be listed for each test performed to
aid in performing the test to OEM standards and
ensure proper readings.
4. The troubleshooting and repair of the Ultrasound
Therapy Systems should be performed only by
authorized technicians trained and certified by
Chattanooga Group.
C. Equipment Required
1. Oscilloscope and Probes
2. Electrotherapy Service Technician Interface
(ESTI) Diagnostics Kit.
3. Digital Multimeter
4. Milliohm Meter
5. Dielectric Withstand (Hi-Pot) and ground
resistance tester.
NOTE:
Adjust Dielectric Withstand tester to indicate fault with
120k Ohm Load across the output when at specified test
voltage.
6. Ohmic Instruments UPM DT 10 or UPM DT 100
Ultrasound Power Meter.
NOTE:
The Ohmic Industries UPM DT 10 or UPM DT 100
Ultrasound Power Meters are the only power meters on
the market that will meet the strict specifications set forth
for Chattanooga Group Ultrasound Products. It is
absolutely necessary for the Field Technician to have
available and use the Ohmic Industries UPM DT 10 or
UPM DT 100 Power Meter when performing any service or
calibration of any Chattanooga Group Ultrasound
products.
7. Degassed Water (< 5 ppm) for Ultrasound Power
Meter.
Recipe(s) for Degassed Water
1) Boil Distilled Water for 30 minutes. Place
water in a nonporous container and
immediately cover with cellophane. Allow to
cool to room temperature of approximately
21°C (70°F). May be refrigerated to aid
cooling time.
2) Bring Distilled Water to a boil. Place the
container under vacuum for 5 to 10 minutes.
8. Dissolved Oxygen Test Kit. Used to test oxygen
level of degassed water.
NOTE:
Two liter softdrink bottles are ideal storage and transport
containers for degassed water as they are designed to
keep oxygen out. Do not allow aeration of degassed water
during transport or filling of the power meter.
Do not use Tap Water or Distilled water in the Ultrasound
Power Meter. Use only Degassed Water in order to obtain
correct test results. The chart below illustrates the oxygen
content of Degassed, Tap and Distilled Water.
9. Ultrasound Applicators (Intelect/Genisys
Accessories).
Intelect®/Genisys®Ultrasound Therapy Systems
10
WATER TYPE ppm of Oxygen
Degassed
(per recipe 1 or 2) Less than 5 ppm
Tap Water Up to 35 ppm
Distilled Water Up to 20 ppm

5.3 Visual Inspection
A. General
Visually inspect the Ultrasound Therapy System. A
visual inspection can, to an experienced Technician,
indicate possible abuse of the system and/or
internal problems.
5.4 Leakage Tests
Conduct all necessary leakage tests as required per
“Chapter 7 Electrical Equipment” of the 1999, or later,
edition of the NFPA (National Fire Protection
Association) “Health Care Facility” standards. See
Figure 5.1.
5.5 Unit Startup and Fan Testing
A. Equipment Required
1. N/A
B. Test
1. Place unit face up on work surface.
2. Connect power cord to unit and plug into proper
power receptacle.
3. Turn system on. Adjust intensity up and press
Start. Fan will begin to run after the audible beep
tones.
4. Place hand at the back of unit to verify fan is
blowing out. See Figure 5.2.
C. Test Results
1. Unit will not Start= Unit Failed Test
a) Possible Bad Power Supply
2. Main menu does not display= Unit Failed Test
a) Possible Bad Control Board
b)Possible Bad Power Supply
1). Visually check power button LED. If
flashing, Power Supply is good, replace
Control Board. If not flashing, replace
Power Supply.
3. Fan not blowing outward= Unit Failed Test
a) Fan Blowing Inward
1) Fan wired wrong- Rewire or replace fan
b)Fan not blowing
1) Possible Bad Fan
2) Possible Bad Power Supply
Intelect®/Genisys®Ultrasound Therapy Systems
11
5- TROUBLESHOOTING
WARNING
!
UNIT FAILING DIELECTRIC WITHSTAND AND/OR LEAKAGE
TESTS COULD INDICATE SERIOUS INTERNAL SYSTEM
PROBLEMS.
DO NOT PLACE UNIT BACK INTO SERVICE! SEND UNIT TO
FACTORY FOR REPAIR! DO NOT ATTEMPT TO REPAIR IN
THE FIELD!
FIGURE 5.1
FIGURE 5.2
VERIFY FAN IS
BLOWING OUT

5.6 Ultrasound Tests
A. Equipment Required
1. Degassed Water. Refer to page 10 for Degassed
Water Recipes.
2. Ohmic Instruments UPM DT 10 or UPM DT 100
Ultrasound Power Meter.
3. Dissolved Oxygen Test Kit. Used to test oxygen
level of degassed water.
4. Known good Ultrasound Applicator
5.7 Ultrasound Applicator Identification Test
NOTE:
Use any Ultrasound Applicator for this test.
A. Ultrasound Applicator Identification Test
Procedures
1. Without Applicator installed, turn unit on.
2. Look at the display center. The Applicator not
detected icon should appear. See Figure 5.3.
3. Plug Applicator into Applicator port on the front
R.H. corner of the system. Applicator LED should
flash five (5) times. See Figure 5.4.
4. Look at the display center. The Applicator
detected icon should appear. See Figure 5.5.
B. Ultrasound Applicator Identification Test Results
1. Unit operates as described in steps 2 and 4.
a) Unit passed test.
2. “NO CAL” icon displays center of system display.
a) Applicator not calibrated.
b) Possible bad Applicator. Re-test with known
good Applicator.
c) Possible bad Ultrasound PCB.
3. Not detected icon displayed after ten seconds of
Applicator being plugged in.
a) Possible bad applicator. Re-test with known
good Applicator.
b) Possible bad Ultrasound Board.
Intelect®/Genisys®Ultrasound Therapy Systems
12
5- TROUBLESHOOTING
FIGURE 5.3
FIGURE 5.4
FIGURE 5.5

5.8 Ultrasound Applicator Output Test
Perform this test using all available Applicators for the unit
being tested.
A. Ultrasound Applicator Output Test Procedures
1.Set up Ohmic Instruments UPM DT 10 or UPM DT
100 Ultrasound Power Meter per Operator’s
Instructions and fill test reservoir with Degassed
Water.
2.Place an Applicator into the Power Meter retainer.
As per Ohmic Manual, make certain the Applicator’s
aluminum face is submerged in the degassed water
and centered directly over the S.S. cone.
3. “Zero” the Power Meter.
4. Turn the Ultrasound Therapy System on.
5. Press the button until “Continuous” is
displayed in the Duty Cycle area of the display.
6. Press the button until “Watts” appears in the
intensity area of the display.
7. Increase Intensity for the applicator being tested
according to Figure 5.6
8. Press “Start”.
9. Compare Power Meter readings, displayed on
power meter for all the settings for each respective
applicator being tested to the values in Figure 5.6.
10. Press the button until “3.3 MHz” is diplayed in
the Frequency area of the display. Repeat test and
compare readings to Figure 5.6.
B. Ultrasound Applicator Output Test Results
1. Output ranges fall within the specified ranges as
listed in Figure 5.6.
a) Unit passed test.
2. Readings fall outside specified ranges of Figure 5.6.
a)Possible bad Degassed Water in Power Meter.
b)Possible use of Power Meter other than Ohmic
Instruments UPM DT 10 or UPM DT 100
Ultrasound Power Meter.
c)Possible bad or out of calibration Applicator.
d)Possible bad Ultrasound Board.
Intelect®/Genisys®Ultrasound Therapy Systems
13
5- TROUBLESHOOTING
WARNING
!
USE ONLY DEGASSED WATER IN POWER METER FOR
TESTING ULTRASOUND APPLICATORS. USE OF OTHER
TYPES OF WATER WILL CAUSE FALSE TEST RESULTS.
SEE PAGE 10 FOR DEGASSED WATER RECIPES.
DO NOT AERATE WATER WHEN FILLING POWER METER.
FIGURE 5.6
APPLICATOR OUTPUT SPECIFICATIONS
APPLICATOR SIZE POWER SETTING
(WATTS) OUTPUT RANGE
1 cm21
2
0.8 - 1.2
1.6 - 2.4
2 cm2
1
2
4
0.8 - 1.2
1.6 - 2.4
3.2 - 4.8
5 cm2
1
2
5
10
0.8 - 1.2
1.6 - 2.4
4.0 - 6.0
8.0 - 12.0
10 cm2
1
5
10
15
20
0.8 - 1.2
4.0 - 6.0
8.0 - 12.0
12.0 - 18.0
16.0 - 24.0

Intelect®/Genisys®Ultrasound Therapy Systems
14
5- TROUBLESHOOTING
5.9 Ultrasound Duty Cycle Test
This test is performed using only the 5 cm2Applicator.
A. Ultrasound Duty Cycle Test Procedures
1. Set up Ohmic Instruments UPM DT 10 or UPM DT
100 Ultrasound Power Meter per Operator’s
Instructions and fill test reservoir with Degassed
Water.
2. Place an Applicator into the Power Meter retainer. As
per Ohmic Manual, make certain the Applicator’s
aluminum face is submerged in the degassed water
and centered directly over the S.S. cone.
3. “Zero” the Power Meter.
4. Turn the Ultrasound Therapy System on.
5. Press the button until “Watts” appears in the
intensity area of the display.
6. Increase Intensity ( ) to maximum.
7. Press “Start”.
8. Press the button until “10%” is displayed in the
Duty Cycle area of the display.
9. Compare Power Meter readings to Figure 5.7 for
each of the following Duty Cycle settings listed in the
chart.
10. Press the button until “3.3 MHz” is displayed in
the Frequency area of display. Repeat test and
compare readings to Figure 5.7.
B. Ultrasound Duty Cycle Test Results
1. Duty Cycles fall within the specified ranges as listed
in Figure 5.7.
a) Unit passed test
2. Readings fall outside specified ranges of Figure 5.7.
a) Possible bad Degassed Water in Power Meter.
b) Possible use of Power Meter other than Ohmic
Instruments UPM DT 10 or UPM DT 100
Ultrasound Power Meter.
c) Possible bad or out of calibration Applicator.
d) Check Ultrasound Board.
e) Check Control Board.
FIGURE 5.7
WARNING
!
USE ONLY DEGASSED WATER IN POWER METER FOR
TESTING ULTRASOUND APPLICATORS. USE OF OTHER
TYPES OF WATER WILL CAUSE FALSE TEST RESULTS. SEE
PAGE 10 FOR DEGASSED WATER RECIPES.
DO NOT AERATE WATER WHEN FILLING POWER METER.
DUTY CYCLE SPECIFICATIONS
APPLICATOR SIZE DUTY CYCLE OUTPUT RANGE
5 cm2
10%
20%
50%
100% (Continuous)
0.8 - 1.2
1.6 - 2.4
4.0 - 6.0
8.0 - 12.0

Intelect®/Genisys®Ultrasound Therapy Systems
15
6- REMOVAL & REPLACEMENT
6.1 General
A. Tools & Equipment Required
1. #1 Phillips Screwdriver
2. Flat Blade Screwdriver
6.2. Top & Bottom of Unit
A. Removing Top from Bottom
1. Place unit face down on a grounded work surface.
NOTE:
Use a clean, soft cloth or cushion underneath the display lens
to prevent scratching or damage to the lens.
2. Remove the plynth from the bottom of the system.
See Figure 6.1.
3. Remove the Mains Power Cord from the system.
See Figure 6.1.
4. Remove Battery Cover with the Flat Blade
Screwdriver and remove Battery from the system if
equipped. See Figure 6.2.
5. Remove the Rear Fan Grill from the system to gain
access to the two rear mounting screws. See Figure
6.2.
6. Remove the two front feet from the system to gain
access to the two front screws. See Figure 6.3.
7. Remove the four mounting screws from the bottom
housing using the #1 Phillips Screwdriver. See
Figure 6.3.
8. Carefully separate the upper and lower housings of
the system. It may be necessary to pry the housings
apart at the Applicator Hook. See Figure 6.4.
9. Disconnect the Power Supply and Fan Harnesses
from the Control PCB of the system. See Figure 6.4.
B. Installing Top to Bottom
1. With top laying face down, carefully place the bottom
housing in position over the top housing.
2. Connect the Power Supply and Fan Harnesses to
the Control PCB onto their respective connectors.
3. Make certain the front insert and the Applicator Hook
are in position, then lightly press housings together
to properly seat them.
4. Secure housings together with the four phillips head
screws.
NOTE:
Do not overtighten the screws. Overtightening will damage the
threads of the brass inserts.
5. Follow Steps 1 - 7 in 6.2, A above in reverse order to
complete reassembly of system.
WARNING
!
UNPLUG THE UNIT FROM THE POWER SOURCE
AND/OR REMOVE BATTERY BEFORE ATTEMPTING
ANY REMOVAL OR REPLACEMENT PROCEDURES
TO PREVENT ELECTRICAL SHOCK.
FIGURE 6.1
FIGURE 6.2
FIGURE 6.3
FIGURE 6.4
REMOVE
PLYNTH
REMOVE MAINS
POWER CORD
REMOVE BATTERY
COVER AND BATTERY
REMOVE
FAN GRILL
REMOVE
FRONT FEET
REMOVE
FOUR SCREWS
APPLICATOR
HOOK
CAREFULLY PRY APART
HERE IF NECESSARY
DISCONNECT POWER
SUPPLY AND FAN
HARNESSES

6.3 Fan Removal & Replacement
A. Fan Removal
1. Separate Top from Bottom. Refer to 6.2, part A.
2. With #1 Phillips screwdriver, remove the 2 screws
securing the Fan. See Figure 6.5.
3. Remove Fan from the unit.
4. Remove Fan Baffle from fan. See Figure 6.5.
B. Installing Fan
1. Route Fan Harness underneath fan as shown in
Figure 6.6.
2. Install Fan Baffle onto fan as shown in Figure 6.6.
3. Place new Fan, Part Number 27266, into system
base.
4. Make certain the Fan Baffle sits onto System
Housing Baffle Tabs as shown in Figure 6.7.
5. Secure fan to housing with the 2 mounting screws.
See Figure 6.8.
NOTE:
Do not overtighten the screws. Overtightening will damage the
threads of the brass inserts.
6. Reassemble the Top and Bottom Housing. Refer to
6.2, part B.
Intelect®/Genisys®Ultrasound Therapy Systems
16
WARNING
!
UNPLUG THE UNIT FROM THE POWER SOURCE
BEFORE ATTEMPTING ANY REMOVAL OR
REPLACEMENT PROCEDURES TO PREVENT
ELECTRICAL SHOCK.
6- REMOVAL & REPLACEMENT
FIGURE 6.5
FIGURE 6.6
REMOVE SCREWS
FIGURE 6.7
FIGURE 6.8
FAN
BAFFLE
FAN
BAFFLE
ROUTE
HARNESS
AS SHOWN
BAFFLE
TABS
SECURELY TIGHTEN
MOUNTING SCREWS