Ormed OptiFlex-K1 User manual

Service
Manual
OptiFlex
-
K1

1.
History
2
2. Purpose 2
3. General 2
4.
Packing
and
unpacking
OptiFlex
-
K1
5. Block diagram of the electronic parts OptiFlex-K1
6. Bill of material for service parts OptiFlex -K1
7. Figure for bill of material
8. Special function Service menu for OptiFlex-K1
9. How to perform repairs
10. Checklist of safety and function test OptiFlex-K1
5
6
7
8
10
12
13
2
The
purpose
of
this
Service
Manual
is
to
help
you
make
simple repairs on the OptiFlex -K1. Only authorized staff may
perform repairs and maintenance as the manufacturer’s
warranty
and liability would otherwise be invalidated.
Only original parts may be used for servicing in accordance
with
the attached spare parts list.
3.
1
Electronics,
connection
cables
1
2
3
4
No
plugs
may
be
connected
or
disconnected
while
the
unit is switched on. Always switch the OptiFlex -K1
off before connecting or disconnecting a plug.
The locks for spiral cable for the hand-held program-
ming 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: Errors will be displayed on the hand-
held programming unit as follows shown:
Potentiometer
error:
Wrong angle information
-
>
Check
the
femur
settings
-> Replace knee electronics (Pos. 3)
-> Replace motor control (Pos. 20)
Failure
at
the
potentiometer:
Connection to the potentiometer is interrupted
-
>
Replace
the
spiral
cable
of
the
potentiometer
(Pos.
19)
-> Replace knee electronics (Pos. 3)
-> Replace motor control (Pos. 20)
Motor
drive
r
error:
The motor driver IC reported an error
-
>
Replace
motor
control
(Pos.
20)
Motor
error:
The motor did not turn properly
-
>
Replace
motor
control
(Pos.
20)
-> Replace the motor (Pos. 21)
Table
of
contents
2.
Purpose
1.
History
Revision
Date
Name
Change
1 01.08.2007 S. Herr Service Manual
created
3.
General
ERROR
XX
(XX
=
N
umber
of
the
error)

5
Motor
over
current:
The current for the motor exceeded the maximum limit
-
>
Check
the
mechanics
(Pos.
25)
-> Replace motor control (Pos. 20)
-> Replace the motor (Pos. 21)
6 Motor
control
error:
Internal error in the motor control.
-
>
Replace
motor
control
(Pos.
20)
7 Eprom
access
error:
Memory error in the access of the EPROM
-
>
Replace
the
hand
hel
d
programming
unit
(Pos.
14)
8 CPM
ROM
error:
Memory error in the motor control
-
>
Replace
motor
control
(Pos.
20)
9 Communication:
Communication to the motor control is not possible
-
>
Check
spiral
cable
and
connector (Pos. 15)
-> Replace the hand held programming unit (Pos. 14)
-> Replace motor control (Pos. 20)
10 General
error
in
the
motor
control:
Unknown error in the motor control
-
>
Replace
motor
control
(Pos.
20)
11 Motor
enable
timeout
Motor could not be enabled in time
-
>
Replace
motor
control
(Pos.
20)
12 Invalid
parameter
motor
error:
Motor has received a invalid parameter
-
>
Replace
motor
control
(Pos.
20)
-> Replace the hand held programming unit (Pos. 14)
13 Stop
release
error:
The motor could not be released
-
>
Replace
motor
control
(Pos.
20)
-> Replace the hand held programming unit (Pos. 14)
14 Unexpected
motor
Stop:
-
>
Check
spiral
cable
and
connector (Pos. 15)
-> Replace motor control (Pos. 20)
15 Motor
disabled:
Motor control disabled the motor.
-
>
Replace
motor
control
(Pos.
20)
16 Wrong
command
in
the
motor
:
-
>
Replace
motor
control
(Pos.
20)
-> Replace the hand held programming unit (Pos. 14)
17 5V
supply
error:
5V supply of motor control not sufficient
-
>
Replace
motor
control
(Pos.
20)
18 Initialise
error
real
time
clock:
-
>
Replace
the
hand
held
programming
unit
(Pos.
14)
19 Communication
error
real
time
clock:
-
>
Replace
the
hand
held
programming
unit
(Pos.
14)
20 Error
real
time
clock
:
-
>
Replace
the
hand
h
eld
programming
unit
(Pos.
14)
3
21
Range
exceeded:
The measured angle is out of the range of motion
-
>
Replace
motor
control
(Pos.
20)
22 ROM
error
in
the
hand
held
programming
unit:
Memory error in the hand held programming unit
-
>
Replace
t
he
hand
held
programming
unit
(Pos.
14)
23 Invalid
parameter:
Internal error in the hand held programming unit
-
>
Replace
the
hand
held
programming
unit
(Pos.
14)
24 24V
supply
error
motor
control:
Error in the 24V supply in the motor control
-
>
Replace
motor
control
(Pos.
20)
-> Replace the power supply electronics (Pos. 23)
25 Bus
error:
Bus system error
-
>
Replace
the
spiral
cable
of
the
hand
held
programming unit (Pos. 15)
-> Replace the hand held programming unit (Pos. 14)
-> Replace motor control (Pos. 20)
26 24V
supply
hand
held
programming
unit:
24V supply of the hand held programming unit is
defective
-
>
Replace
the
hand
held
programming
unit
(Pos.
14)
27 5V
supply
hand
held
programming
unit:
5V supply of the hand held programming unit is defective
-
>
Replace
the
hand
held
programming
unit
(Pos.
14)
28 3.3V
supply
hand
held
programming
unit:
3.3V supply of the hand held programming unit is
defective
-
>
Replace
the
hand
held
programm
ing
unit
(Pos.
14)
29 Calibration:
The calibration data in the motor control are wrong.
-
>
Perform
a
calibration
(see
chapter
8.1)
30 Calibration
error:
-
>
Repeat
the
calibration
(see
chapter
8.1)
-> Replace knee electronics (Pos. 3)
-> Replace motor control (Pos. 20)
31 Calibration
timeout
:
-
>
Replace
motor
control
(Pos.
20)
32 Motor
enable
error:
The motor could not be enabled
-
>
Replace
motor
control
(Pos.
20)
33 Motor
disable
error:
The motor could not be disabled
-
>
Re
place
motor
control
(Pos.
20)
34 Motor
stop
error:
Motor stop command timeout error
-
>
Replace
motor
control
(Pos.
20)
35 Configuration
error:
Invalid configuration of the hand held programming unit
-
>
Replace
the
hand
held
programming
unit
(Pos.
14)

45 Wrong
product
combination:
Mixup between non compatible device and hand held
programming unit
-> Use the correct hand held programming unit (Pos. 14)
46 Handset error internal communication:
Invalid interchip communication inside the hand held
programming unit
-> Replace the hand held programming unit (Pos. 14)
47 Internal communication error motor control:
Internal communication error motor control.
-> Replace motor control (Pos. 20)
48 User stoped the special function
49 Unknown error in the motor control:
-> Replace motor control (Pos. 20)
3.2 Mechanics
The movable screws should not be completely unscre-
wed when adjustments are being made. Make sure
that the movable screws are tightened for operation
and transport.
The frame is unstable:
Possible cause: Bolt / screws missing or loose. Tighten
the screws / bolts.
3.3 Others
Do not clean the housing or the support with grease or
oil.
No solvents may be used when cleaning the
OptiFlex-K1.
4

The
following
settings
must
be
made
to
transport
the
OptiFlex-K1:
Set
the
packing
setting
in
the
menu
or
move
the
device
in a position of EXTENSION 0 degrees.
Switch off the OptiFlex-K1.
Remove the power cord and disconnect the hand
held programming unit.
Only use original packaging for transport.
Put the hand-held programming unit into the extra box.
Set the femur lenght on maximum and the lower leg
setting on 42 cm.
Set the angle joint horizontal.
5
Move
the
two
styrofoam
parts
and the extra
protection for the knee joint on the device
First put the power cord and the extra box with the hand
held programming unit on the bottom of the box as shown
on the figure below and then the OptiFlex-K1 with the two
styrofoam parts.
4.
Packing
and
unpacking
the
OptiFlex
-
K1
Extra box with the hand
-
held
programming unit
Extra protection for
the knee joint

6
5.
Block
diagramm
of
the
electronic
part
s
OptiFlex
-
K1
Display
Control
-
logic
Motor
driver
Micro
-
processor
Motor
Control
Hand
-
held programming unit
Microprocessor
Control
-
logic
Pot.
Control
Motor
Pot.
Power
supply
24
V
DV
Keypad
5
2
24
V
Ground
Memory
Clock
Stop

6.
Bi
ll
of
material
for
service
parts
OptiFlex
-
K1
Position
Description
Ordernumber
7
2
Fixation
screw
GN534
-
32
-
M5sw
Washer DIN125D6A2
Countersunk screw DIN933M5x20A2
3Knee electronics complete 0.0037.041
4 Fixation screw GN534-32-M5sw
Washer DIN125D6A2
Countersunk screw DIN933M5x20A2
Distance disk DIN988D6x12x0,3
6 Footplate 0.0037.045
7 Fixation screw GN534-40-M6sw
Rubber puffer complete for angle joint 0.0037.202
9 Connection hand held programming unit 2.0037.004
10 + 12 Power switch (ON/OFF) with connection 0.0034.245
11 Fuses cap 0.0034.246
Fuses 1 AT 0.0000.005
14 Hand held programming unit with spiral cable OptiFlex 0.0037.062
Protection for hand held programming unit 0.0037.103
Holder K1 hand held programming unit 0.0037.076
15 Spiral cable hand held programming unit 2.0037.035
16 Holding clip 0.0031.004
17 Housing cover OptiFlex-K1 with sticker 0.0037.205
18 Housing cover OptiFlex-K small 0.0037.206
19 Spiral cable black for potentiometer 0.0037.007
20 Motor control K1 2.0037.901RevB
21 Motor complete 0.0037.075
22 Wire set 2.0037.005
23 Power supply electronics 0.0034.244
24 Lip 2.0037.105
Wire for lip 0.0031.300
25 Spindle complete K1 with alu profile 0.0037.210
Power cord USA version 0.0034.011
Option: Frame adapter add-on-kit 0.0037.204

8
7.
Figure
for
bill
of
material
7
6
4 2 3
17 10/11/12
9 14
18
19
15
16
10/11/12 23
24 9 20 21 22

9
Position
25

10
8.
Special
function
Service
Menu
OptiFlex
-
K1
Function
of
service
Menu
Calibration
Display contrast
Error log
Device runtime
Entering
the
service
menu
:
Switch off the OptiFlexK1.
When you switch on the device press simultaneously
the Extension control
and the Flexion control
Display will show following symbol:
Entering code.
For the code press the control as shown below:
1 3 2 4
Now you see the symbols of the service menu:
8.1
Calibration
ATTENTION!
Before you do a calibration switch the device
OFF and ON.
Femur
setting:
49
cm.
Press the Extension control.
Display:
Keep on pressing the control
Extension (OptiFlex-K1 move in
direction Extension)
Flexion (OptiFlex-K1 move in
direction Flexion)
until the OptiFlex-K1 reach 0 degrees.
Press START, the calibration starts automatically. The
device will reach both maximum points and move
between –10 bis 120 degrees with different speed.
Wait until the OptiFlex-K1 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 10).
8.2
Display
contrast
Press the speed control.
Display:
XX %
Press the control
Extension (value decrease)
Flexion (value increase)
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.

11
8.3
Error
log
Press
the pause control
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.
Lower line: Error message
Left side: The symbol of the causer.
= Hand held programming unit = Motor
Press the control
Extension (last entry)
Flexion (next entry)
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.
8.4
Device
runtime
Keep on pressing
the
Flexion control.
The display shows the device runtime
Display: XX (XX = Runtime in hours).
Press STOP twice to leave the service menu.

9.
How
to
perform
repairs
9.1
How
to
remove
the
housing
cover
(Pos.
17
+
18).
Move
OptiFlex
-
K1
in
a
position
approximately
80 degrees.
Turn of the power OFF at the OptiFlex-K1 and
remove the power cord.
Move the OptiFlex-K1 in a stable side position.
Loosen the 4 outside torx screws to remove the hou-
sing cover K1 with sticker (Pos. 17).
Loosen the 2 torx screws to remove the housing cover
small (Pos. 18).
If you have to exchange any of the printed circuit boards
including the knee electronics or motor control you have to
perform a calibration.
9.2
How
to
exchange
the
motor
control
(Pos.
20).
ATTENTION!
When you assembling with electronic parts make
sure to use ESD (Electro Static Discharge) equipment.
Remove
the
housing
cover,
see
chapter
9.1.
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.
Perform a calibration.
Finally, a safety and function test has to be performed.
9.3
How
to
exchange
the
power
supply
elect
ronics
(Pos. 23).
ATTENTION!
When you assembling with electronic parts make sure
to use ESD (Electro Static Discharge) equipment.
Remove
the
housing
cover,
see
chapter
9.1.
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.
Perform a calibration.
Finally, a safety and function test has to be performed.
12
9.4
Repairs of the drive unit
(Pos. 21 + 25).
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.

10.
Checklist
of
safety
and
function
test
OptiFlex
-
K1
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
≤
≤
≤
Measured
value
Date/
Signature
0,1 Ohm Ohm
500 µA µA
300 µA µA
OK Error
1.
Switch
on
the
OptiFlex
-
K1.
Press
the
two
outer control
(Extension/ Flexion)
simultaneously.
Display:
Software
version
VX.X
XX.XX.XX
(X
=
optional)
Keep
on
pressing.
Display: Artromot K1 Classic
2. The
maximum
range
of
motion
for
Extension/
Flexion
is
-
10
to
120
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 OptiFlex K1 in any mode.
Press
any
control,
the
OptiFlex
-
K1
will
stop
immediately.
Check this for all controls.
5. Start
the
OptiFlex
-
K1
in
the
motion
range
between
–
10
to
120
degrees.
Set the speed to 100%.
Both
extre
me
points
should
be
reached
within
45
–
65
seconds.
13
4. Checking the "PAUSE" function.
Select the following settings:
Extension = 10 degrees
Flexion = 90 degrees
Speed = 50%
Pause = 10 seconds
Start the OptiFlex-K1.
At the reversal points (at 10 / 90 degrees) the pause must be lasting 10 seconds
(+/- 2 seconds).
The speed is substantially lower than in a 100% setting.

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]