QAL Medical 480 User manual

480 / 480E / 480E PRO CPM
Service and Technical Manual
©2011 QAL Medical • 05070812.3 Rev. C 08/11

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TABLE OF CONTENTS
1 General Overview.............................................................................................................................................................. 4
1.1 Introduction for 480/480E/480E PRO .......................................................................................................................4
1.2 Safety Considerations ................................................................................................................................................4
1.3 Specifications ...........................................................................................................................................................6
1.4 Symbols ...................................................................................................................................................................6
1.5 Suggested Maintenance Schedule ..............................................................................................................................7
2 Covers (480/480E/480E PRO)...........................................................................................................................................7
2.1 Bottom Cover ............................................................................................................................................................7
2.2 Top Cover .................................................................................................................................................................8
3 Cradle (480/480E/480E PRO) ...........................................................................................................................................8
4 Kneepot (potentiometer) (480/480E/480E PRO)) ............................................................................................................9
4.1 Kneepot Cover ..........................................................................................................................................................9
4.2 Kneepot Cable ..........................................................................................................................................................9
4.3 Knee Potentiometer (POT) Replacement .................................................................................................................... 9
5 Motor (480/480E/480E PRO) ..........................................................................................................................................10
6 Ballscrew (480/480E/480E PRO) ...................................................................................................................................11
7 Power Supply (480 ONLY) ...............................................................................................................................................11
8 Motion Controller (480/480E)..........................................................................................................................................11
8.1 Controller Cable .......................................................................................................................................................11
8.2 Controller Keypad ....................................................................................................................................................12
8.3 Controller Printed Circuit Board ................................................................................................................................13
9 PRO Controller (480E PRO ONLY) ...................................................................................................................................13
9.1 Front Cover/Keypad Replacement ............................................................................................................................13
9.2 Speaker Replacement ..............................................................................................................................................13
9.3 Display Replacement ...............................................................................................................................................14
9.4 Battery replacement for real time clock .....................................................................................................................14
9.5 PCB Printed Circuit Board (PCB) or PCBA (assembly) ..............................................................................................14
10 MAIN PRINTED CIRCUIT BOARD (PCB) ........................................................................................................................14
10.1 Replacing PCB (480/480E) ...................................................................................................................................14
10.2 Replacing PCB (480E PRO) ..................................................................................................................................15
11 Calibration .....................................................................................................................................................................15
11.1 Calibration (480/480E) ..........................................................................................................................................15
11.2 Calibration Diagram (480/480E) ............................................................................................................................16
11.3 Calibration (480E PRO) .........................................................................................................................................16
12 Error Codes....................................................................................................................................................................18
12.1 Error Codes (480/480E) .......................................................................................................................................18
12.2 Error Codes (480E PRO) .......................................................................................................................................22
13 Troubleshooting .............................................................................................................................................................23
13.1 Troubleshooting (480/480E ONLY) ........................................................................................................................23
13.2 Troubleshooting (480E PRO ONLY) ........................................................................................................................24
14.0 Assembly Drawings ...................................................................................................................................................25
14.1 Main Assembly .....................................................................................................................................................25
14.2 Thigh Assembly .....................................................................................................................................................26
14.3 Foot Assembly ......................................................................................................................................................27
14.4 Foot Cradle ...........................................................................................................................................................28
14.5 Ballscrew Assembly ..............................................................................................................................................29
14.6 480 U-Bracket/Slider Assembly .............................................................................................................................30
14.7 480E/480E PRO U-Bracket/Slider Assembly .........................................................................................................31
14.8 480 Motor Assembly (Globe) ..................................................................................................................................32
14.9 480E (or 480E PRO) Motor Assembly (Faulhaber) ..................................................................................................33
14.10 Motion Controller Assembly (480/480E) ...............................................................................................................34
14.11 480E PRO Controller Assembly ............................................................................................................................35
14.12 480 Wiring Diagram ............................................................................................................................................36
14.13 480E Wiring Diagram ..........................................................................................................................................37
14.14 480E PRO Wiring Diagram ..................................................................................................................................38
14.15 480/480E Electrical Schematic ............................................................................................................................39

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1 General Overview
1.1 Introduction
The purpose of this manual is to provide instructions for the basic maintenance, repair and service for the 480,
480E and 480E PRO CPM systems.
1.2 Safety Symbols
Danger!
Warning messages regarding possible risks of accident or injury.
Attention!
Warning messages regarding possible technical damages.
Note!
Information regarding operation of the device.
Note!
Information for service staff.
Attention!
Please read the Instructions for Use rst.
1.2.2 General Safety Considerations
When using your CPM, to reduce the risk of fire, electric shock and injury to persons, basic safety precautions
should always be observed, including the following:
Danger!
Keep hair, loose clothing, fingers, etc., away from moving components of the device.
Danger!
Do not expose the device to water, including ice bags. Do not expose to extreme temperatures.
Danger!
Turn the power off before unplugging.
Note!
Read and understand all instructions.
Note!
Follow all warnings and instructions marked on the product.
Danger!
Never install the power supply in wet locations.
Danger!
Never touch uninsulated wires or terminals unless the power supply has been unplugged from the wall.
Danger!
Unplug the power supply from the wall outlet before cleaning the unit. Do not use liquid cleaners or
aerosol cleaners. Use a damp cloth for cleaning.
Danger!
Do not use this product near water.
Danger!
Do not place this product on an unstable cart, stand, or table. The product may fall causing serious
injury to thepatient or damage to the CPM.

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Danger!
If you are not sure of the type of power supply, consult your Otto Bock representative or local power
company.
Danger!
Do not overload wall outlets or use extension cords as this may result in the risk of fire or electric shock.
Danger!
Never insert objects into the drive unit casing as they may touch dangerous voltage points or short out
parts that could result in a risk of fire or electric shock.
Danger!
To reduce the risk of electric shock, do not disassemble this product. Take it to a qualified serviceperson
when service or repair work is required. Opening or removing covers may expose you to dangerous
voltages or other risks. Incorrect re-assembly can cause electric shock when the unit is subsequently
plugged in.
Danger!
If at any time during therapy the patient experiences extreme pain or discomfort, stop therapy and
consult their physician.
Danger!
Unplug the product from the wall outlet and refer servicing to qualified personnel under the
following conditions:
a. If the power supply cord is damaged or frayed.
b. If liquid had been spilled into the product.
c. If the product has been exposed to water.
d. If the product has been dropped or the unit casing has been damaged.
e. If the product exhibits a distinct change in performance.
f. If the product does not operate normally according to the operating instructions.
Danger!
Patient Safety: Patients must be advised to keep clear of moving parts. The unit is designed to force-
reverse if an obstruction is under the cradle; however, a patient could experience pain or be injured by
the downward pressure of the cradle if a body part is positioned under the cradle.
Danger!
Equipment not suitable for use in the presence of flammable anaesthetic mixture with air or
Nitrous Oxide.
Danger!
Unplug the product from wall outlet before servicing.
Attention!
Use only Otto Bock parts for repair and/or replacement.
Attention!
Never use parts from other manufacturers even though they may seem to fit
Attention!
This product should be operated only from the type of power source indicated on the marking label.
Attention!
Do not allow anything to rest on the power cord. Do not locate this product where the cord will
become damaged.
Attention!
Adjust only those controls that are covered by the operating instructions.

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1.3 Specifications
Weight Approximately 24 lbs. (11 kg)
480
Standard
480
Pediatric
480E/480E PRO
Standard
480E/480E PRO
Pediatric
Limb Length 30.5 - 42 in (77 - 107 cm) 19.5 - 34.5 in (50 - 88 cm) 28.5 - 41 in (73 - 104 cm) 21.5 - 35.5 in (53 - 90 cm)
Calf Length 16.5 - 24 in (43 - 61 cm) 9.5 - 18.5 in (24 - 47 cm) 16.5 - 24 in (43 - 61 cm) 9.5 - 18.5 in (24 - 47 cm)
Thigh Length 14 - 18 in (36 - 46 cm) 10 - 16 in (25 - 41 cm) 12 - 17 in (30 - 43 cm) 12 - 17 in (30 43 cm)
Range of Motion -5º extension to 110º flexion -5º extension to 110º flexion -5º extension to 120º flexion
Speed 16 - 160 degrees per minute
Pause 0 - 30 seconds at maximum programmed extension and/or flexion
Mode of Operation Continuous
480 Only Power Suppy Input: 120 VAC 0.12A 60Hz or 230 VAC 0.6A 50 Hz
Output: 14 VDC 730 mA
Power Supply Input: 100 - 240 VAC 1.6A 50 - 60 Hz
Output: 15 VDC 2.0A
NMES 480/480E Only – Compatible with various NMES devices
Shock Classification Type B
Classification Class 1 Medical Device (USA); Class 11a (93/42/EEC)
Environmental -10° to 35°C (14° to 95°F) temperature, 90% max. humidity
Conditions ATM pressure 750 hPa to 1040 hPa
The device must remain in the operational environment a minimum of one hour
prior to use.
Type of Shock Protection: Class 11
Degree of Shock Protection: Type B applied part
1.4 Symbols
Fig 1
Power Off
Type B Applied Part
Power On
Attention:
Consult Accompanying Documents
Danger Electric Shock:
Service by qualified individual only
Danger Explosive Risk:
If used with flammable anaesthetic Fragile
Keep Dry
This Way Up
Extension
Flexion
Speed
Hours/Cycles
Pause
Standby/Enter
Start/Stop
Warm Up
Lock/Set
Stopped
Seconds
Decrease
Increase Timer
Minutes
Use specified power supply only.
Alternating Current
Direct Current
Protective Earth (Ground)
Dispose of through your Registered
Waste Carrier or Take-back Facility
Indicates CSA certification to
North American standards
Indicates compliance to safety and
quality standards throughout all
member states in the EC
230604

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1.5 Suggested Maintenance Schedule
Between Patients
1. Check entire unit for any visible evidence of damage, such as bent sliders, cracked or broken covers,
frayed or damaged wires, etc. If any signs of damage are found, the unit must be repaired before use.
2. Ensure that all knobs and/or levers are usable and in place.
3. Ensure that all moving components move freely as required.
4. Check all displays and electronic controls for proper operation.
5. Check all mechanical pivot and linkage points for smooth operation and secure mechanical connection.
Make sure all screws, nuts, bolts, rivets, pivot pins, and other fasteners are secure.
6. Gently wipe clean all exposed surfaces with a soft cloth dampened with a mild soap solution or alcohol.
Avoid abrasive cleansers. To disinfect, wipe all exposed surfaces with a 1% to 10% solution of bleach
and water, or other suitable disinfectants.
7. Ensure that all labels are present.
8. Replace patient softgoods.
9. Verify that the device operates to its set limits over several complete cycles.
10. For devices offering absolute Range of Motion (ROM) settings, verify device calibration by observing
the ROM of the device while taking a visual reading using a goniometer at the machine’s pivot points.
Compare the ROM settings of the device with the goniometer readings. ROM readings should be within
+/- 5 degrees of the set parameters. If the readings do not fall within the set parameters, the unit needs to
be checked and recalibrated by a properly trained Service Technician.
Every six Months
1. Repeat steps 1 through 10 of “BETWEEN PATIENTS” procedures.
2. Verify ground continuity where applicable from the device frame to ground pin of the power supply, if so
equipped, using a Safety Analyzer or appropriate device.
Every Eighteen Months
A full inspection of the device by a properly trained Service Technician is recommended every 18 months. The
following points should be covered:
1. Steps 1 and 2 of “EVERY SIX MONTHS” above.
2. Fully inspect all internal and external mechanical and drive components, and repair or replace as
necessary.
3. Fully inspect all internal and external electrical components (including wires, connectors and solder joints),
and repair or replace as necessary.
4. Perform a complete recalibration and subsequent check of electronic and mechanical safety systems
including Reverse-On-Load and Range of Motion.
5. Complete a final check of the device in accordance with Otto Bock Final Inspection criteria (these are
available in the appropriate Technical Service Manual or on request from Otto Bock).
2 COVERS (480/480E/480E PRO)
2.1 Bottom Cover
Removal:
Note: Avoid cutting the heads off the plastic fasteners as these can be reused to reattach the covers.
1. Remove the Handle by removing the two Phillips screws located at each end of the Handle attachment.
2. Remove all 11 plastic fasteners from around the cover and separate the bottom cover from the unit.

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Installation:
1. With the unit upside down, carefully place the bottom cover on the exposed frame.
2. Align the bottom cover’s holes with the holes in the top cover.
3. Insert the female halves of the plastic fastener into the holes from which they came and insert one male
half into each of the female halves.
4. With a small hammer gently seat the male halves of the fastners.
5. Reinstall the handle. Use one drop of Loctite #425 on each attachment screw.
2.2 Top Cover
Removal:
1. Remove bottom cover (refer to section 2.1).
2. Remove cradle (refer to section 3).
3. With the bottom cover and cradle removed, the top cover comes free.
Installation:
1. Place the top cover on top of the exposed base frame.
2. Install cradle (refer to section 3).
3. Install bottom cover (refer to section 2.1).
3 CRADLE (480/480E/480E PRO)
Removal:
1. Remove the bottom cover (refer to section 2.1).
3. Using a pair of diagonal cutters, remove the ty-rap that holds the kneepot cable secure to the base.
4. Remove the kneepot cable strain relief from the top cover by removing the underside nut.
5. Pull the kneepot cable gently through the hole in the top cover.
6a. (480)
Remove both 3/16" cradle pivot cap screws from the U-bracket assembly to detach the cradle from the
ballscrew. (If you run into difficulty removing the cap screw, apply a slight tilt to the Allen wrench and pull
the entire cap screw, threaded insert, and pivot sleeve straight out.
6b. (480E)
Remove the six cap screws that fasten the U-bracket and angle brackets to the sliders.
7. Lift the cradle through the top cover.
Installation:
1. Gently spread apart rubber track seals and slide cradle struts (480) or angle brackets (480E) between
the track seals through the top cover.
2a. (480)
Replace the slider blocks with new ones. Position the cradle strut between the slider blocks and the
U-bracket, and reinsert the spacer into the hole in the cradle strut. Place both pivot sleeves into their
proper locations. Apply one drop of Loctite #242 on the threads of each cradle pivot Allen bolt and using
a 3/16" hex key, install the two cap screws into the U-bracket assembly.
2b. (480E)
Replace the slider blocks if they are worn. On one side, line up the slider block, angle bracket, and
U-bracket and fasten them together with three of the cap screws passing through star washers. Repeat
on the other side.
3. Slide the kneepot cable through both the top cover and the base frame.
4. Reinstall the kneepot cable (refer to section 4.2)

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4 KNEEPOT (Potentiometer)
(480/480E/480E PRO)
4.1 Kneepot Cover
Note: Plastic rivets may be re-used if not damaged during removal.
Removal:
1. With a pair of diagonal cutters, carefully remove the rivets to free the kneepot cover.
2. Remove the kneepot cover.
Important: Remove center of kneepot rivet from casting by moving outer thigh tube so they fall out.
Installation:
1. Install the kneepot cover over the casting, aligning the cable with the small divot in the cover and the holes
in the plastic with the holes in the casting.
2. Install the rivets in their appropriate holes and insert the plastic rivet centers.
3. With a small hammer gently tap the centers of the plastic kneepot rivets flush with the rivet casting.
4.2 Kneepot cable
Removal:
1. Remove the bottom cover (refer to section 2.1).
2. Remove kneepot cover (refer to section 4.1).
3. Remove kneepot cable plug from the socket on the main PC board.
4. With diagonal cutters, remove all ty-raps from the kneepot cable.
5. Remove strain relief from top cover by removing the nut on the underside strain relief side of the top cover.
6. Pull cable through cover.
7. De-solder the cable from the terminals on the kneepot.
Installation:
1. Wrap wires one and one-quarter turns around kneepot terminals and solder as follows:
480: pin #1 - white, pin #2 - red, pin #3 - black
480E: pin #1 - black, pin #2 - red, pin #3 - white
2. Install kneepot cover (refer to section 4.1 ).
3. Carefully put kneepot cable through top cover. Feed the free end of the cable through the hole in the top
cover until the cable strain relief is reached (only tighten the strain relief nut 1/4 turn past finger tight).
4. Put rubber washer on kneepot cable.
5. Install bottom strain relief nut on kneepot cable.
6. Tighten strain relief bottom nut 1/4 turn past finger tight.
7. Install the kneepot cable plug onto the main PC board connector pins 1,2,3.
8. Gather excess cable and secure to the front of the base frame with a ty-rap.
9. Install bottom cover (refer to section 2.1).
4.3 Knee Potentiometer (POT) Replacement
Removal:
1. Remove Knee Potentiometer cover (4.1).
2. De-solder wires from Potentiometer.
3. Insert the tip of a small screwdriver into the notch in the casting beside the Potentiometer and pry
Potentiometer away from casting.
4. Retain Potentiometer Drive Coupling.

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Installation:
1. Solder the Potentiometer cable wires to replacement Potentiometer if required. (See section 4.2)
2. Install the Potentiometer Drive Coupling end with the short slot into the casting. Make sure that the slot
engages with the inside pin.
(Steps for 480/ 480E)
3. Enter calibration mode using the Calibration Procedure in section 11.1, steps 1 through 13. The motion
controller screen will display “EXT [40-50] xx” where xx is a number indicating the angle the Potentiometer
is currently at.
4. Gently insert the Potentiometer into the casting. The Potentiometer must be able to rotate in the casting.
Make sure that the pin on the Potentiometer shaft enters the long slot end of the Potentiometer Drive
Coupling.
5. Rotate the body of the Potentiometer until xx number on the controller screen is between 40 & 50.
6. Press the Potentiometer firmly into the casting until the shoulder of the Potentiometer contacts the casting.
Confirm that the xx number on the controller screen is between 40 & 50.
7. Confirm that the Potentiometer is secure in the casting.
8. Proceed with steps 14 through 27 of the Calibration Procedure in Section 11.1.
(Steps for 480E PRO)
9. Switch the 480E PRO power on.
10. Gently insert the Potentiometer into the casting. The Potentiometer must be able to rotate in the casting.
Make sure that the pin on the Potentiometer shaft enters the long slot of the Potentiometer Drive Coupling.
11. Rotate the Potentiometer body until the angle indicated on the Motion Controller is “0” degrees.
12. Press the Potentiometer body firmly into the casting until the shoulder of the Potentiometer contacts the
casting. Confirm that the angle indicated on the Motion Controller is “0” degrees +/- 3 degrees.
13. Confirm that the Potentiometer is secure in the casting.
14. Proceed with the Calibration Procedure in Section 11.3.
5 MOTOR (480/480E/480E PRO)
NOTE: Transfer the ferrite loops to the new motor and install them in the same location on the cable.
Removal:
1. Remove bottom cover (refer to section 2.1).
2. Remove motor plug from main PC board in 480/480E (from Motor Board in 480E PRO) and pull
connector through the hole in base frame.
3. Remove the four nuts from the rubber mounts inside the bearing bracket assembly.
4. Take the motor out of the assembly.
5. Remove the rubber coupling from either the motor or ball screw assembly.
Installation:
1. Insert the rubber coupling onto the end of the ballscrew bearing bracket assembly.
2. Place two internal star tooth washers on each of the rubber mounts (part number 13585 motors only).
3. Insert the four motor mount bolts through the base and into the mounting bracket and tighten nuts. (Take
care not to twist the rubber mounts when tightening nuts.)
4. Reattach motor cables.
5. Reinstall the bottom cover.