Zimmer Soleoline Assembly instructions

Zimmer M edizinSysteme GmbH Tel. 0731 / 9761-0 [e-mail]
Junkersstraße 9
89231 Neu-Ulm Fax 0731 / 9761-118 w w w .zimmer.de
Product documentation
Project: Soleoline
Topic: Service Manual
Revision: Rev. B
Date: 26.07.2010
riginator: R. Alareki

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Document history
Rev. Date Change riginator
A 14.10.2009 Initi l Rele se R.Al reki
B 26.07.2010 Upd te of inform tion R. Al reki

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Table of content
1. S fety Instructions 5
2. Returning device 6
2.1. P ck ging 6
3. Rep iring Printed Circuit Bo rds 6
4. Speci l incidents 6
5. Device gener l description 7
5.1. Over view 7
6. Electronic 8
6.1. Overview 8
6.1.1. Electronic description of Soleoline 8
6.1.2. Electronic description of the V co device 10
6.2. Pin Assignments 12
6.2.1. Overview Soleoline 12
6.2.2. Overview V co device 12
6.2.2.1. Connector Stimul ting current (ST3303) 13
6.2.2.2. Connecter Controller progr mming (ST2001) 13
6.2.2.3. Seri l interf ce connection ( ST2401 ) 13
6.2.2.4. Jumper (JP1001-JP1004) 13
6.2.2.5. W ter level sensor connection 13
7. Softw re 14
8. Mech nic 15
8.1. Gener l Overview 15
8.1.1. Device Structure nd p rts List of the Soleoline 15
8.1.2. Device Structure nd P rt list of the V co device 17
8.2. Accessory List 18
8.3. Repl cement of the Components 18
8.3.1. Repl cement of Soleoline components 18
8.3.1.1. Opening the cover 18
8.3.1.2. Mount the cover 18
8.3.1.3. Repl cement of the spe ker 19
8.3.1.4. Repl cement of the m in bo rd 19
8.3.1.5. Repl cement of the Displ y 20
8.3.2. Repl cement of V co’s components 20
8.3.2.1. Opening the cover 20
8.3.2.2. Repl cement of the pump 21
8.3.2.3. Repl cement of the w ter sep r tor 21
8.3.2.4. Repl cement of the m in bo rd 22
9. Technic l D t 23
Housing dimensions 23
Weight 23
Transport 23
10. Troubleshooting 24
10.1. Sp re P rts H ndling 24
10.2. Required Equipment 24
10.3. St rting Problems 25
10.3.1. The device does not run, the displ y is d rk nd there is no coustic sign l. 25
10.3.2. The device is running, the coustic sign l fter switching on the device w s there but the displ y does
not run 25

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10.3.3.
The device is running, the coustic sign l fter switching on the device w s there, the st rt window is
displ yed but there is no re ction to the touch of the screen 25
10.3.4. The device is running, the coustic sign l fter switching on the device w s there but the displ y is d rk
nd there is not re ction to touch of the screen 25
10.3.5. There is no coustic sign l even if n error mess ge is displ yed. 25
10.3.6. The mess ge “W ter cont iner full” is displ yed 26
10.4. Error Mess ges 26
10.4.1. Gener l description 26
10.4.2. M ster Processor 26
10.4.3. Sl ve Processor 28
10.4.4. C ble Control Problems 29
10.5. Problems without Error mess ge 30
10.6. Test Run 31
10.6.1. Soleoline 31
10.6.2. V co 31
11. Service report 32
12. S fety check 33
12.1. Soleoline 33
12.2. V co device 34

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1. Safety Instructions
Zimmer MedizinSysteme GmbH s the m nuf cturer of electro medic l devices c n only ccept li bility for the s fety
nd reli bility of the device under the following conditions:
• The electric l inst ll tion conforms to the requirements specified for oper tion of the device
• The device is oper ted s specified by the user m nu l
• Extensions, new settings or ch nges re only c rried out by persons uthorized by Zimmer MedizinSysteme.
Zimmer MedizinSysteme reserves the right to m ke ch nges to delivery options nd technic l fe tures. Contr ct service
p rtners re responsible for ll rep irs th t they conduct.
Screws th t must be removed to open the housing re protected by speci l w rr nty se l. Only uthorized persons re
permitted to remove them. If the se l is missing or h s been m nipul ted, the device will no longer be under w rr nty.
The inform tion in the service document tion is the property of the m nuf cturer nd intended for intern l use by our
technici ns only. Public tion of this inform tion or distribution to un uthorized persons is prohibited. If the service
contr ct is c nceled, the technici n(s) is/ re required returning the service document tion to Zimmer MedizinSysteme
GmbH.
Warning!
Un uthorized modific tions or rep irs to the device m y c use it to m lfunction nd c use serious injuries.

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2. Returning a device
2.1. Packaging
Every unit th t is sent to the m nuf cturer for service must be p cked in the origin l p ck ging to prevent ny
d m ge during shipping. Alw ys include det iled description of ny f ults, therefore use the service report
in (ch pter11).
3. Repairing Printed Circuit Boards
F ulty bo rds must be rep ired by the m nuf cturer only. After repl cing module, the f ulty p rt must be l belled with
the seri l number of the device nd returned to the m nuf cturer with the service report in (ch pter 11).
4. Special incidents
Zimmer MedizinSysteme is required to record m lfunctions nd incidents of ny type. Ple se report ll unusu l incidents
(e.g. electric shock, burns etc.) Ple se use the service report included with the document tion (ch pter 11). Your reports
will contribute to improving the qu lity nd reli bility of our products.

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5. Device general description
5.1. ver view
The ther py device Soleoline includes stimul tion current ther py nd ultr sonic ther py with the possibility to combine it
with the V co device to suction-w ve m ss ge.
There re three different device v ri nts. The first one is Galva, which only includes stimul tion current ther py
module. The second device v ri nt is Sono, which only includes n ultr sonic module. The third device v ri nt is the
Sonostim, this v ri nt includes stimul tion current module nd ultr sonic module. Only the device v ri nts Galva nd
Sonostim re combin ble with the suction-w ve module Vaco.
The stimul tion current module is used for stimul tion current ther py nd -di gnostics ccording to the st nd rd
medic l pr ctices lso in combin tion with the intern l ultr sonic module (simult neous procedure). The ultr sonic
module is used for ultr sonic ther py ccording to st nd rd medic l pr ctices lso in combin tion with the intern l
stimul tion current module (simult neous procedure). The suction-w ve module is used for suction-w ve ther py nd in
combin tion with the stimul tion current module is lso used for positioning the suction electrodes.
Soleoline h s pl stic housing, the m ins power inlet, m ins fuses nd the power switch re pl ced on the b ckside of
the device.
The device is oper ted by 2 ctu tors nd touch screen. All device functions re controlled by microprocessor.
The device consists 2 g lv nic lly sep r ted stimul tion current modules, where the ultr sonic module is lso integr ted
in one of those modules for ther py in the simult neous procedure mode.
The ultr sonic component gener tes the necess ry sign ls for tr nsmitting the selected coustic power to the p tient vi
tr nsducer.
The suction-w ve component is loc ted in the V co device nd c n only be oper ted by microprocessor situ ted in the
Soleoline.
The communic tion between SoleoLine nd the V co device is re lised by n IR-interf ce. A microcontroller in the V co
device controlled the system intern l processes of the V co components nd in c se of f ilure or m lfunctions the v co
device will be stopped independent of the Soleoline.
Figure 1
Figure 2
SoleoLine V co

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6. Electronic
6.1. verview
6.1.1. Electronic description of Soleoline
The whole electronic h rdw re of the Soleoline is pl ced on the m in bo rd.
The m in bo rd cont ins the power supply unit, output st ge with v rious rel ys, the microprocessor nd DSP’s
sections.
The next figure shows the v rious circuit sections on the m in bo rd.
Figure 3
The electric/ electronic of the Soleoline st rts t the m ins socket. It is designed s high-current type of non-
he ting device socket to llow different m ins c ble to be supplied for different countries.
The m ins switch is designed for m ins volt ges between 85V to 265 VAC. 2x 2A m ins fuses re integr ted in
the m ins socket to monitor both m ins c bles nd it provides 2-w y shutdown.
The m ins volt ge is distributed to the power supply unit, where the p rts of the switched-mode power supply
re loc ted. The switched-mode power supply gener tes the needed volt ges of 200V nd 15V for the different
units on the m in bo rd. Diverse DC-DC converters gener te the necess ry low-volt ges of 1.8V, 2.5V, 3.3V
nd 5V for the different logic l components nd the volt ge r nge for the output-st ge.
PCB
-
block to gener te nd regul te
the p tient stimul ting current nd
ultr sonic for ch nnel 1
PCB
-
block to gener te nd regul te
the p tient stimul ting current for
ch nnel 2
Microprocessor
Switching
-
mode power supply
unit
Fl t c ble of the LCD-Displ y
M ins c ble
Spe ker c ble

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All components (solid st te rel y, tr nsformers nd optocouplers) connected to low volt ge nd m ins volt ge
re tested with n electric l isol tion of 4 kV nd re defined s UL-listed components.
NOTE: Don’t use other types then the defined ones.
The following figure shows the block di gr m of Soleoline with the electric l isol tion between the units.
Figure 4: Block diagram Soleoline

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6.1.2. Electronic description of the Vaco device
The V co device cont ins sep r te power supply nd power switch. The m ins switch is designed for the
m ins volt ges 115V nd 230VAC. 2x m ins fuses 0,25AT (230-240V device) or 0,4A (100-120V device)
re integr ted in the m ins socket to monitor both m ins c bles nd it provides 2-w y shutdown. The
supply volt ge is distributed by c ble to the m in bo rd, where the line filter is loc ted. The low volt ge on
the m in bo rd is supplied by tr nsformer. It h s 2x 115V prim ry inputs, which c n be switched between
115V or 230V by setting jumpers. The tr nsformer gener tes 12V t second ry side to oper te the pump.
A DC-DC Converter gener tes the necess ry switching supply of the rel ys, pressure sensor, v lve nd
the volt ge to oper te the logic l components s well.
The V co s sl ve device c n only be oper ted by the Soleoline.
All device functions, regul tion nd monitoring re controlled directly by the soleoline microprocessor.
The communic tion between the devices is re lized by n optic l seri l interf ce (IR-Interf ce).
In ddition the intern l processes of the components re supervised by the µC in the V co device. In c se
m lfunction or excess limit v lue of one of the critic l components the ther py will be stopped
independent of the Soleo device. Figure 5 shows the l yout of the m in bo rd
Figure 5
Stimul ting current
connections
Line filter
Connection to
progr mming the
controller
Connection for
the section-cup
m ss ge
Controller
Rel is
Tr nsformer
Jumper to switch between
115V nd 230V of the pirm.
volt ge
Connection
of Pump
Connection of the
w ter level sensor
Seri l interf ce for
Service
IR-Interf ce

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Figure 6 shows the block di gr m of the V co device with the volt ge v lues.
Figure 6: Block diagram Vaco

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6.2. Pin Assignments
6.2.1. verview Soleoline
Name Note
X1 Stimul ting current connection ch nnel 2
X7 Stimul ting current connection Ch nnel 1
X13 SD c rd slot
X2 Service connection DSP
J4 Touch screen connection
J5 Service connection Microprocessor
X8 Service connection DSP2
X17 Ultr sonic connection
X4 L Ph se
X5 N Ph se
X3 PE
X19 Jumper
X20 Jumper
X21 Jumper
X22 F n connection
X15 Displ y connection
X18 Spe ker connection
X25 Displ y connection
X23 Displ y connection
6.2.2. verview Vaco device
Name Note
ST1301 L Ph se
ST1302 PE
ST1303 N Ph se
ST3301 Stimul ting current connection output
Ch nnel 2
ST3302 Stimul ting current connection input
Ch nnel 2
ST3303 Stimul ting current connection output
Suction-cup
ST3304 Stimul ting current connection output
ch nnel 1
ST3305 Stimul ting current connection input
ch nnel 1
ST2001
Controller progr mming connection
ST2002 W ter level sensor connection
ST2401 Seri l interf ce connection (Service)
ST3001 Pump connection
ST3201 V lve connection
JP2101 H rdw re W tchdog
JP1001
-
JP1004
Jumper for switching the input power supply (110V or
220V)
SI1001 Fuse

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6.2.2.1. Connector Stimulating current (ST3303)
Name Note
1 Anode 1
2 C thode 1
3 Anode 2
4 C thode 2
5 Shielding
6.2.2.2. Connecter Controller programming (ST2001)
Name Note
1 -
2 GND
3 XRES
4 ISSP SCCLK
5 ISSP SDATA
6.2.2.3. Serial interface connection ( ST2401 )
Name Note
1 RS232 TX
2 RS232 RX
3 GND
6.2.2.4. Jumper (JP1001-JP1004)
Name Note
JP1001 and JP1002 For 230V power supply
JP1003 and JP1004 For 115V power supply
6.2.2.5. Water level sensor connection
Name Note
1 LEVELSENSOR
2 GND
3 5V
4 -

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7. Software
In c se of softw re-error or n error in the pplic tion or log files, ple se copy the whole contents of the SD-c rd nd
send it to the Service dep rtment of Zimmer MedizinSysteme.

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8. Mechanic
8.1. General verview
8.1.1. Device Structure and parts List of the Soleoline
Figure 7
14
16
2
7
5
13
6
11
10
1
15
4
8
3
9
12

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Spare Parts List:
Note:
The l st digit t the p rt number c n v ry s it indic tes the l test revision of the desired p rt. Zimmer
will lw ys send the l test comp tible revision to your ttention. Therefore lw ys dd the device seri l
number to your order!
Link Part number Part name
1 6591021x Housing bottom
2 6891041x Power inlet element with c ble
3 9291011x M in bo rd (Sonostim/G lv )
9291012x M in bo rd (Sono)
4 6591101x Actu tor
5 6591121x Isol tion foil
6 4670000x Displ y
7 6591071x Fixing pl te for displ y
8 6591011x Housing cover
9 6591031x Shelf for ultr sonic he d (left)
6591032x Shelf for ultr sonic he d (right)
10 6391011x Adjusting knob
11 6580041x Oper ting pen
12 6391091x Cover film
13 - Se ling ring
14 6591051x Cover for ch nnel’s output (ultr sonic connection)
6591061x
Cover for ch nnel’s output (Stimul ting current
connections)
15 6591041x Fixing pl te for spe ker
16 6891051x Spe ker with c ble

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8.1.2. Device Structure and Part list of the Vaco device
Figure 8
Spare Parts List:
Note:
The l st digit t the p rt number c n v ry s it indic tes the l test revision of the desired p rt. Zimmer
will lw ys send the l test comp tible revision to your ttention. Therefore lw ys dd the device seri l
number to your order!
Link Part number Part name
1 6592021x Housing bottom
2 8020005x Quick connector
3 8020004x Silicone tube
4 6892011x Power inlet element with c ble
5 3401103x M ins switch
6 6589201x W ter sep r tor
7 6592011x Housing cover
8 3701201x Di phr gm pump
9 3880050x Vibr tion d mper
10 9292011x M in bo rd
1
10
2
3
4
5
6
9
8
7

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8.2. Accessory List
The v lid ccessory list is in the User m nu l implemented.
If ccessories re combined, note the pproved combin tions nd the relev nt leg l regul tions. If third-p rty
ccessories re used, this will result in new medic l system nd the user will be solely responsible for the correct
combin tion or modific tion.
8.3. Replacement of the Components
Safety Note.
Do not touch modules or parts in the device when working on an open device with the power cable plugged in.
Electrical cables and wires ma have a voltage up to 120V/ 240 V. Unplug power cable before opening and
closing the device.
8.3.1. Replacement of Soleoline components
8.3.1.1. pening the cover
! Caution mains voltage inside
1. Unplug power c ble from power source.
2. Unplug ll c bles from the housing.
3. Removing the Cover
 Unscrew the 7 Screws (PT EJOT 4,0x 14mm) loc ted t the bottom of the housing.
 Remove the cover c refully nd fold it to the re r
 Unplug the spe ker c ble nd the power supply connectors from the m in bo rd.
 Now housing c n be pl ced side.
8.3.1.2. Mount the cover
Before closing the housing lw ys check the following:
 The bo rd nd ll other components re f stened in pl ce.
 All connectors re fixed.
 No loose p rts (such s screws) in the housing.
Mount the cover
 Plug ll c bles to the m in bo rd
 Pl ce the cover on the housing nd fix the cover with 7 Screws (PT EJOT 4,0x 14mm) loc ted t the
bottom of the housing.

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8.3.1.3. Replacement of the speaker
 Opening the cover (see 8.3.1.1).
 Unscrew the 2 Screws (PT EJOT 3,0x8 mm) nd remove the fixing pl te.
 Now the spe ker c n be t ken out nd be ch nged.
 After ch nging the spe ker mount the cover (see 8.3.1.2).
8.3.1.4. Replacement of the main board
 Opening the cover (see 8.3.1.1)
 Unplug ll c bles (touch screen c ble, displ y seri l c ble, spe ker c ble nd the power supply c bles).
 T ke out of the djusting Knobs.
 Unscrew the 14 screws (PT EJOT 3,0x8 mm) loc ted on the m in bo rd (see Figure 9).
 Now the m in bo rd c n be pl ced side.
 After ch nging the m in bo rd pl ce the new bo rd on the cover nd screw the 14 screws (PT EJOT 3,0x8
mm) (see Figure 9)
Figure 9
 Now tt ch ll c bles
 Mount the cover (8.3.1.2).
 Push the knobs to ctu tors.
 Run the device nd run function check (use the S fety check in ch pter 12).

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8.3.1.5. Replacement of the Display
 Opening the cover (see 8.3.1.1).
 Remove the m in bo rd (8.3.1.4).
 Remove the fixing pl tes, therefore unscrew the 4 screws (PT-EJOT 3,0x8 mm).
Figure 10
 Now the displ y c n be pl ced to side.
 After ch nging the displ y, pl ce the new displ y to its pl ce s shown in figure 10.
 Mount the m in bo rd nd plug ll c bles.
 Mount the cover.
 Push the knobs to ctu tors.
 Run the device nd run function check (use the S fety check in ch pter12).
8.3.2. Replacement of Vaco’s components
Safety Note.
Do not touch modules or parts in the device when working on an open device with the power cable plugged in.
Electrical cables and wires ma have a voltage up to 120V/ 240 V. Unplug power cable before opening and
closing the device.
8.3.2.1. pening the cover
! Caution High voltage inside
1. Unplug power c ble from power source.
2. Unplug ll c bles from the housing.
3. Removing the Cover.
 Unscrew the 4 Screws (PT (Ejot) screws 4,0x16 mm) loc ted t the bottom of the housing.
 Remove the cover to side.
Fixing pl te