TRU-Trac and TX Models 4779 and 4759 Service Manual 2006

TABLE OF CONTENTS FOREWORD .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1 1 THEORY OF OPERATION.. .. .. .. .. .. .. .. .. .. .. .. .. 2 1.1 OVERVIEW . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..2 2 SAFETY PRECAUTIONS . .. .. .. .. .. .. .. .. .. .. .. .. 35 2.1 PRECAUTIONARY DEFINITIONS .. .. .. .. .. .. 3 2.2 PRECAUTIONARY INSTRUCTIONS .. .. .. . 35 3 NOMENCLATURE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6 3.1 TRUTRAC AND TX UNIT EXTERNAL COMPONENTS .. .. .. .. .. .. .. .. .. ..6 3.2 INTERNAL COMPONENTS .. .. .. .. .. .. .. .. .. ..7 4 SPECIFICATIONS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 8 4.1 PHYSICAL SPECIFICATIONS .. .. .. .. .. .. .. .. ..8 5 TROUBLESHOOTING .. .. .. .. .. .. .. .. .. .. .. .. .. 926 5.1 TRUTRAC AND TX ERROR MESSAGES.. .. .. .. .. .. .. .. .. .. .. ..9-13 5.2 TRUTRAC AND TX TRACTION UNIT TESTING .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 14 5.3 VISUAL INSPECTION . .. .. .. .. .. .. .. .. .. .. .. 15 5.4 GROUND RESISTANCE TEST .. .. .. .. .. .. .. 15 5.5 LEAKAGE TESTS .. .. .. .. .. .. .. .. .. .. .. .. .. .. 15 5.6 ON/OFF SWITCH TEST . .. .. .. .. .. .. .. .. .. .. 16 5.7 ON/OFF SWITCH TROUBLESHOOTING . 16 5.8 PATIENT INTERRUPT SWITCH TEST . .. .. 17 5.9 CORD RELEASE AND RETRACT TEST.. .. 18 5.10 CORD RELEASE TROUBLESHOOTING . .. .. .. .. .. .. .. .. .. 19-20 5.11 LOAD CELL TEST .. .. .. .. .. .. .. .. .. .. .. .. .. .. 21 5.12 LOAD CELL TROUBLESHOOTING .. .. 22-23 5.13 TOUCH SCREEN TEST .. .. .. .. .. .. .. .. .. .. .. 24 5.14 TOUCH SCREEN TROUBLESHOOTING .. 25 5.15 POWER SUPPLY TROUBLESHOOTING .. 26 6 REMOVAL & REPLACEMENT . .. .. .. .. .. .. .. .2751 6.1 SIDE COVER REMOVAL & REPLACEMENT .. .. .. .. .. .. .. .. 27 6.2 TOP AND CORD GUIDE COVER REMOVAL & REPLACEMENT .. .. .. .. .. .. .. .. 28 6.3 REAR COVER REMOVAL & REPLACEMENT .. .. .. .. .. .. .. .. 29 6.4 FRONT COVER REMOVAL & REPLACEMENT .. .. .. .. .. .. 30-31 6.5 MOTOR CONTROL BOARD REMOVAL & REPLACEMENT .. .. .. .. .. .. .. .. 32 6.6 TOUCH SCREEEN ASSEMBLY REMOVAL & REPLACEMENT .. .. .. .. .. 33-34 6.7 LOAD CELL ASSEMBLY REMOVAL & REPLACEMENT .. .. .. .. .. 35-36

Tru-Trac and TX® Therapeutic Traction Unit

6.8 CLAMP SPRING ASSEMBLY REMOVAL & REPLACEMENT .. .. .. .. .. .. .. 37 6.9 TRACTION CORD REMOVAL & REPLACEMENT .. .. .. .. .. 38-43 6.10 CORD TENSION SPRING REMOVAL & REPLACEMENT .. .. .. .. .. 44-45 6.11 SOLENOID ASSEMBLY REMOVAL & REPLACEMENT .. .. .. .. .. .. .. 46 6.12 POWER SUPPLY REMOVAL & REPLACEMENT .. .. .. .. .. 47-48 6.13 MOTOR ASSEMBLY REMOVAL & REPLACEMENT .. .. .. .. .. 49-50 6.14 MOTOR DRIVE GEAR REMOVAL & REPLACEMENT .. .. .. .. .. .. .. 51 7 CALIBRATION .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .5256 7.1 UNIT CALIBRATION .. .. .. .. .. .. .. .. .. .. .. 52-54 7.2 TOUCH SCREEN CALIBRATION .. .. .. .. .. .. 55 7.3 UNIT BURN IN . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 56 8 PARTS.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .5764 8.1 TOP COVER ASSEMBLY .. .. .. .. .. .. .. .. .. .. .. 57 8.2 SIDE COVERS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 58 8.3 FRONT AND REAR COVERS . .. .. .. .. .. .. .. .. 59 8.4 BASE AND EXTRUSION ASSEMBLY . .. .. .. 60 8.5 CHASSIS ASSEMBLY . .. .. .. .. .. .. .. .. .. .. .. .. 61 8.6 TRACTION CORD SPRING ASSEMBLY AND POWER SUPPLY .. .. .. .. .. .. .. .. .. .. .. .. 62 8.7 SOLENOID AND CLAMP ASSEMBLIES .. .. 63 8.8 LARGE DRIVEN GEAR AND SPOOL ASSEMBLY .. .. .. .. .. .. .. .. .. .. .. .. .. .. 64 9 SCHEMATICS . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .6573 9.1 TRUTRAC AND TX TRACTION UNIT SCHEMATICS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 65-73 CONTROL BOARD . .. .. .. .. .. .. .. .. .. .. .. .. 66-68 MOTOR CONTROL BOARD . .. .. .. .. .. .. .. 69-70 PATIENT INTERRUPT SWITCH.. .. .. .. .. .. .. .. 71 SERIAL INTERFACE .. .. .. .. .. .. .. .. .. .. .. .. .. .. 72 SMART CARD .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 73 BLOCK DIAGRAM .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 74 10- SPECIAL FIXTURES . .. .. .. .. .. .. .. .. .. .. .. .. .. 75-78 CALIBRATION FIXTURE .. .. .. .. .. .. .. .. .. .. .. 75-78 11 WARRANTY . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .79

FOREWORD

Tru-Trac and TX® Therapeutic Traction Unit

Read, understand, and follow the Safety Precautions and all other information contained in this manual. This manual contains the necessary safety and field service information for those field service technicians, certified by Chattanooga Group, to perform field service on the Tru-Trac and TX unit. 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 traction therapy, 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 for certified field technicians to stay informed and trained in the latest technology utilized in the Tru-Trac and TX units by Chattanooga Group. From time to time, as significant improvements are incorporated, service bulletins will be produced and made available on our web site (chattgroup.com) in lieu of reprinting a complete manual prematurely. These service bulletins will provide updated service information and technological improvements to the Tru-Trac and TX unit for use by certified service technicians. 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 the sole risk and liability of the certified field service technician performing such troubleshooting techniques. Performance of such techniques may render the warranty null and void. Tru-Trac and TX® are prescription devices to be used only under the supervision of and by the order of a physician or other licensed health care provider.

©2006 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.

1

1 THEORY OF OPERATION

Tru-Trac and TX® Therapeutic Traction Unit

1.1 OVERVIEW The Tru-Trac and TX traction unit is comprised of several pieces of proprietary hardware and software causing the unit to function as required allowing administration of traction therapy under the prescription and supervision of a licensed medical practitioner. The Touch Screen Assembly houses the necessary hardware and software to communicate to the Motor Control Board. Communicates commands and limits as established by the user through use of the Touch Screen. The Touch Screen Assembly, in conjunction with the Motor Control Board, monitors the functionality of the entire system during the course of the traction therapy being administered. Should the unit malfunction or a communication error occur, the unit will stop treatment and generate an error message to notify the operator of a possible problem. The Touch Screen Assembly communicates to the Motor Control Board Assembly via a proprietary bus. The Motor Control Board communicates to the Touch Screen Assembly throughout the therapy session all parameters via feedback from the Motor Assembly and the Load Cell Assembly. The Touch Screen Assembly incorporates a Patient Data Card Reader/Writer for the purpose of storing Patient Treatment Data that can then be downloaded to a PC equipped with the optional PDMS System.

2

2 SAFETY PRECAUTIONS

Tru-Trac and TX® Therapeutic Traction Unit

2.1 PRECAUTIONARY DEFINITIONS The precautionary instructions found in this section and throughout this manual are indicated by specific symbols. Understand these symbols and their definitions before operating this equipment. The definition of these symbols are as follows:

2.2 PRECAUTIONARY INSTRUCTIONS A. Cautions

• Read, understand, and practice all precautionary instructions found in this manual. Know the limitations and hazards associated with using any electrical traction device. Observe the precautionary and operational decals placed on the unit. • Do not use accessories other than those supplied with the unit or recommended by Chattanooga Group. The safety of other products has not been established, and their use could result in injury to the patient. • This unit should be transported and stored in temperatures between 0°F and 140°F (-18°C and 60°C) to prevent damage to the unit or its components. • DO NOT operate this unit in an environment where other devices are being used that intentionally radiates electromagnetic energy in an unshielded manner. Portable and mobile RF communications equipment can affect Medical Electrical Equipment. • This unit generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to other devices in the vicinity. However, there is no guarantee that interference will not occur in a particular installation. Harmful interference to other devices can be determined by turning this (table, unit, device, etc.) on and off. Try to correct the interference using one or more of the following: reorient or relocate the receiving device, increase the separation between the equipment, connect the equipment to an outlet on a different circuit from that which the other device(s) are connected and consult the Chattanooga Group Service Department for help. • The unit should be routinely checked before each use to determine all controls function normally. • Handle the unit with care. Inappropriate handling of the unit may adversely affect its characteristics. • Before each use, inspect the Traction Cord for wear. Prolonged wear on the cord will cause it to break, which may cause sudden release of traction pressure on a patient. • Test the Patient Interrupt Switch before each use for power operation.

A. Caution Text with a “CAUTION” indicator will explain possible safety infractions that could 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. Dangerous Voltage Text with a “Dangerous Voltage” indicator serves to inform the technician of possible hazards resulting in the electrical charge disbursement from certain components if handled or serviced improperly.

E. NOTE Throughout this manual, “NOTE” may be found. These Notes are helpful information to aid in the particular area or function being described.

3

2 SAFETY PRECAUTIONS

Tru-Trac and TX® Therapeutic Traction Unit

2.2 PRECAUTIONARY INSTRUCTIONS (continued) B. Warnings

• Use of controls or adjustments or performance of procedures other than those specified herein may result in a hazardous traction related injury. • Before connecting the unit to an electrical outlet, make certain the unit is electrically grounded by connecting only to a grounded electrical service receptacle conforming to the applicable national and local electrical codes. • Do not use a damaged Mains Power Cord. Using a damaged Mains Power Cord may cause unit damage, malfunction, electrical shock, fire, or personal injury. If the Mains Power Cord becomes damaged, discontinue use immediately and contact the dealer for replacement of the Mains Power Cord. • This device should be kept out of the reach of children. • Always hand tighten the Lock Knob securely to avoid any slippage. • Care must be taken when operating this unit, adjacent to or stacked with other equipment. Potential electromagnetic or other interference could occur to this or other equipment. Try to minimize this interference by not using other equipment in conjunction with it. • In the event of a loss of power to the unit, traction tension should only be released by gradually lengthening the patient harness adjustment straps. • Dispose of all products in accordance with local and national regulations and codes. • In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the system and contact the dealer or Chattanooga Group for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by Chattanooga Group or a Field Service Technician certified by Chattanooga Group before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury to the patient, user, or may cause extensive internal damage to the unit. • Unit failing Dielectric Withstand and/or Leakage Tests could indicate serious internal problems. DO NOT place the back into service! Send unit to factory for repair! DO NOT attempt to repair the unit in the field! • Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock. • When performing Unit Calibration Procedure, the Calibration Fixture Load Cell must be set to US lbs.

• Do not remove the cover. This may cause unit damage, malfunction, electrical shock, fire, or personal injury. There are no user-serviceable parts inside the unit. If a malfunction occurs, discontinue use immediately, disconnect the Mains Power Cord from the outlet, and consult the dealer for repair service. • Do not use sharp objects such as a pencil point or ballpoint pen to operate the buttons on the LCD base as damage may result. • Do not permit any foreign materials or liquids to enter the unit. Take care to prevent any foreign materials including, but not limited to, inflammables, water, and metallic objects from entering the unit. These may cause unit damage, malfunction, electrical shock, fire, or personal injury. • Do not disassemble, modify, or remodel the unit or accessories. This may cause unit damage, malfunction, electrical shock, fire, or personal injury. • Do not use the traction unit near devices such as X-ray units or diathermy units. These units may emit high frequency noise that may affect the operation of the unit. • Failure to use and maintain the traction unit and its accessories in accordance with the instructions outlined in this manual will render the warranty void. • In the event of a loss of power to the unit or when quick release is needed, traction tension should only be released by having the patient move towards the traction head to release the tension on the rope. Once the tension on the rope has been released, loosen the patient harness adjustment straps. • The tool, lubrication, and locking compound requirements listed are critical to component removal and replacement of the unit. • The hardware, bolts, nuts, and screws used to assemble the Tru-Trac and TX are SAE and Metric. Therefore, it will be necessary to obtain both SAE and Metric tools for removal and replacement of components. • The lubricant and locking compound listed are crucial in the assembly of certain components to ensure patient safety and efficient operation of the unit.

4

2 SAFETY PRECAUTIONS

Tru-Trac and TX® Therapeutic Traction Unit

2.2 PRECAUTIONARY INSTRUCTIONS (continued) C. Dangers • Use only accessories that are specially designed for this unit. Do not use accessories manufactured by other companies on this (table, unit, device, etc.). Chattanooga Group is not responsible for any consequence resulting from using products manufactured by other companies. The use of other accessories or cables may result in increased emissions or decreased immunity of this (table, unit, device, etc.). • This component removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

• DO NOT connect the unit to an electrical supply without first verifying that the power supply is the correct voltage. Incorrect voltage may cause unit damage, malfunction, electrical shock, fire, or personal injury. Your unit was constructed to operate only on the electrical voltage specified on the Voltage Rating and Serial Number Plate. Contact the Chattanooga Group dealer if the unit is not properly rated. • Power Supplies retain High Voltage! • Discharge the C4 Capacitor prior to complete removal of the Power Supply. • Discharge the C4 Capacitor prior to handling of the new Power Supply. • Tru-Trac and TX® is a prescription device to be used only under the supervision of and by the order of a physician or other licensed health care provider. • Do not use any other knot styles in the Cord other than those specified in this manual. Use of other knot styles could cause Cord to completely disengage from the system and may cause serious injury to patient and personnel.

COMPLETE CALIBRATION OF UNIT Refer to Section 7 AND MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION Refer to Section 7 Failure to perform either of these procedures, after a component or assembly replacement will void warranty and may result in injury to patients and/or severe equipment damage. • It is not recommend tying a new knot in a cord that has frayed or failed in use or is worn in an area from constant use. The cord must be replaced.

5

3 NOMENCLATURE

Tru-Trac and TX® Therapeutic Traction Unit

3.1 TRUTRAC AND TX UNIT EXTERNAL COMPONENTS The nomenclature graphics below, Figure 3.1, Know the components and their functions before indicate the general locations of the major external performing any operation of or service to the components of the Tru-Trac and TX traction unit. Tru-Trac and TX traction unit. 1

2

3

7

6

4 5

8

10 9

FIGURE 3.1

1. 2. 3. 4. 5.

Touch Screen Assembly Top and Cord Guide Cover Traction Cord Knuckle Front Cover Patient Interrupt Switch Receptacle

6. Side Cover 7. Clamp Assembly Knob 8. Rear Cover 9. Mains Power Cord Receptacle 10. On/Off Power Switch

6

3 NOMENCLATURE

Tru-Trac and TX® Therapeutic Traction Unit

3.2 INTERNAL COMPONENTS The nomenclature graphics below, Figure 3.2, indicate the locations of the major internal components of the Tru-Trac and TX traction unit.

Know the components and their functions before performing any operation of or service to the Tru-Trac and TX traction unit. 1 2 3 4 9

5

8 7 6 10

12

11

FIGURE 3.2 1. 2. 3. 4. 5. 6.

Chassis Load Cell Top Front Traction Cord Guide Traction Cord Front Cover Mounting Bracket Motor Control Board

7. Motor Assembly 8. Power Supply 9. Cord Tension Spring and Housing 10. Clamp Spring Assembly 11. Large Driven Gear 12. Solenoid Assembly

7

4 SPECIFICATIONS

Tru-Trac and TX® Therapeutic Traction Unit

4.1 PHYSICAL SPECIFICATIONS

HEIGHT

DEPTH

WIDTH

FIGURE 4.1

Width... 24 cm (9.5 in) Depth... 45 cm (17.5 in) Height... 45 cm (17.5 in) Weight Standard Weight...14 kg (30 lbs) Shipping Weight...18 kg (40 lbs) Power Voltage... 100 V-240 V (50/60 Hz) Power Consumption... 75 VA Current Consumption... 3.2 A Max Electrical Class...Class I Electrical Type...Type B

PARAMETERS Traction Period Hold Period Rest Period Traction Tension Progrssive and Regressive Steps

Traction Modes... Static, Intermittent, Cyclic, and their combinations. Traction Type... Mechanical LCD Display...High contrast monochrome Touch Screen Regulatory Compliance Meets Directive 93 /42 /EEC IEC/UL/EN: 60601-1 and 60601-1-2 CAN C22.2 No. 601.1-M90w/AZ 0413

TRACTION TENSION SPECIFICATIONS MINIMUM MAXIMUM 1 minute 99 minutes 0 seconds 99 seconds 0 seconds 99 seconds 0 kg (0 lb/0 N) 90 kg (200 lb/890 N) 1 step 9 steps

8

INCREMENTS 1 minute 1 second 1 second 1 kg (1 lb/5 N) 1 step

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.1 TRUTRAC AND TX ERROR MESSAGES A. The following information is provided as an aid in defining the Software Error Messages of the Tru-Trac and TX traction unit. Once a particular Error Message is defined, the information will also list probable causes and possible remedies. Once the problem area is determined, subsequent tests for verification will be necessary to determine the subassembly or PC Board to be replaced.

ERROR ERROR CODE TYPE

DEFINITION

In the case of PC Boards, all troubleshooting and 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 PC board components. B. Once a particular subassembly or PC Board has been determined as bad, refer to the appropriate Removal & Replacement Section for the board affected and follow the instructions for replacement of the board.

PROBABLE CAUSES

POSSIBLE REMEDY

USER CORRECTABLE WARNING MESSAGES 100

WARNING

Treatment has been running for 8 seconds, but no tension is detected on the Cord.

Too much slack in Traction Cord

Remove Traction Cord Slack.

101

WARNING

Patient pressed Patient Switch.

Patient Interrupt Switch button pressed.

Touch the Touch Screen to clear message.

102

WARNING

Patient Switch is unplugged.

Patient Interrupt Switch not properly connected to unit.

Properly connect Patient Interrupt Switch and touch Touch Screen to clear message.

104

WARNING

User selected Patient Card button on utilities screen, but no traction treatments were found on the card.

Wrong or bad Patient Data Card inserted into unit.

Insert correct Patient Data Card.

105

WARNING

User selected save to card, but no card is inserted into the unit.

No Patient Data Card inserted.

Properly insert correct Patient Data Card into unit.

106

WARNING

User selected save to card, but the card currently inserted is not a Patient Card.

Wrong or bad Patient Data Card inserted into unit.

Insert correct Patient Data Card.

107

WARNING

User selected save to card, but the card currently inserted is full.

Memory full on Patient Data Card used.

Save Data to PDMS and erase Patient Data Card.

108

WARNING

User typed in a blank patient name.

No Patient ID assigned.

Enter Patient ID.

109

WARNING

User typed in a blank protocol name.

No Protocol name entered.

Enter Protocol name.

110

WARNING

User attempted to access a MMC function, but no MMC is inserted into the unit.

No Multimedia Card (MMC) inserted into unit.

Insert Multimedia Card (MMC) into unit.

111

WARNING

User attempted to upgrade software, but the MMC in the unit is not a software upgrade MMC.

Wrong Multimedia Card (MMC) inserted into unit.

Insert proper Mutimedia Card (MMC).

112

WARNING

Error upgrading Control Board software.

Unknown

Contact Dealer or Chattanooga Group for Service.

113

WARNING

Error upgrading motor board software.

Unknown

Contact Dealer or Chattanooga Group for Service.

114

WARNING

User pressed START, but has not yet set the Max Level value to a value greater than zero.

User has not completed Treatment Set Up.

Complete Treatment Set Up prior to pressing START.

115

WARNING

User pressed HOME button from treatment Home button has been pressed. review screen while a treatment was running.

9

Press STOP to end treatment prior to pressing HOME.

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.1 TRUTRAC AND TX ERROR MESSAGES (continued)

In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the unit and contact the dealer or Chattanooga Group for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by Chattanooga Group or a Field Service Technician certified by Chattanooga Group before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury to the patient, user, or may cause extensive internal damage to the unit. ERROR ERROR CODE TYPE

DEFINITION

PROBABLE CAUSES

POSSIBLE REMEDY

ERROR MESSAGES (200-223) REQUIRING TECHNICAL ASSISTANCE 200

ERROR

The motor PCB has reset.

Motor Control Board is bad.

If the Error repeats routinely, replace Motor Control Board.

201

ERROR

Error communicating with the realtime clock chip.

Control Board Communication Error.

If the Error repeats routinely, replace Touch Screen Assembly.

202

ERROR

The motor PCB returned an error while performing the zero Load Cell function.

Bad Load Cell Assembly Motor Control Board Communication Error.

1. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 2. Replace Load Cell Assembly. 3. Replace Motor Control Board. 4. Replace Touch Screen Assembly.

203

ERROR

Timeout waiting for the motor PCB to perform the zero Load Cell calibration.

Bad Load Cell Bad Motor Control Board

1. Ensure there is slack in the Cord. 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Load Cell. 4. Replace Motor Control Board.

204

ERROR

Timeout waiting for the motor PCB to perform the motor current calibration.

Motor Control Board Communication Error.

1. Ensure there is no slack in the Cord. 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Load Cell. 4. Replace Motor Control Board.

205

ERROR

A Motor fault error has occurred while a treatment was running.

Internal mechanical jam of unit. Bad Motor Control Board or Motor Assembly.

1. Correct any internal mechanical jam. 2. Replace bad Motor Control Board or bad Motor Assembly.

206

ERROR

The Motor PCB cannot get to the desired tension.

Internal Mechanical Jam of unit. Bad Motor Control Board or Motor Assembly.

1. Correct any internal mechanical jam. 2. Replace bad Motor Control Board or bad Motor Assembly.

207

ERROR

We have detected a motor current error (MC_MON pin on motor PCB).

Unit out of calibration.

Perform Unit Calibration and Burn In procedures.

208

ERROR

We have detected a Load Cell limit error (LC_MON pin on motor PCB).

Unit is out of calibration. Bad Motor Control Board. Bad Load Cell Assembly.

1. Perform Unit Calibration and Burn In procedures. 2. Replace Motor Control Board. 3. Replace Load Cell Assembly.

209

ERROR

Error erasing a patient card.

Bad Patient Data Card. Bad Touch Screen Assembly.

1. Try known good Patient Data Card. 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Touch Screen Assembly.

210

ERROR

CRC not correct on treatment just read from Patient Card.

Bad Patient Data Card. Bad Touch Screen Assembly.

1. Try known good Patient Data Card. 2. Replace Touch Screen Assembly.

211

ERROR

Error reading default protocol on power up so must rebuild protocols to factory presets.

EEPROM is corrupt.

If the Error repeats routinely, replace Touch Screen Assembly.

212

ERROR

The Motor PCB flagged a comm watchdog error.

Touch Screen Assembly did not poll Motor Control Board in a reasonable amount of time.

1. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 2. If the Error repeats routinely, replace Touch Screen Assembly.

213

ERROR

Motor PCB has indicated that the zero calibration value is invalid and needs to be calibrated.

Unit is out of calibration.

Perform Unit Calibration and Burn In procedures.

10

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.1 TRUTRAC AND TX ERROR MESSAGES (continued)

In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the unit and contact the dealer or Chattanooga Group for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by Chattanooga Group or a Field Service Technician certified by Chattanooga Group before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury to the patient, user, or may cause extensive internal damage to the unit. ERROR ERROR CODE TYPE

DEFINITION

PROBABLE CAUSES

POSSIBLE REMEDY

ERROR MESSAGES (200-223) REQUIRING TECHNICAL ASSISTANCE (continued) 214

ERROR

User has configured a treatment such that it takes Under normal operating conditions, this Error should too much memory to compute the treatment never appear. steps. Unit will default back to the default power up protocol.

Remove unit from service and report exact treatment parameters to Chattanooga Group.

215

ERROR

Internal error, unit cannot get the next treatment step information, treatment is terminated.

Multimedia Card (MMC) Data is corrupt. Multimedia Card (MMC) interface not working.

1. Try known good Multimedia Card (MMC). 2. Remove unit from service and report exact treatment parameters to Chattanooga Group.

217

ERROR

Error reading a MMC.

Bad Mutimedia Card (MMC). Improper cable connection to Motor Control Board. Bad Touch Screen Assembly.

1. Try known good Multimedia Card (MMC). 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Touch Screen Assembly.

218

ERROR

Error upgrading Control Board software.

Bad Mutimedia Card (MMC). Improper cable connection to Motor Control Board. Bad Touch Screen Assembly.

1. Try known good Multimedia Card (MMC). 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Touch Screen Assembly.

219

ERROR

Error upgrading Control Board software.

Bad Mutimedia Card (MMC). Improper cable connection to Motor Control Board. Bad Touch Screen Assembly.

1. Try known good Multimedia Card (MMC). 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Touch Screen Assembly.

220

ERROR

Error upgrading Motor Control Board software.

Bad Mutimedia Card (MMC). Improper cable connection to Motor Control Board. Bad Motor Control Board. Bad Touch Screen Assembly.

1. Try known good Multimedia Card (MMC). 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Motor Control Board. 4. Replace Touch Screen Assembly.

221

ERROR

Error upgrading Motor Control Board software.

Bad Mutimedia Card (MMC). Improper cable connection to Motor Control Board. Bad Motor Control Board. Bad Touch Screen Assembly.

1. Try known good Multimedia Card (MMC). 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Motor Control Board. 4. Replace Touch Screen Assembly.

222

ERROR

Patient switch is shorted.

Patient Interrupt Switch not completely seated in connector. Bad Patient Interrupt Switch. Bad Patient Interrupt Switch Connector.

1. Properly connect Pateint Interrupt Switch to unit. 2. Use a known good Pateint Interrupt Switch. 3. Replace Patient Interrupt Switch Connector on unit.

223

ERROR

Beta version evaluation period has expired.

Unit is designated BETA Test Unit.

Immediately return unit to Chattanooga Group.

11

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.1 TRUTRAC AND TX ERROR MESSAGES (continued)

In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the unit and contact the dealer or Chattanooga Group for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by Chattanooga Group or a Field Service Technician certified by Chattanooga Group before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury to the patient, user, or may cause extensive internal damage to the unit. ERROR CODE

ERROR TYPE

DEFINITION

PROBABLE CAUSES

POSSIBLE REMEDY

300 through 307

CRITICAL ERROR

Communication Error between Touch Screen and Motor Communication Error. Control Board.

1. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 2. Replace Motor Control Board. 3. Replace Touch Screen Assembly.

308

CRITICAL ERROR

We are supposed to be increasing tension, but tension is not increasing.

Slack in Cord. Bad Load Cell. Bad Motor Control Board.

1. Remove slack in Cord. 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Load Cell. 4. Replace Motor Control Board.

309

CRITICAL ERROR

We are supposed to be decreasing tension, but tension is actually increasing.

Unit out of calibration. Bad Harness connection. Bad Load Cell. Bad Motor Control Board.

1. Perform Unit Calibration and Burn In procedures. 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Load Cell. 4. Replace Motor Control Board.

310

CRITICAL ERROR

We are reading > 0 tension when we should be reading zero.

Unit out of calibration.

Perform Unit Calibration and Burn In procedures.

311

CRITICAL ERROR

We are reading < 0 tension when we should be reading zero.

Unit out of calibration. Bad Load Cell. Bad Motor Control Board.

1. Perform Unit Calibration and Burn In procedures. 2. Check Cables and Harnesses for proper seating and connection on Motor Control Board. 3. Replace Load Cell. 4. Replace Motor Control Board.

312

CRITICAL ERROR

We have detected that the motor is running too fast.

Bad Motor Control Board. Bad Motor Assembly.

1. Replace Motor Control Board. 2. Replace Motor Assembly.

313

CRITICAL ERROR

Internal memory error.

Bad Touch Screen.

Replace Touch Screen Assembly.

314

CRITICAL ERROR

Error reading EEPROM.

Bad Touch Screen.

Cycle power to unit. If the Error repeats, then replace Touch Screen Assembly.

CRITICAL ERRORS (300-314) DEMANDING TECHNICAL SERVICE

12

Tru-Trac and TX® Therapeutic Traction Unit

NOTES

13

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.2 TRUTRAC AND TX TRACTION UNIT TESTING A. General- Electronic 1. Information within this section in respect to electronic components is intended to aid in troubleshooting the PCB's of the Tru-Trac and TX units to “Board Level” only. These tests are the standard testing procedures and methods used at the factory before shipment of the unit. 2. Due to the complex nature of the technology utilized by Chattanooga Group, the recommended PCB troubleshooting techniques are to determine “Bad Board” and board replacement only. No PCB component level troubleshooting is recommended nor will information or parts be supplied by Chattanooga Group. Any PC board component level troubleshooting performed will be at the sole risk and liability of the Service Technician performing such troubleshooting techniques. 3. Once a particular PCB has been determined as bad, replace the PCB. Use only Chattanooga Group replacement parts and hardware. B. General- Replacement Components Critical component replacement parts for the traction unit are available as subassemblies only. This is due to the accuracy required and the critical nature of the subassembly within the unit for power function and operation. Individual components of these subassemblies will not be made available by Chattanooga Group. C. General- Tests and Repair Procedures 1. Certain tests and repair procedures 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. Test equipment settings will be listed for each test performed prior to the respective test to ensure the test is performed to Chattanooga Group standards and ensure power readings. 3. The troubleshooting and repair of the units are to be performed only by authorized technicians trained and certified by Chattanooga Group. D. Tools, Fixtures, and Equipment Required 1. Dielectric Withstand (Hi-Pot) and ground resistance tester.

NOTE: Adjust Dielectric Withstand tester to indicate fault with 120 kOhm load across the output when at specified test voltage. 2. Milliohm Meter 3. Digital Multimeter 4. Required Hand Tool • #1 Phillips Screwdriver • #2 Phillips Screwdriver • Flat Blade Screwdriver • Calibrated Torque Wrench- 200 inch pound or 2,500 Newton meter minimum capacity. • Allen Wrenches • SAE- 3/32, 5/32, and 9/64 in • Metric- 3 mm • Hex Key Sockets for Torque Wrench • SAE- 3/32 and 5/32 in • Metric- 4 mm • Needle Nose Pliers • Tape Measure- 12 ft (3 meter) minimum • Ratchet • 7mm Box End Wrench • Pick for removing connector wires. 5. Touch Screen to Cover Assembly Jig 6. Calibration Fixture with calibrated Strain Meter. 7. Solenoid Assembly Mounting Jig. P/N 48139.

The tool, lubrication, and locking compound requirements listed are critical to component removal and replacement of the unit. The hardware, bolts, nuts, and screws used to assemble the Tru-Trac and TX are SAE and Metric. Therefore, it will be necessary to obtain both SAE and Metric tools for removal and replacement of components. The lubricant and locking compound listed are crucial in the assembly of certain components to ensure patient safety and efficient operation of the unit.

14

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.3 VISUAL INSPECTION A. General Visually inspect the unit. A visual inspection can, to an experienced Technician, indicate possible abuse of the unit and internal problems. 5.4 GROUND RESISTANCE TEST A. Voltage Specifications Models 4759 and 4779... Input: 100-240 VAC 50/60 Hz, 75 VA B. Specification Maximum Acceptable Resistance: 100 milliohms C. Equipment Required Milliohm Meter D. Test Place unit on level work surface. Place one meter probe on the ground prong of power supply and the other to any exposed metal or screw on the unit. See Figure 5.1.

5.5 LEAKAGE TESTS

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! Test Voltage Spec...1000 V 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 Facilities” standards. See Figure 5.2.

EXPOSED METAL

FIGURE 5.2 GROUND PRONG

NOTE: The NFPA "Health Care Facilities" standards are specific to the U.S.A. All other technicians should verify their country's requirements for these tests.

FIGURE 5.1 NOTE: U.S.A. Power Cord Illustrated. Unit is illustrated on its side.

15

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.6 ON/OFF SWITCH TEST A. Specification Unit turns Off and On B. Equipment Required None C. On/Off Switch Test Procedure 1. Place unit on level work surface. 2. Plug Power Cord into grounded power source with appropriate voltage. See Specifications on page 8. 3. Turn unit Off and back On with Power Switch. See Figure 5.3. D. Test Result 1. If unit turns Off and On, unit passed test. 2. If unit does not turn Off and On, unit failed test. Refer to: 5.7 On/Off Switch Troubleshooting below. 5.7 ON/OFF SWITCH TROUBLESHOOTING A. Specification Appropriate AC voltage. B. Equipment Required Digital Multimeter 3/32 in Allen Wrench C. On/Off Switch Troubleshooting Procedure 1. Disconnect unit from power source.Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement. 2. Remove Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement. 3. Remove Rear Cover leaving harnesses connected. Refer to 6.3 Rear Cover Removal and Replacement. 4. Disconnect the Blue and Red wires from the Power Supply to the Power Switch. See Figure 5.4. 5. Set Multimeter to AC and to the appropriate voltage setting. Connect Multimeter Leads to the Blue and Brown wire Connectors from the Power Switch. See Figure 5.5. 6. Plug unit into a grounded power source with appropriate voltage. Turn Power Switch On and take reading from Multimeter. D. Test Result 1. If Multimeter reads appropriate voltage, unit passed test. If unit will not power up, refer to 5.15 Power Supply Troubleshooting. 2. If Multimeter does not read appropriate voltage. Replace Power Switch.

ON/OFF SWITCH

FIGURE 5.3

DISCONNECT RED AND BLUE POWER SUPPLY WIRES

FIGURE 5.4 ON/OFF SWITCH

MULTIMETER CONNECTED TO BLUE AND BROWN WIRES

FIGURE 5.5

16

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.8 PATIENT INTERRUPT SWITCH TEST A. Specification Unit displays Error 101 or 102 at the respective test. B. Equipment Required None C. Patient Interrupt Switch Test Procedure 1. Place unit on level work surface. Plug Power Cord into grounded power source with appropriate voltage. 2. Connect Patient Interrupt Switch to unit making certain it is completely seated in the Patient Interrupt Switch connector. See Figure 5.6. 3. Turn unit On with Power Switch. After unit has completely booted up, disconnect the Patient Interrupt Switch. Unit should display Error 102. See Figure 5.7. 4. Reconnect the Patient Interrupt Switch. Touch the Touch Screen anywhere to clear the Error. 5. Turn unit Off. with Patient Interrupt Switch connected to the unit, turn unit On with Power Switch. 6. After unit has completely booted up, depress the Patient Interrupt Switch button. The unit should display Error 101. Touch the Touch Screen anywhere to clear the Error. See Figure 5.8. D. Test Result 1. If unit displays Errors 101 or 102 at the respective test, unit passed test. 2. If unit does not display Errors 101 or 102 at the respective test, unit failed test. Repeat test with a known good Patient Interrupt Switch. 3. If known good Patient Interrupt Switch resolves the problem, replace existing Patient Interrupt Switch with new part. 4. If the known good Patient Interrupt Switch does not remedy the problem, Replace Patient Interrupt Switch Jack.

FIGURE 5.6

FIGURE 5.7

FIGURE 5.8 17

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.9 CORD RELEASE AND RETRACT TEST A. Specification Release... Cord releases with less than 5 lbs tension Retract...Cord completely retracts B. Equipment Required Calibration Fixture with calibrated Strain Meter. C. Cord Release and Retract Test Procedures 1. Secure unit to the Calibration Fixture. See Figure 5.9. 2. Plug unit into approved power source and turn unit On. 3. After unit has completely booted, press and hold Rope Release on Touch Screen, and pull Cord out. Release Rope Release while holding Cord out. See Figure 5.10. NOTE: It may be necessary to pull and release slight tension on the Cord to allow the internal mechanism to release the stop on the Cord. 4. While holding on to extended Cord, press Rope Release on the Touch Screen and guide Cord back into unit. 5. Repeat step 3 above to connect the Cord to the Calibration Fixture. See Figure 5.11. 6. Set up unit for a static pull of 100 lbs. Refer to User Manual if necessary. 7. Press the START button. After the 100 lbs has been reached, press the STOP Button and view the Rope Release on the Touch Screen, it should be inactive. 8. Watch as the tension decreases. Once the tension decreases to below 5 lbs, the Rope Release should become active. Immediately press the Rope Release on the Touch Screen, pull enough Cord out to facilitate disconnection from the Calibration Fixture. Release the Rope Release control. Disconnect the Cord from the Calibration Fixture. NOTE: It may be necessary to apply and release slight tension on the Cord to allow the internal mechanism to release the stop on the Cord. 9. Repeat step 4. D. Test Result 1. If Cord fails to release, unit failed test. Refer to 5.10 Cord Release Troubleshooting. 2. If Cord fails to completely retract, unit failed test. Adjust Cord Retraction Spring. Refer to page 42 beginning with step 13 for adjustment procedures.

FIGURE 5.9

FIGURE 5.10

FIGURE 5.11 18