BTL-CPMOTION K

SERVICE MANUAL
 About Document

Document Revisions and History

Date: Date: Previous

Version: Change description:
Created by: Approved by: version:

Added information about Unit 2016-12-22 2016-12-22

101 100
version 102 Tomáš Jindra Viktor Pokorný

2016-03-10 2016-03-10
100 Initial version N/A
Tomáš Jindra Viktor Pokorný

i
Versions of Units and Accessories Covered by the Document
This Service manual covers below stated versions of BTL-CPMotion K:

Unit Version Unit Name Manufactured from - to

100 093-PSUNIT100 12/2015 03/2016

101 093-PSUNIT101 03/2016 08/2016

102 093-PSUNIT102 08/2016 In production

ii 093-82ServiceManualEN101
 About Document

The Serial number of each Unit can be found on the Label placed at rear side of the Unit.

The Serial number of the Ankle module can be found on the white Label tag on the cable
of the Ankle module and on the bottom side of the main plastic cover.

iii
 The Serial number of the Touchscreen remote control can be found on the white Label
tag on the cable of the Touchscreen remote control. There is also QR code placed on the
back side of the Touchscreen remote control which can be scanned to obtain the Serial
number as well.

The Serial number of the Start/stop button can be found on the white Label tag on the
cable of the Start/stop button. There is also QR code placed on the back side of the
Start/stop button which can be scanned to obtain the Serial number as well.

NOTE: Following terms are used in the document:

Device = BTL-CPMotion K = Unit + Accessories

iv 093-82ServiceManualEN101
 About Document

Symbols and Comments

General warning, caution, risk or danger

IMPORTANT Please pay close attention to the information given

NOTE Additional recommendation

IMPORTANT: This service documentation has been designed to provide

information required for performing safe service repairs and Maintenance tasks
on the Device.

All service and Maintenance tasks stated in the service documentation can be
only performed by properly trained service personnel.

Do not service any parts, components and accessories of the Device for which
there is no repair description stated in the service documentation.

Only the spare parts listed in the service documentation can be used for repairs
of the Device.

For general Maintenance and safety requirements, Device transport, Firmware

update, display calibration and event logging please refer to the document
“General Instructions and Common Service Tasks”.

For detail or specific information from Operator’s point of view please refer to
the “Operator’s Manual”.

Failing to follow the instructions given in the service documentation can result in
loss of warranty.

v
Service Documentation Structure
Service Manual is divided into four color parts - Green, Blue, Red and Yellow, where each
part is represented by a color strip placed in the header of the document:

Green Part contains information about safety, Maintenance and basic service tasks. This
part is further divided into two subparts:

• The first subpart is an external document called “General Instructions and

Common Service Tasks” which contains general information and tasks common
to all BTL Devices.
• The second subpart contains complementary information specific for a particular
Device and is part of this manual.

Green part describes procedures which require basic servicing skills and knowledge
every service technician should be familiar with.

Blue Part describes repairs done by replacement of whole component blocks. This
chapter should represent standard servicing skills and knowledge of a service technician.
The Blue part can also be complemented by description of the Device operation.

Based on the type of the document (“Service Manual” / “Service Quick Guide”) and the
technical complexity of the concerned Device the Blue part can describe all possible
component exchanges on the Device, or can be omitted in cases when such information
is not necessary (e.g. due to simplicity of some Devices).

NOTE: The preferred way of servicing BTL Devices is replacement of either

individual components or larger functional blocks of the Device. All potential
hardware problems can be resolved in this manner.

Red Part contains guide for repairs that are alternative to the repairs specified in the Blue
part. Repairs mentioned in the Red part are generally more complex and skill demanding
(e.g.: exchange of components by soldering on a PCB or difficult component
replacements) and therefore considered as a non-standard way. There are however
cases, when mentioning of alternative ways of repair is beneficial.

Procedures described in the Red part must be carried out by experienced and
appropriately qualified service technician.

vi 093-82ServiceManualEN101
 About Document

Yellow Part represents the core of the document, a minimum that should be present in
both types of the document (“Service Manual” / “Service Quick Guide”) for BTL Device.
Yellow part contains mainly Device troubleshooting and spare part list.

The “Service Manual” is a document that is not a subject of frequent revisions. It is

recommended that the printed version of the document should be put into a binder
where each part is divided by colored tabulators. This will greatly enhance speed of
finding the requested information.

Service Manual Appendix contains the latest known service information and know-how
that is available to service technicians. The information is put into this section in its
original layout (e.g. “Service Bulletin”).

The Appendix is kept as an external document as it can be a subject of frequent changes.

After printing, the Appendix becomes the latest chapter of the “Service Manual”.

NOTE: Before starting using the document it is strongly recommended to make sure,
that you are using the latest available revision of the “Service Manual Appendix”.
When looking for any advice regarding to service repair please check the Appendix
chapter first as it can contain the most up-to-date information for the required repair.
Then continue with searching in the chapter Troubleshooting Guide of the “Service
Manual”.

In case any of the respective documents (“Service Manual”, “General Instructions and
Common Service Tasks”, “Service Manual Appendix”) do not contain the required
information, or when further assistance is needed, please refer to chapter
Technical Support Contact.

vii
viii 093-82ServiceManualEN101
 BTL-CPMOTION K
TABLE OF CONTENTS

Document Revisions and History .................................................................................................... i

Versions of Units and Accessories Covered by the Document .............................................. ii

Symbols and Comments................................................................................................................... v

Service Documentation Structure ................................................................................................. vi

ix
 1 Device Specific Instructions and Service Tasks ................................................................. 1-1

1.1 Model Identification .......................................................................................................... 1-2

1.2 Important Facts from the Operator’s Manual ............................................................. 1-2

1.3 Service Features................................................................................................................. 1-3

2 Device Description ..................................................................................................................... 2-1

2.1 Operation Block Diagram ................................................................................................ 2-2

2.2 Component Blocks and Names...................................................................................... 2-3

2.3 Components Description ................................................................................................. 2-5

3 Disassembly / Components Exchange ................................................................................. 3-1

3.1 Components Interconnection ......................................................................................... 3-3

3.2 Components Disassembly/Exchange .......................................................................... 3-5

4 Advanced Repair Instructions ................................................................................................. 4-1

5 Troubleshooting Guide .............................................................................................................. 5-1

5.1 Troubleshooting Features................................................................................................ 5-2

5.2 General Issues .................................................................................................................... 5-3

5.3 Error Codes ....................................................................................................................... 5-10

5.4 Device Inspection Faults ............................................................................................... 5-33

6 Spare Part and Tool List ............................................................................................................ 6-1

6.1 Electronic Parts .................................................................................................................. 6-2

6.2 Electrical/Electromechanical Parts ............................................................................... 6-4

6.3 Mechanical Parts ............................................................................................................... 6-8

6.4 Accessories and Consumables ................................................................................... 6-13

6.5 Used Tools ........................................................................................................................ 6-14

7 Technical Support Contact ...................................................................................................... 7-1

8 Index .............................................................................................................................................. 8-1

9 Appendix....................................................................................................................................... 9-1

x 093-82ServiceManualEN101
 Device Specific Instructions and Service Tasks

BTL-CPMOTION K
1 DEVICE SPECIFIC INSTRUCTIONS
AND SERVICE TASKS

1.1 Model Identification .............................................................................................................. 1-2

1.2 Important Facts from the Operator’s Manual ................................................................. 1-2

1.3 Service Features ..................................................................................................................... 1-3

1.3.1 Firmware Update .......................................................................................................... 1-3

1.3.2 Setting Codes ................................................................................................................. 1-7

1.3.3 Service Mode ................................................................................................................. 1-8

1.3.4 Unit Log Data Export ................................................................................................. 1-10

1.3.5 Parking Position .......................................................................................................... 1-12

1.3.6 Calibration of Knee Angle Sensor .......................................................................... 1-12

1.3.7 Calibration of Ankle Angle Sensor ......................................................................... 1-13

1.3.8 Calibration of the Touchscreen Remote Control................................................ 1-13

1.3.9 Motion Screw Lubrication ....................................................................................... 1-14

1.3.10 Mains PCB Fuse Check ............................................................................................. 1-15

1-1
1.1 Model Identification
The exact version of the Unit can be found on the white Label placed on the bottom side
of the Unit. The main differences between the models of the Unit are stated in the table
below. For further information please see the section 2.2 Component Blocks and Names.

Model name Model features

BTL-CPMotion K EASY Basic model with Start/Stop remote control

Touchscreen remote control is supplied with this model. It
BTL-CPMotion K PRO
enables using of advanced therapy and Unit settings.
Touchscreen remote control and Ankle module are
supplied with this model. The Touchscreen remote
BTL-CPMotion K ELITE
control enables using of advanced therapy and Unit
settings.

1.2 Important Facts from the Operator’s Manual

The BTL-CPMotion K is a motor driven continuous passive motion (CPM) system that
works on a principle of increasing range of motion to an extremity through an externally
applied force. The CPMotion system is used for treatment of injuries, diseases and in
postoperative treatment of joints and to prevent negative effects of joints immobilization.
Main indications are:

• improvement of joint metabolism and prevention of joint stiffness

• promotion of the regeneration and healing of cartilage and damaged ligaments
• faster hematoma/fluid resorption and improved lymph and blood circulation
• thrombosis and embolism prophylaxis

The Device consists of main Unit and Accessories.

The Unit contains:

• Mechanical Motion frame, Thigh and Calf support mechanism and a Footplate
which allows proper adjusting of the extremity on the Device

Accessories are:

• Handheld remote controls - Start/stop remote control for EASY variant and
Touchscreen remote control for PRO and ELITE variants.
• Ankle module - additional module with own motor allowing treatment of an ankle
area. Ankle module is mounted on the Motion frame instead of the Footplate.
Ankle module is standard accessory for BTL-CPMotion K ELITE and optional
accessory for BTL-CPMotion K PRO.

1-2 093-82ServiceManualEN101
 Device Specific Instructions and Service Tasks

1.3 Service Features

CAUTION: Electronic components in the Device are ESD (Electrostatic

discharge) sensitive. Therefore follow general rules for handling such
components and use antistatic wrist band (see section 6.5 Used Tools).

NOTE: Text in this chapter contains complementary (Device-specific) information to

the information given in document “General Instructions and Common Service
Tasks”.

It is strongly recommended to read the above mentioned document too, as it

contains overview of the essential skills and knowledge required for servicing the
BTL Devices.

1.3.1 Firmware Update

There are two main parts in the Device which the firmware can be uploaded into:

• Generator PCB
• Touchscreen remote control

Each of these components requires a different method of firmware upload.

GENERATOR PCB FIRMWARE UPDATE

To perform firmware upload of the Generator PCB prepare the following tools:

• CPM generator loading cable (with RS232 - USB converter)

• Firmware loader for service
• Latest Multibin file (*.mbin)

CPM generator loading cable (with RS232 - USB converter)

1-3
 Once all tools are prepared, connect the Unit to the mains and CPM generator loading
cable to the PC.

IMPORTANT: At this stage do not connect the CPM generator loading cable to
the Unit! Wait for the next steps!

In the Firmware loader select correct communication port assigned to the RS232 - USB
converter and press “Switch to boot” button.

1-4 093-82ServiceManualEN101
 Device Specific Instructions and Service Tasks

In subsequent screen check the “Expert mode” checkbox. New option “Custom Generator
ID” should appear. Select the radio button selector and type ID number “49” to field
“Custom Gen. ID:”. Press the “Start search” button.

The program will start searching for connected Unit.

Connect the prepared CPM generator loading cable to the Unit.

The Firmware loader detects and establishes the connection with the Unit. Verify the
connection by pressing button “Check connection”. After that the Generator is ready for
Firmware update.

NOTE: In case the connection is not established, restart the Unit and repeat the
complete process again.

If the connection is successfully established, continue with Firmware update process as

described in section ”Generator programming” in the document “General Instructions and
Common Service Tasks”.

1-5
 TOUCHSCREEN REMOTE CONTROL FIRMWARE UPDATE
To perform Firmware update of the Touchscreen remote control prepare following tools:

• Remote control loading tool

• Remote control loading software (4D_SystemsDisplayLoader)

Connect the Remote control loading tool to the PC and the Touchscreen remote control
to the tool. The screen of the Touchscreen remote control should turn ON.

Remote control loading

tool

Start the Remote control loading software. Select correct COM port assigned to the
Remote control loading tool in PC and press “Load file” button in order to select the
firmware file from the location in the PC.

In the subsequent browser window select file type “MultiFirmware Files”, otherwise the
firmware file will not be visible.

1-6 093-82ServiceManualEN101
 Device Specific Instructions and Service Tasks

Press the “!!! GO !!!” button to start the firmware upload.

IMPORTANT: Upload of the firmware takes approx. 15 minutes - do not turn your
computer OFF during this time! In case the Firmware update fails, repeat the
process.

For more information about using of the Remote control loading tool see document
“Instruction for use“.

1.3.2 Setting Codes

All models of the Unit accept special numeric codes which are used for change or
configuration of the specific Unit settings or activation of Service functions.

The setting codes can be divided into two groups:

• User codes
o Available in User and Service mode of the Unit
o Consist of 2-4 digit numbers
o Can be entered on Control panel or on Touchscreen remote control
• Service codes
o Available only in Service mode of the Unit
o Consist of 5-digit numbers
o Can be entered only by using Touchscreen remote control

1-7
 There are two ways of entering the setting codes into the Unit:

• By Control panel
o Press + and – together, text “CODE” appears on Control panel display
o Only User codes can be entered
• By Touchscreen remote control

o Go to 5th screen and press the icon

o Both User and Service codes can be entered

USER CODES
Code Description
11 Activation of sound for Generator PCB
12 Deactivation of sound for Generator PCB
21 Displaying of Multibin version
23 Displaying of Generator firmware version
25 Displaying of Touchscreen remote control firmware version
1112 User password setup (see details in “Operator’s Manual”)
1113 Deleting of user settings
1114 Reset to default settings
1115 Knee angle sensor calibration
1116 Ankle angle sensor calibration

1.3.3 Service Mode

To enter the Service mode turn the Unit ON and press “SET” and “+” on Control Panel or
on the Touchscreen remote control immediately after Unit self-test is finished (running
segments on Control panel). A numeric keyboard screen will appear on the Touchscreen
remote control and status “Code” appears on the Control panel.

1-8 093-82ServiceManualEN101
 Device Specific Instructions and Service Tasks

Enter the Service password on Touchscreen remote control. To check successful

entering to the Service mode, go to the 5th screen and click icon . Check that letter “S”
marking the Service mode is present in the end of the first line.

IMPORTANT: Service mode password and Service codes can be entered only
through the Touchscreen remote control (customer’s or service one).

SERVICE FUNCTIONS
Service functions can be only run in Service mode and are intended for independent
functionality check of the selected Unit’s parts.

Some service functions require interaction from the service technician and must be
performed within 90s timeframe. The result of the service function run can be as follows:

• The successfully done test is indicated by code “0x000” on the Touchscreen

remote control display.
• The failed test is indicated by code “0xF02” on the Touchscreen remote control
and “F02” on Control panel. For the list of error codes refer to chapter
5 Troubleshooting Guide.

1-9
 IMPORTANT: Before starting with the below tests it is necessary to activate
sound for the Generator PCB. For more information about Generator PCB sound
activation see table “User codes” in the subsection 1.3.2 Setting Codes.

SERVICE CODES
Code Description
Reset of forgotten password.
13113 After entering the code, the user password will be reset and
disabled.
Front panel buttons check (test sequence).
Press consecutively following buttons, passing of each step is
confirmed by beep signal:
+
12265 set
–
on/off
+ and – buttons together.
Touchscreen remote control buttons check (test sequence).
Press consecutively following buttons, passing of each step is
confirmed by beep signal:
+
12266 set
–
on/off
+ and – buttons together.
Front panel backlight check (test sequence)
Proceed by pressing „set“ button.
12267 All segments and buttons light, „ on/off “ button is orange
All segments and buttons light, „on/off“ button is white
Backlight of all segments and buttons are turned OFF

1.3.4 Unit Log Data Export

The Unit log data contains information about events which occurred during the Unit’s
operation (Setting codes and passwords entered to the Unit including user passwords,
basic and extended error codes, present firmware versions and running time of the Unit).

Required tools for correct Unit log data export:

• CPM generator loading cable (with RS232 - USB converter)

• Unit log data export software (Gener093UtilityVx.x.x_AIO)

1-10 093-82ServiceManualEN101
 Device Specific Instructions and Service Tasks

UNIT LOG DATA EXPORT PROCEDURE

Turn the Unit OFF. Hold the “Set” button and press the “On/Off” button to turn the Unit
ON in mode when the Unit log data can be obtained from the Unit. The mode is indicated
on the Control panel as shown in the picture below.

Connect the CPM generator loading cable to the Unit’s Remote control connector and to
the PC. Start the Unit log data export software and select correct communication port
assigned to the RS232 - USB converter in PC. Press “Open” button to establish the
connection.

Once the connection is established, press “Download unit logs” button. Once the
download is finished, save the log file to your computer.

1-11
1.3.5 Parking Position
This function allows the Knee module or Ankle module (whichever is being active), to
automatically return to its parking position when therapy is finished in standard manner
or when required by the operator.

Parking position for Knee module is10°, which is most suitable angle for transporting the
Unit and for mounting and running the Ankle module.
Parking position for the Ankle module is 0°.
It is possible to manually trigger this function by going to 4th screen of the Touchscreen

remote control menu, select the option next to the icon and press “+” button. After
this the Knee or Ankle module returns to its parking position.

1.3.6 Calibration of Knee Angle Sensor

Before you start the calibration, make sure you are familiar with the parts of the
Unit. For more information see chapter 2 Device Description.

Make sure that the Unit is without any mechanical load, no objects are placed on the
Motion frame, Calf and Thigh supports and no objects are placed in the operation area of
the moving parts.

The actual calibration of the Knee angle sensor is automatic; however, the Unit must be
correctly set in order to run the calibration.

IMPORTANT: Thigh telescopes must be set to the position marked “50”

otherwise the calibration will not be correct.

1-12 093-82ServiceManualEN101
 Device Specific Instructions and Service Tasks

Go to mode for entering User codes. Insert code “1115“ and press “OK”. The calibration
will start. When the process is successfully finished the Unit beeps shortly and message
“Operation done!” is displayed on the Touchscreen remote control. For more information
how to insert User codes refer to subsection 1.3.2 Setting Codes.

1.3.7 Calibration of Ankle Angle Sensor

For calibration of the Ankle angle sensor, make sure that the Unit is in Parking position
(10°). For more instructions see subsection 1.3.5 Parking Position.

Go to mode for entering User codes. Insert code “1116“ and press “OK”. The calibration
will start. Wait until the Unit beeps to signalize that the process is finished. If the
calibration is successful, message “Operation done!” is displayed on the Touchscreen
remote control.

For more information how to insert User codes refer to subsection 1.3.2 Setting Codes.

1.3.8 Calibration of the Touchscreen Remote Control

Go to 5th screen of the Touchscreen remote control and press the icon representing
the touchscreen calibration.

In case the touchscreen does not respond use the navigation buttons on the
Touchscreen remote control to navigate to the 5th screen. Then press „on/off” button to
run the calibration function.

1-13
 In the calibration screen you will be prompted to touch mark points in the top-left and
bottom-right corners. Then touch any location within the screen area. A red dot mark
appears at the centre of the screen. Click on the red dot to finish the calibration process.

1.3.9 Motion Screw Lubrication

The Motion screw should be lubricated during each Periodical inspection or in case there
occurs a squeak sound during Unit’s operation.

Set the Motion frame to 75°. Spread both rubber covers by fingers and apply lubricant to
locations indicated in the picture. Cover the motion screw by the lubricant on top part
only. Avoid smearing the lubricant onto the rubber covers. Use lubricant
193-CPMLUBRIC (type “LUBRIPLATE DS-ES”).

After applying the lubricant run therapy with parameters (-10°, +123°, 100%, 2min) and
make sure the Motion frame has reached both limit positions in order to distribute the
lubricant along the entire length of the Motion screw.

approx. approx.
15 cm 15 cm

approx.
5 cm

1-14 093-82ServiceManualEN101
 Device Specific Instructions and Service Tasks

1.3.10 Mains PCB Fuse Check

Use a multimeter to check continuity of the Fuse F1. Measure conductivity between
Fuse’s pins on solder side of the Input PCB.

In case the Fuse is interrupted, replace the Mains PCB according to subsection
3.2.10 Mains PCB. Alternatively follow instructions given in chapter 4 Advanced Repair
Instructions.

1-15
1-16 093-82ServiceManualEN101
 BTL-CPMOTION K
2 DEVICE DESCRIPTION

2.1 Operation Block Diagram ................................................................................................ 2-2

2.2 Component Blocks and Names ..................................................................................... 2-3

2.3 Components Description ................................................................................................. 2-5

2.3.1 Generator PCB ........................................................................................................... 2-5

2.3.2 Control panel.............................................................................................................. 2-6

2.3.3 Knee Angle Sensor ................................................................................................... 2-7

2.3.4 Power Supply ............................................................................................................. 2-7

2.3.5 Motion Module .......................................................................................................... 2-9

2.3.6 Motion Frame ......................................................................................................... 2-10

2.3.7 Accessories ............................................................................................................. 2-11

2-1
2.1 Operation Block Diagram

2-2 093-82ServiceManualEN101
 Device Description

2.2 Component Blocks and Names

Following pictures are describing the CPMotion ELITE variant. CPMotion PRO and EASY
variants may contain different parts.

Touchscreen remote control Footplate

Calf support Thigh support
Ankle module motor Knee angle sensor

Ankle module PCB

RJ11 coupler

Control panel

Motion module

Power adaptor
Motion module motor

Cam buckle
Calf telescope
Ankle module

Thigh telescope

Telescope locking system

Motion frame

Mains PCB Generator PCB

2-3
 Remote control
connector Mains socket

Type label

Ankle module
connector

2-4 093-82ServiceManualEN101
 Device Description

2.3 Components Description

2.3.1 Generator PCB

Generator PCB is the main control board of the Device. It communicates with
Touchscreen remote control, Base display and Ankle module to control Device functions.
Analog signals from Knee and Ankle angle sensors, speed sensors of Motion module
motor, buttons of Start/stop remote control, Touchscreen remote control and Control
panel are processed here.

Generator PCB contains CPU and internal memory which stores the Unit’s FW and Unit
log data, preset therapies and calibration data for both angle sensors, Motion module
and Ankle module motors.

Power supply 24VDC for the Generator PCB is delivered from Power adaptor and further
supplies internal circuits and all connected accessories.

2-5
2.3.2 Control panel
Control panel provides user interface for controlling and setting up the Device and for
displaying the Device status. Control panel consists of two parts:

• Control panel keyboard

• Base display PCB

CONTROL PANEL KEYBOARD

Control panel keyboard is a foil type and is attached to the upper part of the Control
panel and as such it comes as one part.

BASE DISPLAY PCB

Base display PCB indicates the Device status based on the signals from the Generator
PCB. It contains 7-segment LED display which can show up to 4 digits or characters and
backlight SMD LEDs for “on/off” button (white and orange backlight) and backlight for
buttons SET, + and – and status indicators of the Control panel keyboard. Base display
PCB transfers analog signals from buttons of Control panel keyboard to Generator PCB.

2-6 093-82ServiceManualEN101
 Device Description

2.3.3 Knee Angle Sensor

Knee angle sensor is used for sensing an angle between thigh and calf part of Motion
frame, which represents the actual angle of the patient’s knee. The part consists of a PCB
with electromechanical rotation sensor which has its axis placed in the main joint of the
Motion frame. The rotation sensor is of magnetic type and may be influenced by external
magnetic field. For this reason there are metal shielding parts located in surrounding
plastic housing of the sensor to eliminate external magnetic field influence. It’s not
recommended to place any strong magnets around the sensor as it may affect precision
of measured angle value.

The Knee angle sensor is connected to the Generator PCB via two cables and a RJ11
coupler placed under Rear cover.

2.3.4 Power Supply

The Unit is internally powered by 24VDC/60W Power adaptor located inside front plastic
part. The Power adaptor is supplied by mains voltage in range of 100-240VAC through
Mains PCB.

POWER ADAPTOR
Power adaptor provides 24VDC/60W to the Generator PCB from which the voltage is
further distributed to the other parts and also provides necessary galvanic separation
from the mains.

2-7
 MAINS PCB
The Mains PCB filters mains voltage to protect internal electronic components from
mains surges and blocks noise generated by the Unit. Through the PCB the Power
adaptor is supplied.

2-8 093-82ServiceManualEN101
 Device Description

2.3.5 Motion Module

Motion module is the driving element of the Motion frame. The module consists of:

• Encased motion screw with teflon coating and nut. It is recommended to add
lubricant to the motion screw during Periodical inspection or in case there occurs
some squeak sound during Motion screw operation. Find more details in
subsection 1.3.9 Motion Screw Lubrication
• Motion module motor of BLDC type with Hall sensors of rotation
• Drive pulley

IMPORTANT: The Motion module comes in a set pre-calibrated in the production.

Do not loosen, disassemble or replace any of its parts!

2-9
2.3.6 Motion Frame
Motion frame provides main support for the patient’s leg. The Motion frame consists of:

• Upper and bottom frame

• Thigh telescopes
• Telescopes locking system
• Footplate
• Calf and Thigh supports with belts and Cam buckles

IMPORTANT: During Motion frame assembling it is necessary to fasten screws

with defined torque (by using a torque screwdriver) and to apply thread locking
glue! Find details in section 3.2 Components Disassembly/Exchange.

2-10 093-82ServiceManualEN101
 Device Description

2.3.7 Accessories
START/STOP REMOTE CONTROL
The Start/stop remote control allows user to start or stop running therapy. The
Start/stop remote control is standard accessory for BTL-CPMotion K EASY.

TOUCHSCREEN REMOTE CONTROL

Touchscreen remote control is standard accessory for BTL-CPMotion K PRO and ELITE
Units. Touchscreen remote control enables user to set all therapy parameters and service
functions available in the Unit.

It is equipped with 3.2” color LCD display with touchscreen and foil keyboard user
interface. Touchscreen remote control allows accessing the Unit Service mode. Main
parts are:

• Touchscreen remote control keyboard

• Display PCB (with 3.2” LCD display and micro SD card slot)
• Control PCB

2-11
 NOTE: A service version of Touchscreen Remote control is also available. It is
intended solely for BTL service technicians who are certified to service the
BTL-CPMotion K.

TOUCHSCREEN REMOTE CONTROL KEYBOARD

Touchscreen remote control keyboard is a foil type. It comes together as one part with
front cover of the Touchscreen remote control. The keyboard is connected to the Control
PCB.

2-12 093-82ServiceManualEN101
 Device Description

DISPLAY PCB
Display PCB is mounted on the front cover of the Touchscreen remote control and
contains 3,2” color LCD, touch panel of a resistive type and micro SD card slot. The
SD card (microSD/SDHC, 2GB or higher, file system FAT16) is inserted to the slot as
shown in the picture below.

When the Display PCB is replaced always upload the latest FW version to the Generator
PCB and Touchscreen remote control (see subsection 1.3.1 Firmware Update).

CONTROL PCB
Control PCB serves as an interface between the Touch panel, Display PCB and Generator
PCB and also provides backlight for the 3.2” LCD display. The Control PCB is connected
directly to the Display PCB using 10-pin SIP connector.

2-13
 ANKLE MODULE
Ankle module allows treatment of the ankle area of leg and it is a standard accessory for
BTL-CPMotion K ELITE and optional accessory for BTL-CPMotion K PRO.

The Ankle module consists of:

• Ankle module frame and Footplate

• Drive mechanism
• Ankle module motor
• Incremental speed sensor
• Ankle module PCB with Ankle angle sensor

2-14 093-82ServiceManualEN101
 Device Description

Ankle Module PCB

Ankle module serves as a driver board for the Ankle module motor and as an interface for
digital/analog signals between the Ankle module and Generator PCB. The PCB also
distributes power supply for the above mentioned components. Ankle module PCB
contains Ankle angle sensor used for sensing an angle of the Ankle module Footplate.
Analog signal from the sensor is transferred directly to the Generator PCB to be
processed.

Ankle Module Motor

The Ankle module motor is of BLDC type with Hall sensors of rotation. It drives the Ankle
module Footplate to which is connected via Drive mechanism. Speed of the Ankle
module motor is controlled by PWM from Generator PCB, power supply for the motor is
delivered from the Ankle module PCB. The green-yellow cable serves for ESD protection
and must be connected to Ankle module PCB using cable eyelet.

2-15
 On the rear axis of the motor an Incremental speed sensor is attached. The sensor
improves precision of driving the motor.

IMPORTANT: The Incremental speed sensor rotation disk mounted on the motor
axis is very sensitive to damage. Do not manipulate with the rotational disc.

Drive mechanism
The Drive mechanism on the Ankle module transfers driving force from the motor to the
axis of the Ankle module Footplate using a flexible coupler. The Drive mechanism also
contains a pair of gearwheels which transfer the motor axis rotation to the Ankle angle
sensor.

During disassembling / assembling the drive mechanism pay attention to orientation of

gearwheels. For more information refer to subsection 3.2.20 Ankle Module PCB.

2-16 093-82ServiceManualEN101
 BTL-CPMOTION K
3 DISASSEMBLY / COMPONENTS
EXCHANGE
3.1 Components Interconnection ............................................................................................. 3-3

3.1.1 Electrical Components Interconnection .................................................................. 3-4

3.2 Components Disassembly/Exchange .............................................................................. 3-5

3.2.1 Leg Support System ..................................................................................................... 3-6

3.2.2 Telescope Locking System ......................................................................................... 3-8

3.2.3 Control Panel .................................................................................................................. 3-9

3.2.4 Base Display PCB ....................................................................................................... 3-11

3.2.5 Left and Right Upper Covers ................................................................................... 3-12

3.2.6 Knee Angle Sensor .................................................................................................... 3-13

3.2.7 Knee Angle Sensor Cable ........................................................................................ 3-14

3.2.8 Generator PCB ............................................................................................................ 3-15

3.2.9 Power Adaptor ............................................................................................................ 3-18

3.2.10 Mains PCB .................................................................................................................... 3-19

3.2.11 Remote Control Connector ...................................................................................... 3-20

3.2.12 Ankle Module Connector ......................................................................................... 3-22

3.2.13 Motion Module ........................................................................................................... 3-23

3-1
 3.2.14 Thigh Telescopes........................................................................................................ 3-26

3.2.15 Motion Frame .............................................................................................................. 3-29

3.2.16 Touchscreen Remote Control Cable...................................................................... 3-30

3.2.17 Touchscreen Remote Control Display .................................................................. 3-33

3.2.18 Ankle Module Cable .................................................................................................. 3-34

3.2.19 Ankle Module Frame ................................................................................................. 3-36

3.2.20 Ankle Module PCB ..................................................................................................... 3-37

3.2.21 Ankle Module Motor.................................................................................................. 3-41

3-2 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.1 Components Interconnection

IMPORTANT: When disassembling a Device always note down the original

connection and try to assembly the Device in the same manner. The connection
mentioned in this chapter is valid for all currently produced Devices.

NOTE: The highlighted colors of cables and connections may not match the actual
color of cable inside the Unit. Coloring serves only to help identify the connections
within the Unit and should be understood only as a guideline for disassembly and
assembly of the Unit.

3-3
3.1.1 Electrical Components Interconnection

LEGEND: POWER
Power cable SOCKET Mains PCB
Digital signal cable 100-240VAC, MEC63
Analog signal cable 50-60Hz MEC2 J2 J1
100-240VAC,

100-240VAC,
50-60Hz

50-60Hz

MEC31
Connector at the end of
cable
Wire terminal at the end of Angle
cable sensor
Faston connector at the MEC11
end of cable

Power adaptor
Header connector

MEC15

MEC6
Insulating barrier 4kV Control panel
keyboard
SET2

RJ11 coupler
MEC100

24±2VDC
J3

MEC14
Base display PCB
MEC35
J1 MEC32
J15 J5 J6
J10
Motion module
SET1
MEC23
J13
Remote control
J2 J3 MEC3 MEC4 J3
keyboard
SET3
Control PCB J11
LCD display Generator PCB
LCD1 MEC30
Touchscreen remote control

MEC39 MEC37 MEC5

SW1 J1 J5 J2
MEC29
Ankle module Ankle module J4
motor PCB
MEC18
J3 MEC24
Ankle module

3-4 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2 Components Disassembly/Exchange

CAUTION: Some parts, cables or connectors in the Unit are fixed by hot
glue. Use alcohol (e.g. IPA) to remove the hot glue safely. Do not try to release
cables/connector using force while hot glue is still present as this can result in
damaging the connector or PCB components close to it.

CAUTION: If you remove the hot glue on some parts during disassembly
process ALWAYS fix them again with hot glue during assembly process.

If you remove the thread glue on some parts during disassembly process
ALWAYS fix them again with thread glue during assembly process.

NOTE: Pay attention to those parts during assembly/disassembly process.

Parts fixed by hot glue are marked in the pictures with this symbol:

Parts fixed by thread-locking glue are marked in the pictures with following symbol.
For more information see section 6.5 Used Tools.

Parts tightened with defined torque are marked with this symbol:

3-5
3.2.1 Leg Support System
REMOVE BEFORE: ----

(A) Release eight Cam buckles. Make sure the locks are in opened position. Using a flat
screw driver remove hooks from axis of the Cam buckles. Remove the Calf and Thigh
supports out of the Unit.

(B1) Unlock the locking system by turning the wheels. Remove the Foot support frame
(EASY or PRO variant).

(B2) Unlock the locking system by turning the wheels. Remove the Ankle module (ELITE
variant).

(C) Loosen the screw holding the Footplate and remove the Footplate.

.A.

.B1.

3-6 093-82ServiceManualEN101
 Disassembly / Components Exchange

.B2.

.C.

3-7
3.2.2 Telescope Locking System
REMOVE BEFORE: -----

(A) Unscrew two screws M3x8 (Allen 1,5) and remove the Telescope locking system.

.A.

ASSEMBLY NOTES
(A) When assembling the Telescope locking system back make sure that the screws are
aligned with the plastic cover.

.A.

3-8 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2.3 Control Panel

REMOVE BEFORE: ----

(A) Release the rubber protector and unscrew three screws M4x8 (Torx 10).

(B) Carefully tilt the Control panel. Be careful not to damage the two flat cables
connected to the Base display PCB.

(C) Unscrew two screws for plastic 3x6 (Torx 10). Carefully tilt the Base display PCB so
you have better access to the connectors.

(D) Remove hot glue and unplug cable from connector J1. Do not unplug the cable from
connector J3 on the Base display PCB.

.A.

.B.

3-9
 .C.

.D.

3-10 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2.4 Base Display PCB

REMOVE BEFORE: 3.2.3 Control Panel

(A) Remove hot glue and unplug cable from connector J3. Remove the Base display PCB.

.A.

3-11
3.2.5 Left and Right Upper Covers
REMOVE BEFORE: 3.2.1 Leg Support System, 3.2.3 Control Panel

(A) Unscrew eight screws 4x14 (Torx 20) and two screws 4x25 (Torx 20) from the
bottom of the Unit. Do not remove the screws with flat head.

(B) Remove the Left and Right upper covers.

.A.

.B.

3-12 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2.6 Knee Angle Sensor

REMOVE BEFORE: 3.2.1 Leg Support System

(A) Remove and discard the sticker. Cut the cable tie and unplug the Knee angle sensor
cable.

(B) Unscrew two screws 2.9x32 (Torx 10) and remove the plastic cover.

(C) Carefully pull out the Knee angle sensor.

IMPORTANT: It is necessary to always perform the calibration after

disassembling or replacing the Knee angle sensor. For further information about
calibration see the subsection 1.3.6 Calibration of Knee Angle Sensor.

.A. .B.

.C.

3-13
3.2.7 Knee Angle Sensor Cable
REMOVE BEFORE: 3.2.1 Leg Support System

(A) Unscrew two screws 40x35 (PH 2). Remove the Rear Upper Cover.

(B) Unplug the cable from the RJ11 coupler leading to the Knee angle sensor. Remove
the cable with plastic bushing. Slide the bushing from the cable away.

;A. ;B.

3-14 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2.8 Generator PCB

REMOVE BEFORE: 3.2.1 Leg Support System, 3.2.3 Control Panel, 3.2.5 Left and Right
Upper Covers

(A) Cut the five cable ties.

(B) Remove the hot glue from connectors J3, J4, J5, J11 and J15 on the Generator PCB.
Unplug the cables from connectors J2, J3, J4, J5, J6, J10, J11, J13 and J15.

(C) Unscrew four screws for plastic 3x8 (Torx 10). Remove the Generator PCB out of the
Unit.

(D) Remove the plastic cable tie holder using needle nose pliers.

IMPORTANT: When assembling the Generator PCB back into the Unit, always
connect the grounding cable from Motion module into the connector J13
outside of the Unit and support the PCB with your hand to prevent the PCB from
cracking.

.A.

3-15
 .B.

.C.

3-16 093-82ServiceManualEN101
 Disassembly / Components Exchange

.D.

3-17
3.2.9 Power Adaptor
REMOVE BEFORE: 3.2.1 Leg Support System, 3.2.3 Control Panel, 3.2.5 Left and Right
Upper Covers, 3.2.8 Generator PCB (only step A)

(A) Unscrew two screws for plastic 3x8 (Torx 10). Remove the metal cover plate.

(B) Unplug the cable from connector J6 on the Generator PCB. Unplug the cable from the
Power adaptor and remove it out of the Unit.

.A.

.B.

3-18 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2.10 Mains PCB

REMOVE BEFORE: 3.2.1 Leg Support System, 3.2.3 Control Panel, 3.2.5 Left and Right
Upper Covers, 3.2.8 Generator PCB

(A) Cut the cable ties and unplug the cables from connectors J1 and J2 on the Mains
PCB.

(B) Unscrew three screws for plastic 3x8 (Torx 10) and remove the Mains PCB out of the
Unit.

.A.

.B.

3-19
3.2.11 Remote Control Connector
REMOVE BEFORE: 3.2.1 Leg Support System, 3.2.3 Control Panel, 3.2.5 Left and Right
Upper Covers

(A) Cut the cable tie, remove the hot glue and unplug cables from connectors J3 and J11
on the Generator PCB.

(B) Loosen the nut using connector wrench 193-KEYNEXT.

(C) Push the connector through the hole and remove the connector with the cable out of
the Unit.

.A.

.B.

3-20 093-82ServiceManualEN101
 Disassembly / Components Exchange

.C.

3-21
3.2.12 Ankle Module Connector
REMOVE BEFORE: 3.2.1 Leg Support System, 3.2.3 Control Panel, 3.2.5 Left and Right
Upper Covers, 3.2.8 Generator PCB (only step A)

(A) Loosen the nut using Connector wrench 193-KEYNEXT.

(B) Push the connector through the hole and remove the connector with the cable out of
the Unit.

.A.

.B.

3-22 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2.13 Motion Module

REMOVE BEFORE: 3.2.1 Leg Support System, 3.2.3 Control Panel, 3.2.5 Left and Right
Upper Covers, 3.2.8 Generator PCB (only step A)

NOTE: If possible, get the Unit into the lowest limit position e.g. by turning the
wheels on the Motion module according to the picture.

Doing this will ensure that you have better access to the screws.

(A) Cut the two cable ties.

(B) Unscrew eight screws M6x16 (Torx 20) from the Bottom frame.

(C) Unscrew two screws M5x20 (Torx 15) from the Bottom cover.

(D) Remove the Bottom Cover.

(E) Unscrew two screws M8x20 (Allen 5) with washers.

(F) Unscrew two screws M5x20 (Torx 15) from the other side of the Motion Module.

(G) Slightly lift up the Motion Frame and carefully remove the Motion Module out of the
Unit

3-23
 .A.

.B.

.C.

3-24 093-82ServiceManualEN101
 Disassembly / Components Exchange

.D.

.E. .F.

.G.

3-25
3.2.14 Thigh Telescopes
REMOVE BEFORE: 3.2.1 Leg Support System, 3.2.3 Control Panel, 3.2.5 Left and Right
Upper Covers

NOTE: If possible, get the Unit into the lowest limit position e.g. by turning the
wheels on the Motion module according to the picture.

Doing this will ensure that you have better access to the screws.

NOTE: The spare part 093-59TELESCOPE does not include Telescope locking
system. Use the original parts or order particular set.

(A) Unscrew two screws M5x10 (Torx 25) with washers and remove the metal part.

(B) Unscrew two screws M5x10 (Torx 25) with washers. Carefully push out the joint hub.
Pay attention to the washers – the larger washer is located on the outside. It is necessary
to place the washers back in correct position when assembling the Unit!

(C) Use flat screwdriver to remove the metal fastener and discard it. Carefully pull out the
telescope.

(D) Unscrew two screws M5x10 (Torx 25) with washers and remove the metal part.

(E) Unscrew two screws M5x10 (Torx 25) with washers. Carefully push out the joint hub.
Pay attention to the washers – the larger washer is located on the outside. It is necessary
to place the washers back in correct position when assembling the Unit!

(F) Use flat screwdriver to remove the metal fastener and discard it. Carefully pull out the
telescope.

3-26 093-82ServiceManualEN101
 Disassembly / Components Exchange

.A.

.B.

.C.

3-27
 .D.

.E.

.F.

3-28 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2.15 Motion Frame

REMOVE BEFORE: 3.2.1 Leg Support System, 3.2.3 Control Panel, 3.2.5 Left and Right
Upper Covers, 3.2.14 Thigh Telescopes (only steps A,B,D,E)

(A) Unscrew two screws M8x20 (Allen 5) with washers.

(B) Lift up the Motion Frame.

.A.

.B.

3-29
3.2.16 Touchscreen Remote Control Cable
REMOVE BEFORE: ----

(A) Remove the rubber cover and slide it out of the cable.

(B) Unscrew five screws for plastic 3x8 (Torx 10).

(C) Remove the plastic rear cover.

(D) Unscrew four screws M2.5x6 (Torx 8) and pull out the Control PCB.

(E) Carefully unplug the flat cable from connector J2. Remove the PCB out of the Remote
Control.

(F) Carefully tilt the Control PCB and unplug the cable from connector J3.

(G) Unscrew two screws for plastic 3x6 (Torx 10) and remove the metal plate. Remove
the cable out of the Touchscreen remote control.

.A. .B.

3-30 093-82ServiceManualEN101
 Disassembly / Components Exchange

.C. .D.

.E. .F.

3-31
 .G.

3-32 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2.17 Touchscreen Remote Control Display

REMOVE BEFORE:3.2.16 Touchscreen Remote Control Cable (only steps A-F)

(A) Push the plastic holders on the upper and lower side of the Display PCB. Remove the
Display PCB out of the Remote Control.

IMPORTANT: In case of Display PCB replacement always use the washers which
come with the spare part. It is important for correct height positioning of the
Display PCB in plastics.

After the replacement always upload the latest FW version to the Generator PCB
and Touchscreen remote control (see subsection 1.3.1 Firmware Update).

(B) Unscrew four screws M2.5x6 (Torx 8) with washers.

.A. .B.

3-33
3.2.18 Ankle Module Cable
REMOVE BEFORE: 3.2.1 Leg Support System (only steps B - C)

IMPORTANT: The Incremental speed sensor rotation disk mounted on the motor
axis is very sensitive to damage. Do not manipulate with the rotational disc.

(A) Unscrew one screw M5x30 (Allen 2,5) and one screw M4x8 (Torx 20). Remove the
plastic cover.

(B) Cut the cable ties. Unplug the cable from connector J5 on the Ankle Module PCB.
Unscrew one screw M5x6 (Torx 25) with washer and one screw M4x8 (Torx 20). Slide
the plastic back cover away.

(C) Unscrew screw M8x40 (Torx 40) with two washers. Remove the support frame with
the plastic back cover.

(D) Slide the back plastic cover with Ankle module cable away from the support frame.

.A.

.B.

3-34 093-82ServiceManualEN101
 Disassembly / Components Exchange

.C.

.D.

IMPORTANT: It is always necessary to perform the calibration after

reassembling the Ankle module. For further information about calibration see the
subsection 1.3.7 Calibration of Ankle Angle Sensor.

3-35
3.2.19 Ankle Module Frame
REMOVE BEFORE: 3.2.1 Leg Support System (only step B), 3.2.18 Ankle Module Cable

IMPORTANT: The Incremental speed sensor rotation disk mounted on the motor
axis is very sensitive to damage. Do not manipulate with the rotational disc.

(A) Unscrew one screw M5x6 (Torx 25) with washer. Remove the plastic cover and
unscrew one nut M5 (Tube spanner 8mm). Remove the nut with two washers. Be careful
when you put the washers back – you must put the plastic washer first!

NOTE: Secure BOTH the screw and the nut with thread-locking glue when
assembling the Ankle Module.

(B) Remove the Footplate holder.

.A.

.B.

IMPORTANT: It is always necessary to perform the calibration after

reassembling the Ankle Module. For further information about calibration see
the subsection 1.3.7 Calibration of Ankle Angle Sensor.

3-36 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2.20 Ankle Module PCB

IMPORTANT: The Incremental speed sensor rotation disk mounted on the motor
axis is very sensitive to damage. Do not manipulate with the rotational disc.

REMOVE BEFORE: 3.2.1 Leg Support System (only step B), 3.2.18 Ankle Module Cable

(A) Unscrew three screws M5x35 (Torx 25) with three square nuts. Remove the rest of
the support frame. Make sure to position the nuts with the flat surface towards the
screws’ heads when assembling the Ankle module.

(B) Remove the shaft of the coupling.

(C) Loosen one screw M3x6 (Allen 1,5) and remove the plastic Gearwheel.

(D) Remove hotglue from connector J1. Unplug cables from connectors J1 and J3 on the
Ankle module PCB. Unscrew one screw M3x6 (Torx 10). Carefully remove the metal
holder with the Ankle module PCB. Pay attention to the grounding cable.

(E) Unscrew four nuts M3 (Spanner 5.5mm) and release the grounding cable.

(F) Remove the Ankle module PCB.

.A. .B.

3-37
 .C. .D.

.E. .F.

3-38 093-82ServiceManualEN101
 Disassembly / Components Exchange

ASSEMBLY NOTES
(A) Assemble the Ankle module PCB and gearwheels. Leave the nuts holding the Ankle
module PCB loosened. Pay attention to correct positioning of the gearwheels. They must
be in the same height and fit to each other.

(B) Tighten the nuts securing the Ankle module PCB after setting the gearwheels into the
correct position.

(C) Rotate the motor shaft using the Spanner 11mm so the shaft edges are parallel to the
metal cover edges. Remove the motor shaft gearwheel. Set the Angle sensor gearwheel
so that the flat side of the sensor axis is parallel to the metal cover edge near the
connectors. Place the motor shaft gearwheel back.

.A.

.B.

3-39
 .C.

IMPORTANT: It is always necessary to perform the calibration after

reassembling the Ankle Module. For further information about calibration see
the subsection 1.3.7 Calibration of Ankle Angle Sensor.

3-40 093-82ServiceManualEN101
 Disassembly / Components Exchange

3.2.21 Ankle Module Motor

REMOVE BEFORE: 3.2.1 Leg Support System (only step B), 3.2.18 Ankle Module Cable,
3.2.20 Ankle Module PCB

IMPORTANT: The Incremental speed sensor rotation disk mounted on the motor
axis is very sensitive to damage. Do not manipulate with the rotational disc.

(A) Remove the three plastic dowels and unscrew four screws M4x20 (Torx 20). Remove
the grounding cable.

(B) Remove the plastic spacer.

(C) Unscrew one screw (Allen 2) and remove the coupling from the Ankle module motor.

.A. .B.

.C.

3-41
 ASSEMBLY NOTES
(A) Be careful when connecting the cable back to the Incremental speed sensor – the red
cable must be connected to the pin marked as “V” and the black cable to the pin “G”.

.A.

IMPORTANT: It is always necessary to perform the calibration after

reassembling the Ankle Module. For further information about calibration see
the subsection 1.3.7 Calibration of Ankle Angle Sensor.

3-42 093-82ServiceManualEN101
 BTL-CPMOTION K
4 ADVANCED REPAIR
INSTRUCTIONS

Mains PCB Fuse................................................................................................................................... 4-2

4-1
Mains PCB Fuse
VERIFICATION OF FAULT
The Unit can’t be turned ON, the “on/off” button on Control panel is not orange
illuminated. Remove the Mains PCB from the Unit (see subsection 3.2.10 Mains PCB).
Locate the Fuse F1 on the Mains PCB and check if it is interrupted (see subsection 1.3.10
Mains PCB Fuse Check).

F1

REQUIRED SPARE PARTS AND TOOLS

Spare Parts

Part number Part description PCS Reference

093-59FUSES Fuse T1A-H 1 F1

4-2 093-82ServiceManualEN101
 Advanced Repair Instructions

Beyond the tools described in section 6.5 Used Tools you will need the following:

Selected tools from Tool set

The recommended tools below are part of a Tool set for servicing all BTL devices. The
Tool set can be ordered from the BTL ISC (see chapter
7 Technical Support Contact).
Type Tool Description
Others ESD Snap anti-allergic Wrist band

Other Tools
Tools that have to be purchased separately by each service facility:
Tool Description
Soldering iron
Stand with sponge for soldering iron
Desoldering pump, mechanical
Desoldering braid 2mm
Solder 250g
Flux (colophony) 30g

REPLACEMENT PROCEDURE

• Carefully unsolder two joints of the faulty Fuse F1.

• Place the new Fuse F1 and solder it.
• Clean the soldered joints by alcohol (IPA) and check their quality.
• Place the Mains PCB back into the Unit.
• Reconnect all cables and reassemble the Unit.

FINAL TESTING

• Test the normal function of the Unit.

• Perform inspection according to the document “Final Inspection Report”.

4-3
4-4 093-82ServiceManualEN101
 BTL-CPMOTION K
5 TROUBLESHOOTING GUIDE

5.1 Troubleshooting Features .................................................................................................... 5-2

5.2 General Issues......................................................................................................................... 5-3

5.3 Error Codes ........................................................................................................................... 5-10

5.3.1 Runtime errors ............................................................................................................ 5-13

5.3.2 Selftest errors .............................................................................................................. 5-32

5.4 Device Inspection Faults ................................................................................................... 5-33

5-1
5.1 Troubleshooting Features
Before troubleshooting the problem read the document “General Instructions and
Common Service Tasks” which contains troubleshooting basics - the description of the
error types/categories a service technician can encounter during servicing.

CAUTION: Electronic components in the Device are ESD (Electrostatic

discharge) sensitive. Therefore follow general rules for handling such
components and use antistatic wrist band (see section 6.5 Used Tools).

IMPORTANT: Always follow the steps in the order given in the troubleshooting
guide. Skipping any of the given steps can cause an inappropriate action will be
taken.

NOTE: Prior troubleshooting of any service case, always check the latest version of
the “Service Manual Appendix” for possible solution that might be written there. The
Appendix chapter contains the latest known service information and know-how that
is available to service technicians.

If there is no information regarding to the particular problem, use the

Troubleshooting guide from this chapter.

If no solution is found, contact the BTL ISC (see chapter

7 Technical Support Contact) for assistance.

Finding the solution this way brings best results.

5-2 093-82ServiceManualEN101
 Troubleshooting Guide

5.2 General Issues

All variants

Fault description Check Result Action

Plug the device to the mains

No socket with mains voltage
Is the mains voltage present in present.
the mains socket and Unit
connected to the mains Check the mains cable
socket? connection.

Yes Check the mains cable for

any signs of damage.

Replace the mains cable.

Disassemble Unit according
to the subsection 3.2.5 Left
and Right Upper Covers.

Reconnect cable MEC32

between connector J15 of
Try turning the Unit ON using Generator PCB and
The Unit cannot be functional Touchscreen connector J1 of Base
turned ON. The remote control. display PCB.
“on/off” button on Yes
the Control panel Is it possible to turn the Unit Replace cable MEC32.
is not illuminated. ON?
Replace Base display PCB
(see subsection 3.2.4 Base
Display PCB).

Replace the Generator PCB

(see subsection 3.2.8
Generator PCB).
Disassemble the Unit
according to the subsection
3.2.5 Left and Right Upper
Covers.
Replace the Generator PCB
Disconnect the cable from
Yes (see subsection 3.2.8
Power adaptor from connector
Generator PCB).
J6 on the Generator PCB

Is 24VDC present between pin

1 and 3 at the Adaptor cable
connector?

5-3
 Disconnect the cable MEC31
from the Power adaptor. Replace the Power adaptor
Yes (see subsection 3.2.9 Power
Is mains voltage present on Adaptor).
the cable connector?
Disassemble the Unit
according to subsection Reconnect / replace the
3.2.10 Mains PCB. cable MEC2 between the
Mains power connector and
No
Is mains voltage present the Mains PCB (see
between the pin 1 and 5 on subsection 3.2.10 Mains
the connector J2 on the Mains PCB).
PCB?
The Unit cannot be
turned ON. The Is mains voltage present
Replace the cable MEC31
“on/off” Button on between the pin 1 and 5 on
Yes (see subsection 3.2.10
the Control panel the connector J1 on the Mains
Mains PCB).
is not illuminated. PCB?
Replace the Mains PCB. See
subsection 3.2.10 Mains
PCB.
Disconnect the mains cable
from the Unit. Yes Alternatively replace the F1
Fuse according to part
Measure continuity of the Fuse Mains PCB in chapter
F1 on the Mains PCB. 4 Advanced Repair
Instructions.
Is the Fuse interrupted?
Replace the Mains PCB (see
No subsection 3.2.10 Mains
PCB).

5-4 093-82ServiceManualEN101
 Troubleshooting Guide

Try turning the Unit ON using

functional Touchscreen
Replace the Generator PCB
remote control.
No (see subsection 3.2.8
Generator PCB).
Is it possible to turn the Unit
ON?
Reconnect / replace cable
Disassemble the Unit MEC32.
according to subsection
Yes
3.2.3 Control Panel. Replace the Control panel
keyboard (see subsection
The Unit cannot be
Is the ribbon cable from the 3.2.3 Control Panel).
turned ON. The
Control panel keyboard Reconnect the ribbon cable
“on/off” button is
properly connected to the in connector J3.
orange illuminated.
connector J3 on the Base
No
display PCB and without any Replace the Control panel
signs of damage? keyboard (see subsection
3.2.3 Control Panel).
Disassemble the Unit
according to the subsection Reconnect / replace cable
No
3.2.5 Left and Right Upper MEC 32.
Covers.

Is the cable MEC 32 properly Replace the Generator PCB

connected to connector J15 Yes (see subsection
on the Generator PCB and 3.2.8 Generator PCB).
without any signs of damage?
Replace the Control panel
The Control panel Disassemble the Unit keyboard (see subsection
keyboard is according to subsection 3.2.3 Control Panel).
Yes
partially or 3.2.3 Control Panel.
completely Reconnect / replace cable
irresponsive. Is the ribbon cable from the MEC32.
It is possible to Control panel keyboard Reconnect the cable.
control the Unit properly connected to the
using Touchscreen connector J3 on the Base No Replace the Control panel
remote control. display PCB? keyboard (see subsection
3.2.3 Control Panel).
Disassemble the Unit Reconnect / replace the
according to subsection No
cable MEC 32.
The Control panel 3.2.3 Control Panel.
display and Replace the Base Display
backlight for Is the cable MEC32 between PCB (see subsection
buttons are connector J15 of Generator 3.2.3 Control Panel).
partially or PCB and connector J1 of Base Yes
completely dark display PCB properly Replace the Generator PCB
connected and without any (see subsection
signs of damage? 3.2.8 Generator PCB).

5-5
 Is the Touchscreen remote
control properly connected to No Reconnect it.
the Unit?
Replace the Touchscreen
Is there any visible damage to remote control cable (see
the Touchscreen remote Yes subsection
control cable or its connector? 3.2.16 Touchscreen Remote
Control Cable).
Replace the Touchscreen
remote control cable (see
subsection
3.2.16 Touchscreen Remote
Control Cable).

Connected Replace Display PCB (see

Yes
Touchscreen subsection
remote control is 3.2.17 Touchscreen Remote
not working - LCD Control Display).
is dark, “on/off”
button is not Exchange the faulty
illuminated. Is any other Touchscreen Touchscreen remote
remote control working when control.
connected to the Unit? Disassemble the Unit
according to section
3.2.5 Left and Right Upper
Covers.

Check cable MEC 4 for

No proper connection or any
signs of damage. Replace it
if necessary.

Replace the Generator PCB

(see subsection
3.2.8 Generator PCB).

5-6 093-82ServiceManualEN101
 Troubleshooting Guide

Check the Touchscreen

remote control cable for any
signs of damage and
replace it if necessary (see
subsection
3.2.16 Touchscreen Remote
Yes Control Cable).

Replace Display PCB in the

Connected Touchscreen remote control
Touchscreen (see subsection
remote control is 3.2.17 Touchscreen Remote
Is any other Touchscreen
not working - LCD Control Display).
remote control working when
is partially or Disassemble the Unit
connected to the Unit?
completely dark according to section
“on/off” button is 3.2.5 Left and Right Upper
orange illuminated. Covers.

Check cable MEC 4 for

No proper connection and for
any signs damage. Replace
it if necessary.

Replace the Generator PCB

(see subsection
3.2.8 Generator PCB).

5-7
 Disassemble the
Touchscreen remote
control according to
subsection 3.2.16
Touchscreen Remote
Control Cable.

Check/reconnect ribbon
cable from the
Touchscreen remote
Yes
control keyboard in
connector J2 on the
Control PCB.
The Touchscreen
remote control Is any other Touchscreen Replace the Touchscreen
buttons are partially remote control working when remote control front cover
or completely connected to the Unit? with keyboard (see
irresponsive. subsection
3.2.17 Touchscreen
Remote Control Display).
Check/reconnect/replace
cable MEC4 between
Remote control connector
and the Generator PCB
(connectors J3, J11). See
No subsection 3.2.11 Remote
Control Connector.

Replace Generator PCB

(see subsection 3.2.8
Generator PCB).
Replace the Start/stop
Yes
remote control.
Check/reconnect/replace
The Start/stop cable MEC4 between
remote control is Connect any functional Remote control connector
partially or Touchscreen remote control. and the Generator PCB
completely (connectors J3, J11). See
irresponsive (therapy Is it possible start or stop No subsection 3.2.11 Remote
cannot be running therapy? Control Connector.
started/stopped)
Replace Generator PCB
(see subsection 3.2.8
Generator PCB).

5-8 093-82ServiceManualEN101
 Troubleshooting Guide

Disassemble the
Touchscreen remote control
(see subsection
Touchscreen 3.2.16 Touchscreen Remote
remote control Control Cable) and re-insert
keeps restarting the SD card on the Display
Re-connect the Touchscreen
with message PCB.
remote control and restart the Yes
“Drive not
Unit.
mounted…” and Replace the SD card.
error message
Does the problem persist?
“Er02” is shown Replace the Display PCB.
on the Base
display. Replace the Touchscreen
remote control.
No Problem solved.
Remove all impurities from
Motion screw of Motion module and check
Motion module is Motion screw for particles
producing ----- ----- or dust. Lubricate the
squeeking sound Motion screw according to
during operation. subsection 1.3.9 Motion
Screw Lubrication.

5-9
5.3 Error Codes
Error messages are outputted to the Unit Control panel, Touchscreen remote control and
to the Unit log file. The error codes are divided into:

• Runtime error codes

o Basic error codes
o Extended error codes
• Selftest error codes

BASIC ERROR CODES

Basic error codes describe general type of error which occurred. The codes are made of
2-digit numeric value and are displayed on the Control panel and the Touchscreen
remote control.

On the Control panel the basic error codes come in a form of message “ErXX” where

• Er is a prefix of an error code

• XX denotes the actual Basic error code

On the Touchscreen remote control the Basic error codes are preceded by message “An
internal exception XX has occurred” where “XX” represents the Basic error code (the
same as displayed on the Control panel).

5-10 093-82ServiceManualEN101
 Troubleshooting Guide

EXTENDED ERROR CODES

Extended error codes are extension of the Basic error code and specify detailed root
cause of the fault.

Extended error codes are only displayed on the Touchscreen remote control and in the
device log and come in a form of “0xYYYYYYYY” hexadecimal string where:

• 0x is a prefix denoting the Extended error code

• YYYYYYYY represent the actual Extended error code (HEX value)

Extended Error Codes Merging

In case more Extended error codes related to the same Basic error code, their codes will
be summed together as hexadecimal values.

Each position of the Extended error code can get value of 0, 1, 2, 4 or 8. If more
Extended error codes are merged, values at the same position are summed together. It
results in hexadecimal value in range 0 – F.

To get individual Extended error codes from the merged Extended error code, it is
necessary to subtract successively the values 1, 2, 4 or 8 from the stated error code.

Example:

Faulty Unit is signalizing Basic error code 16. Extended error code stated in Unit log and
on the Touchscreen remote control is 0x000B0000.

Due to multiple root causes there occurred combination of a few Extended error codes
(0x00010000, 0x00020000, 0x00080000). Getting of individual Extended error codes
from stated value “B” is following: B (HEX) = 11 (DEC) = 1 + 2 + 8.

For further information about Extended error codes merging contact BTL ISC (see
chapter 7 Technical Support Contact).

5-11
 SELFTEST ERROR CODES
The Selftest error codes signalize error which occurred in selftest procedures during
Unit’s start-up. The Selftest error code is announced as Basic error 13. Selftest error
details are displayed in a form of extended error code on Touchscreen remote control or
in the Unit log file.

5-12 093-82ServiceManualEN101
 Troubleshooting Guide

IMPORTANT: In the following list of Runtime errors only single Extended error
codes are stated. Multiple Extended error codes related to the same Basic error
code are merged together while reported by the Unit. If an Extended error code
is not present in the list, the code must be decomposed to individual Extended
error codes. For more details see subsection 5.3 Error Codes.

5.3.1 Runtime errors

Error code Fault description /
Action
Basic Extended possible cause
Restart the Unit.
0x00000800
Check / reconnect the Touchscreen
0x00001000 remote control cable.

Re-insert /replace the SD card (see

0x00002000 subsection 3.2.16 Touchscreen
Remote Control Cable.
Touchscreen remote control
communication or SD card
2 0x000040YY Upload the latest FW version to the
fault.
Generator PCB and Touchscreen
remote control (see subsection 1.3.1
Firmware Update).

Replace the Touchscreen remote

0x000080YY control.

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).
Restart the Unit.
3
If the problem persists, download Unit
0xYYYYYYYY Internal communication error.
log file and send it with problem
description to BTL ISC (see chapter
4 7 Technical Support Contact).
Restart the Unit.

If problem persists, download Unit log

file and check recorded error codes. If
the Runtime error 5 is combined with
Runtime error 2, solve the problem
Touchscreen remote control
5 ----- according to troubleshooting for
communication fault.
Runtime error 2.

If only Runtime error 5 is present in

the log file, send the file with problem
description to BTL ISC (see chapter
7 Technical Support Contact).

5-13
 Restart the Unit.

Communication timeout Reconnect or exchange Touchscreen

7 ----- between Touchscreen remote remote control.
control and Generator PCB.
Disassemble the Unit according to
section 3.2.8 Generator PCB.

Check /reconnect/replace cable

HW fault on Touchscreen MEC4.
8 ----- remote control or Generator
PCB. Replace Generator PCB.
Restart the Unit and check the
environment for possible sources of
electromagnetic interference.

If the problem persists, disassemble

the Unit according to the subsection
3.2.5 Left and Right Upper Covers.

Check / reconnect / replace cable

Base display PCB
9 ----- MEC32 between Generator PCB
communication error.
(connector J15) and Base display PCB
(connector J1)

Replace Base display PCB (see

subsection 3.2.4 Base Display
PCB1.1.1).

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).
Restart the Unit.

If the problem persists, download Unit

10 ----- Internal software error.
log file and send it with problem
description to BTL ISC (see chapter
7 Technical Support Contact).

5-14 093-82ServiceManualEN101
 Troubleshooting Guide

Restart the Unit.

If the problem persists, disassemble

Unit according to the subsection
3.2.5 Left and Right Upper Covers.

Check / reconnect / replace cable

Base display PCB MEC32 between Generator PCB
11 -----
communication error. (connector J15) and Base display PCB
(connector J1)

Replace Base display PCB (see

subsection 3.2.4 Base Display PCB).

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).
Restart the Unit and check the
environment for possible sources of
electromagnetic interference.
12 ----- EEPROM communication error.
Replace Generator PCB (see
subsection 3.2.8 Generator PCB).
YYYY = selftest error code (HEX)

ZZZZ = number of basic error code

(HEX) which occurred before or
together with the Selftest error.
13 0xYYYYZZZZ Selftest error detected.
Troubleshoot the problem according
to the given selftest error code. Find
the selftest error code description in
subsection 5.3.2 Selftest errors.
Restart the Unit.
14 0x000000Y
If the problem persists, download Unit
Internal software error.
log file and send it with problem
15 0x000000Y description to BTL ISC (see chapter
7 Technical Support Contact).

5-15
 Check whether the Unit has not been
overloaded by user.

Disassemble the Unit according to the

subsection 3.2.5 Left and Right Upper
Covers.

Check / reconnect the cable MEC23

between the Generator PCB
(connector J10 and J13) and the
Motion module motor.

Check whether pulley belt on the

Motion module motor is correctly
Motion module motor is
placed. Disconnect cable MEC23 from
0x00000004 overloaded, short circuited or
connector J10. Try if it is possible to
there is a Generator PCB fault.
freely rotate with the pulleys and the
Motion screw and nut are moving.

Remove any objects which may block

the Motion module or Motion frame. If
necessary, add lubricant to the Motion
module (see subsection 1.3.9 Motion
Screw Lubrication).
16
Replace Motion module (see
subsection 3.2.13 Motion Module).

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).

0x00000008 Generator PCB temperature is Replace Generator PCB (see

0x00000010 out of limits – HW error. subsection 3.2.8 Generator PCB).

Disassemble the Unit according to the

subsection 3.2.5 Left and Right Upper
Covers.

Check / reconnect cable from Power

adaptor in connector J6 on the
Generator PCB
Power supply voltage is less
0x00000020
than 20,4VDC.
Check voltage of the Power adaptor. If
the voltage is out of range 24±2VDC,
replace the Power adaptor (see
subsection 3.2.9 Power Adaptor).

Replace the Generator PCB (see

subsection 3.2.8 Generator PCB).

5-16 093-82ServiceManualEN101
 Troubleshooting Guide

Check voltage of the Power adaptor. If

the voltage is out of range 24±2VDC,
replace the Power adaptor (see
Power supply voltage is above
0x00000040 subsection 3.2.9 Power Adaptor).
27,6VDC.
Replace the Generator PCB (see
subsection 3.2.8 Generator PCB).
Disconnect the Touchscreen or
Start/stop remote control.
If the fault disappears exchange the
Touchscreen or Start/stop remote
control. Alternatively replace the
Touchscreen remote control cable
(see subsection 3.2.16 Touchscreen
Remote Control Cable).
Voltage for control buttons is
16 below its expected value.
Disassemble the Unit according to the
subsection 3.2.5 Left and Right Upper
Possible short circuit in the
0x00000080 Covers.
cable MEC32 to the Base
display PCB or in the cable to
Check / reconnect / replace cable
the Touchscreen or Start/stop
MEC32 between the Generator PCB
remote control.
(connector J15) and Base display PCB
(connector J1).

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).

Replace Base display PCB (see

subsection 3.2.4 Base Display PCB).

Generator PCB voltage Replace Generator PCB (see

reference error. subsection 3.2.8 Generator PCB).

5-17
 Restart the Unit.

Check the Touchscreen or Start/stop

remote control keyboard for any signs
of damage and jammed buttons.

Connect a functional Touchscreen or

Start/stop remote control to the Unit.
If the error is still present, disassemble
the Unit according to the subsection
3.2.5 Left and Right Upper Covers,
check condition of cable MEC4 and
reconnect / replace it. Replace
Generator PCB (see subsection 3.2.8
Generator PCB).

If the problem disappeared after

connecting another remote control,
follow these steps:

Touchscreen or Start/stop Start/stop remote control:

16 0x00000200
remote control buttons error. Exchange the accessory.

Touchscreen remote control:

Disassemble the Touchscreen remote
control (see subsection 3.2.16
Touchscreen Remote Control Cable).

Check condition of the flat cable

between the keyboard and Control
PCB (connector J2) and reconnect it.

Replace Touchscreen remote control

keyboard (see 3.2.17 Touchscreen
Remote Control Display).

Replace Touchscreen remote control

cable (see subsection 3.2.16
Touchscreen Remote Control Cable).

Exchange Touchscreen remote

control.

5-18 093-82ServiceManualEN101
 Troubleshooting Guide

Restart the Unit.

Check the Control panel buttons for

any signs of damage and jammed
buttons.

Start the Unit in Service mode and run

Control panel buttons test 12265 (see
subsection 1.3.3 Service Mode) to
identify the faulty button.

Disassemble the Unit according to the

0x00000400 Control panel buttons error. subsection 3.2.5 Left and Right Upper
Covers.

Check / reconnect / replace cable

MEC32 between the Generator PCB
16 (connector J15) and Base display PCB
(connector J1).

Replace Base display PCB (see

subsection 3.2.4 Base Display PCB).

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).
Turn the Unit OFF and wait several
minutes for cool down of the
Generator PCB. Check if the Unit is
operated within the ambient
Generator PCB temperature is temperature limits specified in the
0x00000800
above limits. device “Operator’s Manual”.

In case of repetitive occurrence of the

error message replace Generator PCB
(see subsection 3.2.8 Generator PCB).

5-19
 Perform calibration of the Knee angle
sensor (see subsection 1.3.6
Calibration of Knee Angle Sensor).

Check connection of cable MEC15 to

Knee angle sensor.

Disassemble the Unit according to the

subsections 3.2.5 Left and Right
Upper Covers and 3.2.7 Knee Angle
Sensor Cable.

Angle measured by the Knee Check / reconnect / replace the cable

0x00001000
angle sensor is out of limits. MEC15 between the Knee angle
16 sensor and RJ11coupler and cable
MEC14 between the RJ11 coupler
and Generator PCB.

Check whether the Knee angle sensor

is correctly mounted (see subsection
2.3.3 Knee Angle Sensor).

Replace the Knee angle sensor.

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).
Touchscreen or Start/stop Follow instructions for Basic error 16,
0x00002000
remote control buttons fault. Extended error 0x00000200.

5-20 093-82ServiceManualEN101
 Troubleshooting Guide

Set the Footplate manually

approximately to the position 0° and
run the therapy again.

Check whether the Ankle module is

properly connected to the Unit.

Perform calibration of the Ankle angle

sensor (see section 1.3.7 Calibration
of Ankle Angle Sensor).

Disassemble the Ankle module

according to subsection 3.2.20 Ankle
Module PCB.

Check that Drive mechanism of Ankle

module is correctly set (see Assembly
Angle measured by Ankle
0x00004000 notes in subsection 3.2.20 Ankle
angle sensor is out of limits.
Module PCB).

Check / reconnect / replace the Ankle

module cable (SET 4).

Disassemble the Unit according to the

subsection 3.2.5 Left and Right Upper
Covers.
16
Check / reconnect / replace cable
MEC5 between the Generator PCB
and the Ankle module connector.

Replace the Ankle module PCB.

Replace Generator PCB (see

subsection 3.2.8 Generator PCB.
Disassemble the Unit according to the
subsection 3.2.5 Left and Right Upper
Covers.

Check / reconnect / replace cable

MEC32 between the Generator PCB
Base display PCB reference (connector J15) and Base display PCB
0x00008000
voltage error. (connector J1).

Replace Base display PCB (see

subsection 3.2.4 Base Display PCB.

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).
Generator PCB reference Replace Generator PCB (see
0x00010000
voltage error. subsection 3.2.8 Generator PCB).

5-21
 Motion module motor is
overloaded, the Unit is
probably subjected to an Follow instructions for Basic error 16,
0x00020000
excessive load or mechanical Extended error 0x00000004.
resistance in the Motion
module.
Generator PCB temperature is Replace Generator PCB (see
0x00040000
out of limits – HW error. subsection 3.2.8 Generator PCB).
Turn the Unit OFF and wait several
minutes for cool down of the
0x00080000 Generator PCB. Check if the Unit is
operated within the ambient
Generator PCB temperature is temperature limits specified in the
above limits. device “Operator’s Manual”.

0x00100000 In case of repetitive occurrence of the

error message replace Generator PCB
(see subsection 3.2.8 Generator PCB).
Check whether the Ankle module has
16 not been overloaded by user.

Remove the Ankle module cover

(see subsection 3.2.18 Ankle Module
Cable).

Disconnect the cable of Ankle module

motor from connector J3 on Ankle
module PCB. Check if the Footplate
can be easily rotated to identify
0x00200000 Ankle module is overloaded.
possible mechanical problem in Drive
mechanism.

Replace the Ankle module PCB (see

subsection 3.2.20 Ankle Module PCB).

Replace the Ankle module motor (see

subsection 3.2.20 Ankle Module PCB).

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).
Current in the Motion module
Replace Generator PCB (see
0x00000001 motor has exceeded limit at
subsection 3.2.8 Generator PCB).
idle state.

17 Replace the Ankle module PCB (see

Current measured in the Ankle subsection 3.2.20 Ankle Module PCB).
0x00000002 module has exceeded limit at
idle state. Replace Generator PCB (see
subsection 3.2.8 Generator PCB).

5-22 093-82ServiceManualEN101
 Troubleshooting Guide

Check whether the Ankle module has

not been overloaded by user.

Remove the Ankle module cover

(see subsection 3.2.18 Ankle Module
Cable) and check whether the
gearwheels of Ankle angle sensor are
properly assembled as described in
Assembly notes in subsection
3.2.20 Ankle Module PCB.

Disassemble the Unit according to the

Ankle module has not changed subsection 3.2.5 Left and Right Upper
0x00000001 angle within 4s timeframe. No Covers. Check / reconnect /replace
motion registered. cable MEC5 between the Generator
PCB (connector J2 and J4) and the
Ankle module connector.

Check / reconnect / replace the Ankle

module cable (SET 4).

Replace the Ankle module PCB.

Replace the Ankle module motor.

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).
18
Check whether the Ankle module has
not been overloaded by user.

Remove the Ankle module cover

(see subsection 3.2.18 Ankle Module
Cable) and check whether the
gearwheels of Ankle angle sensor are
properly assembled as described in
Assembly notes in subsection
3.2.20 Ankle Module PCB.

Check / reconnect / replace the Ankle

module cable (SET 4).
0x00000002 Ankle module control error.
Disassemble the Unit according to the
subsection 3.2.5 Left and Right Upper
Covers.

Check / reconnect /replace cable

MEC5 between the Generator PCB
(connector J2 and J4) and the Ankle
module connector.

If the problem persists, download Unit

log file and send it with problem
description to BTL ISC (see chapter
7 Technical Support Contact).

5-23
 Disassemble the Unit according to the
subsection 3.2.5 Left and Right Upper
Covers.

Check whether pulley belt on the

Motion module has not Motion module is without any signs of
changed angle within 16s damage and correctly placed.
0x00000004
timeframe. No motion
registered. Disassemble the Unit according to
subsection 3.2.6 Knee Angle Sensor
and check correct mounting of the
Knee angle sensor.

Replace the Knee angle sensor.

If the problem persists, download Unit
log file and send it with problem
0x00000008 Motion module control error.
description to BTL ISC (see chapter
7 Technical Support Contact).
Restart the Unit.

If the problem persists, download Unit

0x00000020 Internal software error.
log file and send it with problem
description to BTL ISC (see chapter
18 7 Technical Support Contact).
Perform calibration of the Knee angle
sensor (see subsection 1.3.6
Calibration of Knee Angle Sensor).

Disassemble the Unit according to

Angle measured by the Knee
subsection 3.2.6 Knee Angle Sensor
0x00000040 angle sensor is lower than -
and check correct mounting of the
20°.
Knee angle sensor.

Disassemble the Unit according to the

subsections 3.2.5 Left and Right
Upper Covers and 3.2.7 Knee Angle
Sensor Cable.

Check / reconnect / replace the cable

MEC15 between the Knee angle
sensor and RJ11coupler and cable
Angle measured by the Knee MEC14 between the RJ11 coupler
0x00000080
angle senor is more than 130°. and Generator PCB.
Replace the Knee angle sensor.

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).

5-24 093-82ServiceManualEN101
 Troubleshooting Guide

Restart the Unit.

Perform calibration of the Ankle angle

sensor (see subsection
1.3.7 Calibration of Ankle Angle
Sensor).

0x00000100 Remove the Ankle module cover

(see subsection 3.2.18 Ankle Module
Cable) and check whether the
gearwheels of Ankle angle sensor are
properly assembled as described in
Assembly notes in subsection
3.2.20 Ankle Module PCB.
Angle measured by Ankle
18 angle sensor is out of expected Check / reconnect / replace the Ankle
range. module cable (SET 4).

Disassemble the Unit according to the

subsection 3.2.5 Left and Right Upper
Covers.

Check / reconnect /replace cable

0x00000200 MEC5 between the Generator PCB
(connector J2 and J4) and the Ankle
module connector.

Replace the Ankle module PCB.

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).
Check whether the Motion module
has not been overloaded by user.

Disassemble the Unit according to the

subsection 3.2.5 Left and Right Upper
Covers.

Check /reconnect the cable MEC23

between the Generator PCB
(connector J10 and J13) and the
Motion module motor has not
Motion module motor.
19 0x00000001 reached required speed within
given 4s timeframe.
Replace Motion module (see
subsection 3.2.13 Motion Module).

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).

If the problem persists, download Unit

log file and send it with problem
description to BTL ISC (see chapter
7 Technical Support Contact).

5-25
 Check whether the Ankle module has
not been overloaded by user.

Remove the Ankle module cover

(see subsection 3.2.18 Ankle Module
Cable).

Check /reconnect / replace the cable

MEC39 between Ankle module PCB
(connector J1) and Incremental speed
sensor on Ankle module motor
(connector SW1).

Check if the Incremental speed sensor

wheel is without any signs of damage
or dust.
Ankle module motor has not
0x00000002 reached required speed within Check / reconnect / replace the Ankle
given 4s timeframe. module cable (SET 4).

19 Disassemble the Unit according to the

subsection 3.2.5 Left and Right Upper
Covers.

Check / reconnect /replace cable

MEC5 between the Generator PCB
(connector J2 and J4) and the Ankle
module connector.

Replace the Ankle module PCB.

Replace the Ankle module motor.

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).
Restart the Unit.

If the problem persists, download Unit

0x00000004 Ankle module control error.
log file and send it with problem
description to BTL ISC (see chapter
7 Technical Support Contact).

5-26 093-82ServiceManualEN101
 Troubleshooting Guide

Check whether the Ankle module has

not been overloaded by user.

Remove the Ankle module cover

(see subsection 3.2.18 Ankle Module
Cable).

Disconnect the cable of Ankle module

motor from connector J3 on Ankle
module PCB. Check if the Footplate
There has not been registered
can be easily rotated to identify
any decrease of back pressure
possible mechanical problem in Drive
on the Ankle module motor
20 0x00000001 mechanism. If the Footplate is not
after change of the motion
blocked, go to 4th menu of the
direction or the motor has not
Touchscreen remote control and
set in motion at all.
increase value of the load reversal.

Replace the Ankle module PCB (see

subsection 3.2.20 Ankle Module PCB).

Replace the Ankle module motor (see

subsection 3.2.20 Ankle Module PCB).

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).

5-27
 Check whether the Unit has not been
overloaded by user.

Disassemble the Unit according to the

subsection 3.2.5 Left and Right Upper
Covers.

Check / reconnect the cable MEC23

between the Generator PCB
(connector J10 and J13) and the
Motion module motor.

Check whether pulley belt on the

Motion module motor is correctly
placed. Disconnect cable MEC23 from
connector J10. Try if it is possible to
freely rotate with the pulleys and the
Motion module - there has not Motion screw and nut are moving.
been registered any decrease
of back pressure on the Motion If the Motion module is not blocked,
0x00000002
module motor after change of go to 4th menu of the Touchscreen
motion direction or the motor remote control and increase value of
has not set in motion at all. the load reversal.
20
Remove any objects which may block
the Motion module or Motion frame. If
necessary, add lubricant to the Motion
module (see subsection 1.3.9 Motion
Screw Lubrication).

Replace Motion module (see

subsection 3.2.13 Motion Module).

Replace Generator PCB (see

subsection 3.2.8 Generator PCB).

If the problem persists, download Unit

log file and send it with problem
description to BTL ISC (see chapter
7 Technical Support Contact).
Restart the Unit.

If the problem persists, download Unit

0x00000004 Internal communication error.
log file and send it with problem
description to BTL ISC (see chapter
7 Technical Support Contact).

5-28 093-82ServiceManualEN101
 Troubleshooting Guide

Exchange the Touchscreen or

Touchscreen or Start/stop Start/stop remote control.
0x00000001 remote control power supply
voltage is too low. Replace Generator PCB (see
21 subsection 3.2.8 Generator PCB).

0x00000002 Touchscreen or Start/stop

remote control power supply Replace Generator PCB (see
voltage is out of expected subsection 3.2.8 Generator PCB).
0x00000003 limits.
Restart the Unit.

Go to 4th menu of the Touchscreen

remote control and increase value of
the load reversal.
Required angle on the Ankle or
Check for jam or any visible blockage
Knee module cannot be
22 0x0000YYYY of the Motion or Ankle module
reached, therapy cannot be
mechanics and remove it when
started.
possible.

If the problem persists, download Unit

log file and send it with problem
description to BTL ISC (see chapter
7 Technical Support Contact).

0x00000001 Restart the Unit.

If the problem persists, download Unit

23 0x00000002 Internal software error.
log file and send it with problem
description to BTL ISC (see chapter
0x00000004 7 Technical Support Contact).
Too many errors registered. Download Unit log file and start with
24 ----- Fault management system troubleshooting of 1st error logged for
queue is full. particular problem.

5-29
 Check that the Touchscreen or
Start/stop remote control is properly
connected to the Unit.

Connect a functional Touchscreen or

Start/stop remote control to the Unit.
If the error is still present, disassemble
the Unit according to the subsection
3.2.5 Left and Right Upper Covers,
check condition of cable MEC4 and
reconnect / replace it. Replace
Generator PCB (see subsection 3.2.8
Generator PCB).

If the problem disappeared after

connecting another remote control,
follow these steps:

Start/stop remote control:

Request for therapy start is Exchange the accessory.
registered but neither
25 -----
Start/stop nor Touchscreen Touchscreen remote control:
remote control is connected. Upload the latest FW version to the
Generator PCB and Touchscreen
remote control (see subsection 1.3.1
Firmware Update).

Disassemble the Touchscreen remote

control (see subsection 3.2.16
Touchscreen Remote Control Cable).

Check / reconnect / replace

Touchscreen remote control cable
(see subsection 3.2.16 Touchscreen
Remote Control Cable).

Replace Display PCB (see subsection

3.2.17 Touchscreen Remote Control
Display).

Exchange Touchscreen remote

control.
Restart the Unit.

If the problem persists, download Unit

26 ----- Internal software error.
log file and send it with problem
description to BTL ISC (see chapter
7 Technical Support Contact).

5-30 093-82ServiceManualEN101
 Troubleshooting Guide

Check that the Touchscreen remote

Therapy on Ankle module control is properly connected to the
cannot be started, the Unit.
27 ----- Touchscreen remote control is
either not connected or does Continue in troubleshooting according
not communicate. to instructions for Touchscreen
remote control in Basic error 25.
Set the Motion frame to the Parking
position (10°).
Motion frame is not in parking
28 ----- position (10°), therapy with
Continue in troubleshooting according
Ankle module cannot be run.
to instructions for Basic error 18,
Extended error 0x00000080.
The version of the Ankle
29 ----- module is not supported by the Upload the latest FW version to the
FW in Generator PCB. Generator PCB and Touchscreen
FW of Touchscreen remote remote control (see subsection
30 ----- control is compatible with FW 1.3.1 Firmware Update).
of Generator PCB.

5-31
5.3.2 Selftest errors
Selftest error codes are part of Basic error code 13. The codes are displayed as
hexadecimal values.

Error number
Error Description Action
from to
Restart the Unit.

If the problem persists,

perform Unit log data export
1 2 Internal software error (see subsection 1.3.4 Unit Log
Data Export) and send the file
with problem description to
BTL ISC (see chapter
7 Technical Support Contact).
3 1A EEPROM error
Generator PCB reference voltage error
1B 1D Replace the Generator PCB
(Touchscreen remote control is OFF)
(see subsection 3.2.8
Generator PCB reference voltage error Generator PCB).
1E 21
(Touchscreen remote control is ON)
22 23 Generator PCB analog inputs error.

5-32 093-82ServiceManualEN101
 Troubleshooting Guide

5.4 Device Inspection Faults

At the time of publishing this document there are no available troubleshooting
procedures for documents “Maintenance and Safety Report” and “Final Inspection
Report” stored in chapter 9 Appendix.

5-33
5-34 093-82ServiceManualEN101
 BTL-CPMOTION K
6 SPARE PART AND TOOL LIST

6.1 Electronic Parts....................................................................................................................... 6-2

6.2 Electrical/Electromechanical Parts ................................................................................... 6-4

6.2.1 SET 5 – Cables with Connectors ............................................................................... 6-6

6.3 Mechanical Parts ................................................................................................................... 6-8

6.3.1 SET 20 - Fasteners ..................................................................................................... 6-11

6.4 Accessories and Consumables ....................................................................................... 6-13

6.5 Used Tools ............................................................................................................................ 6-14

6-1
 This chapter contains list of spare parts and accessories for BTL-CPMotion that can be
ordered from the BTL ISC. When placing an order always use the Part number code
together with Part description. The list may change, ask BTL ISC (see chapter 7 Technical
Support Contact) for actual list and prices of spare parts and accessories.

6.1 Electronic Parts

Signal Electronics

MEC35. MEC30.

LCD1. KON1.

MEC11. MEC24.

Part number Part description Reference

093-59BASEDISP BTL-CPMotion Base display PCB MEC35
093-59GENER BTL-CPMotion Generator PCB MEC30
093-59RMLCD BTL-CPMotion Remote control display LCD1
093-59RMSDCARD BTL-CPMotion micro SD card KON1
093-59KNEEANG BTL-CPMotion Knee angle sensor MEC11
093-59ANKPCB BTL-CPMotion Ankle module PCB MEC24

6-2 093-82ServiceManualEN101
 Spare Part and Tool List

Power Supply

MEC63.

MEC6.

F1.

Part number Part description Reference

093-59MAINS BTL-CPMotion Mains PCB MEC63
093-59ADAPTOR BTL-CPMotion Power adaptor MEC6
093-59FUSES BTL-CPMotion Fuse T1A-H F1

6-3
6.2 Electrical/Electromechanical Parts
MEC18.

SET1.

SET2.

SET3.

6-4 093-82ServiceManualEN101
 Spare Part and Tool List

MEC3. SET4.

Part number Part description Reference

093-59ANKMOTOR BTL-CPMotion Ankle module motor MEC18
093-59MOTION BTL-CPMotion Motion module SET1
093-59KEYBOARD BTL-CPMotion Control panel keyboard SET2
093-59RMCOVER BTL-CPMotion Remote control covers SET3
093-59RMCABLE BTL-CPMotion Remote control cable MEC3
BTL-CPMotion Ankle module cable with
093-59ANKCABLE SET4
back Cover

6-5
6.2.1 SET 5 – Cables with Connectors
Part number Part description PCS Reference
Knee angle sensor – RJ11
093-5505ANGIN 1
coupler (4x1320mm)
MEC14

RJ11 coupler – Generator PCB

093-5513ANG 1
(4x180mm)
MEC15

Touchscreen remote control –

093-5507PENDNEXTIN Generator PCB interconnection 1
cable (8x180mm)

MEC4

Ankle module – Generator PCB

093-5509ANKNEXTIN interconnection cable 1
(7x560mm)

MEC5

Base display PCB – Generator

048-5501FFC28W 1
PCB (28x250mm)
MEC32

Power adaptor – Mains PCB

093-5512MAINSIN 1
(2x250mm)

MEC31

Power connector – Mains PCB

093-5518MAINSIN 1
(2x55mm)

MEC2

6-6 093-82ServiceManualEN101
 Spare Part and Tool List

EJ-6P6CCOUPLINGXX RJ11 coupler 1

MEC100

EKON-BUSHF9.5XX Cable bushing 1

KON9

Incremental sensor – Ankle module

093-5520ANKINCR 1
PCB (3x130mm)
MEC39

Ankle module grounding cable

093-5519ANKESD 1
(1x115mm)
MEC29

Motion module grounding cable

093-5504ESDIN 1
(1x140mm)
MEC23

NOTE: Parts listed above are for reference only and cannot be ordered separately.

6-7
6.3 Mechanical Parts
SET6. SET7.

SET8 SET9

SET10 MEC37

MEC38. SET11.

6-8 093-82ServiceManualEN101
 Spare Part and Tool List

SET12. SET13

SET14. SET15.

SET16. SET17.

MEC42. SET18.

6-9
 MEC40

Part number Part description Reference

093-59BACKCOVER BTL-CPMotion Rear cover SET6
BTL-CPMotion Motion frame bottom
093-59CONSTRUCTBOT SET7
part
093-59CONSTRUCTTOP BTL-CPMotion Motion frame upper part SET8
093-59COVERBOT BTL-CPMotion Bottom cover SET9
093-59COVERSENSOR BTL-CPMotion Knee angle sensor cover SET10
093-59COVERTOPL BTL-CPMotion left Upper cover MEC37
093-59COVERTOPR BTL-CPMotion right Upper cover MEC38
093-59LEVER BTL-CPMotion strap locking system SET11
BTL-CPMotion telescope locking
093-59LOCKING SET12
system
093-59CONTROLPINS BTL-CPMotion control pins SET13
093-59STRAP BTL-CPMotion strap SET14
093-59SUPPORT BTL-CPMotion Thigh and Calf supports SET15
093-59TELEFOOT BTL-CPMotion telescopes for Footplate SET16
093-59TELESCOPE BTL-CPMotion Thigh telescopes SET17
093-59ANKCOVER BTL-CPMotion Ankle module cover MEC42
093-59FOOTPLATE BTL-CPMotion Footplate SET18
093-59BUMP BTL-CPMotion Bumper MEC40
093-59LABELS BTL-CPMotion Labels SET19

NOTE: For some countries there are special variants of Device Labels. Before place
order please contact BTL ISC (see chapter 7 Technical Support Contact).

6-10 093-82ServiceManualEN101
 Spare Part and Tool List

6.3.1 SET 20 - Fasteners

Part Number Part description Size ISO PCS
D=25 mm;
093-1183BUSHING Plastic bushing N/A 10
d=13.1 mm;
D=21 mm;
093-1192WASHER Plastic washer N/A 10
d=8.2 mm;
EKON-CLIPFTH-
Cable tie holder 6.35mm N/A 10
9XX0
EKON-F0301CVXX1 Cable tie L100H2.5 N/A 10
EKON-F0301CVXX2 Cable tie L140H3.2 N/A 20
EKON-F0301CVXX3 Cable tie L250H4.8 N/A 10
D=16.3 mm;
EKON-
Starlock round cap d=8mm; N/A 10
STARLOCK8XX0
h=5.1 mm;
EPOD-
Plastic washer 14.5x25 N/A 10
14.5PA25XX0
EPOD-14PA20XX0 Plastic washer 14x20 N/A 10
EPOD-19PA30XX0 Plastic washer 19x30 N/A 10
EPOD-8.4PA16XX0 Plastic washer 8.4x16 N/A 10
EPOD-8.4PA17XX0 Plastic washer 8.4x17 N/A 10
EPOD-9.2PA16XX0 Plastic washer 9.2x16 N/A 10
Torx hex screw for plastic,
ESRO-2.9x32TX0 2.9x32 ISO14586 10
Zn
Torx hex screw for plastic,
ESRO-3.0x12TX1 3x12 BN11308 10
Zn
Torx hex screw for plastic,
ESRO-3.0x6TX0 3x6 BN13265 10
Zn
Torx hex screw for plastic,
ESRO-3.0x8TX0 3x8 BN84229 10
Zn
Torx hex screw for plastic,
ESRO-4.0x14TX0 4x14 BN20138 10
Zn
Torx hex screw for plastic,
ESRO-4.0x25TX0 4x25 BN84229 10
Zn
Pozidrive hex screw for
ESRO-40x35XX0 4x35 WN5412 10
plastic, Zn
ESRO-M2.5x8XX5 Torx head screw M2.5x8 ISO4026 10
ESRO-M3x8XX7 Torx head screw M3x8 ISO4026 10
ESRO-M4x8TX3 Torx head screw M4x8 BN9524 10
ESRO-M5x10TX4 Torx head screw M5x10 ISO7380 10
ESRO-M5x20TX0 Torx head screw M5x20 BN9524 10
ESRO-M6x16TX2 Torx head screw M6x16 BN9524 10
ESRO-M8x20XX0 Allen head screw M8x20 ISO7380 10
EPOD-5.3PA10XX0 Plastic washer 5.3X10 N/A 10
Washers for cheese and
EPOD-5XX1 5.3X9 ISO 7092 10
mushroom head
EPOD-5XX5 Plain washer 5.3X15 DIN9021 10

6-11
 EPOD-
Plastic washer 12.2X24 N/A 10
12.2PA24XX0
ESRO-M4x8TX4 Torx head screw M4X8 DIN7500C 10
ESRO-M5x30XX3 Allen head set screw M5x30 ISO 4026 10
ESRO-M4x8TX0 Torx head screw M4X8 ISO 7380 10
Hexagon lock nut, low type,
EMAT-M3STXX0 M3 ISO10511 10
Zn
ESLO-HSM3-6.4-20- Plastic Hex stand-offs,
M3 L20mm N/A 10
2XX0 internal/external
ESRO-M3x5TX0 Torx head screw M3X5 ISO 7380 10
ESRO-M5x12XX1 Allen head screw M5X12 ISO 10642 10
ESRO-M2.5x6TX0 Torx head screw M2.5X6 ISO 7380
ESRO-M3x6XX6 Allen head set screw M3X6 ISO 4026 10
ESRO-M5x35TX0 Torx head screw M5X35 ISO 7380 10
ESRO-M5x6TX0 Torx head screw M5X6 ISO 7380 10
ESRO-M8x40TX0 Torx head screw M8X40 ISO 7380 10
ESRO-M1.2x4XX0 Slot head screw M1.2X4 ISO 1207 10
ESRO-M6x16TX3 Torx head screw M6X16 ISO 7380 10
ESRO-M4x5XX2 Allen head set screw M4X5 ISO 4027 10
ESRO-M4x20TX0 Torx head screw M4X20 ISO 7380 10
Hexagon lock nut, low type,
EMAT-M5STXX0 M5 ISO10511 10
Zn
Hexagon lock nut, low type,
EMAT-M2.5ZnXX0 M2.5 ISO10511 10
Zn
Hexagon lock nut, low type,
EMAT-M5ZnXX3 M5 ISO10511 10
Zn
093-
Plastic spacer 75x26 N/A 2
1174PLASTINSERT
EPOD-8XX0 Plain washer 8.4x16 ISO 7089 10
EPOD-
Saddle plastic washer 8.2x22 N/A 5
8.2PA22SXX0

NOTE: Parts listed above are for reference only and cannot be ordered separately.

6-12 093-82ServiceManualEN101
 Spare Part and Tool List

6.4 Accessories and Consumables

P093.012 P093.015CS/EN

P093.011

Part number Part description PCS

P093.012 BTL-CPMotion Ankle module upgrade 1
P093.015.CS/
BTL-CPMotion Trolley (CS/EN version) 1
P093.015.EN
P093.011 BTL-CPMotion Start/stop remote control 1
P093.025 BTL-CPMotion transportation bag 1

6-13
6.5 Used Tools
SELECTED TOOLS FROM TOOL SET
The recommended tools below are part of a Tool Set for servicing all BTL Devices. The
Tool Set can be ordered from the BTL ISC (see chapter 7 Technical Support Contact).

Type Tool Description

Screwdriver Torx TX8
Screwdriver Torx TX10
Screwdriver Torx TX15
Torx screwdrivers
Screwdriver Torx TX20
Screwdriver Torx TX25
Screwdriver Torx TX40
Philips screwdrivers Screwdriver Philips PH2
Slot screwdrivers Screwdriver Slot 5.5 mm
Spanner 5.5x7 mm
Spanners
Spanner 8x10 mm
Pliers Cutting pliers (Electric) 160 mm
Cables/convert. RS232 – USB converter
Tweezers straight 130 mm
Allen keys 7pcs. HX1.5 - HX6.0
Hot glue gun 7mm
Other
Hot glue sticks for HPK 220
Spray bottle with alcohol
ESD Snap anti-allergic Wrist band

SPECIFIC TOOLS
Tools that can be ordered separately from the BTL ISC:

Order Number Tool Description

193-KEYNEXT Wrench for connector nuts
193-CPMLUBRIC Lubricant for motion screw
193-GENLOAD CPM generator loading cable
193-RMLOAD Remote control loading tool
ELEP-AN30241XX0 Thread-locking glue

6-14 093-82ServiceManualEN101
 Spare Part and Tool List

OTHER TOOLS
Tools that have to be purchased separately by each service facility:

Tool Description
Torque screwdriver with range of torques 1 – 10Nm
Multimeter
Electrical safety analyzer Fluke ESA612
PC laptop with Ansur Test Automation Software and ESA612 Plug-in, USB cable
Air duster spray - dry inert pressurized gas
ESD Brush
Vacuum cleaner
Spanner 11 mm
Spanner Tube 8 mm

6-15
6-16 093-82ServiceManualEN101
 BTL-CPMOTION K
7 TECHNICAL SUPPORT
CONTACT

7-1
 Please prepare following information with any service enquiry:

• Device Model, Type.

• Complete Serial Number. The Serial Number (S/N) is on the Unit’s bottom side.

• Firmware version. This can be found in the Unit’s menu.

• Detailed description of the problem. Include information such as description of

the therapy during which the fault occurred.

• Log files downloaded from the concerned Device.

• Other supporting materials: pictures or videos describing the problem.

BTL International Service Center (BTL ISC)

E-mail: [email protected]

Tel: +359 32 624 440

Address:

BTL Industries LTD

30 Peshtersko Shouse Blvd

4002 Plovdiv

Bulgaria

7-2 093-82ServiceManualEN101
BTL-CPMOTION K
8 INDEX

8-1
 accessories ............................ iv, 2-11, 6-13 lubrication ............................................... 1-14
address....................................................... 7-2 mains PCB...................... 2-3, 2-8, 3-19, 6-3
ankle angle sensor calibration .. 1-8, 1-13 mains PCB fuse..................... 1-15, 4-2, 6-3
ankle module ...............................2-14, 3-34 mains socket .................................. 2-3, 3-19
ankle module connector ............. 2-3, 3-22 maintenance and safety check ......... 5-33
ankle module cover .......... 2-14, 3-34, 6-9 multibin version ........................................ 1-8
ankle module frame .............................. 3-36 model identification ................................ 1-2
ankle module motor . 2-3, 2-15, 3-41, 6-4 motion frame ........................ 2-3, 3-29, 6-8
ankle module PCB ..... 2-3, 2-15, 3-37, 6-2 motion module ............. 2-3, 2-9, 3-23, 6-4
appendix ...................................................... viii motion module motor ............................. 2-3
base display PCB .................. 2-6, 3-11, 6-2 motion screw ............................................ 2-9
basic error code ..................................... 5-10 motion screw lubrication .................... 1-14
block diagram........................................... 2-2 multimeter .............................................. 6-15
blue part........................................................ vii parking position.......................... 1-12, 1-13
bottom cover ............................................ 6-8 password......................................... 1-8, 1-10
bottom frame ........................................... 6-8 phone .......................................................... 7-2
bumper ............................................ 3-9, 6-10 power adaptor .............. 2-3, 2-7, 3-18, 6-3
cables ...................................... 6-5, 6-6, 6-14 rear cover ........................................ 3-14, 6-8
calf support ................... 2-3, 2-10, 3-6, 6-9 red part ......................................................... vii
calf telescopes ................................. 2-3, 6-9 remote control connector .. 2-3, 3-20, 6-6
cam buckle ............................... 2-3, 3-6, 6-8 remote control loading tool ........ 1-6, 6-14
color parts .................................................... vii runtime errors ........................................ 5-13
contact ....................................................... 7-2 selftest errors .............................. 5-12, 5-32
control panel.................... 2-3, 2-6, 3-9, 6-4 serial number ............................................... iii
control panel keyboard .......................... 2-6 service bulletin........................................... viii
CPM gen. loading cable ... 1-3, 1-10, 6-14 service codes ............................................ 1-7
device ............................................................. iv service documentation structure ........... vii
disassembly .............................................. 3-5 service functions ...................................... 1-9
display PCB .................................... 3-33, 6-2 service manual............................................ vii
drive mechanism ................................... 2-16 service manual appendix ........................ viii
electrical safety analyzer ..................... 6-15 service mode ............................................. 1-8
error codes .............................................. 5-10 setting codes............................................. 1-7
extended error code ............................. 5-11 start/stop remote control ........ 2-11, 6-13
fasteners .................................................. 6-11 straps .......................................................... 6-9
faults ........................................................... 5-3 telescope locking system...... 2-3, 3-8, 6-9
firmware update ...................................... 1-3 thigh support................. 2-3, 2-10, 3-6, 6-9
firmware verison...................................... 1-8 thigh telescopes ........ 2-3, 2-10, 3-26, 6-9
final inspection ....................................... 5-33 tool set ..................................................... 6-14
footplate ................................. 2-3, 2-14, 6-9 tools .......................................................... 6-14
forgotten password .............................. 1-10 touchscreen calibration....................... 1-13
gearwheels.............................................. 3-39 touchscreen remote control.... 2-11, 3-30
general issues........................................... 5-3 trolley ....................................................... 6-13
generator PCB .............. 2-3, 2-5, 3-15, 6-2 troubleshooting ........................................ 5-2
green part ..................................................... vii unit ..........................................................iv, 3-4
incremental speed sensor ........2-16, 3-42 unit log data export .............................. 1-10
interconnection of components .......... 3-3 unit settings ............................................... 1-7
knee angle sensor ....... 2-3, 2-7, 3-13, 6-2 upper covers .......................2-10, 3-12, 6-8
knee angle sensor cable ...................... 3-14 user codes.................................................. 1-7
knee angle sensor calibration ... 1-8, 1-12 user password .......................................... 1-8
knee angle sensor cover........................ 6-8 version ............................................................ ii
labels .............................................................. iii yellow part .................................................. viii
leg supports ...................................... 3-6, 6-9

8-2 093-82ServiceManualEN101
BTL-CPMOTION K
9 APPENDIX

9-1
 The Appendix is kept as an external document “Service Manual Appendix”. As it can be a
subject of frequent changes. After printing, the Appendix becomes this latest chapter.

9-2 093-82ServiceManualEN101