QAL Medical OrthoAgility E3
QAL Medical · Model OrthoAgility E3
Programmable ROM from 145° to -5° flexion/extension and 80° – 80° pronation/supination Synchronization mode between elbow and forearm Warm up feature Programmable pause Variable settings for speed and force Patient lock-out feature Patient compliance monitor Rechargeable battery pack Safety feature of reverse on load Synchronized Motion mode.
Key tips
- ·Most "no output" stim-unit complaints are cable-side - check electrode/lead continuity before assuming a unit fault.
- ·Frame and strap wear on mechanical rehab equipment is a real fall/injury risk - don't defer it as cosmetic.
Typical Failure Modes
Compiled for this model from its own documentation and established engineering knowledge for this equipment class - not from a verified service record. Confirm against the manufacturer's service manual.
Motor / actuator / drive will not run or is weak
HighSymptoms: Traction force not applied, CPM carriage will not move or stalls, drive assist weak, motion one direction only.
Root cause: Worn drive motor / leadscrew / actuator, a hand-control fault, or a control-board fault.
Force / range / position inaccuracy
MediumSymptoms: Set traction force or CPM angle not reached, load cell drifts, carriage overshoots or stalls short.
Root cause: Load-cell / position-sensor drift, a potentiometer fault, or a limit-switch fault.
Hand control / patient-control fault
MediumSymptoms: Hand control unresponsive, the patient stop / reverse button does not work.
Root cause: Worn hand control or a damaged cable.
Frame / bearing / cable wear
MediumSymptoms: Rough or noisy travel, play in the carriage, frayed traction cord or rope.
Root cause: Worn bearings / slides or a frayed cable / cord.
Power / battery fault
LowSymptoms: Will not power on, short battery run time.
Root cause: Power supply / fuse or an aged battery.
Serviceable Parts & Consumables
Serviceable items for this model, compiled from its documentation and engineering knowledge for this equipment class. Service class and relative cost are estimates, not manufacturer figures; no part numbers are given. Confirm intervals and pricing against the manufacturer.
Drive motor / leadscrew / actuator
Class Major service partRel. cost $$$R&R Difficult
Load cell / position sensor / potentiometer
Class Major service partRel. cost $$R&R Moderate
Hand control
Class Periodic replacementRel. cost $$R&R Fairly easy
Bearings / slides / traction cord
Class Periodic replacementRel. cost $$R&R Moderate
Power supply / fuse / battery
Class Major service partRel. cost $R&R Moderate
| Part | Service class | Relative cost | R&R difficulty |
|---|---|---|---|
| Drive motor / leadscrew / actuator | Major service part | $$$ | Difficult |
| Load cell / position sensor / potentiometer | Major service part | $$ | Moderate |
| Hand control | Periodic replacement | $$ | Fairly easy |
| Bearings / slides / traction cord | Periodic replacement | $$ | Moderate |
| Power supply / fuse / battery | Major service part | $ | Moderate |
Relative cost: $ lowest · $$$$ highest service-part cost for this equipment class. Not a price.
PM Checklist
Preventive-maintenance tasks typical of this equipment class. Perform to the manufacturer's procedure and your facility's policy - this is general reference, not a schedule for this specific unit.
- ·Frame and strap wear inspection
- ·Electrode lead continuity check
- ·Annual electrical safety test
Error Codes
Extracted directly from this unit's own service manual.
Error Code 0Undetermined
Error Code 1Out Of Range This error includes both the Elbow and Wrist out of range errors. The Out Of Range Error will be set if the device moves beyond its specified limit by 5 degrees or more. This error is generated by the E3 controller, which shuts down the device immediately upon detection.
Error Code 02Elbow Potentiometer Not Changing The processor looks for a potentiometer voltage change when the motor is activated. The E3 controller checks the elbow potentiometer. If the value does not change then the unit stops and the error is displayed.
Error Code 03Wrist Potentiometer Not Changing The processor looks for a potentiometer voltage change when the motor is activated. The E3 controller checks the elbow potentiometer. If the value does not change then the unit stops and the error is displayed.
Error Code 04Actuator Switch This error will check to make sure that the actuator circuit board can be turned on and off by the controller. This is monitored once after power up. The E3 controller then turns on the Actuator switch and makes sure that it goes below 5 volts. If the voltage does not then the device generates an error and shuts down immediately.
Error Code 05Start Stop Switch This is monitored continuously. If the start/stop switch is held low for a short time then an error is flagged and the device shuts down immediately.
Error Code 06Undetermined
Error Code 07Firmware Checksum This error is used to monitor for valid firmware during startup. It is only monitored once after startup and shuts down the device immediately if an error is detected.
Error Code 08False Data in EEPROM This error could be generated whenever a byte is stored into the EE memory. (Data is logged, the user stores parameters, etc.) When data is written into EE memory, the E3 controller reads the EE memory back and verifies that it is correct. If the data appears different than that which was written, an error is flagged and the device is shutdown immediately.
Error Code 11No Elbow Encoder This error has 2 levels of error detection. The first level of detection is provided by the elbow actuator processor. The elbow actuator processor monitors the RPM input on the device. If a pulse is not received within 1.048 seconds of the last pulse, then the elbow actuator processor sets a No encoder flag and transmits this to the E3 controller. If this flag is set for 5 times c
Error Code 12Reversed Elbow Motor This error is monitored by the elbow actuator processor. The elbow actuator processor will make sure that the motor is moving in the correct direction of travel and has not been wired in reverse. This check is performed whenever the device is operating and the angular position of the actuator changes. If an error occurs, the elbow actuator processor will flag the E3 controller
Error Code 13Elbow Angle Position This error is used to monitor the absolute position of the actuators angular position. If the angular position of the actuator is greater than 4.7Volts or less than 0.5Volts then the elbow actuator processor will shutdown the device and flag the E3 controller. The E3 controller will then display the error immediately.
Error Code 14Elbow Encoder Out Of Range This error is generated by the elbow actuator processor. The elbow actuator processor monitors the correct operation of the Elbow Encoder by making sure that the device receives a set number of pulses for every 5 +/-3 degrees of angular position movement., if the position is not changed with in the set perimeters then the E3 controller is notified and the device is shutd
Error Code 15Elbow Load Cell 2 This error code is generated by the elbow actuator processor. It is only monitored in PSR mode. This error will be generated if the LC2 value swings too far away from the 2.5V nominal value. The elbow actuator processor will flag an error if the LC2 A/D reading is greater than 4.5Volts or if the LC2 A/D reading is less than 0.5Volts.
Error Code 16Elbow Load Cell3 This error code is generated by the elbow actuator processor. It is only monitored in PSR mode. This error will be generated if the LC3 value swings too far away from the 2.5V nominal value. The elbow actuator processor will flag an error if the LC3 A/D reading is greater than 4.5Volts or if the LC3 A/D reading is less than 0.5Volts.
Error Code 21No Wrist Encoder This error has 2 levels of error detection. The first level of detection is provided by the elbow actuator processor. The Elbow actuator processor monitors the RPM input on the device. If a pulse is not received within 1.048 seconds of the last pulse, then the elbow actuator processor sets a No encoder flag and transmits this to the E3 controller. If this flag is set for 5 times c
Error Code 22Wrist Motor Reversed This error is monitored by the elbow actuator processor. The elbow actuator processor will make sure that the motor is moving in the correct direction of travel and has not been wired in reverse. This check is performed whenever the device is operating and the angular position of the actuator changes. If an error occurs, the elbow actuator processor will flag the E3 controller
Error Code 23Wrist Angle Position This error is used to monitor the absolute position of the actuators angular position. If the angular position of the actuator is greater than 4.7Volts or less than 0.5Volts then the elbow actuator processor will shutdown the device and flag the E3 controller. The E3 controller will then shut down the device immediately.
Error Code 24Wrist Encoder Out Of Range This error is generated by the elbow actuator processor. The elbow actuator processor monitors the correct operation of the Elbow Encoder by making sure that the device receives a set number of pulses for every 5 +/-3 degrees of angular position movement., if the position is not changed with in the set perimeters then the E3 controller is notified and the device is shutd
Error Code 25Wrist Load Cell1 This error code is generated by the elbow actuator processor. It is only monitored in PSR mode. This error will be generated if the LC1 value
Troubleshooting Approach
A starting sequence for this model, compiled from its documentation and engineering knowledge for this equipment class. Follow the manufacturer's service documentation for the actual procedure.
Symptom: Carriage will not move / stalls / moves one direction only
- Confirm mains / battery and that the patient stop / e-stop is released.
- Try the hand control and, if fitted, the unit buttons to isolate the control.
- Listen for the drive motor and check the leadscrew is not jammed or dry.
- Check the hand-control cable for damage.
- Replace the hand control, drive motor or control board as isolated.
Symptom: Set flexion / extension angle not reached / carriage overshoots or stalls short
- Run the calibration / homing routine.
- Check the position sensor / potentiometer and the limit switches.
- Verify the achieved angles with a goniometer.
- Replace the position sensor if it drifts.
- Re-verify the ROM range and the patient stop.
Symptom: Rough / noisy travel / play in the carriage
- Inspect the carriage bearings / slides for wear.
- Check the leadscrew and its nut for backlash.
- Re-lubricate per the manual.
- Replace worn bearings / slides.
- Confirm smooth quiet travel through the full range.
Typical Location
Where this class of equipment is typically deployed - general reference, not this unit's own placement record.
- Physical therapy / rehab gym
- Outpatient rehab clinic
- Sports medicine
Documents & Manuals
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