14.2.1 Installing the display PCB and/or keyboard........................................................... 54
14.2.2 Installing the ultrasound board .............................................................................. 54
14.2.3 Installing the power supply board.......................................................................... 55
14.2.4 Installing the main PCB. ........................................................................................ 56
14.2.5 Closing the unit and installation of the top cover................................................... 56
15. Compatibility of boards and components ......................................................................... 57
16. Exploded views and spare parts ...................................................................................... 58
Phyaction U/E/I/C – service manual version 0.1Page 3
2. Preface
The Phyaction series are a family of modern electrotherapy units.
As a member of the Uniphy family they are built according to the most recent requirements of
the MDD security standards.
All functions of the unit are controlled by a microprocessor, ensuring a high degree of reliability
and safety.
An integrated service software system gives the service technician a maximum of information,
in order to locate and repair a technical problem in the most efficient way.
This service manual gives a complete and accurate technical picture of the Phyaction series.
In doing so, it will hopefully help you to reach your goal: to form a correct diagnosis and to solve
the client’s problem as thoroughly as possible.
If you have any questions or if you need additional information about this manual or about the
use of the unit, please do not hesitate to contact us.
GymnaUniphy nv, May 2004
Phyaction U/E/I/C – service manual version 0.1Page 4
3. Important remarks
3.1 Safety aspects
To understand and practice all procedures described in this manual a good technical
background is a must.
GymnaUniphy cannot be held responsible for any actions executed on the unit by unauthorised
persons, or for executing any procedures not prescribed in this manual.
All information in this manual has a GymnaUniphy nv. copyright.
3.2 Data registration
The Phyaction series has a defined number of critical parts . All critical parts have a serial- or
batch number (marked with a label). GymnaUniphy has the original configuration of each unit
and its critical parts.
In case of a configuration change to one or more of the critical parts, the distributor has to file
the serial- or batchnumber of the part in question.
The Phyaction U has following critical parts:
Ref 322517: Main PCB Phyaction U
Ref 117162: Ultrasound PCB C/P 200 & Phyaction C/U
Ref 116954: Power supply 200 series & Phyaction I/E/C/U
Ref 130015: AC inlet GymnaUniphy
The Phyaction C has following critical parts:
Ref 322528: Main PCB Phyaction C/E
Ref 117162: Ultrasound PCB C/P 200 & Phyaction C/U
Ref 116954: Power supply 200 series & Phyaction I/E/C/U
Ref 130015: AC inlet GymnaUniphy
The Phyaction E has following critical parts:
Ref 322528: Main PCB Phyaction C/E
Ref 116954: Power supply 200 series & Phyaction I/E/C/U
Ref 130015: AC inlet GymnaUniphy
The Phyaction I has following critical parts:
Ref 324914: Main PCB Phyaction I
Ref 116954: Power supply 200 series & Phyaction I/E/C/U
Ref 130015: AC inlet GymnaUniphy
To file this data, a data registration document is available on next page.
Phyaction U/E/I/C – service manual version 0.1Page 5
Data registration document
Information
Distributor name Distributor address
Customer name Customer address
Instrument name: Serial number:
Date of delivery:
Service activities
Date:
Error complaint:
Service action
Critical spare parts exchange list
Critical part name Old serial number New serial number
Date:
Error complaint:
Service action
Critical spare parts exchange list
Critical part name Old serial number New serial number
Phyaction U/E/I/C – service manual version 0.1 Page 6
4. Technical data
This is a summary of the technical data as described in the user manual.
• Current safety limit: 150% of set current or 110% of the maximum for the selected current
shape.
• Accuracy 10% with a 500 Ω load
• Mode CC/CV except for MF constant rectangular current
4.3 Ultrasound therapy (for Phyaction C/U)
• Treatment time: 0-30 min
• Output power continuous: 0-2 W/cm²
• Output power pulsed : 0-3 W/cm²
• Duty Cycle: 10%, 20%, 30%, 40%, 50%, 100%
• Pulsfrequency: 100 Hz
• Accuracy: +/- 20% at maximum intensity
• Ultrasound head model U91
Power: max 3,8 W at 1,1 MHz
Power: max 2,8 W at 3,2 MHz
ERA: 1,9 cm² at 1,1 MHz
ERA: 1,4 cm² at 3,2 MHz
Frequency: 1,1 and 3,2 MHz
BNR: 5,2 at 1,1 MHz
BNR: 3,3 at 3,2 MHz
• Ultrasound head model U92
Power: max 8,1 W at 1,1 MHz
Power: max 9,5 W at 3,2 MHz
ERA: 4,0 cm² at 1,1 MHz
ERA: 4,8 cm² at 3,2 MHz
Frequency: 1,1 and 3,2 MHz
BNR: 4,5 at 1,1 MHz
BNR: 5,8 at 3,2 MHz
Phyaction U/E/I/C – service manual version 0.1Page 7
5. Unit self test.
The self test checks proper functioning of the product, especially the safety circuits, and is
activated every time the unit is switched on. The tests are performed by the main microcontroller in combination with the safety micro-controller and take approximately 12 seconds.
When one or both of the controllers detect an error, the output will be disabled. A message will
be shown to the user.
The Phyaction series have a safety relay (RLY209). This relay (Normally Open) is integrated in
the applied part of channel A and Channel B (same relay). In case of a problem, the safety relay
will be switched off immediately and the patient becomes disconnected from the unit.
The safety relay driver circuitry is accessible to the main microprocessor for 3 seconds after
power up of the unit. After this period the main micro-controller will not be able to switch the
electrotherapy safety relay on any more. Both the main and the safety micro-controller are able
to switch the electrotherapy safety relay off (the safe state).
During the selftest of the unit, the following items are checked:
1. Main controller test.
2. Safety controller test.
3. Safety software test.
4. Electrotherapy DAC test Channel A
5. Electrotherapy DAC test Channel B
6. Electrotherapy relay test.
7. Electrotherapy safety comparator test.
8. AC/DC relay test.
9. CC/CV mode test.
Phyaction U/E/I/C – service manual version 0.1Page 8
6. Circuit description.
6.1 Block shematics
External device
Ultrasound
Power
Sypply
LCD Display
Keyboard &
Encoders
RS232(TTL)
Display driver
Laser circuit
Laser probe
UI PCB ELAL013
Safety Key
Safety
Control
ET PCB ELSM002
Contact
detection
Current m easuring
Output circuit
Amplitude generator
& Signal processing
ET powerstage
Patient
6.2 Power supply
A Switch Mode Power Supply supplies the PCB with +15V, +5V and –15V.
U114 regulates the –15V down to a –5V supply.
Circuit around U119 is a square wave oscillator that generates a square wave with a maximum
voltage of 0V and a minimum of –15V. Following is a voltage doubler that converts the –15V to
–30V that is then regulated up to –22V by the zener D113 for the LCD contrast.
6.3 User interface board (UI)
The user interface boar is a separate board for the Phyaction U. For the Phyaction E/I/C it is
mechanically linked to the electrotherapy board.
6.3.1 Microprocessor circuits.
U103 is the micro controller. U109, U110, U115 and U116 are static RAM’s. U109
and U110 are 32k Ram’s and U115 and U116 are 128k Ram’s. Only one sort is
placed, the 32k’s or the 128k’s depending on how much memory is needed. IC’s
U101 and U102 are Flash Memories that contain the software.
All these devices are addressed by the address bus CA[0:23] and the data is
transported over the data bus DQ[0:15].
Phyaction U/E/I/C – service manual version 0.1 Page 9
6.3.2 Display and keyboard circuits.
U123 is the LCD display driver with its own RAM’s namely U111 and U112. They are
addressed via VA[0:15] and the data is transported over data bus VD[0:15].
Besides controlling the safety circuits (described further on) the “safety” µprocessor
U122 does the scanning of the keyboard and of the two encoders.
The four ENC pins on port B scan the two encoders. The four KEY_SCAN pins of
port B are used to select the scan lines of the keyboard. KEY_CLK provides the
clock on which the keyboard will be scanned and KEYB_INPUT receives the serial
information from the key scan.
6.4 Electro stimulation PCB
This board is mechanically connected to the user interface board and is installed only in
Phyaction C/E/I.
6.4.1 Amplitude generation and signal processing
The amplitude and signal generation is fully done with D/A converters. U214 is a
quadruple 8-bit D/A converter with each DAC having its own reference input.
Each electrotherapy channel uses two of these DACs in series. The first DAC the
Amplitude DAC has a reference of 2,5 V. This DAC is used too set the Amplitude of
the signal. Its output is used as reference for the second DAC the LFDAC. This DAC
modulates its input and therefore can generate the waveforms such as triangular or
sinusoidal DAC_A/B.
The circuit around Op-Amp U231 inverts the signals DAC_A/B IPAA/B
Via the analogue multiplexer U204 a couple of signals from the ET stage can be fed back to the
ADC input of the micro controller U103 so these can be monitored.
6.4.2 Output circuits
Output circuit A and B are identical, therefore only output circuit A is explained.
The ET power stage has only one configuration in contrary to the 500/800
hardware namely constant current.
At the middle connection of the transformer is the +15V supply voltage connected.
The two other sides of the primary windings are connected to the drains Q206.The
gates of Q206 are connected to NEG_A and POS_A. These are the “chopper” FETs.
The sources of Q206 are coupled together and are connected to the drain of Q208
that is the current regulator MOSFET.
The circuit round Op-Amp U221 and MOSFET Q208 controls the current. The circuit
forces a voltage across current sense resistor R201 by controlling the gate-source
voltage of Q208. IPAA is a measure for this voltage across or the current through
R201 and so the output current.
Phyaction U/E/I/C – service manual version 0.1Page 10
+15V
PO S_ A
NEG_A
IPAA
Figure 6-1 Simplified schematic ET powerstage
By making POS_A or NEG_A high one side or the other of the transformer will
conduct a current and so on the secondary side of the transformer “positive” or
“negative” pulses are generated.
POS_A
10
650µs
-
H
L
L
NEG_A
Figure 6-2 Tens biphasic a-symmetric generation
This can also be done in a constant stream of pulses (f=10kHz), which then
generates a biphasic rectangular pulse train at the output.
POS_A
Amplitude
NEG_A
50µs
Biphasic rectangular pulse train
Figure 6-3 Biphasic pulse train
By varying or modulating IPAA the amplitude and waveform of the output signal is
set.
Constant voltage mode:
The hardware has no real constant voltage mode. Instead a 1kΩ resistor is
switched parallel to the current source. By applying the theorem of Thévenin you
get a non-ideal voltage source with an impedance of 1kΩ.
This results in a behaviour that is close enough to a real constant voltage no
large increase of output voltage when there is no load at the output.
At the secondary side there are some relays with which the rectifying or
combination path can be selected or polarity can be changed.
Phyaction U/E/I/C – service manual version 0.1 Page 11
6.4.3 Poor contact detection
Poor contact detection is done with an opto-coupler U216 in the secondary/patient
circuit. When a current flows through a load/patient the output of U216 will go
“low”. When no current flows through a load (no load poor contact) the output
will go “high”.
Comparator U231 sees to it that no poor contact can be detected when the
amplitude is very low (<10mA). Because opto coupler doesn’t function properly at
low amplitudes.
Only when there is a POS or a NEG signal there can be output. So only then poor
contact detection should work.
Poor contact if: output opto coupler is high AND when POS or NEG is high AND
Amplitude>10mA
6.4.4 Current measuring circuits
The output current is measured at the primary side with a high side current sense
amplifier U212. It measures the voltage over a sense resistor of 80mΩ R320 and
outputs a current equivalent to the current through this sense resistor. The output
current is turned into a voltage by the output resistor so the voltage over R216 is a
measure for the output current.
All component values are chosen so that at maximum allowable output current
+10% (=120mA+10%=132mA) the output voltage of the current measuring is
2.5V
At poor contact the output of the current sense amplifier is shorted to ground with
a MOSFET.
The circuit around Op-Amp U202 and analogue switch U205 is a hold-circuit. So
that at non-continuous currents and/or AC currents the peak levels are holded.
6.4.5 Safety control circuits
The safety control module is built round µProcessor U122. The safety relay is driven
by a RS flip-flop which is build with one NOR and two NAND’s (U219 and U208).
In case of an error detection by one of the micro controllers, the Microchip (U122)
can switch off the safety relay by making MC_SRY_OFF, “high”. The Siemens
µController (U103) can switch off the safety relay by making S_SRY_OFF, “high”.
A “high” level on MC_SRY_OFF or S_SRY_OFF-line will bring the “SET” input of the
flip-flop ‘low’. The output state of the flip-flop becomes “low”. The safety relay is
switched off.
The “SET” input can also be “low” when the UVLO (under voltage lockout) or POR
(power on reset) signals are “low”.
Note that even when error is not longer occurring, the output state of the RS-flipflop stays “low”. The safety relay stays switched off.
In normal operation TIMELOCK is “high”. When the safety relay is switched off,
then the safety relay cannot be switched on again. The only way to reactivate the
safety relay is to switch off and on the power.
When the TIMELOCK signal is “low”, a reset of the RS flip-flop is done. The outputstate of the flip-flop becomes “high”. Safety relay is switched on. The output state
remains as long as no “low” signal is available on the “SET”-input of the flip-flop.
Only during initialisation (self-test) TIMELOCK is low, so then the state of the safety
relay is equal to (MC_SRY_OFF NOR S_SRY_OFF) NAND !PROTECTION.
Phyaction U/E/I/C – service manual version 0.1 Page 12
Comparator U218 and DAC U206 guard the output level. U218 compares the output
signals from the current measuring circuit CUR_A_SAF/CUR_B_SAF with
FDBACK_SAFA/FDBACK_SAFB reference voltages. These reference voltages are
generated by the safety DAC U206 and are set up by the µProcessor U122 via bus
MC_DATA[0:7]. The levels of these voltages (0,284V-2,5V // 15mA-132mA) are a
measure for the output current and are adjusted when the intensity of the ET
output is altered by the user. U209 serves as a buffer for the
FDBACK_SAFA/FDBACK_SAFB signals. If these signals are exceeded by CUR_A_SAF
and/or CUR_B_SAF then !PROTECTION will go “low”. This will change the state of
the flip-flop from “high” to “low” so the safety relay RLY209 will be switched off.
The ET_ERROR-line is “low” when the safety relay is on. The ET_ERROR-line is
monitored by U103 and U122.
All these situations described above are only valid if CON202 is in OPERATE mode
and CON9 has no jumper.
When CON202 is in service mode then the relay stays switched on even when error
occurs. The error information is now directly linked with the ET_ERROR line.
If CON108s a jumper then the safety relay can be switched on/off at all time
because TIMELOCK will be “low” at all time.
6.4.6 Relay circuits
IC U224 is a Darlington transistor array which makes it possible to drive the relays
with the low power signals from the µC. Diodes for inductive load suppression are
integrated in this IC.
Phyaction U/E/I/C – service manual version 0.1 Page 13
6.4.7
7. Ultrasound heads
The Phyaction U and Phyaction C can be delivered with 2 different multifrequent ultrasound
heads:
Model U91 : 1 cm² 1/3 MHz
Model U92 : 4 cm² 1/3 MHz
(See technical specifications for more details)
The unit has two ultrasound output connectors.
The ultrasound head converts the electric signal into ultrasound using a piezo crystal. This crystal,
with a diameter depending on the desired head size, is glued in an aluminium cup that minimises
electromagnetic radiation and enables the crystal to be used on to operating frequencies.
The aluminium cup can also be used as a second electrode if combination therapy is desired. A
separate electrotherapy device needs to be connected to the safety socket for combination
therapy.
An OTP is installed in the connector of the treatment head to enable the micro controller to detect
whether a head is connected and to recognise the type of head that is connected. It also contains
the calibration values of the head in question.
The ultrasound head has an auditif and visual contact control indication: the treatment heads
are fitted with light of two colours, yellow and green.
The following configurations are possible:
Blinking green: The US head is properly connected
Continuous green: The US head is selected
Continuous yellow: The US-emission is in progress
Alternating yellow/green: Bad contact of the US head with the skin
Blinking yellow: End of treatment
Phyaction U/E/I/C – service manual version 0.1Page 14
7.1 Contact control indication
Depending on the contact between the US head and the patient, the display has the following
possible indications:
Phyaction U/E/I/C – service manual version 0.1Page 15
8. Yearly safety inspection
The ‘Directive on Medical Devices’ from the European Commission (92/42/EEG) requires that
safe devices are used.
It is recommended to perform a yearly technical safety inspection.
If the legislation in your country or your insurer prescribes a shorter period, you must adhere to
this shorter period.
On the following pages the format of the yearly checkup is printed. Fill out this document for
each test.
In order to perform this test, the following devices are needed:
- Digital Ultrasound power meter
- Oscilloscope 20 MHz at least
- 500 Ohm power resistor
- Electrical safety tester (according to IEC or VDE)
Phyaction U/E/I/C – service manual version 0.1Page 16
Safety inspection list
Customer identity
Unit:
Serial number:
Date:
Test 1: General inspection
Pa
Results of earlier safety inspections are available
The logbook is present
The type plate and supplier’s label are legible
The housing, the adjusting knobs, the keys and the display are undamaged
Fail N.A
ss
.
Power connection and power cord are undamaged
The output connectors are undamaged
The electrode connectors and cables are undamaged
(Phyaction E/I/C)
Cable and connector of the ultrasound treatment head(s) are undamaged
(Phyaction C/U)
The US head(s) do not display any cracks or other damage that can endanger the
insulation
(Phyaction C/U)
The automatic self-test when switching on the appliance does not report any
errors
The display does not have any defective points or lines
Remarks:
Phyaction U/E/I/C – service manual version 0.1Page 17
Test 2: Electrotherapy
Skip this test for a Phyaction U
Connect a load of 500 Ω to the electrode cables of both connectors. Hook up an oscilloscope to
the loads (black cable = ground).
Select channel A, program 4: MF Constant Pa
ss
At maximum intensity the output matches the set peak value within ±10%
The output waveform corresponds to photo 1
Fail
The polarity changes over to negative when set to RED-
Disconnecting the load gives “poor contact to patient”
Select channel B, program 4: MF Constant Pa
ss
At maximum intensity the output matches the set peak value within ±10%
The output waveform corresponds to photo 1
The polarity changes over to negative when set to RED-
Disconnecting the load gives “poor contact to patient”
Select channel A, program 23, 2 pole MF mode CV Pa
ss
At maximum intensity the output matches the set peak value within ±10%
The output waveform corresponds to photo 2 and 3
The yellow light next to the output connector is lit when intensity is not 0
Disconnecting the load gives “poor contact to patient”
Select channel B, program 23, 2 pole MF mode CV Pa
ss
Fail
Fail
Fail
At maximum intensity the output matches the set peak value within ±10%
The output waveform corresponds to photo 2 and 3
The yellow light next to the output connector is lit when intensity is not 0
Disconnecting the load gives “poor contact to patient”
Remarks:
Phyaction U/E/I/C – service manual version 0.1Page 18
Photo 1
Photo 2
Photo 3
Phyaction U/E/I/C – service manual version 0.1Page 19
Test 3: Ultrasound
Skip this test for a Phyaction E or a Phyaction I
Connect the treatment head and place it in a calibrated ultrasound power meter.
Select ultrasound therapy
Ultrasound treatment head model U91 with SN Pa
Fail N.A
ss
Select 1 MHz, continuous (duty cycle 100%), 2 W/cm²
Measured value is ±20% of the PPK value in the channel window
Select 1 MHz, duty cycle 50%, 3 W/cm²
Measured value is ±20% of half the PPK value in the channel window
Select 3 MHz, continuous (duty cycle 100%), 2 W/cm²
Measured value is ±20% of the PPK value in the channel window
Select 3 MHz, duty cycle 50%, 3 W/cm²
Measured value is ±20% of half the PPK value in the channel window
Select 3 MHz, duty cycle 50%, 0.5 W/cm²
With a dry treatment surface the PPK value drops to 0
Select 1 MHz, duty cycle 50%, 0.5 W/cm²
With a dry treatment surface the PPK value drops to 0
Ultrasound treatment head model U92 with SN Pa
Fail N.A
ss
Select 1 MHz, continuous (duty cycle 100%), 2 W/cm²
Measured value is ±20% of the P
value in the channel window
PK
Select 1 MHz, duty cycle 50%, 3 W/cm²
Measured value is ±20% of half the PPK value in the channel window
Select 3 MHz, continuous (duty cycle 100%), 2 W/cm²
Measured value is ±20% of the PPK value in the channel window
Select 3 MHz, duty cycle 50%, 3 W/cm²
Measured value is ±20% of half the PPK value in the channel window
Select 3 MHz, duty cycle 50%, 0.5 W/cm²
With a dry treatment surface the PPK value drops to 0
Select 1 MHz, duty cycle 50%, 0.5 W/cm²
With a dry treatment surface the P
value drops to 0
PK
Remarks:
.
.
Phyaction U/E/I/C – service manual version 0.1 Page 20
Test 4: electrical safety test according to VDE 0751
Parameter Measured Limit Comments Pass Fail
Protective earth resistance
Ω < 0.2 Ω
Enclosure leakage current µA < 1000 µA
Patient leakage current µA < 5000 µA
The unit ……. With serial number …… has passed/failed the test
Name service engineer Signature
Phyaction U/E/I/C – service manual version 0.1Page 21
9. System settings menu.
The system settings menu allows the user to personalize a number of parameters, to perform
some tests and to check some machine info.
/ Only the most important menu options are explained in this service manual.
In order to select the system settings menu, press the
The following screen appears:
9.1 System information (8)
key.
This is an important screen for the service department.
It gives an overview of the hard- and software version(s) of the most important boards inside the
unit.
In case of configuration changes, read chapter .
The last service date tells the customer when the machine was last serviced.
Phyaction U/E/I/C – service manual version 0.1Page 22
9.2 Plate electrode test (9).
This menu option allows the customer to check the electrode for a faulty contact
Important: a cable test can only be performed through channel A.
Before checking the electrodes, it is important that the patient cable has been checked and has
proved to be ok. (see point 9.3)
Please follow the procedure below to check both the rubber electrodes.
Select ‘plate electrode test’ in the system settings menu.
Connect a patient cable to the channel A and put the electrode on top of each other like the
photo below.
Turn up the intensity to 10 V and move with the plugs and cable to detect a bad contact.
The unit will now display whether the electrodes are ‘ok’ or ‘bad’.
/ It is recommended to replace electrodes twice a year.
Phyaction U/E/I/C – service manual version 0.1Page 23
9.3 Cable test (9).
Important: a cable test can only be performed through channel A.
Select ‘cable test’ in the system settings menu.
Connect the patient cable to the channel A (without the plate electrodes) and make a shortcircuit with the supplied connector (red female-female connector)
Turn up the intensity to 10 V and move with the plugs and cable to detect a bad contact.
The unit will now display whether the cable is ‘ok’ or ‘bad’.
Perform the same test for the other patient cables.
9.4 Error History(11).
This menu will give detailed information of the last 10 errors that have been occurred.
This is an important tool to detect a problem, especially when it concerns intermittent errors.
In this menu it is not possible to make a reset of the error message (since this is accessible for
the customer: chapter service menus)
Phyaction U/E/I/C – service manual version 0.1Page 24
9.5 Counter working hours.
This menu gives an overview of the working hours per module (ET, US) and per channel.
It can help a service engineer to justify for example a worn-out ultrasound cable.
9.6 Reset menu
The reset menu offers the possibility to reset
1. The working hours for each single module.
2. Restore programs to the original configuration or save a new setting (not for advised
programs)
3. Clear total memory (except counter working hours and error history)
Phyaction U/E/I/C – service manual version 0.1Page 25
10. Service menus.
The Phyaction series have a built in service menu which allows to check different important
service issues.
To enter the service menu, first go to the ‘ system settings’ menu (by pressing
press the ‘Pause’ key (
10.1 Change PCB & HW code
This menu offers the possibility to change the hardware codes of the different PCB’s and to
change the last service date.
) for about 5 seconds. The following screen will appear.
) and then
In case the hardware code of one of the boards changes for any reason, it has to be stored in
the machine via this menu.
In case of replacing the main PCB, the hardware codes of all the other PCB’s have to be
introduced again by using this menu.
/ Each board carries a label with the hardware code.
Phyaction U/E/I/C – service manual version 0.1Page 26
/ It is also possible to enter the last service date. This date will become visible in the system
information menu.
/ We recommend to input the Last service date after each checkup or repair of the machine.
Phyaction U/E/I/C – service manual version 0.1Page 27
10.2 Functional tests
The functional test offers the service engineer to check a number of important items of the
machine.
10.2.1 Electro check
After each repair or during the yearly checkup (chapter 8 ), 2 current wave forms have to be
tested in order to make sure that the machine works fine.
This menu offers the possibility to do this in a semi-automatic way.
Procedure:
Enter the functional test. Program 4 appears on the screen:
Current test 1
After testing this current waveform, press the go back key and re-enter the same menu.
Program 23 appears on the screen:
Phyaction U/E/I/C – service manual version 0.1Page 28
Current test 2
10.2.2 Ultrasound check
The ultrasound check offers the possibility to check the ultrasound module for a longer period
(without timer).
10.2.3 Keyboard check
All the different keys can be tested in this mode.
When pressing a key, the machine must react immediately.
Hold down the STOP key for about 5 sec in order to return to the functional test menu.
10.2.4 Display check
Offers the possibility to check the screen for defective or missing pixels.
Phyaction U/E/I/C – service manual version 0.1Page 29
10.2.5 Invert screen
Offers the possibility to invert the complete screen.
10.3 Count currents.
Sometimes it might be interesting to know what current types the customer is using the most
frequently in order to simulate intermittent problems.
This menu gives an overview of the total working hours per current waveform.
Phyaction U/E/I/C – service manual version 0.1Page 30
10.4 Reset menu
10.4.1 Reset error history
By pressing this key twice, the error history will be restored.
10.4.2 Total reset settings.
By pressing this key twice, a total reset of the machine is executed.
The total reset settings menu makes a reset off ALL the previous settings and information (like
working hours and error history)
Since some boards are being used in several machines, we have an auto detection system. If
we provide a main board, we have done a total reset of all settings. When the board is replaced
and the machine is switched on for the first time, the screen below appears:
( example below of the Phyaction U)
GYMNA-UNIPHY PRODUCT INFORMATION
ELECTROTHERAPY: Y
ULTRASOUND: Y
LASER: N
MYO: N
INTERFERENTIAL N
GYMNA/UNIPHY: U
Determined type: Phyaction C
Press ‘back’ to confirm or any other key to reject
Check whether the determined type in correct and confirm with the go back key.
/ Every main PCB that GymnaUniphy provides, had a ‘total reset’ of it’s parameters. It is normal
that the screen above appears when the unit is switched on for the first time
Now the following screen appears:
Phyaction U/E/I/C – service manual version 0.1Page 31
Now all the hardware codes of the boards have to be introduced in the service menu (Chapter
10.1).
Therefore the unit needs to be opened.
Each board carries a label with the hardware code.
/ This can only be done by a qualified service engineer.
Press the ‘go back’ key after all the data is correct. Now the system settings menu appears.
Change the settings if required.
Now perform a complete check-up of the machine.
Phyaction U/E/I/C – service manual version 0.1Page 32
11. Upgrading system software.
11.1 General information.
The software of the Phyaction series can easily be updated.
There is a flash memory on the main PCB that can be reprogrammed using a special interface
tool.
/ The Medical Device Directive does not allow end users to reprogram medical devices. This is
only reserved to authorized service personnel.
11.2 Which tools are required ?
A PC with Windows 98/98SE/Millenium/NT/XP, CD-rom drive and a free COM/USB port.
The file with the software to be programmed (provided on CD rom)
An USB to RS232 converter when the PC has no RS232 output connector.
A special interface cable (photo below) ordering ref 117.135
A RS232 transceiver (photo below) ordering ref 117.006
Transceiver + interface cable
11.3 Downloading the software.
Please follow the steps below in detail:
Step 1: remove the rubber foot on the right front corner (photo below)
Phyaction U/E/I/C – service manual version 0.1Page 33
Step 2: plug in the interface cable through the hole of the rubber foot (mind the position of the
cable !)
Step 3: Switch on the unit.
Step 4: connect the transceiver to the cable and the PC
Step 5: Open the STT (service test tool) program
Step 6
: Select STT Flash. The following screen appears.
Phyaction U/E/I/C – service manual version 0.1Page 34
Step 7
: Select the COM port Next. The following screen appears.
Switch off the unit, wait for 3 seconds and switch it on again.
Step 8
: Select Next. The following screen appears. This is the preparation step for the flash.
After a short time the different points must all be marked with a √. If a red cross appears, check
the connections.
Phyaction U/E/I/C – service manual version 0.1Page 35
/ The unit now displays the message: STATE: CONNECTED
: Click next and in the list ‘available flash profiles’ select ‘ALL 200’ and click ‘Next’
Step 9
Step 10
: The flash procedure must now start. The following screen appears:
This will take about 7 minutes. When the flashing is finished, click on the button ‘NEXT’. The
following screen must appear:
Phyaction U/E/I/C – service manual version 0.1Page 36
If the flashing was terminated successfully, switch off the unit . Now close the program, remove
the flash cable and install the rubber foot.
Switch on the unit. The new software is now installed.
/ Check the software version in the start-up screen.
11.4 Troubles with flashing.
If the PC cannot connect to the unit, check whether the interface cable is properly connected
and check whether the right COM port has been chosen.
Phyaction U/E/I/C – service manual version 0.1Page 37
12. Hardware labels.
Each PCB (except the display PCB and the power supply) has 2 labels, one with the hardware
code and one with the serial number.
12.1 Label with hardware code and ref number.
The main PCB has an eeprom in which the actual hardware code of the used PCB is saved.
The hardware code consists of 4 characters and is composed as follows (from left to right):
0…
.A..
..A.
…A
Example:
Suppose that resistor R68 changes from 22 K to 100 K.
The actual hardware version 1AAA will be upgraded to 1ABA.
From 1 to 9. Increase in case of a
principle technology change.
A to Z Increase in case of a
principle technology change.
A to Z Increase in case of
component change.
A to Z Increase in case of a PCB
track change.
Hardware is not compatible
anymore.
All previous changes made in
hardware shall be inherited in
the new layout. The last 3
alphanumerical numbers will
begin with A
Components are not anymore
compatible with the previous
layout. All previous changes
made in hardware shall be
inherited in the new layout. The
last 2 alphanumerical numbers
will begin with A
Phyaction U/E/I/C – service manual version 0.1Page 38
12.2 Upgrading the hardware code.
Every hard-or software change will be presented in a technical bulletin. In case of a hardware
change GymnaUniphy will provide the necessary components as well as a new hardware label.
This label must be put on the upgraded PCB.
The hardware code also has to be modified in the serial eeprom. See chapter 10.1 for more
details.
/ The user can easily see the hardware code of each PCB in the system settings menu.
12.3 Label with serial number
Critical parts must be traceable meaning it must be identifiable at least on lot level for source
and destination. To end this, critical parts must be labeled.
Phyaction U/E/I/C – service manual version 0.1Page 39
13. Troubleshooting.
13.1 General information.
In case of a problem the unit will produce an error code. Intermittent error codes can be
recovered by means of the service software, which gives an overview of the last 10 error codes.
13.2 Skipping the self test
When the error code is generated during the self test, and the cause of the problem is difficult to
detect, there is a possibility to skip the self test.
When starting up the machine, press the function keys F1 and F7 at the same time. The self
test will now be skipped.
13.3 De-activate the safety relay (only for Phyaction I/E/C)
In order to deactivate the control of the safety relay, the position of the jumper ‘operate/service,
located on the ET board, must be put from position ‘OPERATE’ to position ‘SERVICE’. Putting
the jumpers into ‘SERVICE’ position will avoid that the safety relay can be switched off.
Since the functioning of the safety relay is tested during the selftest, it will generate an error
code when the unit is in ‘SERVICE’ mode.
Therefore the selftest must be bypassed (13.2: skip of self test)
After both the ‘SERVICE’ jumper and the factory jumper are changed, the unit can be powered
up without performing a selftest and without the possibility to deactivate the safety relay.
/ It is very important that after repairing the unit, the unit will be reset to ‘OPERATE’ Not
following this instruction can bring the safety of the patient and the therapist in jeopardy.
In case the service engineer cannot solve the problem, it is recommended to communicate the
problem with the GymnaUniphy service department.
Phyaction U/E/I/C – service manual version 0.1Page 40
13.4 Interpreting error codes.
In case of an error, the following screen appears:
The unit gives an overview of the actual error. The error code can be traced in the error list
(chapter 12).
Different codes:
Error number: defines the software module in which the error is detected.
Error value 1: the first error value which defines the individual test in the module which
actually generated the error
Error value 1: an additional value which may give more information about the detected error.
Error value 2: (not used).
Phyaction U/E/I/C – service manual version 0.1 Page 41
13.5 List of error codes.
This chapter defines the individual error numbers. Each error number is related to a software
module. For each error number the code used in the software is defined, the number is defined
and a short description about the purpose of the software module is given.
13.6 Error groups
Error group Error group description
1 - 99 Driver errors
100 - 199 Operating system errors
200 - 299 Elektro task errors
300 - 399 Ultrasound task errors
400 - 499 Laser task errors
500 - 599 User interface task errors
600 - 699 System task errors
700 - 799 Hardware Initialisation errors
800 - 899 Not used
900 - 999 Monitor service program errors
1000 - 1099 CPU error
13.7 Error list
Error Nr Name Description
1 1 ADC Not used
2 Not used
3 [x] Invalid ADC channel [x] selected
2 ASCDRV Not used
3 0 0 ASCMAIN Flash application header not OK
1 Flash application checksum not OK
4 0 [x] ASW Invalid Analogue switch channel [x] selected
1 [x] Invalid Analogue switch channel [x] selected for Channel A
2 [x] Invalid Analogue switch channel [x] selected for Channel B
5 BUZ Not used
6 1 [x] CCR Invalid Capture compare channel [x] selected during setting associated
2 [x] Invalid Capture compare channel [x] selected during query for associated
2 [x] Invalid DAC12 Amplitude state [x] selected on Channel A
3 [x] Invalid DAC12 Amplitude state [x] selected on Channel B
4 [x] Invalid DAC12 Amplitude state [x] selected on Channel A & B
5 [x] Invalid DAC12 Amplitude Vector state [x] selected
11 DRW1353 Not used
12 DRWBM Not used
13 DRWGR Not used
14 DRWM Not used
15 DRWTXT Not used
16 DRWVIP Not used
17 1 [x] DS1 Invalid Dallas 1 wire OTP channel [x] selected during OTP initialisation
output pin
pin
output pin direction
Phyaction U/E/I/C – service manual version 0.1 Page 42
Phyaction U/E/I/C – service manual version 0.1 Page 43
20 1 [x] FRQ Invalid Timebase controlled Frequency wave state [x] selected on Channel A
2 [x] Invalid Timebase controlled Frequency wave state [x] selected on Channel B
3 [x] Invalid MF frequency wave state [x] selected on Channel A
4 [x] Invalid MF frequency wave state [x] selected on Channel B
5 [x] Invalid LF frequency wave state [x] selected on Channel A
6 [x] Invalid LF frequency wave state [x] selected on Channel B
7 [x] Invalid Diadynamic frequency wave state [x] selected on Channel A
8 [x] Invalid Diadynamic frequency wave state [x] selected on Channel B
9 [x] Invalid Diadynamic frequency wave state [x] selected on Channel A & B
10 [x] Invalid Rectangular/Triangular frequency wave state [x] selected on Channel A
11 [x] Invalid Rectangular/Triangular frequency wave state [x] selected on Channel B
12 [x] Invalid Tens frequency wave state [x] selected on Channel A
13 [x] Invalid Tens frequency wave state [x] selected on Channel B
21 GPT1 Not used
22 GPT2 Not used
23 1 [x] I2C Invalid I2C channel [x] selected during I2C initialisation
2 [x] Invalid I2C channel [x] selected during I2C read
3 [x] Invalid I2C channel [x] selected during I2C write
4 [x] Invalid I2C channel [x] selected during I2C get time out/reset error flag
24 IMATH Not used
25 KSC Not used
26 LCM Not used
27 LSIO Not used
28 1 [x] LFD Invalid waveform [x] selected during setting of LF to diadynamic surge on Channel
2 [x] Invalid waveform [x] selected during setting of LF to diadynamic surge on Channel
3 [x] Invalid Pulse time [x] selected during setting of LF Triangular pulse time on
4 [x] Invalid Pulse time [x] selected during setting of LF Triangular pulse time on
5 [x] Invalid Amplitude state [x] selected during LF timebase controlled surge on
6 [x] Invalid Amplitude state [x] selected during LF timebase controlled surge on
29 1 0 LSF Invalid laser frequency value during setting of laser frequency for MODx43
1 Invalid laser frequency value during setting of laser frequency for MODx45
2 [x] Invalid laser probe type [x] during setting of laser frequency
30 1 [x] PEC Invalid channel [x] selected during setting of PEC channel source address
2 [x] Invalid channel [x] selected during setting of PEC channel destination address
3 [x] Invalid channel [x] selected during setting of PEC channel mode and count
4 [x] Invalid channel [x] selected during setting of PEC channel properties
31 1 [x] PPI Invalid PPI 8255 port [x] selected during PPI write
2 1 Invalid PPI 8255 line control state during setting of PPI line
2 Invalid PPI 8255 port selected during setting of PPI line
32 1 [x] PWM Invalid PWM mode [x] selected during setting of PWM mode
2 [x] Invalid PWM channel [x] selected during setting of PWM properties
33 1 [x] REL Invalid Relay [x] selected during setting of Relay lines on Channel A
2 [x] Invalid Relay [x] selected during setting of Relay lines on Channel B
3 [x] Invalid Special Relay [x] selected durring setting of special relays (Safety, Test, ..)
34 1 [x] S4W Invalid number of bits [x] selected during write to 4-wire bus
2 [x] Invalid channel [x] selected during initialisation of write to 4-wire bus
A
B
Channel A
Channel B
Channel A
Channel B
Phyaction U/E/I/C – service manual version 0.1 Page 44
35 1 1 SC I2C Error during start of sending I2C command to the Safety controller
2 I2C Error during start of receiving I2C data from the Safety controller
2 1 I2C Error during adressing while sending a command to the Safety
2 I2C Error during adressing while receiving data from the Safety controller
3 1 I2C Error during sending first part of command to the Safety controller
2 I2C Error during sending second part of command to the Safety controller
4 0 I2C Error during receiving bytes from Safety controller
5 128 (0x80) Invalid Reset (not used)
129 (0x81) Safety relay activated
130 (0x82) Error during Selftest
131 (0x83) 18V under voltage lock out detected (18V too low)
132 (0x84) I2C communication time out
133 (0x85) I2C checksum error
134 (0x86) Invalid command scope (invalid I2C command received by Safety
135 (0x87) 2 resettable errors occurred in Safety controller
136 (0x88) 2 channel waveform on B selected = not possible
137 (0x89) Invalid Maximum amplitude while setting step value
193 (0xC1) Invalid command state; Command not accepted (resettable error)
194 (0xC2) Constant voltage CV request not accepted while setting CC/CV
[x] Undefined safety controller return code [x]
256+[x] (0x100 + x) Expected a 1 byte response from Safety controller ([x] = 1st
512+[x] (0x200 + x) Expected a 2 byte response from Safety controller ([x] = 1st
1024+[
x]
36 SER Not used
37 STRC Not used
38 STST Not used
39 1 [x] TENS Invalid Tens pulse mode [x] selected during setting of timer values on
2 [x] Invalid Tens pulse mode [x] selected during setting of timer values on
40 TMB Not used
41 1 0 TSA I2C Error during communication with TSA6057 (PLL on ULS board)
42 1 [x] USD Invalid US PWM dutycycle [x] setting (dutycycle > 100%)
2 [x] Invalid US PWM frequency [x] setting (frequency < 20 or > 500)
43 1 [x] USF Invalid US frequency setting [x] (1MHz : 500 – 1800 kHz / 3MHz : 2000
2 [x] Invalid US frequency range setting [x] (setting is not 1MHz or 3MHz)
44 USIO Not used
45 1 [x] USP Too high US PWM voltage [x] setting (Vset > 5000)
3 [x] Measured US Calibration voltage [x] (VUS) set point 1 out of range
4 [x] Measured US Calibration voltage [x] (VUS) set point 2 out of range
5 [x] Too high US voltage [x] setting while setting VUS (VUS > 20000)
6 0 Missing Calibration settings while setting VUS (calibration not executed)
8 [x] US Head ERA [x] out of range during head calibration
9 [x] US Calibration voltage [x] VCAL out of range during head calibration
10 [x] US Calibration Power PCAL [x] out of range during head calibration
11 [x] US Head factor [x] too high during US Head calibration
12 [x] US Head factor [x] too low during US Head calibration
13 [x] Too high Power setting [x] during US Head Set Power
14 [x] Unitialised Head factor [x] during US Head Set Power (Head factor = 0)
46 UTIL Not used
47 VIO Not used
48 1 [x] E2P Invalid MAIN EEPROM address [x] selected (address out of EEPROM
2 [x] Invalid MAIN EEPROM byte count [x] for reading bytes (count = 0 or out
3 [x] Invalid MAIN EEPROM byte count [x] for writing bytes (count = 0 or out of
4 [x] Time out during I2C communication with MAIN EEPROM ([x] = number of
5 [x] Too many words [x] to read from MAIN EEPROM (out of EEPROM memory
controller
controller)
mode
received byte)
received byte)
(0x400 + x) Expected a 4 byte response from Safety controller ([x] = 1st
received byte)
Channel A
Channel B
– 4000 kHz)
memory range)
of range)
range)
retries)
range)
Phyaction U/E/I/C – service manual version 0.1 Page 45
6 [x] Too many words [x] to write to the MAIN EEPROM (out of EEPROM
7 [x] Invalid US EEPROM address [x] selected (address out of EEPROM memory
8 [x] Invalid US EEPROM byte count [x] for reading bytes (count = 0 or out of
9 [x] Invalid US EEPROM byte count [x] for writing bytes (count = 0 or out of
10 [x] Time out during I2C communication with US EEPROM ([x] = number of
11 [x] Too many words [x] to read from US EEPROM (out of EEPROM memory
12 [x] Too many words [x] to write to the US EEPROM (out of EEPROM memory
49 1 [x] FAN Temperature too high ([x] = measured ADC value corresponding with
50 1 0 GPIO Invalid status of General purpose IO line during setting/resetting line
50 1 1 Invalid General purpose IO line during setting/resetting line
100 Q Not used
200 1 [x] E_CTRLA Invalid Control state [x] selected
2 Not used
3 [x] Invalid Waveform [x] selected
4 [x] Sending Tens pulse time to Safety contoller failed ([x] = pulse time from
memory range)
range)
range)
range)
retries)
range)
range)
temperature)
SC)
Phyaction U/E/I/C – service manual version 0.1 Page 46
201 1 [x] E_CTRLB Invalid Control state [x] selected
2 Not used
3 [x] Invalid Waveform [x] selected
4 [x] Sending Tens pulse time to Safety contoller failed ([x] = pulse time from SC)
202 E_PARA Not used
203 E_PARB Not used
204 0 0 E_TASKA Unable to start ELT task for Channel A
1 [x] Invalid command message [x] sent from UIF task to ELT A task
2 [x] Invalid task state [x] for Channel A
3 [x] Invalid waveform [x] within task for Channel A
4 3 ELT A message qeue full while sending messages to the UIF task
5 [x] ELT A sending Tens pulse time to Safety contoller failed ([x] = pulse time)
205 0 0 E_TASKB Unable to start ELT task for Channel B
1 [x] Invalid command message [x] sent from UIF task to ELT B task
2 [x] Invalid task state [x] for Channel B
3 [x] Invalid waveform [x] within task for Channel B
4 3 ELT B message qeue full while sending messages to the UIF task
5 [x] ELT B sending Tens pulse time to Safety contoller failed ([x] = pulse time)
300 1 [x] U_CTRL Invalid US control state [x]
301 U_CONT Not used
302 1 [x] U_HEAD Invalid US Head OTP page [x] while reading a page from the US Head OTP
303 1 [x] U_SCAN Invalid UFEnd ([x]) < UFStart during US head scan measurement
2 [x] Too low UFStart [x] during US head scan measurement
3 [x] Too high UFEnd [x] during US head scan measurement
4 [x] Too big step : (UFEnd – UFStart) = [x] during US head scan measurement
5 [x] Too low Vus [x] during US head scan measurement
6 [x] Too high Vus [x] during US head scan measurement
304 1 [x] U_TASK ULS message qeue full while sending messages to the UIF task ([x]=ULS
2 [x] Invalid command message [x] sent from UIF task to ULS task
400 1 [x] L_CTRL Invalid Laser operation state [x] while starting or stopping the Laser
401 1 [x] L_PRB Invalid Laser OTP page [x] while reading a page from the Laser Head OTP
402 0 0 L_TASK Unable to start the Laser task
1 3 Laser message queu full while sending messages to the UIF task
2 [x] Invalid command message [x] sent from UIF task to LAS task
500 1 [x] CNTR Invalid Treatment state [x]
2 [x] Time out during stopping UIF task ([x] = current treatment state)
501 DELT Not used
502 DFUM Not used
503 DHLP Not used
504 DIND Not used
505 DISP Not used
506 DOUT Not used
507 DPAR Not used
508 DSCR Not used
509 DTAB Not used
510 DTTL Not used
511 DUTL Not used
512 1 [x] ELT UIF message queu full while sending messages to the ELT tasks ([x] = UIF
2 [x] Invalid command message [x] sent from ELT A & B task
1 EVC Not used
513
2 0 Invalid Program number (program number = 0)
3 Not used
4 0 Laser Probe type parameter missing in laser program (PAR_PROBE_TYPE_115)
5 Not used
6 0 Trying to start ULS funtionality while ULS hardware is not detected
7 0 Trying to start LAS functionality while LAS hardware is not detected
514 10 [x] EVH Treatment state [x] not disabled while trying to activate system
11 [x] Treatment state not disabled while using BACK while a program is selected in
tasknr)
functionality
tasknr)
setting/memory menu
level [x] < 3
Phyaction U/E/I/C – service manual version 0.1 Page 47
515 EVHP Not used
516 16 [x] EVHT Invalid program number [x] while selecting a treatment or copying a program
17 [x] Invalid Sequence step number [x] while selecting a treatment or copying a
517 EVIN Not used
518 1 [x] FK Too many menu screen lines [x] while extracting menu screen records
519 ILST Not used
520 1 [x] LAS Invalid source task (not LAS task) [x] is sending Laser message to UIF task
2 [x] Invalid command message [x] received from LAS task
3 [x] UIF message queu full while sending commands to the LAS task ([x] = UIF
program
tasknr)
521 1 0 MEM Error during initialising of MAIN EEPROM memory
2 [x] Preset Program [x] address out of MAIN EEPROM memory range during reading
3 [x] Error Record [x] address out of MAIN EEPROM memory range during reading
4 [x] Preset Program number [x] is not within the preset program number range
5 [x] Program [x] address out of MAIN EEPROM memory range during reading
6 [x] Trying to save an empty Therapy [x] to the MAIN EEPROM
7 [x] Trying to save a illegal Program [x] to the MAIN EEPROM
8 Not used
9 [x] Trying to load an invalid Program [x] from MAIN EEPROM
10 Not used
11 [x] Trying to load an invalid Preset Program [x] from MAIN EEPROM
12 [x] Trying to save an invalid Preset Program [x] to MAIN EEPROM
13 Not used
522 1 0 MENU No tree active while handling a menu event
2 0 No menu active while handling a menu event
3 0 No search menu number defined while searching for next menu event
4 0 New selected menu is not defined while selecting a menu
1 New selected menu is not defined while getting the menu program number
2 Menu number not defined while getting the menu pointer
5 0 Selected menu does not exist while selecting menu (current menu has no child)
1 Selected menu does not exist while getting menu program nr
523 PAR Not used
524 PLST Not used
525 1 [x] TASK Invalid source task [x] while handling task messages from ELT, ULS, LAS …
2 [x] UIF message queu full while sending commands to itself ([x] = UIF tasknr)
526 1 [x] ULS Invalid source task (not ULS task) [x] is sending message to UIF task
2 [x] Invalid command message [x] received from ULS task
3 [x] UIF message queu full while sending commands to the ULS task ([x] = UIF
527 VAC Not used
528 1 [x] WRNG WARNING queu full while adding a warning to the warning queu ([x]= first free
529 [x] [y] SAFE0 Detected difference between Rotary value of Main uP [x] and Safety uP [y]
530 SAFE1 Not used
600 1 1 SYS UIF task message queue full during broadcasting time event
2 ELT A task message queue full during broadcasting time event
3 ELT B task message queue full during broadcasting time event
4 LAS task message queue full during broadcasting time event
5 ULS task message queue full during broadcasting time event
6 Not used
2 0 Real time operating system : System task timer allocation failed
3 [x] Main controller ET error line is active ([x] = error count > 5) : Safety relay
601 16 0 SCPU (0x10) Internal RAM test failed : found non-zero IRAM byte after initialisation
1 (0x10) Internal RAM test failed : found 2nd non-zero IRAM integer after
2 (0x10) Internal RAM test failed : write & verify byte to IRAM failed
3 (0x10) Internal RAM test failed : write & verify integer to IRAM failed
32 1 (0x20) CPU integer multiplication error
2 (0x20) CPU integer dividing error
33 1 (0x21) GPT1 T3CON register is not zero
2 (0x21) GPT1 T3IC register is not zero
3 (0x21) GPT1 T2CON register is not zero
4 (0x21) GPT1 T4CON register is not zero
34 1 (0x22) GPT2 T6CON register is not zero
2 (0x22) GPT2 T6IC register is not zero
tasknr)
warning index)
active
initialisation
Phyaction U/E/I/C – service manual version 0.1 Page 48
3 (0x22) GPT2 T5CON register is not zero
4 (0x22) GPT2 T5IC register is not zero
5 (0x22) GPT2 CAPREL register is not zero
6 (0x22) GPT2 CRIC register is not zero
35 1 (0x23) CAPCOM1 T01CON register is not zero
2 (0x23) CAPCOM1 T0IC register is not zero
3 (0x23) CAPCOM1 T1IC register is not zero
4 (0x23) CAPCOM1 CCM0–CCM3 registers are not zero
5 (0x23) CAPCOM1 CC0IC–CC15IC registers are not zero
36 1 (0x24) ADC ADCON register is not zero
2 (0x24) ADC ADCIC register is not zero
3 (0x24) ADC ADEIC register is not zero
37 (0x25) Not used
38 0 (0x26) CPU WDTR register is not zero (watchdog timer)
48 [x] (0x30) Not used (see 601,80,[x])
64 [x] (0x40) Found non-zero EXTERNAL RAM bytes in page [x]
602 1 1 SELT Safety controller status error at start of self test
2 Safety controller status error after sending “selftest” command to Safety
3 Safety controller status error after sending “selftest OK” command to Safety
2 [x] Temperature to high at start of self test ([x] = measured ADC value)
3 [x] ADC reference voltage [x] out of range
4 [x] Wrong Safety controller software version [x]
10 10 ET_ERROR line inactive Safety AND Main controller with Output < Safety
11 ET_ERROR line inactive at Safety controller only with Output < Safety value
12 ET_ERROR line inactive at Main controller only with Output < Safety value
20 ET_ERROR line active at Safety AND Main controller after resetting safety
21 ET_ERROR line active at Safety controller only after resetting safety relay
22 ET_ERROR line active at Main controller only after resetting safety relay
30 Main controller unable to deactivate safety relay
31 Safety controller unable to deactivate safety relay
40 ET_ERROR line still active at Safety controller after setting & resetting safety
50 ET_ERROR line inactive at Safety controller after resetting safety relay
60 ET_ERROR line active at Safety controller
71 Not used
72 Not used
80 ET_ERROR line active at Safety controller at Output A = 0 + Test relay
81 ET_ERROR line active at Safety controller at Max Output A & Max Safety
82 ET_ERROR line inactive at Safety controller at Max Output A > Safety value
83 ET_ERROR line active at Safety controller at Output A < Safety value A
90 ET_ERROR line active at Safety controller at Output B = 0 + Test relay
91 ET_ERROR line active at Safety controller at Max Output B & Max Safety
92 ET_ERROR line inactive at Safety controller at Max Output B > Safety value
93 ET_ERROR line active at Safety controller at Output B < Safety value B
11 0 Safety relay or Test relay contacts don’t close for Channel A
12 0 Safety relay or Test relay contacts don’t close for Channel B
13 0 Safety relay contacts don’t open for Channel A
14 0 Safety relay contacts don’t open for Channel B
15 [x] Still current flowing after opening Test relay Channel A : Check Energize or
16 [x] Still current flowing after opening Test relay Channel B : Check Energize or
controller
controller
= Selftest not executed within 3 seconds
value
relay
relay
active
value A
A
= Safety relay contacts don’t open (relay got stuck)
active
value B
B
= Safety relay contacts don’t open (relay got stuck)
AC/DC relay
([x] = number of retries > 3)
AC/DC relay
([x] = number of retries > 3)
Phyaction U/E/I/C – service manual version 0.1 Page 49
20 1 ET_ERROR line active at Safety controller at Min Output A < Minimum
2 ET_ERROR line inactive at Safety controller at Low Output A > Minimum
3 ET_ERROR line active at Safety controller at Min Output B < Minimum
4 ET_ERROR line inactive at Safety controller at Low Output B > Minimum
40 [x] LFDAC=0V/DAC12=1.5V check with ADC (CAL_A) out of range ([x] =
41 [x] LFDAC=0V/DAC12=0V check with ADC (CAL_A) out of range ([x] =
42 [x] LFDAC=1V/DAC12=Max check with ADC (CAL_A) out of range ([x] =
43 [x] LFDAC=0V/DAC12=Max check with ADC (CAL_A) out of range ([x] =
44 [x] LFDAC=0V/DAC12=1.5V check with ADC (CAL_B) out of range ([x] =
45 [x] LFDAC=0V/DAC12=0V check with ADC (CAL_B) out of range ([x] =
46 [x] LFDAC=1V/DAC12=Max check with ADC (CAL_B) out of range ([x] =
47 [x] LFDAC=0V/DAC12=Max check with ADC (CAL_B) out of range ([x] =
50 Not used
51 Not used
60 Not used
61 Not used
70 Not used
71 Not used
72 Not used
73 Not used
74 Not used
75 Not used
80 [x] AC current too low on Channel A ([x] = measured current) : Check AC/DC
81 Not used
82 [x] AC current too low on Channel B ([x] = measured current) : Check AC/DC
83 Not used
603 SULS Not used
604 SLAS Laser sensor not OK (initial voltage over sensor is too high)
Safety value A
Safety value A
Safety value B
Safety value B
measured value)
measured value)
measured value)
measured value)
measured value)
measured value)
measured value)
measured value)
relay got stuck
relay got stuck
700 1 1 PRODID Invalid Product ID (sum of bits is not an even number)
2 1 Product ID doesn’t correspond with the detected hardware (See : 700, 6,
3 1 Hardware configuration on Setup screen not accepted by user (BACK key
6 1 Product ID doesn’t correspond with the detected hardware
900 MPC Not used
901 MPRD Not used
902 MSRV Not used
1000 80 10 CPU (0x50) Found wrong Checksum ID for PAR in FLASH
11 (0x50) Found wrong Checksum ID for SYM in FLASH
12 (0x50) Found wrong Checksum ID for HLP1 in FLASH
13 (0x50) Found wrong Checksum ID for HLP2 in FLASH
14 (0x50) Found wrong Checksum ID for HLP3 in FLASH
15 (0x50) Found wrong Checksum ID for HLP4 in FLASH
16 (0x50) Found wrong Checksum ID for TXT1 in FLASH
17 (0x50) Found wrong Checksum ID for TXT2 in FLASH
18 (0x50) Found wrong Checksum ID for TXT3 in FLASH
19 (0x50) Found wrong Checksum ID for TXT4 in FLASH
20 (0x50) Found wrong Checksum ID for TXT5 in FLASH
21 (0x50) Found wrong Checksum ID for TXT6 in FLASH
22 (0x50) Found wrong Checksum ID for TXT7 in FLASH
2 [x] CPU NMI interrupt error ([x] = trap flag register)
4 [x] CPU Internal Stack overflow error ([x] = trap flag register)
6 [x] CPU Internal Stack underflow error ([x] = trap flag register)
1)
= accepted)
Phyaction U/E/I/C – service manual version 0.1 Page 50
10 [x] CPU Undefined Opcode/Protected instruction/Illegal instruction access,
Illegal external bus access, Illegal Word operand…. ([x] = trap flag
register)
Phyaction U/E/I/C – service manual version 0.1 Page 51
14. Replacement procedures.
The most frequent service operations will be exchanging defective boards rather than repairing
them.
When handling static sensitive devices such as PC boards of the Phyaction, the following
precautions should be observed:
- Persons should be earthed by means of a wrist strap.
- Ground all electrical equipment, work bench, soldering iron…
Depending on the type of machine, different PCB’s are installed. This chapter explains the
assemble and disassemble procedures for the Phyaction C that has all of the different boards
inside.
+ After the machine has been opened for any reason, perform a complete test as prescribed in
chapter
14.1 Disassemble instructions
14.1.1 Opening the unit and removing the top cover.
Step 1: switch of the unit and remove the 3 screws on the rear side.
Step2: remove the 3 screws on the bottom front side of the unit.
Step3: put the machine on a table and smoothly lift up the rear side of the top cover
Step4: unplug the 2 ultrasound connectors on the ultrasound PCB that is installed under the
top cover and unplug the interface cable between the UI board and the Ultrasound board.
Step5: unplug the white flatwire cable of the display (open the white connector by sliding it to
the front)
Step6: unplug the backlight connector the encoder cables and the power led cable
Step7: unplug the flatwire of the keyboard. The top cover can now be removed.
14.1.2 Removing the main PCB.
Step 1: open the unit as explained in 14.1.1
Step 2: pull out the connector between the main PCB and the power supply board.
Step 3: pull out the cable to the fan
Step 4: unscrew the metal plate that secures the ET output connectors (not for Phyaction U)
Step 5: unscrew the 9 screws that fix the board and remove it (4 screws for Phyaction U)
14.1.3 Removing the power supply board
Step 1: open the unit as explained in 14.1.1
Step 2: unplug the mains connector and the connector to the main board
Step 3: remove the 2 screws on the left side of the board and unlock the 2 black supports on
the right side (don’t damage any components on the board !) and take out the board.
14.1.4 Removing the ultrasound board
Step 1: open the unit as explained in 14.1.1
Step 2: remove the 4 screws of the board and unlock the 2 black supports on the right side
(don’t damage any components on the board !) and take out the board.
Phyaction U/E/I/C – service manual version 0.1Page 52
14.1.5 Removing the display PCB and/or keyboard
Step 1: open the unit as explained in 14.1.1 and put the top cover on a table.
Step 2: pull off the black knob(s) of the intensity rotary
Step 3: turn the cover, remove all the screws of the rotary’s and power LED and take them out
Step 4: remove the 4 nuts (M5) of the metal cover and gently remove the metal cover by
removing the cables that feed through the metal cover
Step 5: remove the display board by removing the 4 screws that secure it or remove the
keyboard by pulling it out of the plastic top cover (photo 1)
Photo 1
Phyaction U/E/I/C – service manual version 0.1Page 53
14.2 Assembly instructions
14.2.1 Installing the display PCB and/or keyboard
Follow the steps as explained in 14.1.5 in reverse order.
Especially pay attention to the following points:
- A new display might have a protecting film. Remove it first
- Make sure that the display and the screen is 100% clean before assembling it.
- Don’t forget to put the plastic washers on the 4 screws of the display boards
- Only use the self securing nuts to fix the metal cover
- Make sure that all the cables that are feed through the metal cover are free and show
not any damage (photo 2 )
- Make sure that the rotary encoders and the power led PCB are fitted in a way that the
cable connections are face to face !!!
- After installation check whether the power LED is exactly behind the window in the
front.
Photo 2
14.2.2 Installing the ultrasound board
Follow the steps as explained in 14.1.4 in reverse order.
Especially pay attention to the following points:
- Mind the position of the ultrasound board
- Don’t touch the coils of the ultrasound board
Phyaction U/E/I/C – service manual version 0.1Page 54
14.2.3 Installing the power supply board
Follow the steps as explained in 14.1.3 in reverse order.
Especially pay attention to the following points:
- Mind the position of the power supply board
- Make sure that the special metal washer on the left front side of the board is well fixed
(photo 3)
- After putting the board on the plastic support, check whether the board is well fixed by
pulling it up.
- Make sure that the connectors all well plugged in.
Photo 3
Special metal washer
Phyaction U/E/I/C – service manual version 0.1Page 55
14.2.4 Installing the main PCB.
Follow the steps as explained in 14.1.2 in reverse order.
Especially pay attention to the following points:
- Don’t forget to put the metal washer on each screw point (between the board and the
screw)
- Make sure that the ET output LED’s are properly fit through the hole in the chassis
(photo 4)
- Don’t forget to fit the metal plate that secures the ET output connectors (photo 4)
Don’t forget to put this plate
Both LED’s must fit in the
hole
Photo 4
14.2.5 Closing the unit and installation of the top cover.
Follow the steps as explained in 14.1.1 in reverse order.
Especially pay attention to the following points:
- On each connector of the main board there is an indication of the use of the connector.
Make sure that connectors are not mixed.
- The cables of the Ultrasound output have to be fit UNDER the interface cable of the
ultrasound board
- When closing the cover, make sure that the cover fits onto the bottom without pushing
it. If this is necessary, check the wires for proper installation.
Phyaction U/E/I/C – service manual version 0.1Page 56
15. Compatibility of boards and components
The boards and components of the Phyaction series are not always interchangeable between
the different units.
The following table gives an overview of the items that are not compatible. All the items that are
not indicated in this list are fully compatible:
Ref Item Phyaction C Phyaction E Phyaction I Phyaction U
117.162 Ultrasound PCB C/P 200&Phyaction U/C:x x
322.517 Main PCB Phyaction U:x
322.528 Main PCB Phyaction E/C:x x
324.914 Main PCB Phyaction I:x
Phyaction U/E/I/C – service manual version 0.1Page 57
16. Exploded views and spare parts
The most important spare parts are listed in the exploded views on the next pages. A more
detailed list can be found on the service CD.
Phyaction U/E/I/C – service manual version 0.1Page 58
1
2
3
16
17
18
19
20
21
4
5
6
7
8
9
10
11
12
13
14
15
212117.146
1
20
19
18
171
16
1
1
1
117.142
117.102
117.148
117.162
138.404
154117.144
141
322.627 LOWER METAL HOUSING, PHYACTION C
132322.737
121
322.528 MAIN PCB., PHYACTION E/C
112117.152
101116.954