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ELECTRONICS 102 Diagnostics and Troubleshooting Presented by: Ken Kalinowsk i Senior Service Technician Sunrise Medical LLC MANUAL POWER ADULT PEDIATRICS SEATING GERIATRICS CONTROLS FUNDING Agenda 1. 2. 3. 4. 5. Intro Troubleshooting aspects The LED Tech Aspects R-Net EL – Troubleshooting R-Net – with Displays PC Troubleshooting CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 2 Diagnostic Information • Two m ethods by which the above modules display system status and diagnostic information: – Coded Display – Text Display CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 3 1 Diagnostic Information • Coded Display: Diagnostic information is presented as a sequence or combination of colored LEDs on the battery gauge, also referred to as Battery State Of Charge display (BSOC). CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 4 Diagnostic Information • Text Display: Diagnostic information is presented in technical and non-technical forms in plain text, English and other languages CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 5 Diagnostic Information • Modules with display capabilities used to diagnose system status. – – – – – Hand Control (4 button VR2) - LED Hand Control (6 button VR2) - LED Hand Control (5 Button – R-Net EL- LED) Hand Control (6 button – R-Net – LCD or Color) Omni Specialty Control – (4 button with array R-Net Color Display) • Hand Control (9 button Lights & Indicators) – Attendant Handcontrol – LED CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 6 2 Diagnostic Information • 3 Methods of Testing Diagnostics – Diagnostic Test Tool • DTT – Dongle • OBP • On Board Programming – Dongle • PC Dealer • OEM CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 7 Diagnostic Information • Programming 101 – Dongle and DTT Refresher • You can enter OBP using a key sequence from the JSM also. – With the system off, hold both the ON/OFF and horn buttons. – The system will beep, let go of the horn button but keep the ON/OFF still depressed. – Once the system beeps again, let go of the ON/OFF button and it will go into OBP. – This only works on an LCD joystick (Color or Monochrome). • This also works with the R-Net - Omni by Holding On/Off and P (Profile) button. • Reminder: You can't only have one programming option active at a time. – DTT active = no connection to OBP – OBP active = no connection via Dongle – This is true for all combinations. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 8 R-Net EL-90 Control Inputs Com Connection O.B.C. Motor 1 Po wer Connect Motor 2 Inhibit Line Off Board Charger CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 9 3 Diagnostic Procedure Please follow this procedure: • Read and note the Trip Text displayed, the identified Module and the Trip Code. • Switch off the control system. • Make sure that all connectors on the listed Module and the wheelchair are mated securely. • Check the condition of the battery. • Find the definition of the Trip Code in this Service Guide, or go online to PGDT.com and insert code and take required action. • Switch on the control system again and try to drive the wheelchair. If the safety circuits operate again, switch off and do not try to use the wheelchair. Contact Sunrise Technical Service. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 10 VR2 Diagnostics Using PP1 or Qtronix Programmer Read System Log ? • The control systems have a diagnostics log facility which stores the number of occurrences of the last eight trip codes. This allows you to view the contents. The display format is as below. – 1: Code 2C00, #1 – 2: Code 3C00, #3 • No more entries • This reads line by line as. – Line 1 - trip code 2C00 has occurred once – Line 2 - trip code 3C00 has occurred three times • Only two trip types recorded. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 11 LED Diagnostics – R-Net EL Control LED Control System Status Indication: The battery gauge and Maximum Speed/Profile indicator show the status of the control System. With the help of this listing it is possible to diagnose problems that may appear drastic at first, but may have a ver y simple and easy to fix cause. 1. Batter yGauge is Stead y: This indicates all is well 2. Batter yGauge Flashes Slowly: The control s ystem is functioning correctly, but you should charge the battery as soon as possible. 3. Batter yGauge Steps up: The wheelchair batteries are being charged you will not be able to drive until chair is disconnected from charger. Switched Power On and Off again. 4. Batter yGauge Flashes Rapidly(even when joystick released): The control system safety circuits have operated and the control system has been prevented from moving the chair. This indicates a system trip – The R-Net has detected a problem somewhere in the wheelchairs electrical system. Please follow below procedure: 1. 2. 3. 4. Switc h of the c ontr ol sy stem. Mak e sur e that a ll c on nect ors o n the wh ee lch air an d the c ontr ol sy stem a re m ated c orr ectly. Ch eck th e co nd itio n of the battery. Switc h the c ontr ol syst em o n a ga in a nd try to driv e the wh ee lc hai r. If the safety cir cu its op er ate a ga in. Switc h off an d co ntact y our s ervi ce a ge nt. 5. Speed Indicator Ripples Outwards From Center: In this instance the LEDS make a ripple motion starting with the Middle LED and then stepping outwards on Both sides. The Control System has detected that a new module has been added and is re-configuring. Please allow for a few seconds for this to complete 6. Speed Indicator LED’s 2 & 4 Flash: Then the control system requires a reboot. For example, after a module re-configuration, the second and fourth speed indicator LED’s will flash. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 12 4 LED Diagnostics – R-Net EL Control Note: If the Programmable Parameter, Motor Swap has been enabled, the left and right hand references in the table will be reversed CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 13 Indication of Display Related Faults R-Net LED Joystick • 1 LED – The battery needs charging or there is a bad connection to the battery. Check the connections to the battery. If connections are good, try charging the battery. • 2 LED – The M1 Motor – has a bad connection. Check connections and resistance of motor. • 3 LED – The M1 Motor – has a short circuit to a battery connection. Motor short can lead to damage of control module. • 4 LED – The M2 Motor – has a bad connection. Check connections and resistance of motor. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 14 Indication of Display Related Faults R-Net LED Joystick • 5 LED – • LED SCROLL UP AND REPEAT – • The Charger may be plugged in causing an inhibit – in the past use to be 6 bar flash. Unplug Charger - reset power. 7 LED – • The M2 Motor – has a short circuit to a batter y connection. Motor short can lead to damage of control module. The joystick is giving error – try to reset Power - if held out of neutral for over 5 sec onds will give this code. If fault continues may be gimble – call tech support for part or replacement. 8 LED – The control system is indicating error – reset power - recheck all connections. Reset System by disconnecting Power to Control Module. If still present may have bad module. Contact Tech Support for replacement. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 15 5 Indication of Display Related Faults R-Net LED Joystick • 9 LED – The Brakes or Solenoid have a bad connection or disconnection. Check the motor connection – read resi stance - dead short is “0” - infinite is open either will cause error. Replace motor or if available brake assembly • 10 LED – An excessive voltage has been applied to the control system usually due to power on while charging batteries due to voltage spike. Check all battery connections and check charging system. Replace as needed. • 7 LED + SPEED LED’s – A communication fault is indicated. Make sure that the joystick cable is securely connected and not damaged. This fault will come up for bad cable so if fault occurs and chair drives this is the fault for bad cable. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 16 Indication of Display Related Faults R-Net LED Joystick • Actuator LEDs Flash – An Actuator Trip is indicated. If more than one actuator is attached, check which actuator is not working correctly. Check for resi stance and if any thing is causing excessive current. • Maximum Speed / Profile Indicator Flashes – This indicates the speed of the wheelchair is being limited for safety reasons . The exact reason will depend on if a seating control is on the chair or not. The most common cause is seat is elevated position. • Maximum Speed / Profile indicator Ripples Up and Down – This indicates the control system is locked. Refer to next page for unlocking procedure. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 17 Diagnostic for Unlocking Unit CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 18 6 Display & Screen Diagnostics • Display shows the details that are needed for a Technician to troubleshoot the problems. • Identified Module – Identifies which module has the present problem – – – – – – PM = Power Module JSM = Joystick Module ISM – Intelligent Seating Module OMNI – Specialty Control Device and Display ATT – attendant Control CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 19 Display & Screen Diagnostics • Trip Text – Text Version of the code • Trip Code – Is the Alphanumeric Code indicating the designated code number letter combination. • In the display we have a Power Module with a Trip Text of Low Battery and a Trip Code of 2C00 – depending on type of programming device it will store either a combination of trip code and Text or Text only. • Programmers prior only displayed Trip Codes sometim es making it hard to decide where and what to look for. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 20 Diagnostic Text Definitions • The – – – – R-Net has v arious connections that are ref erred to by the diagnostic text. Power Module (PM) Joystick Module (JSM) Intelligent Seating/Lighting Module (ISM) The Text list is described on the next pages (some of the faults are not described for we don’t use in the USA.) CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 21 7 Diagnostic Text Definitions Text Code May Not have number corresponding to Error 1. Joystick Center Error – 2F00 - Center Joystick The most common cause of this trip is if the joystick is deflected away from center before and during the time the control system is switched on. The joystick displaced screen will be displayed for 5 seconds, if the joystick is not released within that time then a trip is registered. Ensure that the joystick is centered and power-up the control system. If still not working could be internal Gimble or Joystick board itself. 2. Low Battery – 2C00 – Below Operational voltage This occurs when the control system detects that the battery voltage has fallen below 16V. Check the condition of the batteries and the connections to the control system. If the trip is still present after the batteries and connections have been checked, then the Power Module may be defective. Full voltage should be 12.57 or higher per battery lower than 9 volts per battery is designated as depleted or dead. 23.5 volts will indicate a Single Segment on the display screen. 3. High Battery Error – 1600 - Battery Voltage Greatly Excessive This occurs when voltage is over 35 volts – due usually to power on during charging and a voltage spike. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 22 Diagnostic Text Definitions Text Code May Not have number corresponding to Error 4. M1 - Motor Error - 3B00 - Motor 1 Motor Fault This occurs when the control system has detected Motor 1 has become disconnected. Check wiring connections – motor resistance should be low resistance of less than 1 ohm. A quick test is to exchange motor leads from M1 to M2 and see if problem changes or still exists. If after connection and resistance checks are found to be good – replace out control module. If motor fault changes to opposite side check brushe s. 5. M2 – Motor Error – 3C00 - Motor 2 Motor Fault This occurs when the control system has detected Motor 2 has become disconnected. Check wiring connections – motor resistance should be low resistance of less than 1 ohm. A quick test is to exchange motor leads from M2 to M1 and see if problem changes or still exists. If after connection and resistance checks are found to be good – replace out control module. If motor fault changes to opposite side check brushe s. 6. M1 – Brake Error – 1505 - Brake Solenoid Fault Motor 1 This occurs when control does not see good resistance or connector to brake input of motor control. Check brake resi stance and connection to control module. If all are good then control module may need to be replaced. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 23 Diagnostic Text Definitions Text Code May Not have number corresponding to Error 7. M2 – Brake Error – 1506 - Brake Solenoid Fault Motor 2 This occurs when control does not see good resistance or connector to brake input of motor control. Check brake resistance and connection to control module. If all are good then control module may need to be replaced. 8. Inhibit Active – 1E03 – 1E02 – 1E04 – 1E05 – Last 2 Digits specify Module This occurs when any of the Inhibit inputs are active and in a latched state. The actual inhibits listed are referring to JSM - 03 - PM - 02 – ISM for 04 and 05. Cycle the power . Check all wiring and switches connected to inhibits. This can cause lockout of module as in charging chair or limited or no drive for the ISM seating module. No drive if connection to control is not connected. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 24 8 Diagnostic Text Definitions Text Code May Not have number corresponding to Error 9. Joystick Calibration Error – Joystick CAL error – Joystick - SID or Specialty This occurs when Joystick or SID Calibration process has not been successful or failure upon connection to Omni. Enter OBP and attempt calibration. If still present may have bad Gimble internal - contact Technical Service for parts or replacement. Joystick Calibration is shown on next page. 10. Over Current (acts) – Actuator over current This occurs when the control system detects an excessive amount of current in an Actuator Channel. This may be due to a faulty actuator motor, cables or connections or endstop switch. Check the movement of the actuator is not obstructed. If all had been checked and still issue it may be a defective SM or ISM. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 25 Joystick Calibration in OBP • This procedure is for LCD – Monochrome , Color or Omni R-Net Units for Proper Calibration – To begin the procedure you must first enter OBP mode and go to the System branch. Select the listing of Joystick calibration option. – The procedure is automatic, simply follow the on-screen instructions. Values for both the Forward/Reverse and Left/Right SID axes will be displayed. Alongside each value will be an X or a √ symbol: • X - Indicates the axis value is outside of the permitted calibration range for the particular direction • √ - Indicates the axis value is within the permitted calibration value for the particular direction. – Simply deflect the Device in the instructed direction until both values are with the permitted range indicated by advancing automatically to next direction. – A large check will be displayed on screen, for a short period of time to indicate succe ss! The screen will then return to the System Menu. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 26 Diagnostic Text Definitions Text Code May Not have number corresponding to Error 11. Overtemp (acts) Actuator over Temperature Range This occurs when control system detects that the SM or ISM’s actuator circuitry has become too hot. The control system will cease to drive the actuator motor in question. Allow the SM or ISM to cool. If the SM or ISM is frequently overheating check the condition of the actuator motors – re sistance and connections to them. If still occurring may need replacement of the components mentioned above. Detail on ISM shown on Next 3 Pages. 12. DIME Error - Distinguishing ID Memory Error This occurs when the control system detects and identification conflict between 2 modules in the system. If a new module has been added disconnect and recycle power – if no trip present reconnect new module if trip reappears due to new unit. If no new module connected – disconnect from Battery Power for 30 seconds and reconnect power is fault still occurs contact Technical Service to replace out module. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 27 9 Intelligent Seating & Lights Module (ISLM) – Connection Details - 108216 • Inhibit Connections The ISM contains the inhibit 4 and 5 connections. These connections can be used to limit speed, inhibit driv e and/or inhibit actuator channels. • Lighting Connections Each lighting output is rated at 21W maximum. The output is self -protecting against wiring and bulb faults and will shut-off if the max power rating is exceeded. Likewise, if the output becomes too hot it will shut-off to prevent damage to itself • ISLM Each actuator channel is rate at 15A maximum, although only 12A is available when the channel is programmed to 100% speed. If currents of greater than 12A are required, the programmed speeds f or that channel must reduced. The level of reduction is dependent upon the electrical characteristics of the actuator motor, so an empirical process to establish the lev el of the reduction is required. If the wheelchair is f itted with solid mechanical end-stops at the end of the actuator trav el, it is not necessary to f it limit switches as the ISLM can detect when the actuator motor has stopped and will cutoff the power to it. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 28 Intelligent Seating & Lights Module (ISLM) Standard Configuration (108216) – 6L CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 29 Intelligent Seating & Lights Module (ISLM) 1 Tilt 2 Elev ate 3 Left Leg 4 Right Leg 5 Recline 6 Footboard * CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 30 10 DTT Connections • Two Cables – Neutrik Connector for VR2 – R-Net Connector for R-Net • USB a memory stick allows for file transfers and back-up of chair programming CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 31 DTT Diagnostics Immediate Diagnosis System Tests System Logs CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 32 On-Board Programming (OBP) • Performed using the Om ni’s own display and front panel buttons. For details of these buttons, refer to section “Controls and Connections.” From the Omni, all system OBP param eters can be adjusted: for example, Speeds and Accelerations • OBP can be entered in one of two ways depending on the factory programming of the control system CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 33 11 OBP – One of Two Ways • Using Keypad Sequence • Using R-Net Dongle CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 34 PC Diagnostics - Using the Dongle CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 35 Reading System Logs • After entering PC Programming go to top and under the heading Tools. Highlight over menu items and select System Logs • From System Log – Click on Read in order to bring on-screen the log files for each individual unit connected. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 36 12 Reading System Logs • Example shows that the last 3 trips have been due to the joystick being away from centre at power-up. • Prior to these, there was 1 instance of a broken cable, 2+5 instances of a brake being disconnected from each of the motors. Click on + sign for indications of faults that hav e occurred. On right shows how it opens for listing of faults – the ? mark giv es additional info CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 37 Diagnostic Tests CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 38 Diagnostic Tests • SUMMARY OF OTHER DROP DOWNS PC Programming – Print • This will print a copy of the System Logs. Regardless of how they appear on the screen, the print will show all the logs in an expanded f orm. – FILE : • Sav e to File • This allows you to save the system logs to a f ile. The default file name will correspond to the date and the file extension will be .rnsi. While y ou can change the name, the extension should not be changed. – Load f rom File • This allows a log f ile (.rnsi ty pe) to be opened f rom disk and inspected. – Comments • This allows text comments to a log file. – Send • This will attach a log file to an email with the following inf ormation in the subject field RNet system log (User Name* serial number): time and date of sending mail. • *As set in the Conf igure f acility. • The log f ile will assume a name corresponding to the day ’s date and have an extension of .rnsi. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 39 13 Diagnostic Tests • SUMMARY OF OTHER DROP DOWNS PC Programming – MISC : • Clipboard • This is a standard Windows facility that will put the log file onto the clipboard meaning it can then be pasted into • other applications, such as Word. – Expand • This expands the log file display so that all information is visible. – Collapse • This collapses the log file display. – Save the main program file • name xx0x.Rnet is the file extension • R-Net is the availability to manipulate that file without being connected. – This allows for ease of sending file – through Memory Stick or straight from Computer. Omni and Joystick with Micro lite and IR setup.R-net CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 40 Diagnostics Specific to Omni & R-Net TE XT RELATED CODE DESCRIPTION Omni SID Detached 0905 The connection to the Specialty Input Device is not seen by the Omni. Omni Recycle Power 3A05 The Control is indicating to user to turn off the Power Switch and turn back on. User Switch Detached User Switch Detached from U1 or U2 corresponding to Ports – Switch Detect has been turned on to have this occur. Over Pressure Over Pressure to calibration settings – go bac k and recalibrate user Sip or Puff settings found in General on Omni Menu. Gone to Sleep This will occur if Long Mode Switch is held beyond time set such as 1 second. Depress switch again to turn bac k on. Bad Settings This occurs when programmed and values not possible such Fwd/Rev Auto Toggle and Latch is pic ked – it also occurs when an Omni is connected and Input T ype is not set to Omni in the Programming menu. CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 41 Omni Troubleshooting CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 42 14 Intelligent Seating & Lights Module (ISLM) – Connection Details - 108216 CONFIDENTIAL AND PROPRIET ARY Duplic ation or Dis tribution Prohibited 7-20-2012 43 Thank You For Attending! Ken Kalinowski Senior Service Technician [email protected] MANUAL POWER ADULT PEDIATRICS SEATING GERIATRICS CONTROLS FUNDING 15